A.

2-62-0010-SAP15500 :

Replacement of reformer tubes for 1011-F-002 at HGU: Broad Scope of Work :- 45 Nos

-Transportation of reformer tubes from storage area to site.

-Counterweight tension to be released after marking cold position for the tubes, which are to be
removed.

-Removal and re fixing of spring supports.

-Removal and re fixing of top flange of tube and pulley holder.

-Roof sheets are to be removed and re fixed from top pent house for insertion / removal of catalyst
tubes.

-Cutting and re-welding of hair pin Tube to catalyst tube inlet Nozzle joint.

-Cutting & removing and re fixing of catalyst tubes with support as per procedure mentioned below
using crane.

-NDT of catalyst tube joints and hair pin Tube joint, pre heating and post weld heat treatment are
included in the scope of contractor.

-Transportation of old tube to the location as instructed by engineer in charge.

-All necessary blinding/hose connections etc. shall be done by the contractor.

- Removal and Re installation of Insulation.

- Removal and Re installation of refractory in the annular space of the tube.

-All other jobs required for completion of reformer tube replacement shall be in contractors scope &
no further claims shall be allowed.

- Arrangement of all required tools & tackles, lifting carne, workforce, consumable, rigging group,
slings and other lifting arrangements required for the job is in scope of contractor.

- Roof sheet removal & putting back is part of scope of work& shall not be paid separately.

Procedure for Replacement of Reformer Catalyst tube:

1. Before catalyst removal and cutting of the catalyst tubes, ensure locking of tubes with travel stops
in the cold position. The travel stops are to be preserved by keeping it at the top of the spring box
housing of each tube.

2. The calcium silicate blocks and insulation of the cone portion of cold collector stub to be removed
and preserved for reuse. Remove insulation from the inlet nozzle.

3. Hydrogen bake out for the catalyst tube to reducer field weld joint shall be carried out before
cutting the joint.

4. Cut the weld joint of Inlet Nozzle to weldolet of catalyst tube top section.

5. Cutting of catalyst tube to be done at 25mm above the top of the weld between reducer cone and
catalyst tube on cold collector using cutting/grinding wheel.

6. Reformer pent house top roofing sheets to be removed for removal of tubes.

7. Crane ceiling to be fixed with top flange of catalyst tube and tube to be removed.
8. After removing the catalyst tube from the position, inside grating is to be removed carefully by
emptying out the catalyst and light hammering on the tube. In case of any damage of grating, new
grating to be used.

9. After removal of tube, the portion of backing ring, which is remaining inside the cone is to be
removed by grinding. For removal of backing ring, inside castable lining of outlet reducer cone shall
be removed.

10. A transverse cut to identify the depth up to which ring is existing. Further grinding shall be done
to remove the ring portion.

11. After removal of backing strip ring, the reducer cone edge preparation shall be done by grinding
as per Drg. The bevel edge shall be liquid Penetrant tested.

12. Castable lining of cone section shall be done with refractory up to the seal weld of the retainer
plate of the cone (Refer Drg.).

13. The new catalyst tube is to be laid in the horizontal portion on wooden sleepers.

14. The backing strip at the bottom end of catalyst tube is to be seal welded with catalyst tube.

15. The inside seal welding shall be DP checked.

16. Refractory filling of catalyst tube inside the annular space between the catalyst tube and inlet
reducer portion is to be done with insulating castable refractory.

17. Refractory dry out procedure to be carried out using electrical coil heating as per the following
cycle:

a. The dry out start after 24 hours of natural curing of the refractory.

b. Heating at the rate of 20ºC per hour up to 120ºC. i.e. 6 hours

c. Soaking at 120ºC for a period of 8 hours.

d. Rise further at the rate of 20ºC per hour up to 250ºC. i.e. 6.5 hrs.

e. Soak at 250ºC for 8 hours.

f. Stop heating and allowed natural cooling up to ambient temp.

g. The temperatures are to be measured by contact type thermocouple tied to OD of Catalyst Tube
with SS wire and also Thermo Hunter/ contact type thermometer.

18. The external surface of tube is to be thoroughly cleaned with DM water. The inner surface of
catalyst tube is to be thoroughly cleaned from the top end and also from tube outlet end with
acetone. For cleaning, wrap marker cloth around SS rod / non-ferrous rod and thoroughly soak with
acetone solution. The tube shall be cleaned till no dirt/debris are observed.

19. The reducer portion of the cold collector shall be filled with same refractory. Refractory should
be dry out for about 24 hrs. to avoid moisture problem during welding.

20. When lifting the catalyst tube, great care is to be taken to prevent damage to the outlet tube.
The outlet end shall be covered with plastic sheet.

21. The new tube shall be inserted from the roof into the tube hole at the roof and bottom plate.
The ceramic fibre blanket ring shall be placed in both the cone portion and in the tube. The tube
shall be lowered slowly till the backing strip protrusion goes inside the cone.
22. The tube shall be held in place with the existing spring support clevis.

23. To ensure proper protrusion of catalyst tube inner outlet tube into the internal tube of outlet
reducer cone, Radiography -2 shots at 90 deg apart shall be taken. No separate cost shall be paid for
this radiography

24. Welding shall be done after radiography clearance of fit-up. Root DP and radiography shall be
carried out. After clearance, capping passes shall be made. DP of each weld layer shall be carried
out.

25. The completed weld shall be radiographed by using fine grain high contrast film.

26. Thoroughly clean the inlet Nozzle at the bevel portion, inside of Hairpin Tube near the welding
area and catalyst tube weldolet bevel and inside portion.

27. Prepare weld bevels on the weldolet and Hairpin tube and carry out edge DP.

28. Remove top flange and provide argon back purging using soluble dam/purging shield.

29. Welding of Hairpin tube to weldolet to be done. Carry out root DP and final DP and 100% RT of
weld joint.

30. The top flange-insulating plug to be checked and new ceramic fibre blanket/ vacuum formed
ceramic fiber block to be provided.

31. Top Flange along with split ring and loose flange shall be re fixed.

32. Remove travel stop and keep the travel stop on top of the spring housing.

GENERAL REQUIREMENTS: a. Cutting and grinding shall be done with Alumina oxide wheels only to
prevent carbon contamination.

b. Before welding, weld pad is to be prepared for filler composition check.

c. Welder qualification test shall be done in 2G position with simulated restraint.

d. Small flexible pencil grinder shall be made available for removal of the old backing ring at the
reducer cone portion.

e. Sample radiography shots should be taken before actual shots to establish the correct position of
source/ exposure time. Hair pin Tube Welding Procedure

1. Edge preparation by grinding without damaging the pipe and weldolet parent metal.

2. DP of the Edges after edge preparation.

3. Pre heating of joint

4. Welding with ER 347H filler wire.

5. Root and final Dye penetrant testing.

6. Stabilization Heat treatment after welding,

7. 100% Radiography of weld joints with fine grain high contrast film,

GENERAL REQUIREMENTS: a) Cutting and grinding shall be done with Alumina oxide wheels only to
prevent carbon contamination.

b) Before welding, weld pad is to be prepared for filler composition check.

d) Sample radiography shots should be taken before actual, to establish the correct position of
source/ exposure time.

Notes:-1. The above procedure and scope of work is indicative however all connected job, which are
required to be done for completion to tube replacement has to be carried out by the contractor.

2. The contractor has to finish all the catalyst reformer tube replacement job within time schedule
only. The unit 'EA' denotes replacement of each catalyst tube of reformer furnace.