The Fertilisers And Chemicals Travancore Limited Tender

Replacement of Damaged Tubes of W2 Heat Exchanger in SA Plant, FACT-CD, during ATA 2019.

Arrangements for Tube Replacement: Collect required materials for the work and transport to work site. Make necessary site arrangements for the work. Open all manholes of W2 heat exchanger. Arrange required scaffolding. Cut open and remove the top cone W2 HE along with associated outlet and bypass ducts (if necessary) to first bellow. After removing the cone the outlet duct and bypass duct shall be given temporary supports . The northern side (suitable side may be chosen depending upon the site conditions) of the shell along with baffle plate, any other ducts, valves etc. May be dismantled with the concurrence of Site engineer for ease of work for removing / cutting damaged tubes.

Replacement of W2 Heat Exchanger Tubes. The required materials shall be transported from store to site. Make necessary site arrangements for the work. Leak test all the tubes. All arrangements for leak test shall be done. Cut and dismantle the damaged tubes. The already plugged tubes, including the plugs shall also be cut and removed. Clean the tube sheet area and prepare the tube sheet hole area by proper grinding. Edge preparation if required shall be done on the new tubes. Erect / insert new tubes in position, full weld top and bottom of the tube with tube sheet. All plugged tubes shall compulsorily be replaced with new tubes. Any additional tubes to be replaced other than damaged / plugged tubes shall be done as per instructions from competent authority. After completing the work, damaged / removed tubes shall be transported to scrap yard. Usable tubes shall be neatly stacked in area earmarked. [1 no indicates cutting and removing of existing tube including plugs, edge preparation, inserting new tube and full welding on both sides of tube sheets].