|
I. FABRICATION & MANUFACTURING JOBS
Grasim Industries Limited, Nagda,
Madhya Pradesh
Manufacturing of Complete Column
a) Process Condensate Stripper
Shell ID : 1200 mm
Shell thk: 32 mm
MOC : SA 240TP 304L
Heads- Ellipsoidal Thickness: 29 mm/ 36 mm-SA240 TP304
Internals : 18 tray trays support rings – SA 240 TP 304L
Empty Weight: 29000 kg.
Completion Time: 12 weeks
b) Propylene Tower Condenser
Shell ID : 1702 mm
Shell Thk : 22 mm
MOC : SA516 Gr 70
Channel Heads – 2:1 ellipsoidal thk : 15.5 mm/20.0 mm-SA
516 Gr 70
Tube sheet : 1895 dia x 92 thk, 3730 holes of 19.3 dia-
SA 266 cl 2
Straight tubes : 19.5 mm OD x 2.11 mm thk x 6000 mm lg-
SA 179
Strength expanded and seal welded
Overall length : 8163 mm
Empty weight : 41500 kg
Completion time : 15 weeks
c) 9 Heat exchangers, MOC-SA 516 Gr.70 for Shell &
channel and SA 179 for tubes completed in a record time of
45 days
No. of Tubes : 2480
Complete empty weight of 9 Exchangers: 49500 kg.
Ø Larsen & Toubro Ltd, Hazira, Surat
a) Tube Bundle Fabrication of EO Reactor
Fixed tube sheet Vertical Exchanger
Tube size: 50.8 mm OD x 2.03 mm thk x 12060 mm lg
Tube Sheet: 6275 dia x 360thk
Top and Bottom Tube-sheet SA 765 Gr.2 with Weld overlayed
Overlay thk: 5 mm Alloy
Baffles: Grid Baffles
Tube Bundle Weight: 600 MT
| Project No |
Equipment |
Material |
Tubes |
| E-6101R |
EO Reactor |
Duplex SS |
8310 |
b) Tube Bundle Fabrication of EO Reactor
Fixed tube sheet Vertical Exchanger
Tube size: 51 mm OD x 3.4 mm thk x 12800 mm lg- SA 179
Tube Sheet: 6591 dia x 210thk
Top Tube-sheet SA 266 cl 2 and Bottom Tube-sheet overlayed
Overlay thk: 10 mm TP 308L
Tube Bundle Weight: 300 MT
| Project No |
Equipment |
Material |
Tubes |
| 10342 A/B |
EO Reactor |
Carbon Steel |
5001 |
c) Tube Bundle Fabrication of EO Reactor
Fixed tube sheet Vertical Exchanger
Tube size: 51 mm OD x 3 mm thk x 11854 mm lg- SA 179
Tube Sheet: 6591 dia x 210thk
Top Tube-sheet SA 266 cl 2 and Bottom Tube-sheet overlayed
Overlay thk: 10 mm TP 308L
Baffles: Grid Baffles
Tube Bundle Weight: 550 MT
| Project No |
Equipment |
Material |
Tubes |
| 11501 A/B |
EO Reactor |
Carbon Steel |
6891 |
d) Tube Bundle Fabrication of EO Reactor
Tube size: 38.1 mm OD x 3.11 mm thk x 6630 lg
Tube MOC: SA 210 Gr. A1
Tube sheet thk: 150 mm
Baffles: Grid Baffles
Tube Bundle weight : 330 MT
| Project No |
Equipment |
Material |
Tubes |
| 45274 |
EO Reactor |
Carbon Steel |
5465 |
e) Tube Bundle Fabrication of Evaporators for SIDEM
Tube size: 28.6 mm OD x 0.80 mm thk x 8490 lg
Tube MOC: Alumininum Brass
Tube sheet thk: 20 mm
| Equipment |
Material |
Tubes / cell |
Cells/unit |
No. of units |
| Evaporator |
Aluminium Brass |
11631 |
6 |
3 |
f) Tube Bundle Fabrication of Evaporators for SIDEM
Tube size: 28.6 mm OD x 0.80 mm thk x 7440 lg
Tube MOC: Alumininum Brass
Tube sheet thk: 20 mm
| Equipment |
Material |
Tubes / cell |
Cells/unit |
No. of units |
| Evaporator |
Aluminium Brass |
11631 |
2 |
3 |
g) Tube Bundle Fabrication of Evaporators for SIDEM
Tube size: 28.6 mm OD x 0.80 mm thk x 7440 lg
Tube MOC: Titanium
Tube sheet thk: 20 mm
| Equipment |
Material |
Tubes / cell |
Cells/unit |
No. of units |
| Evaporator |
Titanium |
1310 |
2 |
3 |
h) Tube Bundle Fabrication of Evaporators for SIDEM
Tube size: 28.6 mm OD x 0.80 mm thk x 8490 lg
Tube MOC: Titanium
Tube sheet thk: 20 mm
| Equipment |
Material |
Tubes / cell |
Cells/unit |
No. of units |
| Evaporator |
Titanium |
1610 |
6 |
3 |
Ø Reliance Industries Ltd, Surat, Gujarat
a) Solvent Condensate Tank
Shell ID : 800 mm
Shell thk : 8 mm
MOC : SA 516 Gr 70
Tan to Tan Distance : 1600 mm
Overall height : 3000 mm
Weight : 1450 kg
Flanges : SA 105
Pipes : SA 106 B x sch 80
b) Seal Oil Reservoir
2000 x 1250 x 800 x 10 thk
MOC : SA 240 TP 304L
c) Lube Oil Reservoir
800 x 400 x 250 x 12 thk
MOC : SA 240 TP 304L
d) Cooling Water Reservoir
900 x 1500 x 12 thk
MOC: SA 516 Gr 70
Overall Height: 2500 mm
e) DTA Condensate Pot
Shell : 1200 ID x 12 thk
Heads : 1200 x 12 thk (min)/ 15 thk (nominal)
MOC : SA 516 Gr.70
Forgings : SA 105
Seamless Pipes : SA 106 B
Tan to Tan distance : 2600 mm
Weight : 1800 kg
f) Stripper Chilled Water Exchanger
Floating Tubesheet Heat Exchanger
Shell: 8 inch Sch 60
Tubesheet: 300 dia x 25 thk
MOC: SA 240 TP 304L
Tubes: 15.8 OD x 2 thk x 2000 mm lg
Overall Length: 2650 mm
Weight :800 kg
g) Stripper Condensate Pot
Shell ID : 700 mm
Shell thk : 10 mm
MOC : SA 516 Gr 70
Flanges : 300 thk- Sa 105
Pipes : SA 106 Gr B
Tan to Tan : 1900 mm
Overall length : 2270 mm
Weight : 1250 kg
Ø Godrej & Boyce Mfg. Co. Ltd.
a) Fabrication of Heat Exchanger
Overall Length: 8060 mm
Tube Strength welded and lightly expanded.
| Project No |
Equipment |
Material |
Tubes |
Shell Thk |
| 130353 |
Heat Exchanger |
Carbon Steel |
5070
Finned tubes |
18 mm |
b) Tube Bundle Fabrication of NPCL jobs
Tube size: 12.6 mm OD x 1.0 mm thk.
Empty weight of all Exchangers equal to 38900 kg.
| Project No |
Equipment |
Material |
Tubes |
Shell Thk |
| 130293, 294, 297, 298, 301, 302,
305, 306 |
Heat Exchanger |
Stainless Steel SA240 TP 304 |
1650/job |
16 mm |
c) Tube Bundle Fabrication of NPCL jobs
Tube size: 12.6 mm OD x 1.15 mm thk.
Both tube ends welded to tube shell and light expanded
| Project No |
Equipment |
Material |
Tubes |
Shell Thk |
| 130295, 299, 303, 307 |
Heat Exchanger |
Stainless Steel |
90/job |
16 mm |
d) Tube Bundle Fabrication of NPCL jobs
Tube size: 12.6 mm OD x 1.15 mm thk.
| Project No |
Equipment |
Material |
Tubes |
Shell Thk |
| 130296, 300, 304, 308 |
Heat Exchanger |
Stainless Steel |
133/job |
16 mm |
e) Tube Bundle Fabrication of NPCL jobs
Tube size : 19.05 mm OD x 20 BWG x 6000 mm lg
Tubesheet Thk : 130 mm
Shell MOC : SA-516 Gr.70
Tube sheet MOC : SA-266-2
Tube strength welded and light expanded.
| Project No |
Equipment |
Material |
Tubes (U) |
Shell Thk |
| 130255, 262, 269, 276 |
Heat Exchanger |
Stainless Steel |
1906/job |
14 mm |
f) Tube Bundle Fabrication of NPCL jobs
Tube size : 19.05 mm OD x 20 BWG x 8000 mm lg
Tubesheet Thk : 130 mm
Shell MOC : SA-516 Gr.70
Tube sheet MOC : SA-266-2
Tube strength welded and light expanded
| Project No |
Equipment |
Material |
Tubes (U) |
Shell Thk |
| 130225, 263, 270, 277 |
Heat Exchanger |
Stainless Steel SA 240 TP308 |
1157/job |
14 mm |
g) Tube Bundle Fabrication of NPCL jobs
Tube size : 19.05 mm OD x 20 BWG
Tubesheet Thk : 130 mm
Shell MOC : SA-516 Gr.70
Tube sheet MOC : SA-266-2
| Project No |
Equipment |
Material |
Tubes (U) |
Shell Thk |
| 130257, 264, 270, 277 |
Heat Exchanger |
Stainless Steel SA 240 TP308 |
1094/job |
14 mm |
h) Tube Bundle Fabrication of NPCL jobs
Tube size : 19.05 mm OD x 20 BWG
Tubesheet Thk : 130 mm
Shell MOC : SA-516 Gr.70
Tube sheet MOC : SA-266-2
| Project No |
Equipment |
Material |
Tubes (U) |
Shell Thk |
| 130258, 265, 272, 279 |
Heat Exchanger |
Stainless Steel |
1062/job |
12 mm |
i) Tube Bundle Fabrication of NPCL jobs
Tube size : 15.875 mm OD x 20 BWG
Tubesheet Thk : 130 mm
Shell MOC : SA-516 Gr.70
Tube sheet MOC : SA-266-2+ SS-304L
| Project No |
Equipment |
Material |
Tubes (U) |
Shell Thk |
| 130259, 264, 273, 280 |
Heat Exchanger |
Stainless Steel |
902/job |
12 mm |
j) Tube Bundle Fabrication of NPCL jobs
Tube size : 15.875 mm OD x 20 BWG
Tubesheet Thk : 130 mm
Shell MOC : SA-516 Gr.70
Tube sheet MOC : SA-266-2
| Project No |
Equipment |
Material |
Tubes (U) |
Shell Thk |
| 130259, 264, 273, 280 |
Heat Exchanger |
Stainless Steel |
937/job |
10 mm |
Ø Godrej & Boyce Mfg. Co. Ltd.
Ø Reliance Industries Ltd, Kurkhumb, Pune
a) Fabrication of Suction Dampner
MOC : SA240 TP 304 x 10 thk
Tan line to Tan line Distance : 2217 mm
Overall Length : 3550 mm
Weight : 1705 kg.
Equipment completed in 23 days
b) Fabrication of Lime Solution Tank
Pipe MOC : IS 1239
Plate MOC : IS 2062 Gr B
Equipment completed in 28 working days
Ø Relene Petrochemicals (P) Ltd., Navi Mumbai
a) Fabrication of Heat Exchanger
Tube size : 25 mm OD x 2 mm thk
No of tubes : 158
MOC for tubes, tubesheet, baffles : IS 1002
Shell MOC : A 179
b) Fabrication of Heat Exchanger (E-1145)
Tube size : 19.05 mm OD x 1.65 mm thk x 1050 mm lg
MOC : SS 316L
No of tubes : 155
c) Fabrication of Vinyl Acetate Condenser
No of pipes : 42
Pipe MOC : SA 312 TP 304
Shell MOC : A106
Baffles MOC : A285 Gr C
II. PROJECT JOBS
Ø Reliance Industries Ltd, Surat, Gujarat
Fabrication & Erection of Equipments, Piping & Structural
Total Weight : 224 MT
Ø Reliance Industries Ltd, Jamnagar, Gujarat
Fabrication & Erection of Piping & Columns
Total Weight : 185 MT
Ø Reliance Industries Ltd, Kurkhumb, Pune
Fabrication & Erection of Heat Exchangers and Vessels
Total Weight : 38 MT
III. MAINTENANCE JOBS
Ø Reliance Industries Ltd, Surat, Gujarat
a) Insitu Retubing of Heat Exchangers at MEG Plant completed at
a record time of 5 days
Tube size: 25.4 mm OD x 16 BWG x 6000 lg
Tube MOC: SS 304L
Shell MOC: SS 304L
No of tubes: 681
Location: 3rd Platform at 19 mtr. Elevation.
b) Retubing of 12 Heat Exchangers at Cracker Plant
The Exchangers were of both U & Straight Bundles
Tube size : 19.05 x 2.11 thk x 6000 mm lg
Tubes were strength expanded & Seal welded
Time of Completion: 8-days/ job
These all jobs were under the jurisdiction of IBR
c) Inner row Tube replacement for DRIER at PTA Plant completed
in a record time of 4 days.
Tube size : 2 inch x 25 mtr lg.
No. of tubes : 45
MOC : SS 304L sch 160
c) Rewelding of Tube to Tube sheet joints for 12 Heat
Exchangers at Cracker Plant.
It is one of the prestigious jobs of its kind on such a record
time.
Propylene Condenser (E-555)
Tube size : 19.05 OD x 2.11 mm thk
No. of tubes : 3730/job
Tube sheet Thk : 78 mm
No. of jobs : 6
Completion time : 7 days/job
The tubes were strength welded
Propylene Condenser (E-699)
Tube size : 19.05 OD x 2.11 mm thk
No. of tubes : 3390/job
Tube sheet Thk : 78 mm
No. of jobs : 6
Completion time : 7 days/job
The tubes were strength welded
Ø Reliance Industries Ltd, Jamnagar, Gujarat
Re-tubing of Boiler (ME-RH522-Y07) at Hydrogen Plant
Tube size : 44.5 mm OD x 3.4 mm thk x 7315 mm lg
Tube MOC : SA 213 T11
No. of Tubes : 526
Time of Completion : 11 days
This prestigious job was completed in a record time even though
the tubes OD were scaled tremendously thus the tubes were
jam-packed. By resorting the latest method we could complete the
job in time with perfection.
Re-tubing of 2 Heat Exchangers (371-SO2/371-SO3) at Coker Plant
Tube size : 25.4 mm OD x 2.77 mm thk x 12192 mm lg
Tube MOC : SA 179
No. of Tubes : 3600
Time of Completion : 13 days/job
Re-tubing of 41 Heat Exchangers of Different sizes and
materials at VMP Shutdown (October-2005).
| SI No |
Heat Exchanger No |
Area/Plant |
Tube Size |
No Of Tubes |
Material Of
Construction |
| 1 |
MF-RF414-S02A |
FCC/PRU |
¾” |
600 |
SA 179 |
| 2 |
MF-RF414-S02H |
FCC/PRU |
¾” |
600 |
SA 179 |
| 3 |
ME-RF414-S12A |
FCC/PRU |
¾” |
850 |
SA 179 |
| 4 |
ME-RF422-S04 |
FCC/PRU |
¾” |
216 |
SA 179 |
| 5 |
ME-RF423-S03 |
FCC/PRU |
¾” |
90 |
SA 179 |
| 6 |
ME-RF423-S05 |
FCC/PRU |
¾” |
215 |
SA 179 |
| 7 |
ME-RF424-S08 |
FCC/PRU |
¾” |
90 |
SA 179 |
| 8 |
ME-RF424-S09A-B |
FCC/PRU |
¾” |
90 |
SA 179 |
| 9 |
ME-PP551-E5222B |
PP |
16mm |
257 |
A 179 |
| 10 |
ME-PP551-E5226B |
PP |
16mm |
177 |
A 179 |
| 11 |
ME-PP551-E9507 |
PP |
1” |
205 |
A 179 |
| 12 |
ME-PP551-E5261A |
PP |
¾” |
672 |
SA 333Gr.6 |
| 13 |
ME-PP551-E5261B |
PP |
¾” |
672 |
SA 333Gr.6 |
| 14 |
ME-PP551-E5230C |
PP |
¾” |
700 |
SA 333Gr.6 |
| 15 |
ME-RK372-S09B |
COKER |
¾” |
850 |
SA-179 |
| 16 |
ME-RK372-S10B |
COKER |
1” |
700 |
SA-179 |
| 17 |
ME-RK372-S11B |
COKER |
1” |
1400 |
SA-179 |
| 18 |
ME-AY231-S06 |
AROMATICS |
¾” |
1100 |
SA 179 |
| 19 |
ME-AY231-S07 |
AROMATICS |
¾” |
1100 |
SA 179 |
| 20 |
ME-AY281-S23 |
AROMATICS |
38.1mm |
280 |
SA 179 |
| 21 |
ME-AY221-S15 |
AROMATICS |
38.1mm |
280 |
SA 179 |
| 22 |
ME-RF413-A01 to A03 |
FCC/RPU |
1” |
240x3 |
SA 179 |
| 23 |
ME-RH351-A01 to A16 |
CRUDE |
1” |
48 x 16 |
A 516- Gr.60 |
| 24 |
ME-RH521-Y07 |
HYDROGEN |
44.5mm |
100 |
SA 213 T11 |
These all jobs were completed successfully with perfection in a
short period of 30 days.
Re-tubing of 21 Fin Fan Coolers in position at the site
Tube size : 25.4 mm OD x 3.05 mm thk x 11 mtr.lg
Tube sheet Thk : 25.4
No. of Tubes : 120/job
Time of Completion : 5 days/job
Relene Petrochemicals (P) Ltd, Navi Mumbai
a) Completed the re-tubing of 39 jobs at a record time of only
4 months
These jobs included different variety of material and different
sizes of tubes as under:
| SI No |
Heat Exchanger No |
Area/Plant |
Tube Size |
No Of Tubes |
Material Of Construction |
| 1 |
E 7008 |
Benzene |
¾” |
370 |
A-179 |
| 2 |
E 7020 |
Benzene |
¾” |
158 |
A-179 |
| 3 |
E 7024 |
Benzene |
¾” |
56 |
A-179 |
| 4 |
E 6104 A |
Butadiene |
¾” |
400 |
A-179 |
| 5 |
E 6109 A |
Butadiene |
¾” |
352 |
A-179 |
| 6 |
E 2302 |
EO/EG |
1” |
390 |
A-179 |
| 7 |
E 2407 |
EO/EG |
¾” |
52 |
A-179 |
| 8 |
E 1005 A |
Ethylene |
¾” |
1764 |
A-179 |
| 9 |
E 1005 C |
Ethylene |
¾” |
1764 |
A-179 |
| 10 |
E 1008 |
Ethylene |
¾” |
210 |
A-179 |
| 11 |
E 1010 A |
Ethylene |
¾” |
910 |
A-179 |
| 12 |
E 1010 B |
Ethylene |
¾” |
910 |
A-179 |
| 13 |
E 1014 C |
Ethylene |
¾” |
292 |
A-179 |
| 14 |
E 1035 |
Ethylene |
¾” |
320 |
A-179 |
| 15 |
E 1052 B |
Ethylene |
¾” |
326 |
A-179 |
| 16 |
E 1060 B |
Ethylene |
¾” |
1434 |
A-179 |
| 17 |
E 1063 B |
Ethylene |
¾” |
216 |
A-179 |
| 18 |
E 1066 D |
Ethylene |
¾” |
1400 |
A-179 |
| 19 |
E 1066 |
Ethylene |
¾” |
1400 |
A-179 |
| 20 |
E 1072 A |
Ethylene |
¾” |
130 |
A-179 |
| 21 |
E 1078 |
Ethylene |
¾” |
50 |
A-179 |
| 22 |
E 1088 A |
Ethylene |
¾” |
102 |
A-179 |
| 23 |
E 1088 B |
Ethylene |
¾” |
102 |
A-179 |
| 24 |
E 1089 C |
Ethylene |
¾” |
224 |
A-179 |
| 25 |
E 31 E 03 |
EVA |
½” |
23 |
A-179 |
| 26 |
73E04 |
EVA |
20mm |
40 |
SS-321 |
| 27 |
E 4810 |
Solvents |
¾” |
1100 |
A-179 |
| 28 |
E 4208 A |
Solvents |
¾” |
450 |
A-179 |
| 29 |
E 4208 B |
Solvents |
¾” |
450 |
A-179 |
| 30 |
E 4213 A |
Solvents |
¼” |
32 |
A-179 |
| 31 |
E 4213 B |
Solvents |
¼” |
32 |
A-179 |
| 32 |
E 4213 C |
Solvents |
¼” |
32 |
A-179 |
| 33 |
E 4461 |
Solvents |
¾” |
822 |
A-179 |
| 34 |
E 9132 |
Utility |
¾” |
84 |
A-179 |
| 35 |
E 9224 A |
Utility |
¾” |
26 |
A-179 |
| 36 |
E 9224 B |
Utility |
¾” |
26 |
A-179 |
| 37 |
E 9278 /6 |
Utility |
3/8” |
140 |
A-179 |
| 38 |
Ex. Of P 9221 D |
Utility |
¾” |
46 |
A-179 |
| 39 |
E4203 S |
Solvents |
¾” |
430 |
A-179 |
b) Re-tubing and partial Fabrication of TLX (IBR) jobs.
Tube size : 42.4 mm OD x 4.4 mm thk x 6610 mm.lg
Tube sheet Thk : 210 mm
No. of Tubes : 132
Tube MOC : Cromolithin
Time of Completion : 45 days
Ø Reliance Industries Ltd, Kurkhumb, Pune
a) Re-tubing of 13 Heat Exchangers at site of
different sizes.
b) A total no. of 1000 Plugs were welded for Vertical EO
Reactor in position at a short span of 5 days.
Plug size : 31 OD x 176 mm lg
Tube size : 38.1 OD x 3.4 mm thk
MOC : SA 179
Ø Oil & Natural Gas Corporation, Hazira, Surat,
Gujarat
Re-tubing of LPG Condenser E-703 at CFU-1
Tube size : 19.05 mm OD x 2.11 thk x 8000 lg
Tube MOC : SA 179
Shell MOC : SA 515 Gr60
Tubesheet thk : 45 mm
No. of Tubes : 1281
Ø Kribhco Fertilizers Co., Surat, Gujarat
Re-tubing and Tube to Tubesheet welding of E-25-CO2 Compressor-
1st stage Discharge Cooler
Tube size : 20 mm OD x 2 mm thk
Tube MOC : ASTM A213 TP 304L
No. of Tubes : 1026
Tubes were strength welded.
Ø Gujarat State Electricity Board
Re-tubing and expansion of Condenser unit-III
Tube size : 30 OD x 1 mm thk x 10.1 mtr
Tube MOC : CuNi
No of tubes : 15640
In these tedious job approximately 500 tube were removed per
day
i.e. 149 tubes/shift approx (shift of 8 hrs.)
Ø Indian Petrochemicals Corporation Ltd., Nagothane
a) Re-tubing of 30-E-08 & 12(U bundles) at LLDPE
Plant
U Tube: 19.05 mm OD x 2.11 thk
No of tube : 164
Tube MOC : A 179
b) Re-tubing of Heat Exchanger (15-E-301) at Butene-1 plant
Tube: 25.4 mm OD x 2.5 thk x 6700 lg
No of tubes: 1364
Tube sheet thk : 135 mm
Tube MOC : SA 334
Tubesheet MOC : SA 266 Gr.2
The Tubes were strength expanded and seal welded.
Ø Indian Oil Corporation Limited, Vadodara, Gujarat
Re-tubing of Heat Exchangers (21-E-03A/B)-U bundles
Tube size : 20 mm x 2 mm thk
Tube MOC : SA179
No of tubes : 122
6000 mm length of U tubes and inner 1st five rows stress U bend
relieved & PT tested
Tubes strength expanded
Hydro tested to 28 kg/cm2 G
Wt : 12.50 kg each
Insitu Re-tubing of 2 Brass Tube bundles at FCC unit
Tube size : 20 mm x 2 mm thk
Tube MOC : Brass
No of tubes : 2450 |
