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 SEPT - OCT 2007
Units Days 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
FLARE 3+10+1
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 M&I IDLE START UP
# Shutdown & regeneration

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 CMNM-I

S.Mukherjee CMNM-II
Civil maintenance B.P.Sarkar CMNM(Civil)
Electrical maintenance A.E Rao CMNM(EL)
D.K.Pradhan SMNMEL-I
D.P.Ghosh SMNMEL-II
Instrumentation maintenance S.K.Chattopadhyay CITM
Inspection A Ghosh CIPM
Process S Dasgupta CTSM
Engineering Services S K Dutta CESM
Production A B Pathak CPNM
U Kundu CPNM
A Choudhury CPNM
Power & Utility T K Sett CPUM
Materials S Sen CMTM(I/C)
Goutam Das CMTM
Finance D Roy CFM
Project S Mitra CPJM
A.K.Sarkar CPJM
Special Project Cell T K Kar CPJM
Fire & Safety G C Kundu CM(F&S)
Welfare & Administration S K Ganguly CM(A&W)
SHUTDOWN ORGANOGRAMM
Over all Shutdown
Unit Discipline Location Day Night Area In-Charge
Manager
Furnace + Column A.Behra, SMLE

Mech. Maint Reactor + Hot jobs A.Jana, MLE B. K. Dutta, SMLE + External-2 MNM(FOB)
Heat Exchangers + Valve External-1
Vikas Kumar, CLE and N.K.
Civil Maint All civil jobs H Pramanik, DMCL & T Haokip, CLE SMNMCL
Ghosh SCLE
Elect. Maint Over all K D Kalandar, ELE MNMEL-I( S N Jha)
FOB SPNM (FOB)
Inst. Maint
Inspection All Jobs S.Ghosal, DMIP External SIPM
Engg. Serv. B R Naik, MLS(ES) Anil Kr , ESM
Process
Project
Production
Hot Job Nirmal Kumar, SMLE

Valve Job + Unit-84 A.K. Dhar, SMLE
Mech. Maint Column, Vessel, Heat Exchanger. External-3 / HR S. K. Mondal, MLE+ External-5 MNM(LOB)
Furnace K. Kumar, MLE
Other Units External-4
Vikas Kumar, CLE and N.K.
Civil Maint All civil jobs KL Samanta, EA and KS Rajak, DMCL SMNMCL
Ghosh SCLE.
Elect. Maint Over all Santosh Mishra, SELE / S P Sigh, ELE MNMEL-I( S N Jha)
Inst. Maint
M.A.Baig, DMIP
Inspection All Jobs External SIPM
S.K.Mitra, SIPE
LOB SPNM (LOB)
Engg. Serv. Amit Sahai, MLE(ES) S.Roychoudhury, ESM
Process
Project
Unit-31 M S Jana, PNE
Unit-32 & 36 Lalan Paul & Sh A K Chakraborty
Unit-33 P K Das
Production 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
Valve replacement + HE P.Biswas, DMNM
Mech. Maint General rotary jobs A.K.Saha, Ex-Emp D.Yadav, MLE SMNM-II
HOT Jobs + valve revisioning R.K.Das, SMLE
Vikas Kumar, CLE N.K.

Civil Maint All civil jobs H Pramanik, DMCL & T Haokip, CLE SMNMCL
Ghosh SCLE.
Elect. Maint Over all G Maity, ELE MNMEL-I( S N Jha)

TPS SPUM (TPS)
Inst. Maint
Inspection All Jobs S.K.Mitra, SIPE + External External SIPM
Engg. Serv. B.R.Naik, MLE(ES) Anil Kr, ESM
Process
Project
P&U
MAB+WGC S.K. Bandopadhay, DMNM

Catalyst Section+ COB + Reactor N. D. Shah, SMLE
A. Bhengra,SMLE + External-10
Mech. Maint Column+Vessel+HE+F/C External-7 / MR DMNM(FCCU)
Hot Jobs+ Valves External-8 / MR
Belco Section External-9 External- 11
Praveen Kumar, CLE N.K.
Civil Maint All civil jobs SP Mandal, EA and KS Rajak, DMCL SMNMCL
Ghosh SCLE.
Elect. Maint Over all G C Bera, SELE / C R Kapat, ELE MNMEL-II( Archisman Roy)
Inst. Maint
FCCU / VDU-II /
D.P.Ghosh,IPM PNM (DHDS)
MSQ
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
SHIFT OFFICERS
COLUMN/VESSELS/HE/MERICHEM S.MONDAL/K.DHARA
Production
MSQ D.P.CHAKRABORTI
SHIFT OFFICERS
VDU-II SHIFT OFFICERS
24-F-02 A.K. Kulshrestha, DMNM
Mech. Maint Reactors, Hot Jobs, Hydrogen Comp. S.K. Bandopadhay, DMNM C.C. Dhara, SMLE+ External-12 DMNM(DHDS)
All jobs of ARURU N. Aamir, MLE
Praveen Kumar, CLE N.K.
Civil Maint All civil jobs SP Mandal, EA and KS Rajak, DMCL SMNMCL
Ghosh SCLE.
Elect. Maint Over all G C Bera, SELE / C R Kapat, ELE MNMEL-II( Archisman Roy)
Inst. Maint
HGU/ DHDS/ DHDS + ARU + SRU External External IPM PNM (DHDS)
ARU/ SRU Inspection
HGU S.Ghosal,DMIP+ External External SIPM
Engg. Serv. A.Hazra, DMCL(ES) N.K.Sidhu, ESM
Process
Project
HGU D.K.METYA/U.K.PRAMANIK
Production DHDS P.K.MISHRA/V.YADAV SHIFT OFFICERS S.HALDER,DMPN
ARU/SRU H.C.RANJIT/M.K.MISHRA
Flare Tip+ Vessel S.K. Dolui, SMLE

Mech. Maint C.M. Baitalik, SMLE+ External
External- U Khara, SMLE DMNM(O/S)
( )
Fl
Flare line+
li O/S Piping
Pi i
6
Vikas Kumar N.K.
Civil Maint All civil jobs KS Rajak, DMCL and D.Das EA SMNMCL
Ghosh SCLE.
Elect. Maint Over all S P Mondal, DMEL / B P Mandal, ELE MNMEL-I( S N Jha)
Inst. Maint M.W.Beg,SPNM/M.S.
Offsite Chattaraj,SPNM/S.K.D
Inspection All jobs J.K.Besra, IPE + External External IPM as,SPNM
Engg. Serv. A.Sahai,MLE(ES) S.Roychoudhury, ESM
Process
Project
O/S Piping A.K.Sahu/N.C.Barman/B.B.Munuan M.W.Beg
Production Shift Officers
Flare line and related all jobs/ M S Chattaraj SPNM/S.K.Das,SPNM M S Chattaraj
Pump + Fabrication + Machining Jobs R.Naik, SMLE

Mech. Maint SMNM-I
Valve jobs S.Hazra, SMLE
Workshop Inspection Valve jobs C.R.Das, DMIP External IPM
Elec. Maint Over all A K Malik, SELE MNMEL-II( Archisman Roy)
Inst. Maint
B.B.Das, DMNM
Garage All Jobs D.K. Parua, MLE SMNM-I
J.Singh, MLE
FOB + LOB + OFFSITE B.Mallick, MLE
Mech. Maint FCCU + DHDS S.Sharma, MLE SMNM-I
Planning Materials M.S.Ghosh, SMLE
Elec. Maint Over all R P Shukla 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 D. Saha, FM FM
G.K.Sahu, SO (HR)
Welfare All Jobs Manager (HR)
B.Gupta, SO (HR)
Offsite S.K.Bandopadhyay, SMFS

FOB & TPS B.B.Bharasa, MFS
Fire & Safety
FCCU & DHDS Pallab Nath, MSF
LOB K.Ganesh, SF&SO
Telecom/ AC/
Over all R S Vyas, SELE / S P Sahoo, SELE SMNMEL-II ( D P Ghosh)
Fire prot.
Elect Testing Over all A K Malik, SELE / V Joshi, ELE 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 20:00-08:00 Hrs
9/23/2007 B.K.Barik, PSE P.S.Yadav, O(ER) Santosh Kumar, PSE Praveen Kumar, QCO
9/24/2007 A.K.Soreng, DMIS B.K.Barik, PSE P.S.Yadav, O(ER) Santosh Kumar, PSE
9/25/2007 Praveen Kumar, QCO A.K.Soreng, DMIS B.K.Barik, PSE P.S.Yadav, O(ER)
9/26/2007 B.K.Barik, PSE A.K.Soreng, DMIS Santosh Kumar, PSE Praveen Kumar, QCO
9/27/2007 P.S.Yadav, O(ER) B.K.Barik, PSE A.K.Soreng, DMIS Praveen Kumar, QCO
9/28/2007 Santosh Kumar, PSE P.S.Yadav, O(ER) B.K.Barik, PSE A.K.Soreng, DMIS
9/29/2007 B.K.Barik, PSE Praveen Kumar, QCO P.S.Yadav, O(ER) Santosh Kumar, PSE
9/30/2007 A.K.Soreng, DMIS B.K.Barik, PSE Praveen Kumar, QCO P.S.Yadav, O(ER)
10/1/2007 Santosh Kumar, PSE A.K.Soreng, DMIS B.K.Barik, PSE Praveen Kumar, QCO
FOB
10/2/2007 B.K.Barik, PSE Santosh Kumar, PSE A.K.Soreng, DMIS Praveen Kumar, QCO
10/3/2007 P.S.Yadav, O(ER) B.K.Barik, PSE Santosh Kumar, PSE A.K.Soreng, DMIS
10/4/2007 Praveen Kumar, QCO P.S.Yadav, O(ER) B.K.Barik, PSE Santosh Kumar, PSE
10/5/2007 B.K.Barik, PSE A.K.Soreng, DMIS P.S.Yadav, O(ER) Praveen Kumar, QCO
10/6/2007 A.K.Soreng, DMIS B.K.Barik, PSE Santosh Kumar, PSE P.S.Yadav, O(ER)
10/7/2007 Praveen Kumar, QCO A.K.Soreng, DMIS B.K.Barik, PSE Santosh Kumar, PSE
10/8/2007 B.K.Barik, PSE P.S.Yadav, O(ER) A.K.Soreng, DMIS Praveen Kumar, QCO
10/9/2007 Santosh Kumar, PSE B.K.Barik, PSE P.S.Yadav, O(ER) A.K.Soreng, DMIS
10/10/2007 P.S.Yadav, O(ER) Santosh Kumar, PSE B.K.Barik, PSE Praveen Kumar, QCO
9/23/2007 S.Saha, SPSE J.Sharma, SISO N.Mudugal, O(ER) A.C.Kar, QCO

9/24/2007 N.Mudugal, O(ER) S.Saha, SPSE J.Sharma, SISO A.C.Kar, QCO
9/25/2007 N.Mudugal, O(ER) J.Sharma, SISO S.Saha, SPSE S.Sahit,PSE
9/26/2007 S.Saha, SPSE A.C.Kar, QCO J.Sharma, SISO N.Mudugal, O(ER)
9/27/2007 S.Sahit,PSE S.Saha, SPSE A.C.Kar, QCO J.Sharma, SISO
9/28/2007 N.Mudugal, O(ER) S.Sahit,PSE S.Saha, SPSE A.C.Kar, QCO
9/29/2007 S.Saha, SPSE N.Mudugal, O(ER) S.Sahit,PSE A.C.Kar, QCO
9/30/2007 J.Sharma, SISO S.Saha, SPSE N.Mudugal, O(ER) S.Sahit,PSE
10/1/2007 A.C.Kar, QCO J.Sharma, SISO S.Saha, SPSE N.Mudugal, O(ER)
10/2/2007 S.Saha, SPSE A.C.Kar, QCO J.Sharma, SISO N.Mudugal, O(ER)
LOB
10/3/2007 S Sahit PSE
S.Sahit,PSE S Saha SPSE
S.Saha, A C Kar QCO
A.C.Kar, J Sharma SISO
J.Sharma,
10/4/2007 N.Mudugal, O(ER) S.Sahit,PSE S.Saha, SPSE A.C.Kar, QCO
10/5/2007 S.Saha, SPSE N.Mudugal, O(ER) S.Sahit,PSE A.C.Kar, QCO
10/7/2007 A.C.Kar, QCO J.Sharma, SISO S.Saha, SPSE N.Mudugal, O(ER)
10/8/2007 S.Saha, SPSE S.Sahit,PSE J.Sharma, SISO A.C.Kar, QCO
10/9/2007 S.Sahit,PSE S.Saha, SPSE N.Mudugal, O(ER) J.Sharma, SISO
10/10/2007 A.C.Kar, QCO S.Sahit,PSE S.Saha, SPSE N.Mudugal, O(ER)
10/11/2007 S.Saha, SPSE J.Sharma, SISO S.Sahit,PSE A.C.Kar, QCO
9/25/2007 H.K.Bora, DMPS S.Mandal, PSE S.Kumar, ACO Manas Biswas, DMIS
9/26/2007 B.Midya, QCO H.K.Bora, DMPS S.Mandal, PSE E.Gopinathan, IAM
9/27/2007 Manas Biswas, DMIS B.Midya, QCO H.K.Bora, DMPS S.Mandal, PSE
9/28/2007 H.K.Bora, DMPS Manas Biswas, DMIS S.Kumar, ACO B.Midya, QCO
9/29/2007 S.Mandal, PSE H.K.Bora, DMPS Manas Biswas, DMIS T.Ghosal, IAM
9/30/2007 B.Midya, QCO S.Mandal, PSE H.K.Bora, DMPS Manas Biswas, DMIS
TPS 10/1/2007 H.K.Bora, DMPS S.Kumar, ACO S.Mandal, PSE B.Midya, QCO
10/2/2007 Manas Biswas, DMIS H.K.Bora, DMPS S.Kumar, ACO S.Mandal, PSE
10/3/2007 S.Kumar, ACO Manas Biswas, DMIS H.K.Bora, DMPS B.Midya, QCO
10/4/2007 H.K.Bora, DMPS S.Mandal, PSE Manas Biswas, DMIS B.Midya, QCO
10/5/2007 S.Kumar, ACO H.K.Bora, DMPS S.Mandal, PSE Manas Biswas, DMIS
10/6/2007 B.Midya, QCO S.Kumar, ACO H.K.Bora, DMPS S.Mandal, PSE
10/7/2007 H.K.Bora, DMPS Manas Biswas, DMIS S.Kumar, ACO B.Midya, QCO
SAFETY ROTA FOR SHUTDOWN - 2007
AREA DATE 08:00-12:00 Hrs. 12:00-16:00 Hrs 16:00-20:00 Hrs 20:00-08:00 Hrs
9/25/2007 S.K.Mitra, SPNE (E&C) A.Haldar, PSE S.Sen, PSE J.Bag, PSE
9/26/2007 T. Sikdar, QCO S.K.Mitra, SPNE (E&C) A.Haldar, PSE S.Sen, PSE
9/27/2007 J.Bag, PSE T. Sikdar, QCO S.K.Mitra, SPNE (E&C) A.Haldar, PSE
9/28/2007 S.K.Mitra, SPNE (E&C) J.Bag, PSE S.Sen, PSE T. Sikdar, QCO
9/29/2007 A.Haldar, PSE S.K.Mitra, SPNE (E&C) J.Bag, PSE S.Sen, PSE
9/30/2007 T. Sikdar, QCO A.Haldar, PSE S.K.Mitra, SPNE (E&C) J.Bag, PSE
O/S 10/1/2007 S.K.Mitra, SPNE (E&C) S.Sen, PSE A.Haldar, PSE T. Sikdar, QCO
10/2/2007 J.Bag, PSE S.K.Mitra, SPNE (E&C) S.Sen, PSE A.Haldar, PSE
10/3/2007 T. Sikdar, QCO J.Bag, PSE S.K.Mitra, SPNE (E&C) S.Sen, PSE
10/4/2007 S.K.Mitra, SPNE (E&C) A.Haldar, PSE J.Bag, PSE T. Sikdar, QCO
10/5/2007 S.Sen, PSE S.K.Mitra, SPNE (E&C) A.Haldar, PSE J.Bag, PSE
10/6/2007 T. Sikdar, QCO S.Sen, PSE S.K.Mitra, SPNE (E&C) A.Haldar, PSE
10/7/2007 S.K.Mitra, SPNE (E&C) J.Bag, PSE S.Sen, PSE T. Sikdar, QCO
9/19/2007 S.Dey, SPSE S.C. Singh, SO(ER) A.P.Barua, DMIS S.Prabhu, PJE
9/20/2007 S.Das, SQCO S.Dey, SPSE S.C. Singh, SO(ER) A.P.Barua, DMIS
9/21/2007 S.Prabhu, PJE S.Das, SQCO S.Dey, SPSE S.C. Singh, SO(ER)
9/22/2007 S.Dey, SPSE S.Prabhu, PJE A.P.Barua, DMIS S.Das, SQCO
9/23/2007 A.P.Barua, DMIS S.Dey, SPSE S.Prabhu, PJE S.Das, SQCO
9/24/2007 S.C. Singh, SO(ER) A.P.Barua, DMIS S.Dey, SPSE S.Prabhu, PJE
9/25/2007 S.Dey, SPSE S.C. Singh, SO(ER) A.P.Barua, DMIS S.Das, SQCO
9/26/2007 S.Prabhu, PJE S.Dey, SPSE S.C. Singh, SO(ER) A.P.Barua, DMIS
9/27/2007 S.Das, SQCO S.Prabhu, PJE S.Dey, SPSE S.C. Singh, SO(ER)
9/28/2007 S.Dey, SPSE S.Das, SQCO S.Prabhu, PJE S.C. Singh, SO(ER)
FCCU /
9/29/2007 A.P.Barua, DMIS S.Dey, SPSE S.Das, SQCO S.Prabhu, PJE
VDU-II /
9/30/2007 S.C. Singh, SO(ER) A.P.Barua, DMIS S.Dey, SPSE S.Das, SQCO
MSQ
10/1/2007 S.Dey, SPSE S.C. Singh, SO(ER) A.P.Barua, DMIS S.Das, SQCO
10/2/2007 S.Prabhu, PJE S.Dey, SPSE S.C. Singh, SO(ER) A.P.Barua, DMIS
10/3/2007 S.Das, SQCO S.Prabhu, PJE S.Dey, SPSE A.P.Barua, DMIS
10/4/2007 y, SPSE
S.Dey, S.Das,, SQCO S.Prabhu,, PJE g , SO(ER)
S.C. Singh, ( )
10/5/2007 A.P.Barua, DMIS S.Dey, SPSE S.Das, SQCO S.Prabhu, PJE
10/6/2007 S.C. Singh, SO(ER) A.P.Barua, DMIS S.Dey, SPSE S.Das, SQCO
10/7/2007 S.Dey, SPSE S.Prabhu, PJE A.P.Barua, DMIS S.C. Singh, SO(ER)
10/8/2007 S.Das, SQCO S.Dey, SPSE S.Prabhu, PJE A.P.Barua, DMIS
10/9/2007 S.Das, SQCO S.C. Singh, SO(ER) S.Dey, SPSE S.Prabhu, PJE
10/10/2007 S.Dey, SPSE S.Das, SQCO S.C. Singh, SO(ER) S.Prabhu, PJE
9/22/2007 S.Bandopadhyay, SPSE P.K.Banerjee, SITE B.Gupta, SO(ER) M.A.Ali, DMCL

9/23/2007 J.Soren, DMQC S.Bandopadhyay, SPSE P.K.Banerjee, SITE B.Gupta, SO(ER)
9/24/2007 M.A.Ali, DMCL J.Soren, DMQC S.Bandopadhyay, SPSE P.K.Banerjee, SITE
9/25/2007 S.Bandopadhyay, SPSE B.Gupta, SO(ER) M.A.Ali, DMCL J.Soren, DMQC
9/26/2007 P.K.Banerjee, SITE S.Bandopadhyay, SPSE B.Gupta, SO(ER) M.A.Ali, DMCL
9/27/2007 J.Soren, DMQC P.K.Banerjee, SITE S.Bandopadhyay, SPSE B.Gupta, SO(ER)
9/28/2007 S.Bandopadhyay, SPSE J.Soren, DMQC P.K.Banerjee, SITE M.A.Ali, DMCL
9/29/2007 B.Gupta, SO(ER) S.Bandopadhyay, SPSE J.Soren, DMQC P.K.Banerjee, SITE
HGU/ 9/30/2007 M.A.Ali, DMCL B.Gupta, SO(ER) S.Bandopadhyay, SPSE J.Soren, DMQC
DHDS/ 10/1/2007 S.Bandopadhyay, SPSE P.K.Banerjee, SITE B.Gupta, SO(ER) M.A.Ali, DMCL
ARU/ SRU 10/2/2007 J.Soren, DMQC S.Bandopadhyay, SPSE P.K.Banerjee, SITE B.Gupta, SO(ER)
10/3/2007 M.A.Ali, DMCL J.Soren, DMQC S.Bandopadhyay, SPSE P.K.Banerjee, SITE
10/4/2007 S.Bandopadhyay, SPSE B.Gupta, SO(ER) J.Soren, DMQC M.A.Ali, DMCL
10/5/2007 P.K.Banerjee, SITE S.Bandopadhyay, SPSE B.Gupta, SO(ER) J.Soren, DMQC
10/6/2007 M.A.Ali, DMCL P.K.Banerjee, SITE S.Bandopadhyay, SPSE B.Gupta, SO(ER)
10/7/2007 S.Bandopadhyay, SPSE J.Soren, DMQC P.K.Banerjee, SITE M.A.Ali, DMCL
10/8/2007 B.Gupta, SO(ER) S.Bandopadhyay, SPSE J.Soren, DMQC P.K.Banerjee, SITE
10/9/2007 M.A.Ali, DMCL B.Gupta, SO(ER) S.Bandopadhyay, SPSE J.Soren, DMQC
10/10/2007 S.Bandopadhyay, SPSE P.K.Banerjee, SITE B.Gupta, SO(ER) M.A.Ali, DMCL
CRITICAL ACTIVITY JOBS
Area Critical Description Reqd. Total

Time Engg.
(Days) (Days)
1st Catalyst tube replacement 14 14
HGU /
DHDS 2nd Heat Exchangers of HGU 13 14
3rd Air fin coolers of DHDS 16 18
1st CI-BI of GT 7 7
GT /
HRSG 2nd Maintenance of HRSG 7 7
1st CO-Stack 20 20
FCCU
2nd Regenerator 20 20
3rd Exchanger - 59 Nos. 19 20
1st Flare line 10 10

Offsite
2nd Offsite piping 10 10
3rd Flare tip 09 10
1st 11-F-01 14.5 15

FOB
2nd 11-C-01 14 15
3rd 16-F-01 13 14
1st Steam Valve 16 19

TPS
2nd CW Valve 14.33 19
3rd PCT 14 19
1st Pre heat Exchanger - VBU 19 19

LOB
2nd 32-F-01 19.8 20
3rd Heat Exchanger - PDA 17 20

EQUIPMENT TALLY FOR S/D 2007
Eqpt Type Area Nos. Total
HGU 2
FCCU 4
PDA 1
NMP 2
Furnace 13
CDU-I 1
CDU-II 1
VDU-I 1
HRSG 1
FCCU 8
PDA 10
NMP 11
ARU 1
Column 34
CDU-I 1
CRU 1
CIDW 1
VBU 1
O/S 7
TPS 19
HGU 19
Vessel FCCU 23 109
PDA 11
ARU 12
NMP 18
FCCU 3
Reactor/
HGU 5
Regenerator 10
MSQ 1
CRU 1
TPS 8
HGU 41
FCCU 59
PDA 32
Heat Exchanger NMP 39 304
ARU 8
DHDS 39
FOB 40
LOB 38
HGU 3
DHDS 8
Air Cooler FCCU 15 34
PDA 6
NMP 2
O/S 26
TPS 25
HGU 16
FCCU 44
Safety Valve 250
PDA 73
ARU 16
NMP 42
HRSG 8
HGU K1A/B, K2A/B, P11
GT CIBI
Rotary
TPS CW Pumps
FCCU MAB, WGC, Bottom pumps
Under ground and above ground Cooling
Piping LOB, FOB
Water circuit -
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 21-R-01: Skimming of catalyst: 1900 KG. From top

3.1.2 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 Provision of back flushing facility in 11-E-29.
4.1.2 Provision of back flushing facility in 12-E-04.
4.1.3 Modification in discharge & warm up line of 16-P-07 A/B/C.
4.1.4 Replacement of cooling water battery limit valve at FOB (Gr-10)
4.1.5 Provision of bypass facility in naptha caustic and water wash mixing of valve of CDU-I
4.1.6 Routing of PF(11-C-101) & MF(11-C-01) naptha to slop header in CDU-I
4.1.7 Provision of back flushing facility in CDU-I trim coolers
4.1.8 Modification of LPG processing facility in CDU-I
4.1.9 Routing of 90-140 cut Naphtha ex CDU-I to Hy FCC gasoline feed surge drum of Naphtha
Hydro Treatment Unit (U-21)
4.1.10 Modification in discharge and warm up line of RCO pumps (16P07A/B/C of CDU-II)
4.1.11 Provision of isolation valve in the SKCR return line ex 16-E-33 (splitter reboiler) of CDU-II
4.1.12 Provision of back flushing facility in CDU-II trim coolers
4.1.13 Modification of LPG processing facility in CDU-II
5 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)
Sl.No. Description
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)

Sl.No. Description
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 u-
21/22.
U-16 (CDU-II)
Sl.No. Description
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.
6 16C01 & 16C07 PSV platform’s gap are to be provided with gratings & side
railings.
7 Service water valve and steam valve on the pipe rack above 16P16A/B are not
approachable
8 16F01/11F01/22F201 COT thermocouples are not approachable. Plat forms are
to be extended.
9 Gap near 16E43 is to be filled up with new grating
10 16F01 approach stair’s to be replaced completely as it is badly corroded and
unsafe.
RE-ORIENTATION REQUIREMENT w.r.t. SAFETY (SSCM)
Sl.No. Description
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 Thorough external cleaning of all radiation tubes.

1.1.2 Complete replacement of convection studded tubes
1.1.3 Replacement of 8 Nos. modified new burners.
1.1.4 Checking / repair / replacement of thermocouple points.
1.1.5 Repair of damaged entire furnace shell and arch zone refractory / complete
replacement of entire refractory with ceramic fibre lining.
1.1.6 Furnace bulged floors to be repaired.
1.1.7 External patch repair of furnace casing plate in the roof, vertical & arch zone (80
SqM)
1.1.8 Complete replacement of stack with internal castable lining.
1.1.9 Revisioning of stack damper
1.1.10 All hanger supports to be checked and rectified, if required.
1.1.11 All FO burners are to be cleaned and damaged burner tips are to be replaced
1.1.12 Hydraulic testing of convection and radiation coils
1.1.13 Relocation of two Nos. of peep holes as per drawing issued by ES.
1.1.14 Painting of entire furnace along with structural.
1.1.15 Revisioning/Replacement of air registers
1.1.16 Dechoking/Replacement of flue gas sampling point
1.1.17 Revisionin/Replacement of explosion doors(2Nos.) and peephole covers(6Nos.)
2.0 COLUMN
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 C-01A
2.2 C-01B
2.3 C-01C
2.4 C-110
2.5 C-108
2.6 C-02 - Repair/replacement of demister & frame, weld build up of M/H neck
2.7 C-04 - Repair/replacement of demister & frame
2.8 C-05
2.9 C-06
2.10 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 : -
3.1 32B-01 Propane Bullet ¾ External painting to be done

¾ Gratings replacement
¾ Checking of magnetic float
¾ Weld build up of vessel 2.5 SqM
3.2 32B-02 Propane Bullet ¾ External painting to be done
¾ Gratings replacement
¾ Checking and repair of magnetic float
¾ Weld build up of vessel 2.5 SqM
3.3 32B-03 Suction K.O
¾ Repair / replacement of demister pad
individual Drum of K-01/K-
¾ Checking and repair of internal float
compressor 1R
and level switch
K.O pots
3.6 B-06 Flare K.O Drum ¾ Cover plate & 2” dia nozzle to be
replaced. Hydro test of steam coil
3.7 B-07 Flushing Oil ¾ External painting of vessel
Drum ¾ Partial replacement & hydro-testing of
steam coil
3.8 B-08 Defoamer Drum ¾ Level Gauge to be replaced
¾ Partial replacement of bot. shell &
dome
¾ External Painting of vessel
3.9 B-11 Debutaniser ¾ Maintenance of vessel. Partial
replacement of steam coil.
3.10 B-111 Tempered Water
¾ External Painting of vessel
Drum
3.11 B-201 MHP Condensate
¾ External Painting of Vessel
K.O Drum
3.12 B-202 M.P Condensate ¾ Repair of damaged level tapping
K.O Drum ¾ External Painting of vessel
3.13 B-203 LP condensate ¾ External Painting of vessel
Vessel ¾ Demister pad may come for
replacement.
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 32E112A/B
4.2 32E06A/A1
4.3 32E06B/B1
4.4 32E06C/C1
Page 2 of 2
4.5 32E06D/D1
4.6 32E06E/E1
4.7 32E06H/H1
4.8 32E06I/I1
4.9 32E10A
4.10 32E10B
4.11 32E10C
4.12 32E122
4.13 32E05A
4.14 32E05B
4.15 32E114A/B
4.16 32E114C/D
4.17 32E117
4.18 32E121A/B
4.19 32E115
4.20 32E107
4.21 32E08
4.22 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 32-PSV-01K
2 32-PSV-02K
3 32-PSV-03K
4 32-PSV-04K
5 32-PSV-05K
6 32-PSV-06K
7 32-PSV-21K
8 32-PSV-22K
9 32-PSV-23K
10 32-PSV-24K
11 32-PSV-01 32-C-1-A
12 32-PSV-02 32-C-1-A
13 32-PSV-03 32-C-1B
14 32-PSV-04 32-C-1B
15 32-PSV-05 32-C-1-C
16 32-PSV-06 32-C-10
17 32-PSV-07 32-C-3
18 32-PSV-08 32-C-4
Page 3 of 3
19 32-PSV-09 32-B-1
20 32-PSV-10 32-B-1
21 32-PSV-11 32-B-2
22 32-PSV-12 32-B-2
23 32-PSV-3213 32-C-2
24 32-PSV-14 32-C-5
25 32-PSV-15 32-C-6
26 32-PSV-16 32-C-7
27 32-PSV-17 32-B-3
28 32-PSV-20 32-B-3
29 32-PSV-21 32-B-9
30 32-PSV-26 32-E-9
31 32-PSV-27 32-E-10-A
32 32PSV-28 32-E-10B
33 32-PSV-29 32-E-10-C
34 32-PSV-30 32-E-10-A
35 32-PSV-31 32-E-10-A
36 32PSV-32 32-E-10-C
37 32-PSV-33 32-E-3-A
38 32-PSV-34 32-E-3B
39 32-PSV-35 32-E-4
40 32-PSV-36 32-E-5
41 32-PSV-201 32-E-103
42 32-PSV-202 32-C-103
43 32-PSV-203 32-C-104
44 32-PSV-204 32-E-104
45 32-PSV-206 32-E-106
46 32-PSV-207 32-E-107
47 32-PSV-208 32-B-103
48 32-PSV-209 32-E-105
49 32-PSV-210 32-E-108
50 32-PSV-303 Asphal + PVMP
51 32-PSV-304 32-C-05
52 32-PSV-401 32-K-101
53 32-PSV-404A 32-B-01
54 32-PSV-404B 32-B-01
55 32-PSV-405A 32-B-02
56 32-PSV-405B 32-B-02
57 32-PSV-01 100-P-32-D-051
58 32-TSV-303 80-P-32
59 32-TSV-402A 32-E-106A
60 32-TSV-402B 32-E-106B
61 32-TSV-402C 32-E-106C
62 32-TSV-402D 32-E-106D
63 32-TSV-402E 32-E-106E
64 32-TSV-403 32-E-107
65 32-PSV-37 32-K-01
66 32-PSV-38 32-K-01
67 32-PSV-39 32-K-01R
68 32-PSV-40 32-K-01R
69 32-PSV-103A 32-C-101
70 32-PSV-106 32-E-101
Page 4 of 4
71 32-PSV-103B 32-E-101
72 32-PSV-104 32-E-110
73 32-PSV-105 32-E-110
6.0 VALVE JOBS
6.1 Replacement of 20mm FO valve in Burner No. 1 .

6.2 Revisioning/Replacement of NRV’s on discharge of K-01 and K-01R for heavy
passing
6.3 Revisioning/Replacement of discharge valves on K-01/K-01R
6.4 Revisioning of discharge valves of P-110C/D/E
6.5 Revisioning of NRV’s on discharge of P-110C/D/E
6.6 Revisioning of P-103A/B suction valves(2Nos.)
6.7 Revisioning of C-05 to P-103A/B suction valve
6.8 Replacement of C-02 LCV bypass valve
6.9 Replacement of common discharge valve of K-1/1R at the inlet of E-06.
6.10 Replacement of P-102A suction valve.
6.11 Revisioning of 18 Nos. ( dia 6” )of CW supply and return valves of E-06
6.12 Revisioning of Battery limit isolation valves
7.0 REPAIR / REPLACEMENT OF PIPING
7.1 Insulation of transfer line to be removed for complete inspection.

7.2 Replacement of approx 4000 metre of corroded/ leaky tracer lines covering SR feed
circuit, Asphalt circuit, DAO circuit and anti-foam injection lines, etc.
7.3 E-107 inlet line leaky portion to be replaced.
7.4 Replacement of P-104/104R, P-05A/B/C bearing cooling water lines.
7.5 Repair of clamped portion of CW return line ex E-6A/A1.
7.6 All CW oultlet vents /sampling point to be replaced as per inspection recommendation
7.7 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.
7.8 Fire Water sprinkler leak in Bullet area to be attended.
7.9 E-106C/C1 S/S vent line is to be dechoked.
7.10 Replacement of steam traps as required.
7.11 Dechoking of 2” suction /discharge header to/from P-05A/B/C ex –Extractors-Approx
150M length( Pressure:40kg/cm2, Temp:75 C)
7.12 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.
7.13 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.
7.14 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.
7.15 Revival of supply and return line filter/strainer facility in Seal Oil system of all P-
110A/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.
7.16 Positive isolation of VB, VM, CB and CM and all utility lines in U-32 Expansion area-
This involves cutting and providing flanges for blinding( approx 15Nos.)
7.17 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.
Page 5 of 5
7.18 De-choking of ¾” evacuation line of all condensers of 32 E6 ( about 150 Meters)
7.19 De choking / inspection of 10 /12” propane vapour line ex 32C2/C4 to E6 condensers
for suspected chokage.
7.20 Dechoking of shell side inlet line to E-06 E/E1, D/D1 and C/C1.
7.21 Trap monitoring facility in C-110 steam sate lines is to be made functional.
7.22 Deblinding of P-05A suction line ex C-01
7.23 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/C-
02/04/05/06 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 Painting of all bare lines, vessels & columns.
8.4 Repair / replacement of all damaged hot insulation of columns, exchangers, pipes
etc.
8.5 Repair/replacement of damaged refractory in F-01, including stack
8.6 Painting of stack and all structure of furnaces.
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)
9.2 Rectification of FI-26(cooling water to unit )flow indication
9.3 VM and VB B/L flow indications.
9.4 All. faulty draft gauges are to be rectified along with replacement of its chocked /
corroded draft lines.
9.5 Asphalt target flow meter to be recalibrated / rectified.
9.6 All furnace pass flow indications to be checked.(FI-301,302,306 and 307)
9.7 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
9.8 Calibration of FI-50( FO inlet) and FI-51(outlet flow) in F-01

9.9 Calibration of AI-01 Oxygen analyser in 32F-01.
9.10 C-110 bottom LC01Kand FC04K cascade to be changed to LC only (as in other
extractors.)
9.11 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.
9.12 Relocation of C-02 field level transmitter indication at ground level for easier
monitoring.
9.13 Provision of F-01 COT indication in field, for safety of operation
9.14 Zero check/Rectification of tachometers and provision of local rpm indication for P-
110C/D/E/F
Page 7 of 7
9.15 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
9.16 Calibration of all internal float level trolls
9.17 Calibration / stroke checking of all control valves
9.18 Checking of all skin thermocouples
9.19 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.
10.2 Revisioning of motors & micro-switches of soot blower of 32F01.
10.3 Maintenance of following Motors.
S.No. Tag No. Type of Maint

1 32PM 104 "A" Schedule
2 32PM 104R "A" Schedule
3 32PM 110C1 "B" Schedule
4 32PM 110C2 "A" Schedule
5 32PM 110D1 "A" Schedule
6 32PM 110D2 "A" Schedule
7 32PM 110E1 "A" Schedule
8 32PM 110E2 "A" Schedule
9 32PM 110A1 "A" Schedule
10 32PM 110A2 "A" Schedule
11 32PM 110B1 "A" Schedule
12 32PM 110B2 "A" Schedule
13 32PM 110A "A" Schedule
14 32PM 110B "A" Schedule
15 32PM 103 "A" Schedule
16 32PM 103R "A" Schedule
17 32EM 116A1 "A" Schedule
18 32EM 116A2 "A" Schedule
19 32EM116B1 "A" Schedule
20 32E116B2 "A" Schedule
21 32EM116C1 "A" Schedule
22 31EM116C2 "A" Schedule
23 32EM116D1 "A" Schedule
24 32EM116D2 "A" Schedule
25 32EM116E1 "A" Schedule
26 32EM116E2 "A" Schedule
27 32EM116F1 "A" Schedule
28 32EM116F2 "A" Schedule
29 32P-110C3 "A" Schedule
30 32P-110D3 "A" Schedule
31 32P-110E3 "A" Schedule
32 32PM102A "A" Schedule
Page 8 of 8
33 32PM102B "A" Schedule
34 32PM102C "A" Schedule
35 32PM110A1 "A" Schedule
36 32PM110A2 "A" Schedule
37 32PM110B1 "A" Schedule
38 32PM110B2 "A" Schedule
39 32PM102S1 "A" Schedule
40 32PM102S2 "A" Schedule
41 32KM-01 "B” Schedule
42 32KM-01R "B” Schedule
43 36PM01 "A" Schedule
NOTE: For B-schedule maintenance, mechanical maintenance, will decouple and shift
motors to garage.
10.5 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.
10.6 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.
11.2 Existing control valve in Cooling water make up line to 32-C-07 has to be converted
to flow control valve .
11.3 To provide shutdown valve(solenoid operated) based on High furnace box pressure,
Low fuel Oil supply pressure, etc for safety of operation.
11.4 Stack damper to be made pneumatic operated from DCS panel.
11.5 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..
11.6 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.
11.7 Relocation of the common discharge valve of K-01/1R at E-6 inlet to safe location.
11.8 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
11.9 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.
11.10 Relocation of existing PDA furnace 32-F-01 box & coil purging of steam line isolation
valves to safe distance 15 M
11.11 Replacement of inter stage KOD of 32-K-01 for providing auto draining facility
11.12 Piping connections for installation of new propane compressor 32-K-101R
Page 9 of 9
11.13 Provision of minimum circulation line in DAO run down pumps
11.14 Modification of cooling water lines in U-32
11.15 Provision of C2-C2 circulation facility in 32-P-103A/B
11.16 Provision of back flushing facility for 32-E-117A
11.17 Process scheme for providing double isolation valves and flanged ends at high
pressure drain and vent points in U-32
11.18 Provision of ROVs at the suction lines of 32P110 A/B/C/D/E
11.19 Dismantling of redundant lines & equipments in U-32 (PDA)(in addition to PS244)
11.20 Dismantling of redundant lines & equipments in U-32 (PDA)
12.0 AF JOBS
12.1 Implementation of VR burning facility.

12.2 Replacement of propane compressor 32-K-01
12.3 Replacement of 40 Nos. convection studded tubes in 32-F-01
12.4 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 38-C-01
2.1.2 38-C-02
2.1.3 38-C-03
2.1.4 380-C-04
2.1.5 38-C-05
2.1.6 38-C-06
2.1.7 38-C-07
2.1.8 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 38-V-01 (Replacement of Demister)

3.1.2 38-V-02 (Insulation removal around nozzles)
3.1.3 38-V-03
3.1.4 38-V-04
3.1.5 38-V-05
3.1.7 38-V-07
3.1.8 38-V-08
3.1.10 38-V-10
3.1.11 38-V-11
3.1.12 38-V-12
3.1.13 38-V-14
3.1.14 38-V-15
3.1.15 38-V-16
3.1.16 38-V-18
3.1.17 38-V-20
3.1.18 38-V-21
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) 38-E-01 A/B/C
b) 38-E-02 A/B
c) 38-E-03 A/B RETUBING OF 38-E-03A
d) 38-E-04
e) 38-E-05 A/B/C/D
f) 38-E-06
g) 38-E-07 A/B/C
h) 38-E-08
i) 38-E-09 A/B
j) 38-E-11
k) 38-E-12
l) 38-E-13
m) 38-E-14
n) 38-E-15 AIR FIN COOLER
o) 38-E-16
p) 38-E-17 Replacement of tube bundle
q) 38-E-18 AIR FIN COOLER
r) 38-E-19 A/B
s) 38-E-20
t) 38-E-21 A/B
u) 38-E-22 A/B
v) 38-E-23 A/B/C
w) 38-E-24
x) 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. LOCATION
38-PSV-1903 38-P-14A/B
38-PSV-1904 38-P-14A/B
38-PSV-1901 38-P-15A/B
38-PSV-1902 38-P-15A/B
38-PSV-1103A 38-C-01
38-PSV-1105A 38-C-02
38-PSV-1201A 38-C-02
38-PSV-1201B 38-C-02
38-PSV-1202 38-V-06
38-PSV-1301A 38-C-07
38-PSV-1301B 38-C-07
38-PSV-1302A 38-C-06
38-PSV-1302B 38-C-06
38-PSV-1303 38-V-15
38-PSV-1601A 38-V-09
38-PSV-1601B 38-V-09
38-PSV-1602 38-V-01
38-PSV-1801 38-V-12
38-PSV-1802A 38-V-05
38-PSV-1802B 38-V-05
38-PSV-1803A 38-V-04
38-PSV-1803B 38-V-04
38-PSV-2001 38-V-16
38-PSV-2002A 6”-SH-38-1704-B2A
38-PSV-2002B 6”-SH-38-1704-B2A
38-TSV-1101 6”-WCR-38-1102-A3A
38-TSV-1102 6”-WCR-38-1101-A3A
38-TSV-1103 38-C-01
38-TSV-1104 8”-WCR-38-1103-A3A
38-TSV-1105 38-C-02
38-TSV-1302A ¾”-P-38-1367-A1A-IT
38-TSV-1302B ¾”-P-38-1370-A1A-IT
38-TSV-1602 38-E-06
38-TSV-1501 38-E-11
38-TSV-1601 38-E-12
38-TSV-1603 38-E-13
38-TSV-1106A 6”-TWR-38-1106-B2A
38-TSV-1106B 6”-TWR-38-1106-B2A
38-TSV-1201 38-E-17
38-TSV-1301 38-E-20
38-TSV-1901 38-E-22
38-TSV-1902 38-E-21
6.0 VALVE JOBS
The following valve replacement / repair jobs shall be carried out -
a) Revisioning of all AUDCO FG and Pilot Gas valves in F-01 and F-02 – 18 nos
b) Replacement of P-08A/B needle valve on steam quench to seal line
c) Replacement of P-08A seal cooler S/S outlet line needle valve
d) Replacement of P-08A suction drain valve
e) Replacement of P-08A casing drain needle valve
f) Replacement of P-05B casing drain needle valve
g) Replacement of P-18A steam quench to seal line needle valve
h) Replacement of P-07B suction drain to CBD valve
i) Repair/Replacement of P-02A steam quench line to seal valve 1” gland
j) Replacement of P-02A suction drain valve
k) P-09A steam quench line to seal 1” valve gland repair/replacement
l) Replacement of P-09A steam quench line to seal needle valve
m) Repair/replacement of P-09B 1” NRV bypass valve
n) Replacement of P-04B casing drain needle valve
o) Replacement of damaged root valve of PG on DM water make up line to E-25
p) Replacement of damaged PG drain valve on P-09A
q) Replacement of steam trap b/p b/v drain dia 1” u/s of MHP steam to PC 2003 at B/L
r) Replacement of C-09 stripping steam drain, as it is passing on fully closed condition
s) Replacement of all CW sample point drains dia ¾” and dia 1” ~ 20 nos.
7.0 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 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).
7.2 Process lines: Both the transfer lines, 38-T-01/02 to 38-C-10 bottom , 38-V-05 bottom to 38-C-10,38-
V-09 to 38-C-10 , inlet & outlet lines of 38-V-08 , connected piping of the ejector systems.
7.3 The bottom outlet lines of 38-C-11 & recirculating quench water line of 38-C-11 , barometric legs to
hot welletc.
7.4 All pump suction & discharge piping upto pipe racks.
7.5 Condensate water circuit & cooling water circuit.
7.6 LPD & HPV jobs: Stagewise inspection & subsequent root welding of all the LPD & HPV of all the
critical lines.
7.7 Inspection of leaky clamped lines to be done.
7.8 Insulation of transfer line from F-01 to C-07 and F-02 to C-03 to be removed for complete inspection.
7.9 Sample cooler lines of C-06 and C-10 to be dechoked and made operable
7.10 All seal coolers in pumps P-8A/B, P-05A/B and P-18A/B to be taken out and cleaned and boxed up
7.11 Provision to be made for relocation of C-07 LCV to C-08 at technological platform for easier operation
and safe maintenance
7.12 Relocation of E-10 on technological platform for easy/safe maintenance
7.13 Replacement of all choked vent /sampling points from CW outlet of all coolers: E-11/E-12/E-13/E-
24/E-21A/B, E-22A/B
7.14 Replacement of P-04A casing drain line elbow portion for leak.
8.0 TAG JOBS
8.1 FO & FG lines from battery limit to furnace to be flushed with steam / inert gas
8.2 Dechoking/Replacement of flue gas sample point lines in F-01/F-02
8.3 E-05A S/S outlet first isolation valve gland and bonnet flange leak to be rectified
8.4 E-05C to E-05D S/S and T/S interconnecting flange gasket leak to be rectified
8.5 E-05A T/S outlet first isolation valve gland leak and d/s flange gasket leak to be rectified
8.6 E-05A S/S inlet valve gland leak to be rectified
8.7 Dechoking/thoroughness check of following lines:
• F-01 to C-07 transfer line
• F-02 to C-03 transfer line
• C-07 to C-08
• C-03 to C-04
8.7 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/B-
approx dia 1”-20m & 12Nos. 1” valve
8.8 MHP steam PV 2003 d/s b/v u/s flange leak
8.9 VM steam header b/v spectacle blind flange behind V-16 in Tech platform-1
8.10 E-22A/B ejector condensers VM steam line b/v gland leak to be replaced 4 nos
8.11 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
8.12 P-05B suction b/v flange leak to be attended
8.13 F-01 pass flow-2 FCV u/s b/v to be attended
8.14 P-06A discharge b/b u/s flange and its NRV u/s and d/s flange leak to be attended.
8.15 P-06 discharge b/v u/s flange leak to be attended
8.16 Foll leaks in P-03A to be attended- both flanges of NRV d/s spool piece and its discharge b/v
gland
8.17 P-03B discharge b/v gland leak to be attended
8.18 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
8.19 P-18A min circ b/v u/s flange and gland leak, NRV top cover flange and spindle leak to be
attended
8.20 P-09A/B discharge b/v d/s flanges and gland leaks to be attended
8.21 P-11A/B discharge b/v u/s and d/s flanges (4Nos.) to eb attended
8.22 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
9.1 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 (self-
actuating), 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) 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.
12.0 CIVIL JOBS
a) 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.
b) Painting of all bare lines, vessels & columns, as per colour code.
c) Painting of coolers / condensers.
d) Painting of stack and structure of furnaces.
e) All other jobs as per job list.
f) Area development in Furnace and ground floor of technological platform, near V-07, with
proper slope to avoid water-logging.
g) 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 & man-
entry, 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) 18-C-10 Tray nos. 26,27,28&29 including downcomers to be replaced

ii) 18-C-12
iii) 18-C-13
iv) 18-C-14
v) 18-C-15
vi) 18-C-16
vii) 18-C-18
viii) 18-C-19
TOTAL : 08 NOS.
• Inspection approach for thickness survey of all the nozzle locations. Scaffolding erection for un-
approachable 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 & 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 , External painting with
high temperature Al paint.
3.1.1
i) 18-R-01
ii) 19-R-04
4.0 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 AA-
22A, 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 WYE-
segment 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) Arrangement should be made for internal inspection of cyclones using Rope ladder.
ii) Cleaning of External surface of Dip leg of both the cyclones for thorough visual inspection
and thickness survey.
iii) Inspection of Trickle valves to be done for suspected erosion of seating / sealing surface.
iv) 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.
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 & man-
entry, 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) 17-B-01 - SS –316 seal weld of outlet duct flange

ii) 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
iii) 18-B-11 - Anticipated replacement of Demister pad
iv) 18-B-12
v) 18-B-13
vi) 18-B-14
vii) 18-B-15
viii) 18-B-17
ix) 18-B-18
x) 18-B-19
xi) 18-B-20
xii) 18-B-21
xiii) 18-B-22
xiv) 18-B-27 - Coalescer pad replacement in 18-B-27
xv) 18-B-28
xvi) 18-B-29
xvii) 18-B-33
xviii) 19-B-01
xix) 19-B-02
xx) 19-B-03 - Anticipated replacement of Demister pad
xxi) 19-B-06
xxii) 19-B-20 - Anticipated replacement of Demister pad
xxiii) 17-B-04, 17-T-03/ 05/ 06/ 07&10 at BELCO to be cleaned
• 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) Anticipated replacements of grid nozzles.

vi) 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) 18-E-10A/B
ii) 18-E-11
iii) 18-E-12
iv) 18-E-13 A/B
v) 18-E-14
vi) 18-E-15
vii) 18-E-16 A/B
viii) 18-E-18 A/B
ix) 18-E-19 A/B
x) 18-E-21 A/B
xi) 18-E-23
xii) 18-E-24
xiii) 18-E- 25 A/B
xiv) 18-E-26
xv) 18-E-27
xvi) 18-E-28
xvii) 18-E-29
xviii) 18-E-30
xix) 18-E-31
xx) 18-E-32 A/B
xxi) 18-E-33 A/B
xxii) 18-E-34 A/B
xxiii) 18-E-35
xxiv) 18-E-36 A/B/C/D
xxv) 18-E-37
xxvi) 18-E-38 A/B
xxvii) 18-E-40 A/B/C/D/E/F
xxviii) 18-E-41
xxix) 18-E-42 A/B
xxx) 19-E-01
xxxi) 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 heat-
exchangers.
1. Surface condensers
2. Ejector condensers
3. gland steam condensers
4. 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 .
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 PSV/TSV LOCATION

Nos.
18-PSV-1001 18-E-02(DRUM) 18 PSV 6604 LPG
18-PSV-1002 18-E-02(DRUM) 18 PSV 7201 MHP BFW
18-PSV-1003 18-E-02(super heated steam ) 18 PSV 7202 MHP BFW
18-PSV-1004 18-B-51 (FLASH TANK) 18 PSV 7301 LP STEAM
18 PSV 0102A Air Blower Disch 18 PSV 7302 LP STEAM
18 PSV 0102B Air Blower Disch 18-PSV-8601 17-P09A
18 PSV 1103 18-B-06 (2”CT-18-1118-A14A) 18-PSV-8602 17-P09B
18 PSV 1104 18-B-07 (2”-CT-18-1119-A14A) 18 PSV 8701 MERCAP /H2/VAP
18 PSV 1105 18-B-08(2”-CT-18-1120-A14A) 18 PSV 9101 18-B-23(3”P-18-9109-A19A)
18 PSV 1201A 18-B-01(8”-WDM-18-1201-A1K) 18 PSV 9301 18-B-21(rich amine flash drum
18 PSV 1201B 18-B-01(8”-WDM-18-1202-A1K) 18 PSV 9302 18-B-21(rich amine flash drum)
18-PSV-3601 2”-P-18-3603-B4F-IT 18 PSV 9701 18-B25(SL-18-9702-A3A-IH)
18 PSV 3701 O/H LINE OF 18-R-01 18 PSV 9901 AMINE REGENEATOR
18 PSV 3702 O/H LINE OF 18-R-01 18 PSV 9902 AMINE REGENERATOR
18 PSV 3703 O/H LINE OF 18-R-01 18 PSV 9903 MP STEAM TO REBOILER
18 PSV 3801 18-B-11 18 PSV 9904 MP STEAM TO REBOILER
18 PSV 3901 18B12(4”P-18-3905-A16A) 18 TSV 3201 8”P-18-3106-B1A
18 PSV 3902 18B13(3”P-18-3915-A16A) 18 TSV 3202 8”P-18-3201-B1A
18 PSV 4001 2ND STAGE DISCH OF 18-K-10 18 TSV 3203 8”P-18-3202-B1A
18 PSV 4002 2ND STAGE DISCH OF 18-K-10 18 TSV 3204 8”P-18-3203-B1A
18 PSV 4101 18B14(4”P-18-4110-B16A) 18 TSV 3205 8”P-18-3233-B9A
18 PSV 4201 18-C-13 (6”-P-18-4215-B16A) 18 TSV 3206
18 PSV 4202 18-C-13 (6”-P-18-4216-B16A) 18 TSV 3207
18 PSV 4301 18B15(4”P-18-4315-B16A) 18 TSV 3208
18 PSV 4302 18B15(4”P-18-4314-B16A) 18 TSV 3209 8”P-18-3252-B1A
18 PSV 4401 18C15(3”P-18-4410-B16A) 18 TSV 3210 8”P-18-3236-B9A
18 PSV 4402 18C15(3”P-18-4409-B16A) 18 TSV 3801
18 PSV 4501 18-C-16(8”-P-18-4511-B16A) 18 TSV 3901
18 PSV 4502 18-C-16(8”-P-18-4510-B16A) 18 TSV 4101
18 PSV 4601 18B17(4”P-18-4619-B16A) 18 TSV 4301
18 PSV 4701 18C17(12”P-18-4708-A1A) 18 TSV 4401
18 PSV 4702 18C17(12”P-18-4709-A1A) 18 TSV 4901
18 PSV 4703 Naphtha splitter re-boiler 18 TSV 4902
18 PSV 4801 18-B-18 18 TSV 4903
18 PSV 5101 18E18A(SV-18-5101/2-B2A) 18 TSV 4904
18 PSV 5102 18E18B(SV-18-5102/2-B2A) 18 TSV 5001
18 PSV 5103 18E18B(SV-18-5103-B2A) 18 TSV 5002
18 PSV 5104 18E18B(SV-18-5104-B2A) 18 TSV 5003
18 PSV 5301 18-E-20 18 TSV 5004
18 PSV 5302 18-E-20 18 TSV 5005
18 PSV 6501 18B32(4”P-18-6501-A5A) 18 TSV 9901 ¾”P-18-9918-A6K
18 PSV 6601 18B24(3”SL-18-6602/3-A2A) 18 TSV 9902
18 PSV 6602 18B24(3”SL-18-6602/3-A2A)
18 PSV 6603 LPG
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) SLURRY CIRCUIT
b) HEATER TRANSFER CIRCUIT
c) 18 C 10 OVERHEAD LINE UPTO MAIN FRACTIONATOR OVERHEAD RECEIVER CIRCUIT
d) HCO CIRCUIT (RECYCLE)
e) DEBUTANIZER COLUMN FEED CIRCUIT
f) ABSORBER OVERHEAD VAPOUR CIRCUIT
g) DEBUTANIZER OVERHEAD CIRCUIT
h) HCO PUMP AROUND CIRCUIT
i) OVERHEAD RECYCLE VAPOUR CIRCUIT
j) STRIPPER FEED AND ABSORBER FEED CIRCUIT
k) SPONGE ABSORBER FEED VAPOUR & OFFGAS FROM SPONGE ABSORBER CIRCUIT
l) LPG PRODUCT & DEBUTANIZER REFLUX CIRCUIT
m) FCCU FEED CIRCUIT
n) NAPTHA SPLITTER REFLUX & LCN PRODUCT CIRCUIT
o) 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 18-
RG-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.
1) Tray replacement / revamp jobs in 18-C-13 and 18-C-16

2) Dechoking of dia 3” piping about 100 M in BELCO circuit
3) Provision of caustic line in T-109B and caustic supply to MSQ
4) Provision of control valve and flow water in the bypass and inlet of pall filter respectively
5) Process scheme for segregation of wild naptha and MSQ naptha injection to FCCU reactor riser
6) Provision of inter-connection between 18P42A/B and 18P52A/B from discharge
7) Provision of jump over connection in MSQ lean/rich Amine to FCCU Amine section
8) Replacement of RFCCU stack
9) Platform at dosing tank in MAB (only drawing required)
13.0 ROTARY EQUIPMENT
1) Capital overhauling of wet gas compressor & turbine

2) Capital overhauling of MAB compressor & turbine
3) Overhauling of trip oil system of MAB and checking of thermocouple
4) Overhauling of governing oil system of WGC and checking of thermocouple
5) Overhauling of LO & CW pumps of both MAB & WGC
6) Overhauling of bottom pumps
7) 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
1. 18FIC4701 F.O gasket leak. M/M
2. 18E27 LCO I/L and O/L exchanger body nozzle gasket leak. M/M
3. 18TV4201 D/S B/V gasket leak. M/M
4. 18P14A discharge B/V gasket leak. M/M
5. 18P13A/B suction/discharge B/V gasket leaks. M/M
6. 1818TC3406 D/S B/V gasket leak. M/M
7. 18FC3403 U/S and Bypass B/V gasket leak. M/M
8. 18P16B discharge B/V gasket leak. M/M
9. 18FC3202 D/S NRV gasket leak. M/M
10. 18C10 Level tapping body valve gland and gasket leak. M/M
11. 18F10 Hot feed and F10 bypass B/V at manifold gasket leaks. M/M
12. 18FIC 3301 and 18 FiC3303 F.O flange gasket leaks. M/M
13. 18FC3303 CV flange gasket leak. M/M
14. 18FC3303 D/S B/V gasket leak. M/M
15. 18FC3301 U/S B/V gasket leak. M/M
16. Lean and Rich amine charcoal filter manifold B/V gland and gasket leaks.(List M/M
earlier given to M/M)
17. 18P37 Min circulation CV U/S B/V gland and gasket leak. M/M
18. 18E18A/B slurry I/L B/V gasket leaks. M/M
19. 18E21 DW water O/L flange gasket leak.(short bolting). M/M
20. 18E15 BFW O/L flange gasket leak. M/M
21. 18E40 Slurry I/L and O/L and B/V gland and gasket and exchanger Nozzle gasket M/M
leaks.
22. 18E16B channel head gaskets leak. M/M
23. 18E18A BFW I/L D/S B/V bonnet leak. M/M
24. 18E19B slurry I/L flange and.channel head gasket leaks. M/M
25. PALL filter receiver PSVs isolation and bypass B/V gasket leaks.Vessel and PALL M/M
B/L slurry I/L and O/L B/V gasket leaks.
26. 18P60A discharge flange gasket leaks. M/M
27. 18P37A/B suction and discharge B/V gasket leaks. M/M
28. 18P37A/B warm up line break flange Gasket leaks. M/M
29. 18P37B suction and discharge nozzle gasket leak M/M
30. 18P16B discharge Nozzle gasket leak. M/M
31. 18P15B discharge Nozzle gasket leak M/M
32. 18P15B discharge B/V gasket leak. M/M
33. 18P14A/B discharge nozzle gasket leak and 18P14B suction Nozzle gasket leak. M/M
34. 18FIC3505 F.O gasket leak. M/M
35. VR To FCCU 18FV2222 U/S B/V gland leak.
FLANGE JOINTS JOBS
Sl Job description Tag Action

No. by
1 18E29 floating head cover leak –gasket replacement 157 M/M
2 18E27 tube side I/L and O/L nozzle gasket replacement. 162 M/M
3 18TV4201 C/V U/S B/V U/S flange gasket replacement. 163 M/M
4 18TV4201 C/V D/S B/V U/S flange and bonnet gasket replacement. 164 M/M
5 18FV4201(E27) C/V bypass B/V U/S flange, U/S B/V U/S and D/S flange, 165 M/M
and CV U/S flange gasket replacement( 4 nos) 166
6 18FI4201 orifice flange gasket to be replaced. 168 M/M
7 18FV2222 bonnet gasket to be replaced. 171 I/M
8 18P13B discharge B/V D/S flange gasket top be replaced. 217 M/M
9 18P12B suction B/V U/S flange gasket to be replaced. 218 M/M
10 18P14A suction line nozzle flange gasket to be replaced. 220 M/M
11 18P14B suction and discharge nozzle gasket to be replaced. 212 M/M
12 18P13B discharge B/V U/S flange gasket replacement 221 M/M
13 18P13B suction B/V U/S flange gasket replacement 222 M/M
14 18P13A discharge B/V U/S and D/S gasket replacement. 223 M/M
15 18P13A suction B/V U/S flange gasket replacement. 224 M/M
16 18P13A/B discharge line orifice flange gasket replacement. 227 M/M
17 18P15B flushing oil line B/V D/S flange leak . 228 M/M
18 18P15B suction and discharge nozzle flange gasket to be replaced. 229 M/M
19 Slurry quench CV U/S and D/S B/V gasket to be replaced. 234 M/M
20 Slurry quench CV bypass valve bonnet gasket to be replaced. 235 M/M
21 18P16B discharge B/V U/S flange and NRV top flange gasket to be 236 M/M
replaced.
22 18P16B discharge line orifice flange gasket to be replaced. 237 M/M
23 18P37A W/U line B/V flange to be replaced. 244 M/M
24 18P37A discharge valve and NRV top flange gaskets to be replaced. 245 M/M
25 18P37A suction line B/V flange gaskets to be replaced. 246 M/M
26 18P37B warm up line B/V gaskets to be replaced. 248 M/M
27 18P37B discharge B/V U/S gasket to be replaced. 249 M/M
28 18PP37B NRV top flange gasket to be replaced. 250 M/M
29 18P37B suction B/V both gaskets to be replaced. 252 M/M
30 18P37B suction nozzle flange gasket to be replaced. 253 M/M
31 18P37B discharge nozzle flange gasket to be replaced. 254 M/M
32 18P37 FLO line 3 Nos of gaskets to be replaced. 255 M/M
33 HCO to riser line near P16A NRV D/S gasket to be replaced. 258 M/M
34 HCO to riser C/V bypass B/V both gaskets to be replaced. 259 M/M
35 HCO PA C/V bypass B/V U/S flange and B/V bonnet gasket to be 263 M/M
replaced.
36 HCO PA C/V U/S flange gasket to be replaced. 265 I/M
37 18FV3501 CV bypass B/V both gaskets to be replaced. 269 M/M
38 18SOV3401 D/S B/V D/S flange gasket to be replaced. 283 M/M
39 Slurry C/V D/S B/V U/S & D/S flange gasket to be replaced. 284 M/M
40 DCO to 18P37 B/V D/S flange gasket to be replaced. 286 M/M
41 HCO to PALL filter B/V U/S and D/S flange gaskets to be replaced. 287 M/M
42 MHP main header near 18P02 condensate leg end flange gasket to be 295 M/M
replaced.
43 Feed nozzle gasket to be replaced. 301 M/M
44 18C10 level troll nozzle flange gasket to be replaced. 304 M/M
45 Feed Dispersion steam Cv-18FV0505 –U/S and D/S gasket to be 305 I/M
replaced.
46 Fed to riser SDV-18SDV0506- flange gaskets to be replaced. 306 I/M
VALVE-GLAND JOBS

No. by
1 19B06 product B/V gland packing replacement (S/D) 137 M/M
2 19B06 caustic line C/V D/S B/V gland packing (S/D) 138 M/M
3 19B20 caustic manifold 2 nos of B/V gland packing. 141 M/M
4 19B06 caustic line B/V gland packing. 142 M/M
5 19B06 caustic line 2nd B/V gland packing. 143 M/M
6 19B06 product line B/V gland packing. 144 M/M
7 19B06 product O/L B/V gland packing. 145 M/M
8 18P29B discharge B/V gland packing 197 M/M
9 18P12B suction B/V gland packing. 207 M/M
10 18P13A Discharge B/V gland packing to be done. 223 M/M
11 18P13A seal quenching line B/V gland to be tightened. 225 M/M
12 Slurry quench C/V bypass B/V gland packing to be redone. 235 M/M
13 18P37A W/U line B/V gland packing to be changed. 244 M/M
14 18P37B vent line B/V gland packing to be changed. 253 M/M
15 HCO to riser C/V U/S and D/S B/V and bypass B/V gland packing to b 260 M/M
replaced.
16 18P16A/B suction and Discharge B/V gland packing to be redone. 262 M/M
17 HCO PA C/V bypass B/V gland packing to be redone. 263 M/M
18 HCO PA C/V gland packing to be replaced. 264 I/M
19 18FV3501 gland packing to be replaced. 268 I/M
20 MP steam B/L B/V gland leak to be attended. 270 M/M
21 LP steam B/L B/V gland leak to be attended. 271 M/M
22 Tracing steam to Feed line B/B gland leak to be attended. 275 M/M
23 18P13A W/U line B/V gland leak to be attended. 276 M/M
24 18PC1002 U/S B/V gland leak to be attended. 296 M/M
25 Steam to 18P02 C/V and CV D/S B/V gland leak to be arrested. 298 I&M/M
MISCELLANEOUS JOBS

No. by
1 19LC5401 U/S and D/S bleeder lines to be end capped. 128 I/M
2 Service airline drain bleeder wheel to be fixed and line end blinded. 129 M/M
3 Process air line PG drain line valve wheel providing 130 M/M
4 Catalyst pot U/S vent bleeder to be end blinded. 131 M/M
5 19R04 caustic drain line to be end blinded. 132 M/M
6 19B06 ½” caustic line CV U/S&D/S drain bleeder to be end blinded. 135 I/M
7 19B06 caustic line B/V to be replaced.(S/D job) 136 M/M
8 19B20-ex P03 manifold B/V to be replaced.(S/D) 139 M/M
9 19B20 vent line to CBD drain lined end blinding. 140 M/M
10 DM water line U-bend drain bleeder end blinding. 146 M/M
11 DM line U-bend drain bleeder end blinding. 147 M/M
12 18P53A suction line B/V D/S end blinding. 148 M/M
13 18P53A discharge NRV D/S bleeder end blinding. 149 M/M
14 18P53B suction line B/V D/S end blinding 150 M/M
15 18P53B discharge NRV D/S bleeder end blinding. 151 M/M
16 PCV D/S drain bleeder end blinding. 152 M/M
17 Anti-oxidant tank level HP tapping drain end blinding. 153 I/M
18 19B20 caustic mixture drain bleeder wheel fixing and end blinding.(S/D) 154 M/M
19 18E42B CW line drain bleeder end blinding. 155 M/M
20 18E29-18FV3402 C/V U/S drain bleeder end blinding. 156 I/M
21 18LV4702 C/V D/S drain bleeder end blinding. 158 I/M
22 18E30 shell side I/L line B/V U/S drain bleeder end blinding. 159 M/M
23 Near 18C14 fire header B/V D/S adaptor to be fixed. 160 M/M
24 18E27-C13 reboiler line to pump out line inter connection spool drain 161 M/M
line end blinding.
25 18FV4201 C/V U/S drain bleeder end blinding. 167 M/M
26 Fuel gas ex C-18 near 18P19B B/V D/S drain bleeder to be end blinded. 169 M/M
27 18P19B warm up line B/V wheel missing. 170 M/M
28 VR to FCCU C/V bypass B/V replacement 171 M
29 18P19A discharge line drain bleeder B/V wheel missing. 172 M/M
30 18P30A seal pot CW supply B/V wheel missing. 173 M/M
31 18P31B PG drain line cap to be provided. 174 I/M
32 18P30A PG drain line end cap to be provided 175 I/M
33 18P27B lube oil cup to be fixed properly 176 I/M
34 18P27A lube oil cup marking to be done 177 M/M
35 18P28B seal pot drain line B/V wheel to be provided. 178 M/M
36 18P28A seal pot LG H/P tapping B/V to be replaced. 179 I/M
37 18P25B lube oil cup marking to be done 180 M/M
38 18P26B vent line B/V wheel to be replaced. 181 M/M
39 18P24B seal pot TSV O/L piece to be fixed. 182 M/M
40 18P24A seal pot TSV O/L piece to be fixed. 183 M/M
41 18P10B seal pot TSV O/L spool to be fixed. 184 M/M
42 18P10A seal pot TSV O/L spool to be fixed. 185 M/M
43 18P11A PG drain line to be end capped. 187 I/M
44 18P10A lube oil cup marking to be done. 186 M/M
45 18P11A seal pot TSV O/L line spool to be fixed. 188 M/M
46 18P18B PG drain line B/B stem broken-to be replaced. 189 M/M
47 18P18A vent line B/V wheel missing. 190 M/M
48 18P18A lube oil cup marking to be done 191 M/M
49 18P11B seal pot O/L B/V wheel missing 192 M/M
50 18P11A seal pot O/L line B/V wheel missing. 193 M/M
51 18P29B PG 2nd B/V wheel missing and drain end cap 194 I/M
Missing-to be provided.
52 18P29B seal pot view glass long bolting. 195 I/M
53 18P29B TSV O/L line providing. 196 M/M
54 18P29A warm-up line wheel missing. 198 M/M
55 18P29A CW lines B/V wheel missing-2 nos-to provide. 199 M/M
56 18P29A seal pot union joint leak 200 M/M
57 18P50B PG drain line to be end capped. 201 I/M
58 18P50B CW line B/V wheel missing. 202 M/M
59 18FV4302 C/V D/S bleeder to be end blinded. 204 I/M
60 18P12B open cable to be removed. 205 E/M
61 18P50A lube oil cup marking 203 M/M
62 18P12 suction line PG drain to be end capped. 206 I/M
63 18P12A PG drain line B/V to be replaced. 208 M/M
64 18P12A PG to be replaced. 209 I/M
65 18P14B CW supply line leak to be arrested. 210 M/M
66 18P14B warm up line B/V wheel to be provided. 211 M/M
67 18P14B vent line to be end blinded. 213 M/M
68 18P14A vent line to be end blinded. 214 M/M
69 18P14B seal quenching steam B/V gland leak. 215 M/M
70 18P13B seal quenching steam line B/V wheel to be provided. 216 M/M
71 18P14A NRV D/S drain bleeder B/V wheel and end blind to be provided. 219 M/M
72 18LV4401 D/S bleeder to be end blinded. 226 I/M
73 18P15B warm up valve to be replaced. 230 M/M
74 18P15A seal flushing line threaded joint leak to be attended. 231 M/M
75 18P15B seal flushing line threaded joint leak to be attended. 232 M/M
76 18P15A discharge NRV D/S drain bleeder to be end blinded. 233 M/M
77 18P16B vent line B/V wheel to be fixed. 238 M/M
78 18P16A discharge line Plug leak to be attended. 239 M/M
79 18P16A PG tapping B/V and tracing steam B/V wheels to be fixed. 240 M/M
80 18P16A PG diaphragm leak to be attended. 241 I/M
81 18P37A FLO line B/V wheel to be fixed. 242 M/M
82 18P37A discharge line PG drain cap to be fixed. 243 I/M
83 18P37B body discharge line plug leak to be arrested. 247 M/M
84 18P37B PG union leak to be arrested. 251 I/M
85 Sour water B/L B/V U/S bleeder to be end blinded. 256 M/M
86 Preheated feed to HCO line drain bleeder to be end blinded. 257 M/M
87 HCO to riser C/V drain bleeders to be end blinded. 261 I/M
88 HCO PA C/V D/S drain bleeder to be end blinded. 266 I/M
89 18FV3401 drain bleeders to be end blinded. 267 I/M
90 LCN sample line at B/L B/V to be replaced. 272 M/M
91 Condensate B/V passing near 18P30A-to be replaced. 273 M/M
92 Passing steam trap near 18P25A to be replaced. 274 M/M
93 18C12 stripping steam condensate trap is passing to be replaced. 278 M/M
94 Slurry PA C/V drain bleeders to be end blinded. 281 I/M
95 18SOV3401-steam to 18P17 drain bleeder hose to be removed and end 282 M/M
blinded.
96 18P21 PG drain bleeder to be capped. 288 I/M
97 Electrical plug points cover to be provided. 292 E/M
98 Service water point near 18B13 B/V to be replaced. 293 M/M
99 18P02B min circulation line drain point to be end blinded. 297 M/M
100 Steam to 18P02 vent bleeder to be capped. 299 M/M
101 CRWS man holes de-choking 300 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-E-
17 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 EQPT.NO. JOB TO BE DONE

.
1 24-E-01 A/B/C/D/E/F Passivation before opening
2 24-E-02 A/B
3 24-E-03 A/B/C/D
4 24-E-04
5 24-E-05
6 24-E-06 A/B
7 24-E-07
8 24-E-18 A/B
9 24-E-19 A/B
10 24-E-20 A/B
11 24-E-22
12 24-E-23
13 24-E-34
14 24-E-35 A/B
15 24-E-36
16 24-E-38
17 G/C of 24-K-
03A/B
18 G/C of 24-K-
04A/B
19 I/C of 24-K-03A/B
20 I/C of 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. EQPT.NO. JOB TO BE DONE

NO.
1 24-V-01 Cleaning and maintenance
2 24-V-02 Cleaning, Hydro-testing as per factory act.
7 24-V-08 Packing removal, weld joint repair
14 24-V-30 to 36 Scaffolding and external inspection
Total – 18 Nos.
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
SL.NO. EQPT.NO JOB TO BE DONE

1 24-V-05 Opening & cleaning including internals
followed by visual inspection, thickness
survey, offer for IBR inspection.
2 24-E-17 Opening of both manholes, cleaning of tube
bundle, visual inspection, offer of IBR
inspection.
3 24-E-14 All end panels and manholes to be opened,
Cleaning, offer for IBR Inspection.
4 24-E-13 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 24-

E-14) are to be carried out at 78.0 Kg. / Cm2
9.0 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 Set Remarks /
No. Pressure Recommendations
Kg/cm2
1 24-PSV-1558 42.0 `O` Ring to be replaced.
3 24-PSV-1952 89.75 Spring & Disc to be
replaced.
4 24-PSV-1952 89.8 Spring, Nozzle & Disc to be
replaced.
replaced.
replaced.
replaced.
12. 24-PSV-5153 89.8 Spring, Nozzle & Disc to be
replaced.
13. 24-PSV-5154 89.8 Spring, Nozzle & Disc to be
replaced.
14. 24-PSV-5256 7.0 `O` Ring to be replaced.
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 Capital maintenance of FD Fan (24-K-01 A/B)

16.2 Capital Maintenance of ID fan (24-K-02A/B)
16.3 Overhauling of CBD pump (24-P-11)
JOB LIST
ARU
________________________________________ _____________Final List
1.0 COLUMN – 26-C-01
Blinding / De-blinding, opening of manholes, air circulation inside the column, gas test & man-
entry, 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 box-
up 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 & 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.
i) 26-V-01
ii) 26-V-02
iii) 26-V-04
iv) 26-V-06
v) 26-V-07
vi) 26-V-08
vii) 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 & 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.
1. 26-FS-01
2. 26-FS-02A/B
3. 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 box-
up of the equipment after completion of all activities of the heat-exchangers.
Exchangers - 26-E-02A/B & 26-E-03A/B
Coolers - 26-E-01 & 26-E-04 (Replacement, if material is available)
Air Coolers - 26-AC-05 & 26-AC-06
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. PSV/TSV Nos.

1 26-PSV-6605
2 26-PSV-6509A/B
3 26-PSV-6510A/B
4 26-PSV-6603A/B
5 26-PSV-6706
6 26-PSV-6306A/B
7 26-PSV-6403
8 26-PSV-6508
9 26-PSV-6207
10 26-PSV-6305
11 26-PSV-6307A/B
6.0 TAG JOBS
• 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.
7.0 PIPING JOBS
Anticipated replacement as per following
1) Dia 2” – Sch.80 - CS- 80M

2) Dia 3” – Sch.40 - CS- 50M
3) Dia 4” – Sch.40 - CS- 40M
4) Dia 6” – Sch.40 - CS- 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 :
Sl. Tank no Description Anticipated job

No
1.1 51-T-02 FO Tank Partial replacement of roof (6mm thk. Plate) &
steam coil(Dia 2 inch A106 Gr. B sch-40-20
mts)
1.2 51-T-02 A FO Tank Possible replacement of roof & bottom plate
(50 m2) & steam coil(Dia 2 inch A106 Gr. B
sch-40-20 mts)
1.3 51-T-03 LDO Tank Partial replacement of roof (6mm thk. Plate)
1.4 51-T-07 A Cond. Tank Partial replacement of bottom plate (8 mm)-
IS-2062 B ,30 M2
1.5 51-T-08 Cond. Tank Complete bottom plate replacement(8 mm)-
IS-2062 B ,35 M2
1.6 51-T-01 A DM water tank Cleaning and inspection only
1.7 51-T-02 B DM water tank Cleaning and inspection only
1.8 51-T-03 C DM water tank Cleaning and inspection only
2.0 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. Vessel no Description Anticipated job

No
2.1 51-B-02 Deaerator To be offered for internal inspection;
Thorough NDT like LPT, WFMPT, UTG shall
be done
2.2 51-B-102 Deaerator -do-
2.3 55-B-11 A Acid measuring vessel CLEANING & INSPECTION
2.4 57-B-01 Service air vessel -do-
2.5 57-B-02 Instrument air vessel -do-
2.6 55-B-12 A Alkali measuring vessel -do-
2.7 55-B-12 B Alkali measuring vessel -do-
2.8 51-B-06 Fuel Gas Drum -do-
2.9 55-B-10 A Degasser sump -do-
2.10 55-B-10 B Degasser sump -do-
2.11 51-B-08 Flash Drum -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. HX. no Description

No
3.1.1 57-E-01 57-K-01 A intercooler
3.1.2 57-E-02 A Air Cooler
3.1.3 57-E-02 B Air Cooler
3.1.4 51-E-02 Vaporiser
3.1.5 51-E-03 A Oily cond/ DM water
3.1.6 51-E-03 B Oily cond/ DM water
3.1.7 51-E-05 A FO heater
3.1.8 57-E-05 B FO heater
4.0 SAFETY VALVES:
Following PSV s / TSV s are to be sent to workshop for overhauling and testing:
Sl. No PSV No. Location

1 1614 / 1 51-B-102
2 1614 / 2 51-B-102
3 51 SV 19AX 51-B-02
4 51 SV 19BX 51-B-02
5 51-TSV-03 51-T-03
6 51-TSV-04 51-T-04
7 51-PSV-44 A PRDS
8 51-PSV-44 B PRDS
9 51-PSV-44 C PRDS
10 51-PSV-29 51-P-04
11 64-PSV-12 64-P-03E
12 51-PSV-23 A 51-PT-05 A
13 51-PSV-23 B 51-PT-05 A
14 51-PSV-24 A 51-PT-05 B
15 51-PSV-24 B 51-PT-05 B
16 57-TSV-01 Compressor house area : 57 K01 A/B, K02 , K03,K04, E02 ,
17 57-TSV-02 E01, CW Lines
18 57-TSV-03
19 57-TSV-04
20 57-TSV-05
21 57-TSV-06
22 57-TSV-07
23 57-PSV-02X K 02 Disch
24 57-PSV-06X K 01 A/B Disch
25 57-PSV-08X K 03 Disch
5.0 REPAIR/ REPLACEMENT JOBS IN PIPING :
Partial replacement of the following piping circuits during the shut-down :
Sl. Circuit description. Insulation Material Requirement

No removal
Y/N
5.1 FO lines near Tank Farm area & Y Dia 6 inch 106 GR B Sch-40 pipe;
on rack near boilers approx. length-20 mts
Dia 3 inch 106 GR B Sch-40 pipe;
approx. length-30 mts
5.2 LDO lines near Tank Farm area Y Dia 4 inch 106 GR B Sch-40 pipe;
& on rack near boilers approx. length-20 mts
5.3 FG lines near Tank Farm area Y Dia 6 inch 106 GR B Sch-40 pipe;
5.4 LP Condensate lines on rack Y Dia 3 inch 106 GR B Sch-40 pipe;
5.5 MP Condensate lines on rack Y Dia 3 inch 106 GR B Sch-40 pipe;
5.6 HP Condensate lines on rack Y Dia 3 inch 106 GR B Sch-40 pipe;
5.7 LP Condensate lines to Y Dia 3 inch 106 GR B Sch-40 pipe;
Deaerators thru surface approx. length-20 mts
condensers
5.8 Condensate inlet line to Y Dia 4 inch 106 GR B Sch-40 pipe;
Deaerator-1 from units approx. length-20 mts
5.9 Condensate inlet line to Y Dia 4 inch 106 GR B Sch-40 pipe;
Deaerator-2 from units approx. length-20 mts
5.10 Oily Condensate circuit Y Dia 4 inch 106 GR B Sch-40 pipe;
5.11 De-oily condensate circuit Y Dia 4 inch 106 GR B Sch-40 pipe;
5.12 CW Risers in PCT-09 nos. N Replacement of Dia 24 inch CS
welded pipe.
5.13 CW circuits in compressor and N Dia 6 inch A106 GR B Sch-40 pipe;
cooler area approx. length-20 mts
Dia 4 inch A 106 GR B Sch-40 pipe;
5.14 PHE make up water line near N Dia 12 inch API 5L GR B Sch-20
TPS and PCT pipe; approx. length-100 mts
5.15 Acid dosing lines near CT N Dia 4 inch 106 GR B Sch-40 pipe;
5.16 Dewatering lines near CT N Dia 2 inch 106 GR B Sch-40 pipe;
5.17 Motor cooling lines near CT N Dia 1.5 inch 106 GR B Sch-80 pipe;
5.18 Hypo dosing lines in CT N Dia 2 inch 106 GR B Sch-80 pipe;
5.19 VH steam header and entire Y RLA shall be done.
circuit
5.20 VM steam header and entire Y Quantity shall be finalized during
circuit s/d.
5.21 VB steam header and entire Y Quantity shall be finalized during
circuit s/d.
5.22 Boiler Feed water circuit Y Quantity shall be finalized during
s/d.
5.23 Small bore tapping in VH Y Shall be DP tested
circuits- 20 nos.
5.24 Small bore tappings in VM Y Shall be DP tested
circuits-20 nos.
5.25 Small bore tappings in VB Y Shall be DP tested
circuits-20 nos.
5.26 Small bore tappings in BFW and Y Shall be DP tested
CW header circuits-20 nos.
5.27 Instrument air line N Dia 2 inch A 106 GR B Sch-80 pipe;
5.28 Service air line Dia 2 inch A 106 GR B Sch-80 pipe;
5.29 Fire water line N Dia 6 inch A 106 GR B Sch-40 pipe;
5.30 Service water line N Dia 2 inch A 106 GR B Sch-80 pipe;
5.31 VB steam line near PCT Y Dia 16 inch API 5L GR B Sch-30
pipe; approx. length-20 mts
5.32 VM steam line near PCT Y Dia 10 inch A 106 GR B Sch-30
pipe; approx. length-20 mts
5.33 VH, VM ,VB and BFW flow Y For VH, P11 metallurgy is required
impulse lines
5.34 VH, VM ,VB and BFW equaliser T For VH, P11 metallurgy is required
lines
5.35 U/G CW lines 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 Size (Apx) Type End type Qty

No
1 Boiler : 1/2/3 VS 10” #900 Gate Welded 3 Nos.
STM Block Valve
(Boiler G/floor)
2 Boiler : 1/2/3 ¾” #1500 Gate Welded 6 Nos.
Equaliser of VH
STM Block
Valves Boiler
G/floor
3 Boiler : 1/2/3 VH ¾” #1500 Gate Welded 6 Nos.
STM Boot Drain
Valves Boiler
G/floor
4 Boiler : 2 2” #900 Gate Flanged 1 No.
Automising STM (Weld Prfd)
root valve (Burner
floor)
5 LPG Flair STM 2” #300 Gate Flanged 1 No.
Tracing Valve (Weld Prfd)
6 Boiler : 3 FO-in 2” #150 Gate Flanged 1 No.
battery limit valve
(Burner floor)
7 Boiler : 1/2/3 6” #900 Gate Flanged 3 Nos.
BFW Off-take (Weld Prfd)
valve
8 TG : 1,2&3 Aux. 2” #900 Gate Welded 6 Nos.
STM root valve
(Turbine G/floor)
9 TG : 3 VH Steam 10” #900 Gate Welded 1 No.
valve (Turbine
G/floor)
10 TG : 2 Condenser 12” #150 Gate 2 Nos.
in/outlet valves
(Turbine G/floor)
11 VH stm equliser ¾” #1500 Gate Welded 40 Nos.
valve
12 Cooling Tower 14” #150 Gate Flanged 1 No.
TPS CW Pump
“03J” Disch valve
13 PCT : All CW 24” #150 Gate Flanged 7 Nos.
Pump NRV
14 Other steam 12” #900 Gate Welded 1 No.
valves 10” #900 Gate Welded 8 nos.
- Without MOV 3” #900 Gate Welded 11 Nos.
2” #900 Gate Welded 6 Nos.
15 Butterfly valve in 24” #150 Flanged 7 Nos.
CWP I/O Line 30” #150 Flanged 7 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. Equipment External/ Painting Specification

no Internal
1 FO and LDO Tanks Both Roof inside: Self priming epoxy +
Epoxy Zinc phosphate + HB epoxy
External: Self priming epoxy + Epoxy

Aluminum
2 Condensate Tanks- 51-T-07 A/B Both Internal : Self priming epoxy + Epoxy
and 51-T-08 Zinc phosphate + HB epoxy
External : Acrylic aliphatic PU

3 DM water tanks –03 nos. Both Internal : Self priming epoxy + Epoxy
Zinc phosphate + HB epoxy

4 Acid and caustic tanks External External : Acrylic aliphatic PU
5 Raw water tank Both Internal : Self priming epoxy + Epoxy
Zinc phosphate + HB epoxy

6 Un-insulated vessels External External : Acrylic aliphatic PU
7 Insulated vessels External Polysiloxane paint- 2 coats
8 Condensate lines External External: Self priming epoxy + Epoxy
Aluminum
9 Water side of coolers and Internal Roof inside: IOZ silicate + Epoxy Zinc
condensers phosphate + HB epoxy
10 Un-insulated lines near CT area External As per Advanced paint system already
finalized
11 Un-insulated lines near DM External As per Advanced paint system already
plant finalized
12 Equipment near DM plant External As per Advanced paint system already
finalized
13 Sand filters in DM plant Internal IOZ silicate + Epoxy Zinc phosphate
+ HB epoxy
14 CT Risers External Advanced paint system already
finalized
15 CT headers to and from TPS External 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
Testing & commissioning of PC-11
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
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 INSTRUMENT MAINTENANCE JOBS :

10.0 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 ones-
approx. no-100 nos.
e. Repalcement of CS and Brass plugs: approx- 200 nos
f. Provision of suction strainer in CW pump of PCT
11.0 PROCESS MODIFICATION JOBS:
a Installation of welded valve in BFW Line of TPS for boiler No. 1, 2 & 3
b 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. TANK/ DESCRIPTION JOBS

NO. VESSEL NO.
1.1 61B01 FLARE KNOCK OUT POT MAINTENANCE & INSPECTION
SAND BLASTING & GUINNITING
1.2 61B02 H2S KNOCK OUT POT MAINTENANCE & INSPECTION
1.3 79V01 WATER SEAL DRUM MAINTENANCE & INSPECTION
1.4 79V02 KNOCK OUT DRUM MAINTENANCE & INSPECTION
1.5 79V03 KNOCK OUT DRUM MAINTENANCE & INSPECTION
1.6 46B01 L.P.COND.VESSEL MAINTENANCE & INSPECTION
1.7 46B02 H.P.COND. VESSEL 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.
C) Flare lines along St.8
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
D) 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 PRE-
SHUTDOWN OR POST-SHUTDOWN ACTIVITY DEPENDING ON MATERIAL
AVAILABILITY.
3.1 REPAIR / REPLACEMENT OF LPG LINES
3.1.1 Dia.1 ½” = 20 M - U-11 R/D

3.1.2 Dia2” = 60 M - Circulation line of Bullets
3.1.3 Dia.3” = 80 M - U-16 R/D
3.1.4 Dia.4” = 120 M - Propane to U-32
3.2 REPAIR / REPLACEMENT OF H2 LINES
3.2.1 Dia2” = 60 M - CR to U-24/U-25 to U-24/R/D to Bullets

3.2.2 Dia.3” = 84 M - U-22 to U-35
3.2.3 Dia.4” = 36 M - U-24 to Fuel Gas Header/U-24 to U-84
3.3 REPAIR / REPLACEMENT OF NAPTHA LINES
3.3.1 Dia2” = 24 M - Wild Napththa in E-3 T/F

3.3.2 Dia.3” = 200 M - U-16 to R/D to Tkl-203/204 / DSN to DHDS/Rd.D
3.3.3 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 Dia.12”= 120 M - SRN to Mktg.

3.3.5 Dia.16” = 30 M
3.3.6 Dia.20” = 30 M
3.4 REPAIR / REPLACEMENT OF ATF lines
3.4.1 Dia.4” = 60 M - Ex.U-11 to Tk-411/414 / U-11 to Tk-441

3.4.2 Dia.6” = 60 M - Ex.F-2 P/H to Tk-460 / Ex.F-3 P/H to TTL
3.4.3 Dia.12” = 18 M - Ex. Tk-441
3.4.4 Dia.14”= 40 M - AFT Header
3.5 REPAIR / REPLACEMENT OF RTF lines
3.5.1 Dia.6” = 120 M - R/D Ex.U-23 to Tk-458/459 / RTF Circulation to PM
3.6 REPAIR / REPLACEMENT OF MS lines
3.6.1 Dia.4” = 100 M - Ex. Tk-401-405 to F-3 P/H

3.6.2 Dia.6” = 60 M - Ex.F-2 P/H to Tk-451/453 / MS circulation to Tk-403
3.6.3 Dia.8” = 30 M - Small Header
3.6.4 Dia.12” = 160 M - Ex. Tk-405 to F-3 P/H / Export Gr. MS to Mktg.
3.6.5 Dia.14” = 30 M - MS line to jetty
3.6.6 Dia.18” = 30 M - MS big header.
3.7 REPAIR / REPLACEMENT OF SKO lines
3.7.1 Dia2” = 30 M - SKO to BEU

3.7.2 Dia.3” = 84 M - Hydroo treated Keo line, Rd.D / St. 8
3.7.3 Dia.6” = 60 M - U-11 R/D to SR Kero
3.7.4 Dia.10” = 90 M - U-11 R/D to Tk-418 / Ex.U-23 to Tk-417/418
3.7.5 Dia.12” = 60 M - Ex. Tk-206 to U-23
3.7.6 Dia.14” = 120 M - Ex.Tk-434 / Ex. Tk-435 to Tk-434
3.7.7 Dia.20” = 300 M - SKO to jetty
3.8 REPAIR / REPLACEMENT OF HSD lines
3.8.1 Dia.6” = 120 M - Circ. line of Tk-418 I/L to Tk-418 / Ex.U-11 to Tk-424
3.8.2 Dia.8” = 60 M - HSD to Barge
3.8.3 Dia.14” = 60 M - HSD under culvert
3.9 REPAIR / REPLACEMENT OF SLOP LINES
3.9.1 Dia.3” = 2000 M - Slop processing to U-37

3.9.2 Dia.6” = 120 M - Light slop / Slop Header
3.10 REPAIR / REPLACEMENT OF OFF GAS LINES
3.10.1 Dia.2” = 36 M - Ex.U-35 to FOB

3.10.2 Dia.3” = 60 M - Ex. U-35 / 39 to FOB
3.10.3 Dia.4” = 60 M - 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 - Ex.U-37 to U-23
3.12 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 Dia2” = 80 M - FC/Pilot gas to Flare

3.13.2 Dia.4” = 30 M - Sweet fuel Gas to FOB
3.13.3 Dia.6” = 40 M - Ex. Gr.20 / FG to LOB
3.13.4 Dia.8” = 60 M - FG Ex. FOB / FG to FOB
3.14 REPAIR / REPLACEMENT OF AMMONIA LINES
3.14.1 Dia.3” = 24 M -
3.14.2 Dia.4” = 30 M
3.15 REPAIR / REPLACEMENT OF JBO LINES
3.15.1 Dia3” = 60 M - To Tk-303/304

3.15.2 Dia.6” = 160 M - Ex. E-1 to TTL/Circulation line to Tk-427
3.15.3 Dia.8” = 12 M -
3.15.4 Dia.10”=150 M
3.15.5 Dia.14”=24 M
3.16 REPAIR / REPLACEMENT OF MTO lines
3.16.1 Dia3” = 36 M - Treated MTO line

3.16.2 Dia.6” = 30 M - Treated MTO line
3.16.3 Dia.14” = 24 M - MTO to Tanker
3.17 REPAIR / REPLACEMENT OF VB Gasolene lines
3.17.1 Dia.2” =80 M - Ex. U-13

3.17.2 Dia.3” = 36 M - Ex. Tk-201/202
3.18 REPAIR / REPLACEMENT OF Amine lines
3.18.1 Dia.2” = 120 M - Rich Amine ex. U-35 / Lean Amine to U-35
3.18.2 Dia.3” = 60 M - Ex. DHDS
3.19 REPAIR / REPLACEMENT OF IFO lines
3.19.1 Dia.1 ½” = 60 M - Supply line to CDU-1/Gr.-20

3.19.2 Dia.2” = 120 M - Return line from CDU-1 / Gr.-20
3.19.3 Dia.3” = 200 M - 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 Dia.1 ½” = 60 M
3.20.2 Dia.2” = 240 M
3.20.3 Dia.3” = 300 M
3.20.4 Dia.8” = 30 M (Plant air)
3.21 REPAIR / REPLACEMENT OF COOLING WATER LINES
3.21.1 Dia.3” = 800 M

3.21.2 Dia.4” = 1200 M
3.21.3 Dia.6” = 200 M
3.21.4 Dia.18” = 200 M
3.21.5 Dia.24” = 80 M
3.22 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 Dia 2” - Cond. Return ex.U-25- Near U-25 culvert

3.26.2 Dia.2” - Utility line opp.C/T- Opp. TPS C/T
3.26.3 Dia.3” - Instrument air line- Behind SRU-2
3.26.4 Dia.6” - Plant Air line - Behind SRU-2
3.26.5 Dia.10” - FCCU Feed line- Near FOB corner
3.26.6 Dia.32” - CW inlet TO FOB- Near TPS
3.26.7 Dia.32” - CW outlet ex. FOB- 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. TAG NO. LOCATION
1 61T463 (2 NOS.) TANK NO. 463

2 61T464 (2 NOS.) TANK NO. 464
3 46B01 CONDENSATE STATION
4 46B02 (2 NOS.) CONDENSATE STATION
5 61V101A (2 NOS.) ALONG ROAD-G
6 61V101B (2 NOS.) ALONG ROAD-G
7 69B03A1 (2 NOS.) LPG BOTTLING PLANT
8 69B03A2 (2 NOS.) LPG BOTTLING PLANT
9 69B03B1 (2 NOS.) LPG BOTTLING PLANT
10 69B03B2 (2 NOS.) LPG BOTTLING PLANT
11 48B01 (2 NOS.) BITUMEN COOLING STATION
12 48E01A BITUMEN COOLING STATION
13 48E01B BITUMEN COOLING STATION
14 48E01C BITUMEN COOLING STATION
15 48E02A BITUMEN COOLING STATION
16 48E02B 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) Tag No:65FT403 Service: TO TREATED WATER POND

b) Tag No:65FT303 Service: DISCH. HDR. TO RVR HOOGHLY
c) Tag No:65FT304 Service: TO PDA SCRUBBER
d) Tag No:65 FE02 Service: DAF RECYCLE PUMP TO SATURATION VESSEL
e) 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
1.1.2 Following Cooling Water Lines (Under ground) shall be replaced (Annex-III)
Length
1 8 INCH 30 10 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.
Length
1 8 INCH 40 48 MTRS
3 12 NCH 40 44 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 Particulars Size & sch Length

1 φ 4” CW line connected at i/l of 31-E-127 φ4’ sch 40 3 mtrs
2 φ 2 hot well gas oil lines connected to 31-P-111/111R φ 2” sch 80 total 15 mtrs
3 φ 3” hot well gas oil lines connected to 31-P-111/111R φ 3” sch 40 3 mtrs
4 φ 3” sour water lines connected to 31-P-102/102R φ 3” sch 40 3 mtrs
5 φ 6” non condensable line from 31-E-130 to 31-B-07 φ 6” sch 40 10 mtrs
6 φ2” Drain line of 31-B-07 φ 2” sch 80 40 mtrs
7 φ 6” barometric leg from 31-E-128Ato 31-B-02 φ 6” sch 40 40 mtrs
8 8”/12” T portion of CW inlet line to 31-E-128A φ 8 & 12” sch 30 1.5 Mtrs
9 φ2” line of 31-E-116C φ 2” sch 80 4 mtrs
10 φ 12” CW header o/h at pump house near 31-P-114A/B/C φ 12” sch 30 30 mtrs
11 φ 8/12” CW line & header o/h at pump house near 31-E- φ 8” & 12” sch 30 40 mtrs
114A
12 φ 12” CW line & header o/h at pump house near 31-E-114A φ 12” sch 30 10 mtrs
13 φ 4” fire water monitor line at top floor φ 4” sch 40 15 mtrs
UNIT - 32
Sl no Line location Approx Specification Matl
length
1 φ24” inlet header at n/e corner of the main 40 mtrs. φ24” / thk 12 mm API 5L / EFSW
platform
2 φ24” outlet header at n/e corner of the main 43 mtrs. φ24” /thk 12 mm API 5L / EFSW
platform
3 φ8” inlet line (last 2 mtrs including the bottom 18 mtrs. φ8” sch.40 A-106 Gr. B
bends up to the inlet nozzles of 32-E-06
condenser pairs)
4 φ8” outlet line (first 6 mtrs including the bottom 30 mtrs. φ8” sch.40 A-106 Gr. B
bends from the outlet nozzles of 32-E-06A/A1,
C/C1, D/D1, F/F1, I/I1 condenser pairs)
5 φ8” inlet /outlet circuits connected to condenser 24 mtrs φ6” sch 40 A-106 Gr. B
34-E-06B/B1
6 φ3” line going to pumps 32-P-110C/D/E up to 6 mtrs φ3” sch 40 A-106 Gr. B
isolation valve (balance already recommended)
7 φ12” line connected to main header at north of U- 6mtrs φ12 ” sch 30 API 5L / EFSW
32 (rose portion)
8 φ2” line to 32-K-01 6mtrs φ2” sch 80 A-106 Gr. B
9 φ3” inlet header to 32-K-01 15 mtrs φ3” sch 80 A-106 Gr. B
10 φ2” o/l header to 32-K-01 15mtrs φ2” sch 80 A-106 Gr. B
11 φ2” header portion to 32-P-04/5 6 mtrs φ2” sch 80 A-106 Gr. B
12 φ8” ETP treated water to 32-C-107 90 mtrs φ8” sch 40 A-106 Gr. B
13 φ6” ETP treated water to 32-C-107 16 mtrs φ6” sch 40 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.

3) Cooling water Inlet/Outlet of 33-E-06B.

4) Cooling water Inlet/Outlet of 33-E-13D.

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 Line location Appro Specificati Matl
no x on
length
1 φ28” inlet header at n/w corner of the main platform 18 φ28” / thk API 5L /
mtrs. 12 mm EFSW
2 φ28” outlet header at n/w corner of the main platform 12 φ28” /thk API 5L /
mtrs. 12 mm EFSW
3 φ24” inlet sub header below 1st platform 30 φ24” /thk API 5L /
mtrs. 12 mm EFSW
4 φ20” outlet header at n/w corner of the main platform 30 φ20” /thk API 5L /
mtrs. 12 mm EFSW
5 φ6” outlet circuits connected to condenser 34-E-15D 16 mtrs φ6” sch 40 A-106 Gr. B
6 φ8” line to outlet sub header from u/g 16 mtrs φ8” sch 40 A-106 Gr. B
7 φ6” line from inlet sub header to u/g 14 mtrs φ6” sch 40 A-106 Gr. B
8 φ6” inlet line to 34-E-2/I 18 mtrs φ6” sch 40 A-106 Gr. B
9 φ12” inlet line to 34-E-16 10 mtrs φ12” / thk 8 API 5L /
mm EFSW
10 φ12” inlet line to 34-E-17D 10 mtrs φ12” / thk 8 API 5L /
mm EFSW
11 φ16” 2nd inlet sub header connected to coolers 37-E- 6 mtrs φ16” / thk API 5L /
15A/B/C 10 mm EFSW
12 φ12” reduced inlet header (down stream portion of main 35 mtrs φ12” / thk 8 API 5L /
header) at two locations mm EFSW
13 φ8” reduced inlet header ( down stream portion of main 12 mtrs φ12” sch 30 A-106 Gr. B
header)
Annexure-I
14 φ20” reduced outlet header (up stream portion of main 10 mtrs φ20” / thk API 5L /
header) 12 mm EFSW
16 φ6” inlet line of 34-E-10C at 2 locations 20mtrs φ6” sch 40 A-106 Gr. B
UNIT : 35

UNIT –37 :
Sl Line location Approx Specificati Matl

no length on
1 φ3” Header with 1” stubs at circuits connected to pumps 8 mtrs. φ3” sch 40 A-106 Gr. B
03/3R/10/10R
2 φ4” inlet outlet circuits connected to condenser 37-E-06 56 mtrs φ4” sch 40 A-106 Gr. B
3 φ4” inlet drain connected to condenser 37-E-02B 14 mtrs φ4” sch 40 A-106 Gr. B
4 φ16” inlet header connected to cooler 37-E-02B 4 mtrs φ16” sch A-106 Gr. B / API
20 5L
5 φ8” inlet outlet circuits connected to coolers 37-E-03/7 18 mtrs φ8” sch 30 A-106 Gr. B / API
5L
5 φ2” inlet outlet circuits connected to coolers 37-E-03/7 3 mtrs φ2” sch 80 A-106 Gr. B
6 φ12” inlet circuits connected to coolers 37-E-08A/B 10 mtrs φ12” sch A-106 Gr. B / API
30 5l
7 φ6” line connected to coolers 37-E-08A/B inlet circuits 4 mtrs φ12” sch A-106 Gr. B / API
40 5l
JOBS TO BE IMPLEMENTED DURING FORTHCOMING SHUTDOWN
DATE: 03/08/07
Scheme
Sl. No. Name of the Scheme Execution By Agency
No.
Area : CDU-I (U-11)

PROCESS MODIFICATION SCHEMES
1 41 Replacement of cooling water battery limit Maintenance Under lining up
valve at FOB (Gr-10)
2 232 Provision of bypass facility in naptha - do - Available
caustic and water wash mixing of valve of
CDU-I
3 233 Routing of PF(11-C-101) & MF(11-C-01) - do - - do -
naptha to slop header in CDU-I
4 234A Provision of back flushing facility in CDU-I - do - - do -
trim coolers
5 236A Modification of LPG processing facility in - do - - do -
CDU-I
6 237 Routing of 90-140 cut Naphtha ex CDU-I to - do - - do -
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 Project Under lining up
8 140 Modification in discharge and warm up line Maintenance Agency available
of RCO pumps (16P07A/B/C of CDU-II)
9 231 Provision of isolation valve in the SKCR - do - - do -
return line ex 16-E-33 (splitter reboiler) of
CDU-II
10 234B Provision of back flushing facility in CDU-II - do - - do -
trim coolers
11 236B Modification of LPG processing facility in - do - - do -
CDU-II
Area : FCCU (U-17/18/19)

AF JOBS
12 RH0142 Water trim cooler at debutaniser overhead Project Agency available
circuit of RFCCU
13 RH0272 Modification in Belco Filtering Module - do - Under lining up
14 51 Catalyst lift line support modification Maintenance By Maint. Plg.
RFCCU
15 177 Provision of caustic line in T-109B and - do - Agency available
caustic supply to MSQ
16 185 Provision of control valve and flow water in - do - - do -
the bypass and inlet of pall filter
respectively
17 199 Process scheme for segregation of wild - do - - do -
naptha and MSQ naptha injection to FCCU
reactor riser
Scheme
No.
18 200 Provision of inter-connection between - do - - do -
18P42A/B and 18P52A/B from discharge
19 229 Provision of jump over connection in MSQ - do - - do -
lean/rich Amine to FCCU Amine section
20 Replacement of RFCCU stack - do - - do -
21 Platform at dosing tank in MAB (only - do - - do -
drawing required)
Area : CRU (U-22)

22 33 Continuation of 6" fire water header at FOB Maintenance Agency available
along Road-'C4'
Area : KHDS (U-23)

23 15 Use of 23B05 of KHDS unit at FOB as Maintenance Agency available
knock out pot of sour water ex-VisBreaker
Unit
24 Modification of supports of reboiler vapour - do - - do -
return line ex 23E01 to 23C01 due to
vibration problem
25 Water washing facility in 23-E-03A/B - do -
Area : DHDS (U-25)

26 Spill back arrangement in recycle gas Maintenance Agency available
compressor
27 227 Routing of underground fire water header - do - - do -
through covered trench laid in between
DHDS & Hydrogen unit
28 Modification in inlet pass line & its supports - do - - do -
to 25-F-01 ex 25-E-02D in DHDS Unit due
to vibration problem
29 Modification in supports of inlet pass line to - do - - do -
25-F-01 ex 25-E-02B in DHDS Unit due to
vibration problem (only supports)
30 Modification in supports of effluent piping - do - - do -
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 - do - - do -
between 85-P-107discharge and hot
condensate line from TPS at DHDS B/L
Area : SRU-II (U-28)

32 26 Separate service water header for SRU-II Maintenance Agency available
yard Sprinkler
Scheme
No.
Area : VDU-I (U-31)
33 131 Repl of gate valves in the motive steam line Maintenance Agency available
to ejector by globe valves in VDU-I
34 60 VDU-I Furnace (31F01) air preheater hot - do - - do -
air duct modifcation
Area: PDA (U-32)

AF JOBS
35 RH0136 VR Burning in LOB Project Agency lined up
36 RH0186 Repl of existing burners of 32-F-01 with low - do - LOA expected by 16/08/07
NOx burners
37 18 Provision of solonide operated shutdown Maintenance Agency available
valve in 32-F-01
38 20 Rerouting of anti-foam chemical injection - do - - do -
line in U-32
39 21 Provision of depressurising ROV at 32-B- - do - - do -
03 outlet line to flare
40 29 Flow control valve in the cooling water - do - - do -
supply line to 32-C-07
41 3 Relocation of existing PDA furnace 32-F-01 - do - - 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 - - do -
for providing auto draining facility
43 127 Piping connections for installation of new - do - - do -
propane compressor 32-K-101R
44 139 Provision of minimum circulation line in - do - - do -
DAO run down pumps
46 225 Modification of cooling water lines in U-32 - do - - do -
47 230 Provision of C2-C2 circulation facility in 32- - do - - do -

P-103A/B
48 235 Provision of back flushing facility for 32-E- - do - - do -
117A
49 239A Process scheme for providing double - do - - do -
isolation valves and flanged ends at high
50 247 Provision of ROVs at the suction lines of - do - - do -
32P110 A/B/C/D/E
51 248 Dismantling of redundant lines & - do - Separate agency is being
equipments in U-32 (PDA)(in addition to lined up
PS244)
52 244 Dismantling of redundant lines & - do - - do -
equipments in U-32 (PDA)
Scheme
No.
Area : FEU (U-33)
53 238 Process scheme for provision of fuel oil Maintenance Agency available
shutdown valve in 33F01 and 33F02
54 Modification in suction headers & its - do - - do -
supports of 33-P-7/7R/11/11R due to
vibration problem
55 Modification in supports of discharge lines - do - - do -
of 33-P-7/7R/11/11R due to vibration
problem
Area : HFU (U-35)

56 225 Modification of cooling water lines in U-35 Maintenance Agency available
57 239B Process scheme for providing double - do - - do -

isolation valve and flanged end at high
58 240 Process scheme for NRV in make up gas - do - - do -
line in U-35
Area : BBU (U-36)

59 249 Dismantling of redundant lines & Maintenace Separate agency is being
equipments in U-36 (BBU) lined up
Area : VBU (U-37)

AF JOBS
60 RH0186 Repl of existing burners of 37-F-01 with low Project LOA expected by 16/08/07
NOx burners
61 RH0193 Installation of new Preheat exchangers 37- Project LOA expected by 06/08/07.
E-01 E/F in VBU
62 216 Revival of slop transfer facility from 37B01 Maintenance Agency available
using 37P11
63 Modification in supports of suction & - do - - do -
discharge lines of 37-P-4/4R/13/13R due to
vibration problem
Area : NMPEU (U-38)

64 122 Addl fire fighting facility in column nos. 38- Maintenance Agency available
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 - - do -
down cooler 38-E-06
66 Enlargement of duct of 38-F-02 - do - New agency being lined up
Area : VDU-II (U-82)

AF JOBS
67 RH0136 Balance jobs for VR burning facility in VDU- Project Agency available
II
Scheme
No.
Area : SRU-III (U-83)
68 123 Provision stop valve in SRU-III super Maintenance Agency being lined up by
heater header Maint. Plg.
69 241 Recovery of condensate from SRU-III - do - Agency available
Area : CDWU (U-84)

70 207 Additional isolation valve in the suction of Maintenance Agency available
recycle compressor 84K02A/B in CDW Unit
Area : MSQIU (U-85/86/87)

71 220 Rerouting of DIH bottom stream to HGU Maintenance Agency available
naptha pool in MSQ unit
72 214 Modification of existing Pygass filter circuit - do - - do -
for SHU feed at prime G+ unit
Area : TPS
AF JOBS
73 RH0135 VR Burning in TPS Project Agency lined up
74 58 Installation of welded valve in BFW Line of Maintenance Estimate clubbed with
TPS for boiler No. 1, 2 & 3 Maintenance job.
75 Enlargement of suction piping of 64P01L - do - Agency available
Area: GT
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 P&U Agency for motor repl job
(Electrical) / available; coupling repl to be
Maint. (Mech) done by Workshop
78 RH0161 Modernisation of 1st Gantry - Additional Project Estimate shall be prepared
jobs including facelifting after approval of additional
jobs
79 RH0218 Hook-up for Flare Gas Recovery System Maint. Agency available
80 175 Repl of existing impellers & couplings of Maintenance To be done by Workshop
DHDS feed pumps 61-P-101A/B with
higher size impellers
81 Repl of existing impeller of HGU feed pump - do - - do -
61-P-102A with higher dia impeller
82 Flare line replacement - do - Civil: Agencies lined up;
Mech: Agency by Maint. Plg.
83 Modification in supports of MP steam line - do -

in Track-B pipe rack in Offsite
Scheme
No.
Area : REPLACEMENT ITEMS
84 Monel Chimney tray for top portion of main Maintenance By Maint. Planning
CDU column 11-C-01
85 Tube bundles: - do - - do -
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
86 Heat Exchanger Assembly - do - - do -

a) 34-E-3.7A
87 Vessel - do - - do -
a) 61-B-02
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 :
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:
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:
33-E-4, 5A/B, 6, 11C/D, 14
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:
34-E-15A/B/C/D
HFU
EXCHANGER:
35-E-2, 102, 6, 7
VBU
EXCHANGER:
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.
1.1 6” Sour gas battery limit valve – needs hot job for matching flange
1.2 3 Nos 6” B/L Gate valves on Fuel Gas line revisioning / replacement
1.3 6” Audco valve on FG line
1.4 CW return Battery limit valve to provide
1.5 Isolation valve on 3” CW return line of 37E03
1.6 37-P-4 : Suction B/V passing - to rectify
1.7 Rectification of 2” FG burner line from Audco valve to Individual burners
1.8 Repair of 37- E01 and E08 S/S blow down line to 6” blowdown main header before
NRV.
1.9 BPCV –01 droping for cleaning
1.10 Dechoking / inspection of 6” vertical transfer line from BPCV (Approx 20 M) after
opening flanges.
1.11 2” Slop line de-choking from P9/9R to Column bott.
1.12 De-choking of corrosion injection line upto C1 & C4 and providing break flanges for
ease of online maint.
1.13 ¾” leaky tracing steam line at B/limit pipe rack
1.14 Battery limit FO & FG damaged PG manifold to rectify
1.15 Tracing steam line leak near 37P114A inside Trench
1.16 Utility air line tap off for flue gas sampling redundant lines removal
1.17 Steam leak from tracing steam line of Slop header west side of F1
1.18 37E1D:Tube side I/l bleeder valve damaged wheel missing ( Repair)
1.19 About 750 nos of short and long bolts to be rectified. Point wise check list prepared
CIDW
EXCHANGER:
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. Dia 2” Condensate line flange leak near P 02 A

2. Steam leak above P-20A/B
3. Dia 1” F 01 Convection Box purging steam line. (Inside the Explosion door box casing)
4. Condensate header end blind flange at pipe rack near compressor house.
5. Dia 1” Condensate line pinhole leak near B/L, on O/H pipe rack
6. Pin Hole leak at pipe rack inside compressor house.
7. C 05 ejector platform near by steam leak (tracing)
8. Steam traps to be revision/ replaced (Approx 100 Nos)
rd
9. Tracing steam leak from R 02 3 platform.
10. Steam leak from 2” header near u-84 flare KOD
11. Condensate line leak near CBD vessel-on manifold
2.0 Passing Valves Revisioning / Replacement jobs
Sl No Description/ Location Size/ Rating Nos

1 P 02A/B suction valve 6”/150 lb 2
2 P15 A/B min flow C/v bypass line 2”/1500lb 2
valves
3 P 02 A/B seal oil filters isolation ½”/2500lb 12
valves
4 P 14 B discharge bleeder drain valve 1”/1500lb 1
damaged
5 P15 A/B U/S, D/S & By-pass B/V of 2”/1500lb 6 nos
2” Min circl. C/V
6. 84-P2A/B seal oil filters isolation ½”/2500lb 16 nos
valves
3.0 Equipment related jobs
1. M 01 to be opened and cleaned. Cartridges to be replaced if required.

2. M 02 to be opened and cleaned. Cartridges to be replaced if required
3. P 02 A/B seal oil coolers/ lube oil coolers to be cleaned.
4. EA 03/M3 bearing replacement. All Fin fan coolers’ fans to check
5. 84- K 01A/B, K 02 A/B lubricator cleaning and lines dechoking.
6. 84-P19 A/B discharge line to CBD to be provided with NRV.
7. 84-K 01 A/B, K 02 A/B jacket water circuit view glasses to be cleaned.
8. 84-P 02 B seal leak, consuming more lube oil
9. 84-P 02 A/B seal oil filters to be provided.
10. P-02A/B view glasses on CW line to be cleaned
11. G-01A/B –new cartridges to be installed
12. K-01A/B -Jacket water coolers and Lube Oil coolers to be opened and cleaned- 4 Nos.
13. K-02A/B- Jacket water coolers and Lube Oil coolers to be opened and cleaned- 4 Nos.
4.0 Miscellaneous Jobs
1. G 01 A/B drain Spectacle blinds position to be shifted to Upstream of the B/V.

2. B 31 vent to flare line to be dechoked.
3. B 04 level troll diaphragm flanges (3 Nos) leaking.
4. Suction isolation valves to be provided in K 02 A/B
5. Separate C/W lines to be provided for Seal oil coolers in P 02 A/B.
6. P14 A/B lube oil coolers to be cleaned, Seal oil cooler C/W lines to be dechoked.
7. P 15 A/B lube oil coolers to be cleaned
8. P 03 A/B seal oil cooler C/W lines to be dechoked.
9. P 18 A/B seal oil cooler C/W lines to be dechoked
10. P3 A suction strainer flange leak
11. P-15A taking high amps- to be attended
12. Cleaning of all pilot gas/FG burners in F-01/02/03-Total:10X2=20 Nos.
13. 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
5.0 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. CBD level switches and level indicator to be attended.

2. Seal nitrogen Pressure transmitter with DCS indication to be provided for K 02 A like in K 02 B
3. P15 A/B discharge C/Vs FV2402, FV2403 is heavily passing to be attended.
4. FV2401 is heavily passing to be attended.
5. B 04 level troll diaphragm flanges are leaking.
6. P 01 A/B discharge line FT1201 diaphragm flanges leaking.
7. All hydrocarbon, H2S, H2 has detectors to be calibrated and one display page to be provided in DCS.
8. B 32 PG and TG glasses to be cleaned.
9. C/W flow indication causes frequent problems, to be attended. C/W line PGs and TGs to be marked.
10. R 03 bottom bed delta pressure indication erratic.
11. EA 06 louvers frequently cause problem, not operating smoothly.
12. 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 Civil Maintenance
1. DWO and HD lines to HSD header to be painted.

2. Flooring at certain places in TPM viewpoint.
3. Painting, stenciling as per TPM viewpoint.
4. Cleaning of pump bases, Compressors external parts and site area.
5. Insulation of R-03 is damaged-to be attended
8.0 Electrical Maintenance
1. P 02 A motor to be provided.
2. Aviation warning lights of furnace to be rectified
3. F 01/ F 02/F 03 igniters to be rectified.
4. All fused lamps to be replaced.
5. Lighting arrangement to be done for checking P 14 B gearbox lube oil in night shift.
DHDS BLOCK
FCCU

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

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
FCCU
2 MISC S/D MAINT.JOB IN FCCU CITY CONSTRUCTION
FCCU
CHK-III & CHK-II MAINT OF HEAT EXCHANGER/AIR FIN
3 R M WORKS
COOLERS
FCCU
HIRING OF EXPERT FOR MAINT.OF SLIDE VALVES AT
4 Z&J
FCCU
FCCU
5 HIRING OF EXPERT FOR MAINT.OF MAB & WGC BHEL
FCCU
6 REPLACEMENT OF 96" DIA FCCU BELLOW ZENITH
FCCU
7 BLINDING / DEBLINDING OF VAPOUR LINE BAPAN ENTERPRISES
FCCU
DE-CHOKING OF AERATION POINTS OF 18-R-01 BY
8 THE TECHNIC
DRILLING
FCCU
9 FIELD SERVICE FOR DRY GAS SEAL 18-K-10 BURGMANN
HGU
10 ARU MISC.S/D MAIMT.JOB IN HGU & ARU
HGU
11 ARU MISC MAINT OF COLUMN/VESSEL/FURNACE/REACTOR
HGU
CHK-III & CHK-II MAINT OF HEAT EXCHANGER/AIR FIN
12 ARU ROYAL CONSTRUCTION CO
COOLERS
DHDS
DHDS
13 OVERHAULING OF 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
SHU (U-
16 87) SKIMING OF CATALYST OF 87-R-01 DURING S/D-2007 CONTRACT RESOURCES
HGU
TO & FRO TRANSPORATION OF DRUMS & WOODEN
17 MSQ KALPANA ENTERPRISE
PLATFORMS
FOB
MISC.MAINT.JOBS OF FURNACE & COLUMN AT FOB
18 CITY CONSTRUCTION
DURING S/D-2007
FOB
19 MAINT OF 21-C-01 BAPAN ENTERPRISES
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
LOB
26 REP / MAINT OF COLUMNS IN UNIT-32 & UNIT-38 EXPO GAS CONTAINERS
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
LOB
30 PDA & NMP RELATED JOBS+TPS HEAT EXCH BHARAT ENGG
LOB
31 MAINT.OF HEAT EXCH OF U-31 / 33 / 34 / 35 / 37 / 84
LOB
COMPLETE RE-TUBING OF HEAT EXCHANGER 38-E-
32
11/12/13/24 AT LOB
LOB
33 MISC HOT JOB FOR LOB
LOB
34 MAINT.OF 37-C-01
LOB
35 MAINT.OF 84-C-01 CONTRACT RESOURCES
FOB LOB
REPLC.OF A/G , U/G C/W LINE & RISER PIPE OF PROCESS
36 TPS
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
GT
44 REPAIR OF SPARE OF FRAME-5 OF GT BGGT
GT
REMOVAL,CLEANING & FIXING BACK OF AIR FILTER OF
45 BAPAN ENTERPRISES
GT
GT
46 TROUBLE SHOOTING & STARTING ASSISTANCE FOR GT BGGT
VDU-II
47 REP / MAINT OF 82-F-01
GEN
OUTSOURCING MANPOWER TO SUPERVISE S/D JOBS
48
DURING SEPT-OCT ' 07 AT H/R
GEN
49 HYDROBLAST CLEANING OF EXCHANGER USHA HYDROBLAST
GEN
50 VALVE REVISIONING AMRUTHA
GEN MAIMT & INSPECTION OF VARIOUS WASTE HEAT

51
BOILERS,HRSG & OTHER IBR PIPING & ALLIED JOBS
GEN
52 HIRING OF CRANE INDUSTRIAL HANDLING
GEN HYDROBLAST CLEANING OF EXCHANGER U-11 / 16 / 31 /

53
33 / 34 / 35 / 37 / 83 & 84
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. Points Observations

Available Not available
1. Eqpt. Erection plan available.
2. Does deployed crane has been load tested and has valid
test certificate.
3. Does crane has adequate boom length as specified in
erection plan
4. Does crane has Overload cut off facility and same has
been tested. Certificate available.
5. Does crane has load chart with respect to boom length
and angle.
6. Does crane has spark arrester fitted.
7. Are all path way hard surfaced and required plates are
placed for crane positioning and levelling
8. Checked all safety interlocking system
9. Does crane hook has locking arrangement and it is ok.
10. Is Crane movement area cordoned off
11. Are all lifting tools/tackles like slings, D-shackles etc
have min. required load carrying capacity
12. Are tools/tackles like slings, D-shackles etc load tested
and having valid test certificate.
13. Do Erection spreader beam size as per erection plan
14. Are all lifting lugs of specified sizes and thickness
15. Are the riggers involve in the jobs having past
experience?
16. Do Crane operator involve in the jobs experienced and
has valid certificate/License for crane operation?
17. Are all the lifting/ dismantling loads calculated
18. Working at height permit obtained.
19. Are all persons wearing relevant PPE
20. Valid work permit obtained
Signature of EIC Signature of supervisor

ID Task Name Duration Start Finish 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
1 MAINT OF 11C01 19 days Fri 9/21/07 Wed 10/10/07 0%
2 Shutting down of column with KM 124 hrs Fri 9/21/07 Wed 9/26/07 0%
3 Opening of manholes 16 hrs Wed 9/26/07 Thu 9/27/07 0%
4 Provision of exhaust fans 16 hrs Thu 9/27/07 Thu 9/27/07 0%
5 Air circulation and gas test 24 hrs Thu 9/27/07 Fri 9/28/07 0%
6 External scaffolding 48 hrs Wed 9/26/07 Fri 9/28/07 0%
7 Opening of tray manways 24 hrs Fri 9/28/07 Sat 9/29/07 0%
8 Cleaning of column shell and tra 48 hrs Sat 9/29/07 Mon 10/1/07 0%
9 Inspection of column 48 hrs Mon 10/1/07 Wed 10/3/07 0%
10 Repair of column internals as pe 36 hrs Tue 10/2/07 Thu 10/4/07 0%
11 Final inspection by Process/ Pro 16 hrs Thu 10/4/07 Thu 10/4/07 0%
12 Refixing of tray manways 24 hrs Thu 10/4/07 Fri 10/5/07 0%
13 Removal of scaffolding 36 hrs Thu 10/4/07 Fri 10/5/07 0%
14 Box-up of manholes 24 hrs Fri 10/5/07 Sat 10/6/07 0%
15 Deblinding 16 hrs Sat 10/6/07 Sun 10/7/07 0%
16 Start up activities 72 hrs Sun 10/7/07 Wed 10/10/07 0%
Critical Baseline Milestone Split

Critical Split Milestone Task Progress
Critical Progress Summary Progress Baseline
Project: 11C01 Task Summary Baseline Split

Date: Thu 9/6/07 Split Project Summary Baseline Milestone
Task Progress Critical Split Milestone
Baseline Critical Progress Summary Progress
Baseline Split Task Summary
Page 1
ID Task Name Duration Start Finish 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
1 MAINT OF 11F01 19.5 days Fri 9/21/07 Wed 10/10/07 0%
2 Shutting down of furnace 48 hrs Fri 9/21/07 Sun 9/23/07 0%
3 Gas Test & Man entry 4 hrs Sun 9/23/07 Sun 9/23/07 0%
4 Provision of Scaffolding inside Furnace 36 hrs Sun 9/23/07 Tue 9/25/07 0%
5 Preliminary Inspection of Furnace & Mark 8 hrs Tue 9/25/07 Tue 9/25/07 0%
6 Cleaning of Radiation & Convection Tube 48 hrs Tue 9/25/07 Thu 9/27/07 0%
7 Detailed Inspection of furnace 16 hrs Thu 9/27/07 Fri 9/28/07 0%
8 Cutting & removal of Radiation Tubes (4 24 hrs Tue 9/25/07 Wed 9/26/07 0%
9 Insertion of tubes, Edge Preparation & Fi 24 hrs Tue 9/25/07 Wed 9/26/07 0%
10 Welding of new joints (08 Nos.) 72 hrs Wed 9/26/07 Sat 9/29/07 0%
11 Radiography of welded joints 24 hrs Sat 9/29/07 Sun 9/30/07 0%
12 Stress Releiving of New Joints (08 joints) 36 hrs Sun 9/30/07 Mon 10/1/07 0%
13 Post SR Hardness Checking of Weld join 8 hrs Mon 10/1/07 Tue 10/2/07 0%
14 Post SR Radiography of Welded joints 36 hrs Tue 10/2/07 Wed 10/3/07 0%
15 Spring hanger replacement 48 hrs Tue 9/25/07 Thu 9/27/07 0%
16 Ceramic Fibre Repair at Conv. Section 48 hrs Tue 9/25/07 Thu 9/27/07 0%
17 Hydraulic Pressure Testing of Furnace Co 24 hrs Wed 10/3/07 Thu 10/4/07 0%
18 Removal of scaffolding 24 hrs Thu 10/4/07 Fri 10/5/07 0%
19 Floor Repair / Burner Throat Repair 24 hrs Fri 10/5/07 Sat 10/6/07 0%
20 Final Inspection 4 hrs Sat 10/6/07 Sat 10/6/07 0%
21 Repair / replacement of Skin thermocoup 48 hrs Sun 9/23/07 Tue 9/25/07 0%
22 Revisioning of Damper Plates / Explosion 120 hrs Sun 9/23/07 Fri 9/28/07 0%
23 revisioning of Burner Blocks 120 hrs Fri 9/21/07 Wed 9/26/07 0%
24 Boxing up of Burner Blocks 16 hrs Sat 10/6/07 Sun 10/7/07 0%
25 Final Box up of Manway 8 hrs Sun 10/7/07 Sun 10/7/07 0%
26 Start up activities 72 hrs Sun 10/7/07 Wed 10/10/07 0%

Project: 11f01 Task Summary Baseline Split

Page 1
T F S S M T W T F S S M T W T F S S M T W T F
1 MAINT OF 16-F-01 18.33 days Fri 9/21/07 Tue 10/9/07 0%
2 Shutting down of furnace 48 hrs Fri 9/21/07 Sun 9/23/07 0%
3 Gas Test & Man entry 4 hrs Sun 9/23/07 Sun 9/23/07 0%
4 Provision of Scaffolding inside F 36 hrs Sun 9/23/07 Tue 9/25/07 0%
5 Preliminary Inspection of Furnac 8 hrs Tue 9/25/07 Tue 9/25/07 0%
6 Cleaning of Radiation & Convec 48 hrs Tue 9/25/07 Thu 9/27/07 0%
7 Detailed Inspection of furnace 16 hrs Thu 9/27/07 Fri 9/28/07 0%
8 Cutting & removal of Radiation T 16 hrs Tue 9/25/07 Wed 9/26/07 0%
9 Insertion of tubes, Edge Prepara 24 hrs Tue 9/25/07 Wed 9/26/07 0%
10 Welding of new joints (08 Nos.) 56 hrs Wed 9/26/07 Fri 9/28/07 0%
11 Radiography of welded joints 24 hrs Fri 9/28/07 Sat 9/29/07 0%
12 Stress Releiving of New Joints ( 36 hrs Sat 9/29/07 Mon 10/1/07 0%
13 Post SR Hardness Checking of W 8 hrs Mon 10/1/07 Mon 10/1/07 0%
14 Post SR Radiography of Welded 24 hrs Mon 10/1/07 Tue 10/2/07 0%
15 Spring hanger replacement 48 hrs Tue 9/25/07 Thu 9/27/07 0%
16 Ceramic Fibre Repair at Conv. 48 hrs Tue 9/25/07 Thu 9/27/07 0%
17 Hydraulic Pressure Testing of Fu 24 hrs Tue 10/2/07 Wed 10/3/07 0%
18 Removal of scaffolding 24 hrs Wed 10/3/07 Thu 10/4/07 0%
19 Floor Repair / Burner Throat Re 24 hrs Thu 10/4/07 Fri 10/5/07 0%
20 Final Inspection 4 hrs Fri 10/5/07 Fri 10/5/07 0%
21 Repair / replacement of Skin the 48 hrs Sun 9/23/07 Tue 9/25/07 0%
22 Revisioning of Damper Plates / 120 hrs Sun 9/23/07 Fri 9/28/07 0%
23 revisioning of Burner Blocks 120 hrs Sun 9/23/07 Fri 9/28/07 0%
24 Boxing up of Burner Blocks 16 hrs Fri 10/5/07 Sat 10/6/07 0%
25 Final Box up of Manway 8 hrs Sat 10/6/07 Sat 10/6/07 0%
26 Start up activities 72 hrs Sat 10/6/07 Tue 10/9/07 0%

Project: 16F01 Task Summary Baseline Split

Page 1
ID Task Name Duration Start 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
1 MAINT OF 32-F-01 29 days Thu 9/13/07 Fri 10/12/07 0%
2 Shutting down of furnace 120 hrs Thu 9/13/07 Tue 9/18/07 0%
3 Gas Test & Man entry 4 hrs Tue 9/18/07 Tue 9/18/07 0%
4 Provision of Scaffolding inside F 24 hrs Tue 9/18/07 Wed 9/19/07 0%
5 Preliminary Inspection of Furnac 8 hrs Wed 9/19/07 Wed 9/19/07 0%
6 Cleaning of Radiation & Convec 48 hrs Sun 9/23/07 Tue 9/25/07 0%
7 Detailed Inspection of furnace 16 hrs Tue 9/25/07 Wed 9/26/07 0%
8 External Scaffolding 24 hrs Tue 9/18/07 Wed 9/19/07 0%
9 Dismantling of stack 72 hrs Wed 9/19/07 Sat 9/22/07 0%
10 Dismantling of refractory 96 hrs Wed 9/19/07 Sun 9/23/07 0%
11 Erection of stack 72 hrs Sat 9/22/07 Tue 9/25/07 0%
12 Marking of damaged casing plat 24 hrs Sun 9/23/07 Mon 9/24/07 0%
13 Cutting of damaged casing plate 48 hrs Mon 9/24/07 Wed 9/26/07 0%
14 Erection of plates 48 hrs Wed 9/26/07 Fri 9/28/07 0%
15 Welding of new casing plates 96 hrs Fri 9/28/07 Tue 10/2/07 0%
16 Surface cleaning 96 hrs Sun 9/23/07 Thu 9/27/07 0%
17 Lug welding 48 hrs Tue 9/25/07 Thu 9/27/07 0%
18 Painting of casing plate 120 hrs Thu 9/27/07 Tue 10/2/07 0%
19 Re lining with new ceramic fibre 96 hrs Sun 9/30/07 Thu 10/4/07 0%
20 Hydraulic Pressure Testing of Fu 24 hrs Thu 9/27/07 Fri 9/28/07 0%
21 Removal of internal scaffolding 16 hrs Thu 10/4/07 Fri 10/5/07 0%
22 Floor Repair / Burner Throat Re 24 hrs Fri 10/5/07 Sat 10/6/07 0%
23 Final Inspection 8 hrs Sat 10/6/07 Sat 10/6/07 0%
24 Repair / replacement of Skin the 48 hrs Sun 9/23/07 Tue 9/25/07 0%
25 Revisioning of Damper Plates / 120 hrs Sun 9/23/07 Fri 9/28/07 0%
26 Repair/Replc. of Explosion door 48 hrs Sun 9/23/07 Tue 9/25/07 0%
27 revisioning of Burner Blocks 120 hrs Sun 9/23/07 Fri 9/28/07 0%
28 Boxing up of Burner Blocks 16 hrs Sat 10/6/07 Sun 10/7/07 0%
29 Final Box up of Manway 8 hrs Sun 10/7/07 Sun 10/7/07 0%
30 Start up activities 120 hrs Sun 10/7/07 Fri 10/12/07 0%

Project: 32F01 Task Summary Baseline Split

Page 1
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
3 1 1 1 6 30
B u n d . P u llin g
4 15 4 8 6 030
5 19 7 10 8 1 6 30
H y d r o b la s t in g
6 23 11 13 10 4 8 6 3
7 27 15 17 13 7 10 8 6
8 31 19 21 17 11 13 10 8 In s p e c t io n
9 35 23 25 21 15 17 13 10
10 38 26 29 25 19 21 17 13 In s e rt io n
Days
11 38 29 32 29 23 25 21 17
12 38 32 35 32 26 29 25 21 S h e ll T e s t
13 38 32 38 35 29 32 29 25
14 38 32 38 38 32 35 32 29
Tube Tes t
15 38 32 38 38 32 38 35 32
16 38 32 38 38 32 38 38 35
B o x -U p
17 38 32 38 38 32 42 30 38
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 30 O p e n in g
2 7 30
3 11 7 30 B u n d . P u l l in g
4 16 11 7 30
5 21 16 11 7 30
H y d ro b la s t in g
6 26 21 16 11 7 30
7 31 26 21 16 11 7 33
In s p e c t i o n
8 34 31 26 21 16 11 7 7
D ays
9 38 34 31 26 21 16 11 11
In s e r t io n
10 42 38 34 31 26 21 16 16
11 42 38 38 34 31 26 21 21
S h e ll T e s t
12 42 38 42 38 34 31 26 26
13 42 38 42 42 38 34 31 31
Tu b e Te s t
14 42 38 42 42 38 38 34 34
15 42 38 42 42 38 42 38 38
16 42 38 42 42 38 42 42 42 B o x -U p
ID Task Name Duration Start Finish 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
1 FCCU DHUTDOWN JOBS SEPT' 2007 632 hrs Sun 9/16/07 Fri 10/12/07 0%
2 REGENERATOR JOBS 632 hrs Sun 9/16/07 Fri 10/12/07 0%
3 SHUTTING DOWN ACTIVITY 68 hrs Sun 9/16/07 Wed 9/19/07 0%
4 GAS TEST & MAN ENTRY 4 hrs Wed 9/19/07 Wed 9/19/07 0%
5 REMOVAL OF REMAINING CATA 16 hrs Wed 9/19/07 Thu 9/20/07 0%
6 ERECTION OF SCAFFOLDING 24 hrs Wed 9/19/07 Thu 9/20/07 0%
7 OPENING OF CYCLONE MANWA 48 hrs Wed 9/19/07 Fri 9/21/07 0%
8 PROVISION OF ROPE LADDER IN 8 hrs Sun 9/23/07 Mon 9/24/07 0%
9 GENERAL CLEANING OF REGEN 72 hrs Thu 9/20/07 Sun 9/23/07 0%
10 GENERAL INSPECTION OF REGE 120 hrs Sun 9/23/07 Fri 9/28/07 0%
11 MECH. HOT JOB & REFRACTORY 72 hrs Fri 9/28/07 Mon 10/1/07 0%
12 REPAIR / REPLACEMENT OF NO 48 hrs Fri 9/28/07 Sun 9/30/07 0%
13 SUPPORTING OF LIFT PIPE USIN 24 hrs Thu 9/20/07 Fri 9/21/07 0%
14 REMOVAL OF TIE RODS AT THE 24 hrs Fri 9/21/07 Sat 9/22/07 0%
15 CUTTING OF MANWAY OPENING 16 hrs Fri 9/21/07 Sat 9/22/07 0%
16 MAKING CAGE ARRANGEMENT 8 hrs Sat 9/22/07 Sat 9/22/07 0%
17 INSPECTION OF LIFT LINE 8 hrs Sat 9/22/07 Sun 9/23/07 0%
18 MARKING OF LENGTH OF LIFT P 8 hrs Fri 9/21/07 Sat 9/22/07 0%
19 CHIPPING OF REFRACTORY AT 24 hrs Sat 9/22/07 Sun 9/23/07 0%
20 HOLDING OF CATALYST DISTRIB 16 hrs Fri 9/21/07 Sat 9/22/07 0%
21 CUTTING OF 3 NOS. POCKETS A 16 hrs Fri 9/21/07 Sat 9/22/07 0%
22 REMOVAL OF 4 NOS. CLEATS AN 16 hrs Sat 9/22/07 Sun 9/23/07 0%
23 CUTTING OF LIFT PIPE (J-1) BY G 8 hrs Sun 9/23/07 Sun 9/23/07 0%
24 CUTTING OF LIFT PIPE (J-2) BY G 8 hrs Sun 9/23/07 Sun 9/23/07 0%
25 LOWERING DOWN & REMOVAL O 8 hrs Sun 9/23/07 Mon 9/24/07 0%
26 CUTTING OF LIFT PIPE (J-4) BY G 16 hrs Mon 9/24/07 Mon 9/24/07 0%
27 CUTTING OF LIFT PIPE (J-3) BY G 16 hrs Mon 9/24/07 Tue 9/25/07 0%
28 LOWERING DOWN & REMOVAL O 8 hrs Tue 9/25/07 Tue 9/25/07 0%
29 LIFTING OF RISER CATALYST DI 16 hrs Tue 9/25/07 Tue 9/25/07 0%
30 REPAIR OF HEXMESH AND RESC 24 hrs Tue 9/25/07 Wed 9/26/07 0%
31 EDGE PREPARATION AND DP O 16 hrs Tue 9/25/07 Wed 9/26/07 0%
32 ERECTION AND FIT-UP OF J3 16 hrs Wed 9/26/07 Wed 9/26/07 0%

Project: FCCU Task Summary Baseline Split

Page 1
33 WELDING OF J3 WITH STAGE W 16 hrs Wed 9/26/07 Thu 9/27/07 0%
34 LOWERING OF BOTH THE PIECE 8 hrs Thu 9/27/07 Thu 9/27/07 0%
35 ERECTION AND FIT-UP OF J4 32 hrs Thu 9/27/07 Sat 9/29/07 0%
36 WELDING OF J3 & J4 WITH STAG 32 hrs Sat 9/29/07 Sun 9/30/07 0%
37 LIFTING OF RISER PIPE 8 hrs Sun 9/30/07 Sun 9/30/07 0%
38 ALIGNMENT AND FIT UP OF J2, J 16 hrs Sun 9/30/07 Mon 10/1/07 0%
39 WELDING OF J2, J5 & VERTICAL 24 hrs Mon 10/1/07 Tue 10/2/07 0%
40 RADIOGRAPHY INSIDE REGENE 16 hrs Tue 10/2/07 Wed 10/3/07 0%
41 RESCO LINING & CURING OF BA 24 hrs Wed 10/3/07 Thu 10/4/07 0%
42 REMOVAL OF CAGE FROM LIFT 8 hrs Wed 10/3/07 Thu 10/4/07 0%
43 WELDING OF MANWAY OPENING 16 hrs Thu 10/4/07 Thu 10/4/07 0%
44 FILLING OF CEREMIC BLANKET 24 hrs Wed 10/3/07 Thu 10/4/07 0%
45 APPLICATION OF REFRACTORY 16 hrs Wed 10/3/07 Wed 10/3/07 0%
46 WELDING OF 4 NOS. CLEAT ON 16 hrs Wed 10/3/07 Wed 10/3/07 0%
47 CLOSING OF 3 NOS. POCKET & N 16 hrs Wed 10/3/07 Thu 10/4/07 0%
48 FITTING OF LIFT LINE TURN BUC 16 hrs Wed 10/3/07 Thu 10/4/07 0%
49 REMOVAL OF LIFTING LUGS IN R 16 hrs Thu 10/4/07 Fri 10/5/07 0%
50 FITTING OF ALL CONNECTING P 16 hrs Thu 10/4/07 Fri 10/5/07 0%
51 WELDING OF ALL CONNECTING 16 hrs Thu 10/4/07 Fri 10/5/07 0%
52 REVISIONING OF PLUG VALVE O 72 hrs Thu 9/20/07 Sun 9/23/07 0%
53 FINAL CHECKING OF PLUG VALV 8 hrs Fri 10/5/07 Fri 10/5/07 0%
54 REMOVAL OF SCAFFOLDING FR 16 hrs Fri 10/5/07 Sat 10/6/07 0%
55 FINAL CLEANING 8 hrs Sat 10/6/07 Sat 10/6/07 0%
56 FINAL INSPECTION BY PS, PN, IN 8 hrs Sat 10/6/07 Sun 10/7/07 0%
57 BOX UP OF REGENERATOR & CY 24 hrs Sun 10/7/07 Mon 10/8/07 0%
58 DEBLINDING 24 hrs Sun 10/7/07 Mon 10/8/07 0%
59 START UP ACTIVITY 96 hrs Mon 10/8/07 Fri 10/12/07 0%
60 REACTOR JOBS 632 hrs Sun 9/16/07 Fri 10/12/07 0%
63 OPENING OF CYCLONE MANWA 48 hrs Wed 9/19/07 Fri 9/21/07 0%
64 OPENING / CUTTING OF RISER M 48 hrs Wed 9/19/07 Fri 9/21/07 0%


Page 2
65 PROVISION OF INSPECTION CAG 8 hrs Fri 9/21/07 Fri 9/21/07 0%
66 PROVISION OF ROPE LADDERS 8 hrs Fri 9/21/07 Fri 9/21/07 0%
67 REMOVAL OF REMAINING CATA 16 hrs Wed 9/19/07 Thu 9/20/07 0%
68 ERECTION OF SCAFFOLDING IN 72 hrs Thu 9/20/07 Sun 9/23/07 0%
69 GENERAL CLEANING OF REACT 48 hrs Sun 9/23/07 Tue 9/25/07 0%
70 GENERAL INSPECTION OF REAC 24 hrs Tue 9/25/07 Wed 9/26/07 0%
71 MECH. HOT JOB & REFRACTORY 168 hrs Wed 9/26/07 Wed 10/3/07 0%
72 REPAIR / REPLACEMENT OF NO 120 hrs Wed 9/26/07 Mon 10/1/07 0%
73 INSPECTION OF RISER & CYCLO 48 hrs Fri 9/21/07 Sun 9/23/07 0%
74 REPAIR JOBS IN RISER & CYCLO 96 hrs Sun 9/23/07 Thu 9/27/07 0%
75 DECHOKING OF HCO NOZZLES 120 hrs Wed 9/26/07 Mon 10/1/07 0%
76 REPLACEMENT OF VB NAPHTHA 48 hrs Wed 9/26/07 Fri 9/28/07 0%
77 REPAIR OF LDD TUBES, IF REQU 48 hrs Wed 9/26/07 Fri 9/28/07 0%
78 MECHANICAL & REFRACTORY J 96 hrs Wed 9/26/07 Sun 9/30/07 0%
79 FINAL INSPECTION OF RISER & 8 hrs Thu 9/27/07 Thu 9/27/07 0%
80 REMOVAL OF CAGE FROM RISE 24 hrs Thu 9/27/07 Fri 9/28/07 0%
81 REMOVAL OF SCAFFOLDING FR 16 hrs Wed 10/3/07 Wed 10/3/07 0%
82 FINAL CLEANING 8 hrs Wed 10/3/07 Thu 10/4/07 0%
83 FINAL INSPECTION BY PS, PN, IN 8 hrs Thu 10/4/07 Thu 10/4/07 0%
84 WELDING OF RISER MANHOLES 24 hrs Thu 10/4/07 Fri 10/5/07 0%
85 BOX UP OF REACTOR AND CYC 24 hrs Thu 10/4/07 Fri 10/5/07 0%
88 ORIFICE CHAMBER JOBS 632 hrs Sun 9/16/07 Fri 10/12/07 0%
91 REMOVAL OF REMAINING CATA 8 hrs Wed 9/19/07 Wed 9/19/07 0%
92 CUTTING OF GRID MANWAYS 120 hrs Wed 9/19/07 Mon 9/24/07 0%
93 PROVISION OF ROPE LADDER F 8 hrs Mon 9/24/07 Tue 9/25/07 0%
94 GENERAL CLEANING OF ORIFIC 16 hrs Tue 9/25/07 Tue 9/25/07 0%
95 INSPECTION OF ORIFICE CHAMB 16 hrs Tue 9/25/07 Wed 9/26/07 0%
96 MECH. HOT JOB & REFRACTORY 72 hrs Wed 9/26/07 Sat 9/29/07 0%


Page 3
97 FINAL INSPECTION OF ORIFICE 16 hrs Sat 9/29/07 Sun 9/30/07 0%
98 WELDING OF GRID MANWAYS 96 hrs Sun 9/30/07 Thu 10/4/07 0%
99 BOX UP OF ORIFICE CHAMBER M 24 hrs Thu 10/4/07 Fri 10/5/07 0%
102 CO-BOILER JOBS 632 hrs Sun 9/16/07 Fri 10/12/07 0%
105 REMOVAL OF REMAINING CATA 48 hrs Wed 9/19/07 Fri 9/21/07 0%
106 ERECTION OF INTERNAL SCAFF 24 hrs Thu 9/20/07 Fri 9/21/07 0%
107 OPENING AND CLEANING OF ST 72 hrs Wed 9/19/07 Sat 9/22/07 0%
108 CLEANING OF CO-BOILER TUBE 72 hrs Fri 9/21/07 Mon 9/24/07 0%
109 DRY INSPECTION OF COB 16 hrs Mon 9/24/07 Tue 9/25/07 0%
110 REPLACEMENT OF 03 NOS. SCR 48 hrs Tue 9/25/07 Thu 9/27/07 0%
111 REPLACEMENT OF 29 NOS. BAN 120 hrs Tue 9/25/07 Sun 9/30/07 0%
112 REPLACEMENT OF 01 NO SUPER 48 hrs Tue 9/25/07 Thu 9/27/07 0%
113 REPLACEMENT OF LEAKEY DRA 24 hrs Tue 9/25/07 Wed 9/26/07 0%
114 REPLACEMENT OF M/H COVER 24 hrs Tue 9/25/07 Wed 9/26/07 0%
115 BOX-UP OF STEAM DRUMS 16 hrs Sun 9/30/07 Sun 9/30/07 0%
116 INTERNAL HYDROTESTION 24 hrs Sun 9/30/07 Mon 10/1/07 0%
117 HYDROTESTING BY IBR 24 hrs Mon 10/1/07 Tue 10/2/07 0%
118 REMOVAL OF SCAFFOLDING 12 hrs Tue 10/2/07 Wed 10/3/07 0%
119 FINAL INSPECTION OF COB BY P 8 hrs Wed 10/3/07 Wed 10/3/07 0%
120 BOX UP OF COB MANHOLES 16 hrs Wed 10/3/07 Thu 10/4/07 0%


Page 4
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 10
O p e n i n g o f c o ve r s
2 3 10
H y d ro b la s t C le a n in g
3 5 3 1 10
In d i vi d u a l T u b e
T e s t in g
4 7 5 3 3 10
In s p e c t i o n
5 9 7 5 5 3 10 C o ve r B o x u p
6 11 9 7 7 5 3 1 H y d ro t e s t in g
Days
7 13 11 9 9 7 5 3 F in a l b o x u p
8 15 13 11 11 9 7 5
9 15 15 13 13 11 9 7
10 15 15 15 15 13 11 9
11 15 15 15 15 15 13 11
12 15 15 15 15 15 15 13
13 15 15 15 15 15 15 15
ID Task Name Duration Start Finish ep 17 Fri Sep 21 Tue Sep 25
3 12 9 6 3
1 CATALYST TUBE REPLACEMENT JOB 20 days Fri 9/21/07 Thu 10/11/07
2 SHUTTING DOWN/ STEAMING/ BLINDI 72 hrs Fri 9/21/07 Mon 9/24/07 0%
3 GAS TEST AND MANENTRY 4 hrs Mon 9/24/07 Mon 9/24/07 0%
4 ERECTION OF SCAFFOLDING 24 hrs Mon 9/24/07 Tue 9/25/07 0%
5 OPENING COLD COLT M/H 16 hrs Mon 9/24/07 Tue 9/25/07 0%
6 OPENING OF CATALYST TUBE - 60 No 24 hrs Mon 9/24/07 Tue 9/25/07 0%
7 UNLOADING OF CATALYST - 60 Nos. 72 hrs Tue 9/25/07 Fri 9/28/07
8 REMOVAL OF ROOF CORROGATED S 24 hrs Mon 9/24/07 Tue 9/25/07 0%
9 LOCKING OF PIG TAIL TUBE SPRINGS 16 hrs Mon 9/24/07 Tue 9/25/07 0%
10 REMOVAL OF PIG TAIL INSULATION 8 hrs Mon 9/24/07 Mon 9/24/07 0%
11 LOCKING CAT TUBE SPRING 16 hrs Mon 9/24/07 Tue 9/25/07 0%
12 DISMANTLING AND REMOVAL OF SPR 8 hrs Tue 9/25/07 Tue 9/25/07 0%
13 DISMANTLING AND REMOVAL OF SPR 8 hrs Tue 9/25/07 Tue 9/25/07 0%
14 CUTTING OF CATALYST TUBE - 35 JO 48 hrs Tue 9/25/07 Thu 9/27/07
15 CUTTING OF FURNACE ROOF & BOTT 48 hrs Tue 9/25/07 Thu 9/27/07
16 REMOVAL OF REFRACTORY MATERIA 48 hrs Tue 9/25/07 Thu 9/27/07
17 CUTTING OF PIG TAIL BY GRINDING - 24 hrs Mon 9/24/07 Tue 9/25/07 0%
18 LIFTING OF PIPE FROM TOP 48 hrs Wed 9/26/07 Fri 9/28/07
19 EDGE PREPARATOION AND DP TEST 48 hrs Thu 9/27/07 Sat 9/29/07
20 ERECTION OF NEW PIPE 96 hrs Thu 9/27/07 Mon 10/1/07
21 ALIGNMENT AND FIT UP OF CATALYS 96 hrs Fri 9/28/07 Tue 10/2/07
22 RADIOGRAPHY OF JOINTS 96 hrs Sat 9/29/07 Wed 10/3/07
23 WELDING OF JOINTS -35 Nos. 120 hrs Sun 9/30/07 Fri 10/5/07
24 RADIOGRAPHY OF JOINTS 72 hrs Wed 10/3/07 Sat 10/6/07
25 FIXING OF FURNACE ROOF & BOTTOM 24 hrs Tue 10/2/07 Wed 10/3/07
26 FIXING OF REFRACTORY MATERIAL A 48 hrs Wed 10/3/07 Fri 10/5/07
27 FIXING OF SPRING SUPPORT BEAM 48 hrs Tue 10/2/07 Thu 10/4/07
28 FIXING OF SPRING 48 hrs Wed 10/3/07 Fri 10/5/07
29 EDGE PREPARATOION AND DP TEST 48 hrs Thu 9/27/07 Sat 9/29/07
30 ALIGNMENT AND FIT UP OF PIG TAIL T 96 hrs Fri 9/28/07 Tue 10/2/07
31 WELDING OF PIG TAIL TUBES 48 hrs Sun 9/30/07 Tue 10/2/07
32 DP & RADIOGRAPHY OF PIG TAIL JOIN 16 hrs Tue 10/2/07 Wed 10/3/07

Project: HGU Task Summary Baseline Split

Page 1
ID Task Name Duration Start Finish ep 17 Fri Sep 21 Tue Sep 25
3 12 9 6 3
33 PROVIDING INSULATION ON PIG TAIL 24 hrs Wed 10/3/07 Thu 10/4/07
34 UNLOCKING OF PIG TAIL TUBES 24 hrs Thu 10/4/07 Fri 10/5/07
35 LOADING OF CATALYST 48 hrs Thu 10/4/07 Sat 10/6/07
36 INSPECTION OF FURNACE & TUBES 72 hrs Tue 9/25/07 Fri 9/28/07
37 REVISIONING OF BURNERS / DAMPER 96 hrs Tue 9/25/07 Sat 9/29/07
38 REVISIONING OF VALVES 96 hrs Tue 9/25/07 Sat 9/29/07
39 BOX-UP OF CATALYST TUBES 48 hrs Fri 10/5/07 Sun 10/7/07
40 BOX-UP OF COLD COLLECTOR 48 hrs Fri 10/5/07 Sun 10/7/07
41 REMOVAL OF SCAFFOLDING 12 hrs Sat 10/6/07 Sun 10/7/07
42 FURNACE FLOOR REPAIR 12 hrs Sun 10/7/07 Sun 10/7/07
43 BOX-UP OF FURNACE 8 hrs Sun 10/7/07 Mon 10/8/07
44 DEBLINDING ACTIVITIES 8 hrs Mon 10/8/07 Mon 10/8/07
45 START UP ACTIVITIES. 72 hrs Mon 10/8/07 Thu 10/11/07


Page 2
ue Sep 25 Sat Sep 29 Wed Oct 3 Sun Oct 7 Thu Oct 11 Mon O
3 12 9 6 3 12 9 6 3 12 9
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%


Page 3
ue Sep 25 Sat Sep 29 Wed Oct 3 Sun Oct 7 Thu Oct 11 Mon O
3 12 9 6 3 12 9 6 3 12 9
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%


Page 4
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
O p e n in g
2 8 30
3 13 8 30 B u n d . P u llin g
4 18 13 8 3 30
5 23 18 13 8 8 30
6 29 23 18 13 13 9 33
In s p e c t io n
Days
7 35 29 23 18 18 15 9 3
In s e rt io n
8 41 38 29 23 23 23 15 9
9 41 38 35 35 29 30 23 15
S h e ll T e s t
10 41 38 41 41 35 36 30 23
11 41 38 41 41 38 41 36 30 Tube Tes t
12 41 38 41 41 38 41 41 36
B o x -U p
13 41 38 41 41 38 41 41 41
ID Task Name Duration Start Finish Sep 16, '07 Sep 23, '07 Sep 30, '07
T F S S M T W T F S S M T W T F S S M T
1
2 DHDS AIR FIN COOLERS 16 days Fri 9/14/07 Sun 9/30/07 0%
3 BLIBDING 24 hrs Fri 9/14/07 Sat 9/15/07 0%
4 OPENING OF PLUGS - 3264 Nos. 192 hrs Sat 9/15/07 Sun 9/23/07 0%
5 HYDROBLAST CLEANING 192 hrs Sun 9/16/07 Mon 9/24/07 0%
6 DRYING OF TUBES 192 hrs Mon 9/17/07 Tue 9/25/07 0%
7 INSPECTION BY IRIS TECHNIQUE 192 hrs Tue 9/18/07 Wed 9/26/07 0%
8 BOXUP OF PLUGS 192 hrs Wed 9/19/07 Thu 9/27/07 0%
9 HYDROTESTING OF BUNDLES 192 hrs Fri 9/21/07 Sat 9/29/07 0%
10 DEBLING 24 hrs Sat 9/29/07 Sun 9/30/07 0%

Project: AIR COOLERS OF DHDS Task Summary Baseline Split

Page 1
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 10
O p e n in g
2 3 10 B u n d . P u llin g
3 5 3 10
In s p e c t i o n
4 7 5 3 1 10 In s e r t i o n
S h e ll T e s t
5 8 7 5 3 3 10
Tube Tes t
Days
B o x -U p
6 8 8 7 5 5 3 10
7 8 8 8 7 7 5 3 2
8 8 8 8 8 8 7 5 4
9 8 8 8 8 8 8 7 6
10 8 8 8 8 8 8 8 8
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
8 030 O p e n in g
3 1 3 1 7 30
1 8 4 9 7030 B u n d . P u llin g
5 23 7 1 1 9 07 33
28 1 1 1 4 1 11 9 7 7
7 33 16 18 14 411 9 9
38 21 23 18 7 14 11 11
9 43 26 28 23 11 18 14 14 In s p e c t io n
Days
48 31 33 28 16 23 18 18
11 53 36 38 33 21 28 23 23 In s e rt io n
56 41 43 38 26 33 28 28
13 59 46 48 43 31 38 33 33
S h e ll T e s t
59 51 53 48 36 43 38 38
15 59 51 59 53 41 48 43 43
59 51 59 59 46 53 48 48 Tube Tes t
17 59 51 59 59 51 56 53 53
59 51 59 59 51 59 56 56 B o x -U p
19 59 51 59 59 51 59 59 59
S M T W T F S S M T W T F S S M
1 VALVE REPLACEMENT JOBS 12.33 days Mon 9/24/07 Sat 10/6/07 0%
2 STEAM VALVE - 600 Inch Dia 12 days Mon 9/24/07 Sat 10/6/07 0%
3 BLINDING OF CIRCUITS FOR HOT J 16 hrs Mon 9/24/07 Tue 9/25/07 0%
4 CUTTING OF JOINTS-600 IN.DIA 48 hrs Tue 9/25/07 Thu 9/27/07 0%
5 REMOVAL OF OLD VALVES 48 hrs Tue 9/25/07 Thu 9/27/07 0%
6 EDGE PREPARATION OF OLD PIPE 36 hrs Tue 9/25/07 Thu 9/27/07 0%
7 DP TESTING OF OLD PIPE 36 hrs Wed 9/26/07 Thu 9/27/07 0%
8 ERECTION OF NEW VALVES 72 hrs Thu 9/27/07 Sun 9/30/07 0%
9 WELDING OF JOINTS-600 IN.DIA 96 hrs Fri 9/28/07 Tue 10/2/07 0%
10 NDT OF JOINTS 96 hrs Sat 9/29/07 Wed 10/3/07 0%
11 SR OF JOINTS-600 IN.DIA 96 hrs Sun 9/30/07 Thu 10/4/07 0%
12 RADIOGRAPHY OF JOINTS 96 hrs Sun 9/30/07 Thu 10/4/07 0%
13 HYDROTESTING OF LINES 24 hrs Thu 10/4/07 Fri 10/5/07 0%
14 DEBLINDING OF CIRCUITS 16 hrs Fri 10/5/07 Sat 10/6/07 0%
15 CW VALVE - 700 Inch Dia 12.33 days Mon 9/24/07 Sat 10/6/07 0%
16 BLINDING OF CIRCUITS FOR HOT J 16 hrs Mon 9/24/07 Tue 9/25/07 0%
17 CUTTING OF JOINTS-700 IN.DIA 72 hrs Tue 9/25/07 Fri 9/28/07 0%
18 REMOVAL OF OLD VALVES 72 hrs Tue 9/25/07 Fri 9/28/07 0%
19 EDGE PREPARATION OF OLD PIPE 36 hrs Wed 9/26/07 Thu 9/27/07 0%
20 DP TESTING OF OLD PIPE 36 hrs Thu 9/27/07 Fri 9/28/07 0%
21 ERECTION OF NEW VALVES 72 hrs Fri 9/28/07 Mon 10/1/07 0%
22 WELDING OF JOINTS-700 IN.DIA 120 hrs Sat 9/29/07 Thu 10/4/07 0%
23 NDT OF JOINTS 120 hrs Sun 9/30/07 Fri 10/5/07 0%
24 HYDROTESTING OF LINES 24 hrs Fri 10/5/07 Sat 10/6/07 0%
25 DEBLINDING OF CIRCUITS 16 hrs Sat 10/6/07 Sat 10/6/07 0%

Project: TPS Task Summary Baseline Split

Page 1
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 10
O p e n in g
2 3 10 B u n d . P u llin g
H y d r o b la s t in g
3 5 3 10
In s p e c t io n
4 7 5 3 1 10 In s e r t io n
S h e ll T e s t
5 8 7 5 3 3 10
Tube Tes t
B o x -U p
6 8 8 7 5 5 3 10
Days
7 8 8 8 7 7 5 3 2
8 8 8 8 8 8 7 5 4
9 8 8 8 8 8 8 7 6
10 8 8 8 8 8 8 8 8
SHUTDOWN ACTIVITIES IN COOLING TOWER
DURATION Day-1 Day-2 Day-3 D

ACTIVITY 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 Task Name Duration Start Finish Sep 23, '07 Sep 30, '07
S M T W T F S S M T W T
1 CI-BI OF FRAME V GT 8 days Mon 9/24/07 Tue 10/2/07 0%
2 Remove gas & atomising pigtail p 24 hrs Mon 9/24/07 Tue 9/25/07 0%
3 Remove liquid fuel lines 24 hrs Mon 9/24/07 Tue 9/25/07 0%
4 Remove fuel nozzels 24 hrs Mon 9/24/07 Tue 9/25/07 0%
5 Remove spark plugs & flame dete 24 hrs Mon 9/24/07 Tue 9/25/07 0%
6 Remove combustion can covers 24 hrs Tue 9/25/07 Wed 9/26/07 0%
7 Remove combustion liners , X fire 24 hrs Tue 9/25/07 Wed 9/26/07 0%
8 Clean all parts 48 hrs Tue 9/25/07 Thu 9/27/07 0%
9 Disassemble & Inspect Fuel nozz 48 hrs Tue 9/25/07 Thu 9/27/07 0%
10 Inspect liners 24 hrs Wed 9/26/07 Thu 9/27/07 0%
11 Inspect retainers 24 hrs Wed 9/26/07 Thu 9/27/07 0%
12 Inspect Cross fire tubes 24 hrs Wed 9/26/07 Thu 9/27/07 0%
13 Inspect Combustion Chambers 24 hrs Wed 9/26/07 Thu 9/27/07 0%
14 Assemble fuel nozzels 24 hrs Thu 9/27/07 Fri 9/28/07 0%
15 Install liners, X fire tubes & retain 24 hrs Thu 9/27/07 Fri 9/28/07 0%
16 Install Combustion can covers 24 hrs Fri 9/28/07 Sat 9/29/07 0%
17 Install spark plugs & flame detect 24 hrs Fri 9/28/07 Sat 9/29/07 0%
18 Install fuel nozzels 24 hrs Fri 9/28/07 Sat 9/29/07 0%
19 Install liquid fuel lines 24 hrs Sat 9/29/07 Sun 9/30/07 0%
20 Install all gas & atomising piping 24 hrs Sat 9/29/07 Sun 9/30/07 0%
21 Remove boroscope Plugs & Inspe 48 hrs Sat 9/29/07 Mon 10/1/07 0%
22 Crank & check for air leaks 24 hrs Mon 10/1/07 Tue 10/2/07 0%
23 FSNL & load the machine 24 hrs Sat 9/29/07 Sun 9/30/07 0%

Project: CI BI OF GT Task Summary Baseline Split

Page 1
ID Task Name Duration Start Finish Sep 23, '07 Sep 30, '07
S M T W T F S S M T W
1 HRSG JOBS 7.17 days Mon 9/24/07 Mon 10/1/07 0%
2 Opening of manhole of HR 16 hrs Mon 9/24/07 Tue 9/25/07 0%
3 Opening of manhole of ste 16 hrs Mon 9/24/07 Tue 9/25/07 0%
4 Removal of drum internals 24 hrs Tue 9/25/07 Wed 9/26/07 0%
5 Cleaning of vessel 24 hrs Wed 9/26/07 Thu 9/27/07 0%
6 Boxup of drum internals 24 hrs Thu 9/27/07 Fri 9/28/07 0%
7 Box up of steam drum mna 16 hrs Fri 9/28/07 Fri 9/28/07 0%
8 Erection of scaffolding 36 hrs Tue 9/25/07 Wed 9/26/07 0%
9 Cleaning of tubes 24 hrs Wed 9/26/07 Thu 9/27/07 0%
10 Internal Inspection 16 hrs Thu 9/27/07 Fri 9/28/07 0%
11 Dry Inspection by IBR 24 hrs Fri 9/28/07 Sat 9/29/07 0%
12 Internal Hydraulic Testing 16 hrs Sat 9/29/07 Sat 9/29/07 0%
13 Hydraulic Testing by IBR 24 hrs Sat 9/29/07 Sun 9/30/07 0%
14 Box up of HRSG 16 hrs Sun 9/30/07 Mon 10/1/07 0%

Project: HRSG Task Summary Baseline Split

Page 1
ID Task Name Duration Start Finish 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
1 FLARE JOBS 2688 hrs Mon 6/18/07 Mon 10/8/07 0%
2 FLARE LINE REPLACEMENT 2688 hrs Mon 6/18/07 Mon 10/8/07 0%
3 Flare line Pre-Shutdown 1992 hrs Mon 6/18/07 Sun 9/9/07 0%
4 Pilling for supports alo 1464 hrs Mon 6/18/07 Sat 8/18/07 0%
5 Foundation for suppo 1392 hrs Tue 7/3/07 Thu 8/30/07 0%
6 Structural fabrication 720 hrs Wed 8/1/07 Fri 8/31/07 0%
7 Sand blasting & Paint 720 hrs Wed 8/8/07 Fri 9/7/07 0%
8 Erection and alignme 480 hrs Mon 8/20/07 Sun 9/9/07 0%
9 Flare line Pre-Shutdown 1104 hrs Mon 8/6/07 Fri 9/21/07 0%
10 Pre-Fabrication of all 720 hrs Mon 8/6/07 Wed 9/5/07 0%
11 Sand blasting & Paint 720 hrs Fri 8/10/07 Sun 9/9/07 0%
12 Transportation of pipe 480 hrs Wed 8/22/07 Tue 9/11/07 0%
13 Erection of pipe on st 72 hrs Sun 9/9/07 Wed 9/12/07 0%
14 Joint fit up and Weldi 168 hrs Wed 9/12/07 Wed 9/19/07 0%
15 NDT of all Joints as p 120 hrs Sun 9/16/07 Fri 9/21/07 0%
16 Flare line Shutdown Job 336 hrs Mon 9/24/07 Mon 10/8/07 0%
17 Blinding / Deblinding 72 hrs Mon 9/24/07 Thu 9/27/07 0%
18 Cutting of all old lines 72 hrs Thu 9/27/07 Sun 9/30/07 0%
19 Dismantling of pipes 72 hrs Fri 9/28/07 Mon 10/1/07 0%
20 Welding of hook up jo 48 hrs Mon 10/1/07 Wed 10/3/07 0%
21 Cutting of damaged s 48 hrs Sat 9/29/07 Mon 10/1/07 0%
22 Repair of support loca 48 hrs Sun 9/30/07 Tue 10/2/07 0%
23 Bevelling of old lines 48 hrs Fri 9/28/07 Sun 9/30/07 0%
24 Erection of pipes alon 48 hrs Mon 10/1/07 Wed 10/3/07 0%
25 Joint fit-up and weldin 72 hrs Tue 10/2/07 Fri 10/5/07 0%
26 Radiography of balan 48 hrs Thu 10/4/07 Sat 10/6/07 0%
27 Blinding / Deblinding 48 hrs Fri 10/5/07 Sun 10/7/07 0%
28 Start-up activities 24 hrs Sun 10/7/07 Mon 10/8/07 0%
29 Flare tip replacement job 336 hrs Mon 9/24/07 Mon 10/8/07 0%
30 Shutting down / Blinding/ D 72 hrs Mon 9/24/07 Thu 9/27/07 0%
31 Revisioning of Devit and m 16 hrs Thu 9/27/07 Fri 9/28/07 0%
32 Lifting of scaffolding mater 24 hrs Fri 9/28/07 Sat 9/29/07 0%
33 Erection of scaffoldign out 16 hrs Fri 9/28/07 Sat 9/29/07 0%
34 Dismantling of Acid flare ti 8 hrs Thu 9/27/07 Thu 9/27/07 0%
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 0%
38 Grinding & edge preparati 8 hrs Fri 9/28/07 Fri 9/28/07 0%
39 Erection of Acid flare tip to 8 hrs Sun 9/30/07 Sun 9/30/07 0%
40 Fit up & welding of Acid fla 8 hrs Sun 9/30/07 Sun 9/30/07 0%
41 Lowering of Hydrocarbon f 16 hrs Sun 9/30/07 Mon 10/1/07 0%
42 Erection of Hydrocarbon fl 16 hrs Mon 10/1/07 Tue 10/2/07 0%
43 Alignment & boxup of Hyd 16 hrs Tue 10/2/07 Tue 10/2/07 0%
44 Erection of scaffolding insi 16 hrs Tue 10/2/07 Wed 10/3/07 0%
45 Lifting of other accessories 16 hrs Tue 10/2/07 Wed 10/3/07 0%
46 Revisioning of Burners & F 24 hrs Fri 9/28/07 Sat 9/29/07 0%
47 Fitting and welding of all a 16 hrs Wed 10/3/07 Wed 10/3/07 0%
48 Box-up of all connected lin 16 hrs Wed 10/3/07 Thu 10/4/07 0%
49 Dismantlingl of scaffolding 16 hrs Thu 10/4/07 Fri 10/5/07 0%
50 Lowering down of all scaff 16 hrs Fri 10/5/07 Fri 10/5/07 0%
51 Start-up activities 24 hrs Sun 10/7/07 Mon 10/8/07 0%
Critical Split Baseline Milestone Project Summary Split Baseline Milestone
Project: FLARE LINE -2 Critical Split Task Progress Milestone Critical Split Task Progress Milestone
Date: Thu 9/6/07 Critical Progress Baseline Summary Progress Critical Progress Baseline Summary Progress
Task Baseline Split Summary Task Baseline Split Summary
Page 1
S M T W T F S S M T W T F S S M T W
1 OFFSITE PIPING 13.83 days Mon 9/24/07 Mon 10/8/07 0%
2 3.1.3: LPG LINES(3", 80M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
3 Blinding / Deblinding 36 hrs Mon 9/24/07 Tue 9/25/07 0%
4 Steam & Water Washing 24 hrs Tue 9/25/07 Wed 9/26/07 0%
5 Final Blinding 8 hrs Wed 9/26/07 Thu 9/27/07 0%
6 Cold Cutting of pipes 24 hrs Thu 9/27/07 Fri 9/28/07 0%
7 Dismantling of old pipe 16 hrs Fri 9/28/07 Fri 9/28/07 0%
8 Erection of new pipe 24 hrs Fri 9/28/07 Sat 9/29/07 0%
9 Welding of new pipe 72 hrs Sat 9/29/07 Tue 10/2/07 0%
10 NDT 16 hrs Tue 10/2/07 Wed 10/3/07 0%
11 Hydrotest 24 hrs Wed 10/3/07 Thu 10/4/07 0%
12 Draining of water 16 hrs Thu 10/4/07 Fri 10/5/07 0%
13 Deblinding 12 hrs Fri 10/5/07 Fri 10/5/07 0%
14 Start Up activities 24 hrs Sun 10/7/07 Mon 10/8/07 0%
15 3.3.1:NAPTHA LINES(2",24 M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
19 Cold Cutting of pipes 12 hrs Thu 9/27/07 Thu 9/27/07 0%
20 Dismantling of old pipe 8 hrs Thu 9/27/07 Fri 9/28/07 0%
21 Erection of new pipe 8 hrs Fri 9/28/07 Fri 9/28/07 0%
22 Welding of new pipe 24 hrs Fri 9/28/07 Sat 9/29/07 0%
23 NDT 12 hrs Sat 9/29/07 Sat 9/29/07 0%
24 Hydrotest 12 hrs Sat 9/29/07 Sun 9/30/07 0%
25 Draining of water 12 hrs Sun 9/30/07 Sun 9/30/07 0%
26 Deblinding 12 hrs Sun 9/30/07 Mon 10/1/07 0%
28 3.3.2:NAPTHA LINE(3",200 M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
32 Cold Cutting of pipes 48 hrs Thu 9/27/07 Sat 9/29/07 0%

Project: OFFSITE PIPING Task Summary Baseline Split

Page 1
33 Dismantling of old pipe 32 hrs Fri 9/28/07 Sat 9/29/07 0%
34 Erection of new pipe 48 hrs Sat 9/29/07 Mon 10/1/07 0%
35 Welding of new pipe 96 hrs Sat 9/29/07 Wed 10/3/07 0%
36 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
37 Hydrotest 24 hrs Thu 10/4/07 Fri 10/5/07 0%
38 Draining of water 24 hrs Fri 10/5/07 Sat 10/6/07 0%
49 NDT 24 hrs Tue 10/2/07 Wed 10/3/07 0%
52 Deblinding 12 hrs Fri 10/5/07 Sat 10/6/07 0%
54 3.13.1:FUEL GAS LINES(2",80M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
61 Welding of new pipe 48 hrs Sat 9/29/07 Mon 10/1/07 0%
62 NDT 12 hrs Mon 10/1/07 Mon 10/1/07 0%
63 Hydrotest 24 hrs Mon 10/1/07 Tue 10/2/07 0%
64 Draining of water 16 hrs Tue 10/2/07 Wed 10/3/07 0%


Page 2
65 Deblinding 12 hrs Wed 10/3/07 Wed 10/3/07 0%
67 3.13.2:FUEL GAS LINES(4",30m) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
74 Welding of new pipe 24 hrs Sat 9/29/07 Sun 9/30/07 0%
75 NDT 12 hrs Sun 9/30/07 Sun 9/30/07 0%
76 Hydrotest 24 hrs Sun 9/30/07 Mon 10/1/07 0%
77 Draining of water 12 hrs Mon 10/1/07 Tue 10/2/07 0%
78 Deblinding 12 hrs Tue 10/2/07 Tue 10/2/07 0%
80 3.13.3:FUEL GAS LINES(6",40 M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
88 NDT 24 hrs Mon 10/1/07 Tue 10/2/07 0%
89 Hydrotest 24 hrs Tue 10/2/07 Wed 10/3/07 0%
90 Draining of water 24 hrs Wed 10/3/07 Thu 10/4/07 0%
91 Deblinding 12 hrs Thu 10/4/07 Thu 10/4/07 0%


Page 3
100 Welding of new pipe 72 hrs Sun 9/30/07 Wed 10/3/07 0%
101 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
104 Deblinding 12 hrs Sat 10/6/07 Sat 10/6/07 0%
106 3.2.1:H2 LINES(2",60M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
114 NDT 12 hrs Mon 10/1/07 Mon 10/1/07 0%
119 3.2.2: H2 LINES(3",84M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
127 NDT 12 hrs Sat 9/29/07 Sun 9/30/07 0%


Page 4
132 3.2.3:H2 LINES(4",36 M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
140 NDT 12 hrs Sun 9/30/07 Sun 9/30/07 0%
145 3.4.1:ATF LINES(4",60 M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
146 Blinding / Deblinding 36 hrs Tue 9/25/07 Wed 9/26/07 0%
147 Steam & Water Washing 24 hrs Wed 9/26/07 Thu 9/27/07 0%
148 Final Blinding 12 hrs Thu 9/27/07 Fri 9/28/07 0%
149 Cold Cutting of pipes 24 hrs Fri 9/28/07 Sat 9/29/07 0%
150 Dismantling of old pipe 12 hrs Sat 9/29/07 Sat 9/29/07 0%
151 Erection of new pipe 24 hrs Sat 9/29/07 Sun 9/30/07 0%
152 Welding of new pipe 48 hrs Sun 9/30/07 Tue 10/2/07 0%
153 NDT 24 hrs Tue 10/2/07 Wed 10/3/07 0%
158 3.10.1:OFFGAS LINES(2",36M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%


Page 5
162 Cold Cutting of pipes 12 hrs Fri 9/28/07 Fri 9/28/07 0%
164 Erection of new pipe 8 hrs Sat 9/29/07 Sat 9/29/07 0%
166 NDT 12 hrs Sun 9/30/07 Sun 9/30/07 0%
168 Draining of water 12 hrs Mon 10/1/07 Mon 10/1/07 0%
169 Deblinding 12 hrs Mon 10/1/07 Tue 10/2/07 0%
179 NDT 12 hrs Sun 9/30/07 Mon 10/1/07 0%
192 NDT 24 hrs Tue 10/2/07 Wed 10/3/07 0%


Page 6
197 3.11.1:SOURGAS LINES(6",60M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
202 Dismantling of old pipe 24 hrs Sat 9/29/07 Sun 9/30/07 0%
205 NDT 16 hrs Wed 10/3/07 Thu 10/4/07 0%
210 3.18.1:AMINE LINES(2",120 M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
218 NDT 16 hrs Wed 10/3/07 Thu 10/4/07 0%
220 Draining of water 16 hrs Fri 10/5/07 Fri 10/5/07 0%
223 3.18.2:AMINE LINES(3",60M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%


Page 7
231 NDT 12 hrs Mon 10/1/07 Tue 10/2/07 0%
233 Draining of water 16 hrs Wed 10/3/07 Wed 10/3/07 0%
234 Deblinding 12 hrs Wed 10/3/07 Thu 10/4/07 0%
236 3.19.1:IFO LINES(11/2",60M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
244 NDT 12 hrs Sun 9/30/07 Mon 10/1/07 0%
249 3.19.2: IFO LINES(2",120 M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%


Page 8
257 NDT 12 hrs Wed 10/3/07 Wed 10/3/07 0%
262 3.19.3: IFO LINES(3",200M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
266 Cold Cutting of pipes 48 hrs Fri 9/28/07 Sun 9/30/07 0%
267 Dismantling of old pipe 48 hrs Fri 9/28/07 Sun 9/30/07 0%
270 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
275 3.5.1:RTF LINES(6",120 M) 11.83 days Wed 9/26/07 Mon 10/8/07 0%
276 Blinding / Deblinding 36 hrs Wed 9/26/07 Thu 9/27/07 0%
277 Steam & Water Washing 24 hrs Thu 9/27/07 Fri 9/28/07 0%
278 Final Blinding 12 hrs Fri 9/28/07 Sat 9/29/07 0%
279 Cold Cutting of pipes 48 hrs Sat 9/29/07 Mon 10/1/07 0%
280 Dismantling of old pipe 48 hrs Sat 9/29/07 Mon 10/1/07 0%
281 Erection of new pipe 48 hrs Sun 9/30/07 Tue 10/2/07 0%
282 Welding of new pipe 88 hrs Sun 9/30/07 Thu 10/4/07 0%
283 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
288 3.7.2:SKO LINES(3",84M) 11.83 days Wed 9/26/07 Mon 10/8/07 0%


Page 9
292 Cold Cutting of pipes 16 hrs Sat 9/29/07 Sat 9/29/07 0%
294 Erection of new pipe 16 hrs Sun 9/30/07 Sun 9/30/07 0%
295 Welding of new pipe 24 hrs Sun 9/30/07 Mon 10/1/07 0%
296 NDT 12 hrs Mon 10/1/07 Tue 10/2/07 0%
305 Cold Cutting of pipes 24 hrs Sat 9/29/07 Sun 9/30/07 0%
307 Erection of new pipe 24 hrs Sun 9/30/07 Mon 10/1/07 0%
309 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
314 3.8.1:HSD LINES(6",120 M) 11.83 days Wed 9/26/07 Mon 10/8/07 0%


Page 10
322 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%


Page 11
Activity Bar Chart of Refractory Application during Shutdown at P.G.Boiler at IOCL - HALDIA
Sr.No. Activity
No. of Days
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A R.G.Boiler
1 Dismantling & debris cleaning
2 Surface cleaning & anchor welding
3 End Tube Sheet Casting
4 First layer casting using form work
5 Second layer casting
6 Form work removal & natural curing
7 Dry out up to 250 deg C
8 Final Inspection & Boxing up
1 OFFSITE PIPING 13.83 days Mon 9/24/07 Mon 10/8/07 0%
2 3.1.3: LPG LINES(3", 80M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
10 NDT 16 hrs Tue 10/2/07 Wed 10/3/07 0%
13 Deblinding 12 hrs Fri 10/5/07 Fri 10/5/07 0%
23 NDT 12 hrs Sat 9/29/07 Sat 9/29/07 0%
24 Hydrotest 12 hrs Sat 9/29/07 Sun 9/30/07 0%
25 Draining of water 12 hrs Sun 9/30/07 Sun 9/30/07 0%
26 Deblinding 12 hrs Sun 9/30/07 Mon 10/1/07 0%
28 3.3.2:NAPTHA LINE(3",200 M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%


Page 1
35 Welding of new pipe 96 hrs Sat 9/29/07 Wed 10/3/07 0%
36 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
49 NDT 24 hrs Tue 10/2/07 Wed 10/3/07 0%
62 NDT 12 hrs Mon 10/1/07 Mon 10/1/07 0%


Page 2
67 3.13.2:FUEL GAS LINES(4",30m) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
75 NDT 12 hrs Sun 9/30/07 Sun 9/30/07 0%
80 3.13.3:FUEL GAS LINES(6",40 M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
88 NDT 24 hrs Mon 10/1/07 Tue 10/2/07 0%


Page 3
101 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
106 3.2.1:H2 LINES(2",60M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
114 NDT 12 hrs Mon 10/1/07 Mon 10/1/07 0%
119 3.2.2: H2 LINES(3",84M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
127 NDT 12 hrs Sat 9/29/07 Sun 9/30/07 0%


Page 4
132 3.2.3:H2 LINES(4",36 M) 13.83 days Mon 9/24/07 Mon 10/8/07 0%
140 NDT 12 hrs Sun 9/30/07 Sun 9/30/07 0%
145 3.4.1:ATF LINES(4",60 M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
153 NDT 24 hrs Tue 10/2/07 Wed 10/3/07 0%


Page 5
166 NDT 12 hrs Sun 9/30/07 Sun 9/30/07 0%
168 Draining of water 12 hrs Mon 10/1/07 Mon 10/1/07 0%
169 Deblinding 12 hrs Mon 10/1/07 Tue 10/2/07 0%
179 NDT 12 hrs Sun 9/30/07 Mon 10/1/07 0%
192 NDT 24 hrs Tue 10/2/07 Wed 10/3/07 0%


Page 6
197 3.11.1:SOURGAS LINES(6",60M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
205 NDT 16 hrs Wed 10/3/07 Thu 10/4/07 0%
210 3.18.1:AMINE LINES(2",120 M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
218 NDT 16 hrs Wed 10/3/07 Thu 10/4/07 0%
220 Draining of water 16 hrs Fri 10/5/07 Fri 10/5/07 0%
223 3.18.2:AMINE LINES(3",60M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%


Page 7
231 NDT 12 hrs Mon 10/1/07 Tue 10/2/07 0%
233 Draining of water 16 hrs Wed 10/3/07 Wed 10/3/07 0%
234 Deblinding 12 hrs Wed 10/3/07 Thu 10/4/07 0%
236 3.19.1:IFO LINES(11/2",60M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
244 NDT 12 hrs Sun 9/30/07 Mon 10/1/07 0%
249 3.19.2: IFO LINES(2",120 M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%


Page 8
257 NDT 12 hrs Wed 10/3/07 Wed 10/3/07 0%
262 3.19.3: IFO LINES(3",200M) 12.83 days Tue 9/25/07 Mon 10/8/07 0%
266 Cold Cutting of pipes 48 hrs Fri 9/28/07 Sun 9/30/07 0%
267 Dismantling of old pipe 48 hrs Fri 9/28/07 Sun 9/30/07 0%
270 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
275 3.5.1:RTF LINES(6",120 M) 11.83 days Wed 9/26/07 Mon 10/8/07 0%
283 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%


Page 9
292 Cold Cutting of pipes 16 hrs Sat 9/29/07 Sat 9/29/07 0%
294 Erection of new pipe 16 hrs Sun 9/30/07 Sun 9/30/07 0%
295 Welding of new pipe 24 hrs Sun 9/30/07 Mon 10/1/07 0%
296 NDT 12 hrs Mon 10/1/07 Tue 10/2/07 0%
305 Cold Cutting of pipes 24 hrs Sat 9/29/07 Sun 9/30/07 0%
307 Erection of new pipe 24 hrs Sun 9/30/07 Mon 10/1/07 0%
309 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%
314 3.8.1:HSD LINES(6",120 M) 11.83 days Wed 9/26/07 Mon 10/8/07 0%


Page 10
322 NDT 24 hrs Wed 10/3/07 Thu 10/4/07 0%


Page 11
Activity Bar Chart of Refractory Application during Shutdown at P.G.Boiler at IOCL - HALDIA
Sr.No. Activity
No. of Days
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A R.G.Boiler
1 Dismantling & debris cleaning
2 Surface cleaning & anchor welding
3 End Tube Sheet Casting
4 First layer casting using form work
5 Second layer casting
6 Form work removal & natural curing
7 Dry out up to 250 deg C
8 Final Inspection & Boxing up

Shutdown Book 2007

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Shutdown Book 2007

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SHUTDOWN BOOK

(From- 13th September To- 16th October)

Mechanical Maintenance Planning Cell

SHUT DOWN M&I IDLE START UP

# Shutdown & regeneration

Lifting tools Safety

NAME OF SHUTDOWN COORDINATORS

Department / Section Name Designation

Overall Coordinator Amalendu Kumar DGM(MN)

Mechanical maintenance Sudhir Kumar CMNM-I

Furnace + Column A.Behra, SMLE

Hot Job Nirmal Kumar, SMLE

Vikas Kumar, CLE N.K.

Elect. Maint Over all G Maity, ELE MNMEL-I( S N Jha)

MAB+WGC S.K. Bandopadhay, DMNM

Flare Tip+ Vessel S.K. Dolui, SMLE

Pump + Fabrication + Machining Jobs R.Naik, SMLE

Finance Concurrance Jobs D. Saha, FM FM

Offsite S.K.Bandopadhyay, SMFS

9/23/2007 S.Saha, SPSE J.Sharma, SISO N.Mudugal, O(ER) A.C.Kar, QCO

9/22/2007 S.Bandopadhyay, SPSE P.K.Banerjee, SITE B.Gupta, SO(ER) M.A.Ali, DMCL

Area Critical Description Reqd. Total

3rd Air fin coolers of DHDS 16 18

3rd Exchanger - 59 Nos. 19 20

1st Flare line 10 10

3rd Flare tip 09 10

1st 11-F-01 14.5 15

1st Steam Valve 16 19

1st Pre heat Exchanger - VBU 19 19

3rd Heat Exchanger - PDA 17 20

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

3.1.1 21-R-01: Skimming of catalyst: 1900 KG. From top

4.0 MODIFICATION JOBS

5.1.0 VR Burning in CDU-II

6.0 VALVE REVISIONING

6.1.1 Revisioning of valves at U-11

g) 11C104 : PSV isolation valves –4 nos. gate valve

6.1.2 Revisioning of valves at U-16

a)16 E 14 C/D s/s inlet and outlet valves.

GR-20 (NHDT, CRU & KHDS)

4 Platform railing guards in 16-C-01 are completely damaged, particularly 2 nd, 3

PROPANE DEASPHALTING UNIT

1.0 FURNACE (32-F-01)

Blinding / deblinding, decoking, opening of manway, erection of scaffolding inside the

1.1 REPAIR / REPLACEMENT JOBS IN 32-F-01

1.1.1 Thorough external cleaning of all radiation tubes.

Opening of manholes, tray manways, erection of scaffolding wherever required,

Blinding / deblinding of connected lines, opening of manholes, removal of internals,

3.1 32B-01 Propane Bullet ¾ External painting to be done

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

4.0 HEAT EXCHANGER

PAINTING JOBS IN EXCHANGERS

Surface preparation – Grit/sand blasting conforming to Sa2. ½,

5.0 SAFETY VALVES

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

6.0 VALVE JOBS

6.1 Replacement of 20mm FO valve in Burner No. 1 .

7.0 REPAIR / REPLACEMENT OF PIPING

7.1 Insulation of transfer line to be removed for complete inspection.

Small bore piping around furnace Æ ½” – 300m, ¾” – 300m & 1” – 100m.

8.0 CIVIL MAINTENANCE

9.0 INSTRUMENT JOBS

9.1 Rectification / checking of following thermocouples of 32F01 :-

9.8 Calibration of FI-50( FO inlet) and FI-51(outlet flow) in F-01