CFCL - ATR'19 Revised - 25.05.2018

Project Execution Methodology
Project : Dismantling, Erection of Equipments & Piping Work.

Owner : Chambal Fertilizers & Chemicals Limited.
Unit : Gadepan UREA – I
Period : ATR’2019
Reference : COMPOSITE HEAVY ERECTION ENQUIRY/TAR 2018-19/UREA-1
Revision Schedule
Rev. No. Date Description Remarks Signature
We shall strictly follow all HSE requirement & policy during execution of work at
Chambal Fertilizers & Chemicals Limited.
1
TABLE OF CONTENT
No Title Page No.

1 INTRODUCTION 3
2 OBJECTIVES 3
3 GENERAL NOTES 4
4 CRANE DEPLOYMENT 5
4.1 CRANE MOBILIZATION SCHEDULE 5
4.2 MAIN CRANE ASSEMBLY SCHEDULE 5
4.3 CRANE LOAD CHARTS (ATTACHED HERE WITH). 5
5 PRESHUTDOWN ACTIVITY 6
6 SHUTDOWN WORK 6-8
6.1 PROCEDURE FOR REVARSAL OF UREA STRIPPER 11E1 6-8
6.2 LIST OF NOZZLE CONNECTIONS 6-8
7 PROCEDURE FOR REPLACEMENT OF M.P. CONDENSER (21 E-07) 9
8 CONDENSER (11 E-17) REMOVAL, PARTIAL RETUBING & REFIXING 10-11
8.1 DETAILS OF EQUIPMENT 10-11
8.2 MAIN PIPING CONNECTIONS TO DISMANTLE & RE-ERECT 10-11
8.3 SEQUENCES TO EXECUTE THE JOB 11 E-17 10-11
9 PROCEDURE FOR REPLACEMENT OF 11V-01& 11C-05 12-13
9.1 DETAILS OF EQUIPMENT 12-13
9.2 MAIN PIPING CONNECTIONS TO DISMANTLE & RE-ERECT 12-13
9.3 SEQUENCES TO EXECUTE THE JOB 11V-01& 11C-05 12-13
10 MANPOWER DEPLOYMENT 13
11 TOOLS & MACHINERY DEPLOYMENT (Indicating the strength in 14
individual phase)
12 ATTACHEMENTS
SGIL - CFCL-ATR19-001 SHEET 1 OF 5
DEMAG CC – 1800 LOAD CHART
LIEBHERR LTM 1160 LOAD CHART
2
1. INTRODUCTION
Chambal Fertilizers & Chemicals Ltd. (CFCL) is presently running two streams of Fertilizer Plants
(Gadepan-1 & Gadepan-2) at PO Gadepan, District - Kota (Rajasthan). Now, CFCL has proposed
the following jobs in Urea-1 plant:
1. Replacement of M.P. Condenser (21 E-07)

2. Reversal of Urea Stripper (11E-1)
3. Replacement of ammonia receiver (11V-01)& recovery tower (11C-05)
4. Removal, re-tubing & fixing of distillation tower overhead condenser (11E-17)
5. Replacement of 11/21 E-01 to ME-01vapour outlet line
Shutdown of G-1 Plant is proposed in Feb/March 2019; however, actual dates

shall be informed well in advance, before that all the pre-shutdown jobs of G-1
plant to be completed.
Period of shutdown is for 15 days.
2. OBJECTIVES
The main objective of this document creation is to suggest safe and possible good practice
considering timeline and other factors that may affect in achieving the plant objective not limiting to
activities like planning, dismantling, removal and installation scheme for identified equipment’s and
its sequence with respect to HSE and other interfacing activities, as may be applicable during shut
down.
This document is prepared based on the information provided in Enquiry and actual finding during
side visit.
This serves as a guideline to the construction team to foresee the activities involved. This
document suggests use of Crane type and capacity, sequence of crane placement, involvement of
resources & critical path.
 Easier assembly and erection

 Easier construction and hence saving the valuable time
 Safety during construction by reducing the risk
 Improve in accessibility during both pre-shutdown and shutdown phase
3
3. GENERAL NOTES
 All lifting and rigging activities shall be performed as per the acceptable rigging procedures and
safety requirements of the project.
 All personnel must wear Personal Protective Equipment (PPE) at all times. JSA procedure and
posters campaign will apply for the lifting and caring activities.
 All lifting vehicles/equipment must be operated by authorized and competent personnel only.
 The Lead Engineer must ensure that all site personnel are adequately briefed on the contents
of this Method Statement.
 The rigging in-charge shall inspect all lifting equipment prior to everyday use.
 Nylon slings must be protected from sharp corners using timber or other suitable packing.
 It is proposed to use crane to carry out erection of the Equipments as depicted in the enclosed
erection scheme drawings.
 The detail of proposed boom length & operating radius, counter weight trolley with load details,
etc are as indicated in the erection scheme for various equipments.
 The rigging accessories, tools for proposed lifting loads / equipment weight are specified.
 The hardstand preparation/M.S plates as per approved construction / pavement of the different
layers shall be done prior to placement for crane. MS plate of shall be provided between
surface and crane crawler contact area for distribution of equal load (though there is no
requirement of making hard stand.
 Final checking of schemes, tools & machinery and their inspection reports
 Crawler cranes shall work on steel mat plates.
 All the Shutdown work shall be carried out on 24 hrs basis and each shift shall be of 12 hrs.
 No one shall be allowed to work beyond 12 hrs.
 All the tools & machinery shall be in good condition and shall be used after approval of same
from owner Safety department.
Area of Unloading, Assembly & Load Testing of Crane

The position for the Unloading of the main crane will be in 11 unit of Gadepan I, where to be used
for Stripper (as indicated in Drawing No. SGIL-CFCL-ATR19-001). Crane will be unloaded in such
a manner that it would be easier to assemble its parts.
Unloading shall be done with the help of 100 T tyre mounted crane and crane from CFCL. The
assembly schedule is as mentioned below.
Load test shall be carried out by lifting self counter weight & shall be witnessed by M/s. Lloyds.
4
4. CRANE DEPLOYMENT
4.1 Crane Mobilization Schedule

Sl. Specification Start Moving Transportation Load Test
1 DEMAG CC1800 300 Te Crawler 30 days before 20 days 2 days
S/D before S/D
2 LIEBHERR LTM1160 Te Tire 15 days before 10 days 2 days
Mounted S/D before S/D
3 100 Te Tire Mounted 30 days before 10 days
4.2 Main Crane Assembly Schedule

Sl. Activity Day 1 Day 2 Day 3 Day 4 Day 5
1 Mat shifting
2 Car body assembly
3 Crawler & cross bridge assembly
4 Car body counter wt. staging
5 Super structure assembly
6 Operator cabin assembly
7 Platform assembly
8 Winch assembly
9 A frame assembly
10 Main counter wt. & base frame assembly
11 Derrick mast assembly
12 Derrick mast pulled up for equalizer pulley rigging
13 Bottom piece of main boom assemble
14 Winch assemble on main boom
15 Main boom assembly
16 Electrical cables to be installed
17 Assembling main boom pendants
18 Derrick mast to be raised
19 Winch 1 hoist rope to be reeving
20 Hook block assembly
21 All electrical cables installation
22 Boom Up
a. Crane Load charts (attached here with).
5
5. PRESHUTDOWN ACTIVITY
 Deployment of Manpower as per Deployment Schedule
 Mobilization of Tools & Machinery as per Deployment Schedule
 Verification of tools & machinery for use.
 Welder Qualification
 Submission of Documents for finalization & approval
 Crane Deployment, assembly & load test.
 Scaffolding work wherever required & possible.
 Field measurement in respect to receipt ISO’s
 Pre-fabrication of piping spools and NDT
 Area marking for crane placement.
 Pre-fabrication of temporary structure with free issue materials for dismantling & erection of 11V-
01/11C-05
 Erection of above structure at erection site.
 Fixing of suitable chain block for lifting 11C-05
 Additional electrical panel for welding etc.
 Making arrangement for lowering bottom manhole of 11E-1
 Removal of Fire hydrant point from 11 E-1 crane working area.
6. SHUTDOWN WORK
6.1 PROCEDURE FOR REVARSAL OF UREA STRIPPER 11E1

The existing equipment is rested on structural members & top of the equipment is 16.500 Meters
and also is surrounded by structural building up to a height of 22.500 meter. During shutdown the
existing equipment has to be lowered at ground floor and performing some activity same shall be
re-erected at same location after reversal. The following sequence shall be adopted to execute the
job
 Dismounting of connected pipelines by de-bolting / cutting as same has to be re-used.
 Removal of Thermocouple
 Manhole covers opening (Top and bottom- Total 2 Nos Size: 20” x 2500#)
 Dropping down 2 nos control valves (solution inlet &
outlet) DETAILS OF 11 E- 01
 Blind provision for solution inlet, outlet & vapor outlet.
 Reference Drg.:No.7216-01-000-01
 Fixing wooden scaffolding inside bottom of the stripper
Rev.05
 Crane shall be ready (see our Rigging plan)
 Empty Weight – 80500 Kg.
 Top Manhole Weight – 980 Kg.
 Bottom Manhole Weight – 1050 Kg.
6  Overall Height – 12110 mm
 Maximum Diameter – 2900 mm
 Performance of ECT of tubes.

 Removal of wooden scaffolding.
 Removal of structure & gratings.
 Removal of grating and other auxiliary structures which are making hindrances.
 Removal of all tubing work after proper marking as same shall be re-used after reversal process.
 Removal of internals by agency approved by owner.
 There are two pairs of trunnions in shell located at 1350 & 3150 to facilitate the reversal process.
 One equal pair of sling of Ø50 mm x 10 meter long shall be used for lifting.
 Taking 100% load on crane and lifting the job by some millimeter to facilitate to remove the
structure.
 Lifting the job straight to a height that bottom portion comes out completely from the surrounding
structure.
 Now up the boom of crane, thus the radius shall come down to 15-16 meter and swing the crane
in anti-clock direction (as shown in Rigging Plan).
 Lowering the job on saddles with the help of tailing crane.
 Cleaning all the flange seats (Lapping / matching).
 Blinding off all additional nozzles.
 Now start lifting the job with the help of tailing crane.
 As the job becomes vertical position and lift it to a height, so that crane can swing safely and
place the job in its location. During lowering and placement of job the crane boom radius shall be
same as during dismantling.
 Holding the job with crane and fixing the resting supports.
 Now resting the job on foundation after satisfactory checking of its orientation and position.
 Removal of crane.
 Re-installation of internals.
 Re-installation of all piping connections (after modification / new installation).
 Placement of thermocouples.
 Manhole covers installation and bolt tightening.
 Final tightening of all the bolt connection and clearance from Engineer-in-charge.
 Handing over the permit.
 All the gaskets shall be new and will be fixed as per drawing / Engineer-in-charge’s instruction
Main Crane : DEMAG CC – 1800 300 Ton Capacity Crawler in SLL configuration
Tailing Crane : Tadano 100 Ton Capacity Tire Mounted.
Wire Rope Slings : Ø50 mm x 10 meter 2 pairs (100% Tested with TPI Certification)
‘D’ Shackles : 50 Mt Capacities (100% Tested with TPI Certification
7
6.2 LIST OF NOZZLE CONNECTIONS

Sl. Pos. Qty. Size Type Services Remarks
1 N2A 1 10” ANSI 300# LWN-RF Steam Inlet
2. N2B 1 10” ANSI 300# LWN/BL-RF Steam Inlet
3. N3A 1 6” ANSI 300# LWN-RF Condensate Outlet To blind-off for reversal
4. N3B 1 6” ANSI 300# LWN/BL-RF Condensate Outlet ® Present may be blind-off
5. N6 1 1” ANSI 300# LWN-RF Equalizer
6. N7A 1 1/2” ANSI 300# LWN/BL-RF Vent
7. N7B 1 1/2” ANSI 300# LWN/BL-RF Drain
8. N9 1 4” ANSI 300# LWN-RF PSV Connection
9. CN3A/C 3 1-1/2” ANSI 300# LWN-RF Thermocouple
10. CN3D-E 2 1-1/2” ANSI 300# LWN/BL-RF Thermocouple
11. N1A 1 8” Solution Inlet To blind-off for reversal
12 N1B 1 8” Solution Inlet ® Present may be blind-off
13 N5 1 8” Vapor Outlet ® Present may be blind-off
14 N8 1 8” Vapor Outlet To blind-off for reversal
15 N11 1 ½” Sample Connection
16 N12 1 6” Solution outlet
17 CN1A 1 1” Upper Level
18 CN2A 1 1-1/2” Thermocouple To blind-off for reversal
19 CN2B 1 1-1/2” With Blind Cover Thermocouple ® Present may be blind-off
20 CN4A 1 1” See Detail Lower Level To blind-off for reversal
21 CN3B 1 1” With Blind cover Lower Level ® Present may be blind-off
22 CN5 1 3” W. ANSI B16.5 6”-150# Radioactive Level
23 M1A 1 600 With Blind Cover Manhole
24 M1B 1 mm With Blind Cover Manhole
For details please see Rigging Scheme no. SGIL-CFCL-ATR19-001 (1 OF 5 TO 1 OF 5)
Note:
On completion of use of DEMAG CC-1800 crane for reversal of Urea Stripper, the
crane shall be dismantled (boom, super lift structure & counter weight shall be
removed only) & the crane shall march for Urea 21 Unit for execution of 21 E-07.
Crane shall be assembled in 21 Unit (sufficient space is there for assembly work) in
new configuration as mentioned in Rigging Scheme
8
7. PROCEDURE FOR REPLACEMENT OF M.P. CONDENSER (21 E-07)

The existing equipment in Urea Train 21 of Gadepan I have to be replaced by new one. The
equipment is vertical and resting on structure. The location of equipment is such that the working
radius of crane shall be 26- 28 meter. New equipment shall be erected in same location as
existing; some piping requires to be modified at site as per site requirement. Following sequences
shall be adopted for execution of the job.
 Removal of piping connection ( de-bolting or cutting) as mentioned below
Sl. Services Size & Rating MOC

1 CW inlet 18”x 10mm thk CS
2 CW outlet 18”x 10mm thk CS
3 Solution I/L 12”xSch80 SS316L
4 Solution O/L 8”xSch40 SS316L
DETAILS OF 11 E- 01
 Removal of instrument items if any
 Removal of structure & gratings whatever  Reference Drg. No.: PV-02-0215Sht 1 of
2 Rev04 & PV-02-0215 Sht. 2 of 2 Rev05
minimum required in such a manner that it has to  Empty Weight – 10000 Kg.
be re-erected after installation of new equipment.  Overall Height – 8166 mm
 Crane placement as per our Rigging Scheme no.  Maximum Diameter – 1258 mm
SGIL-CFCL-
 Now after checking and assured about that there is no hindrances, job shall be lifted straight so
that it comes out completely from the surrounding structure and up to such height that crane
can swing with job freely & safely.
 Crane shall swing and lower the job on wooden sleepers / saddles with help of 100 Mt crane.
 Now new equipment shall be lifted and placed to the resting structure as reverse process of
dismantling.
 After checking orientation and elevation and clearance from owner’s Engineer’s approval
complete fixing work will be finished.
 Further, piping work shall be completed along with required testing.
 For details please refer Rigging Scheme No.SGIL-CFCL-ATR19-002 (SHEET 1 0F 1)
Main Crane : DEMAG CC – 1800 300 Ton Capacity Crawler in SH configuration
Tailing Crane : Tadano 100 Ton Capacity Tire Mounted.
‘D’ Shackles : 12 Mt Capacities (100% Tested with TPI Certification)
9
8. CONDENSER (21 E-17) REMOVAL, PARTIAL RETUBING & REFIXING

8.1DETAILS OF EQUIPMENT
Total Empty (Dry) weight 11009

Maximum diameter 905
Overall length 12414
Elevation above ground level 23 M(top) 10( Bottom)
Tubes details OD19.05x18BWGx10100 L; MOC-TP-304L
Tube sheet OD:- 1021mm, Thk : 52mm;MOC- SA 182 Gr F-304L
No. of tubes in exchanger 1011
No. of tubes re-tubing to be 100
done.
Drawing No. 1856/D
8.2 MAIN PIPING CONNECTIONS TO DISMANTLE & RE-ERECT
Sl. Services Size & Rating Pipe Thickness MOC

1 CW inlet 20”x150# 6.35 mm CS
2 CW outlet 20”x150# 6.35 mm CS
3 Vapor inlet 16”x150# 4.78 mm SS304L
4 Vapor outlet 8” x150# 3.4 mm SS304L
Main Crane : LIEBHERR LTM 1160 160 Mt capacity; Tire Mounted
Tailing Crane : Hydra 14 Mt Capacity.
‘D’ Shackles : 12 Mt Capacities (100% Tested with TPI Certification)
8.3 SEQUENCES TO EXECUTE THE JOB 11 E-17
 Dismounting of connected pipeline after match marking

 Placement of Crane at a radius of 14 – 16 meter. Pad plates shall be placed below crane jacks.
 Dismantling of equipment and make it horizontal with the help of hydra crane and placement on
wooden sleeper
10
 Cleaning of tube sheet by wire brushes to remove loose scale.

 Trimming / Facing of Projected portion of tubes by grinding and removal of taper plugs.
 Chamfering/Beveling of each tube to tube sheet weld to remove weld run.
 Removal of groove welding by drilling.
 Removal of expanded portion of old tubes in tube sheet by machining & drilling.
 Removal of old tubes by hydraulic pulling mechanism.
 Remove the old tubes alternatively to ensure new tubes insertion in same tube sheet holes and
baffle holes. Remove 10 tubes & insert new tubes. Repeat same procedure for all tubes. Do not
remove all tubes at a time.
 Cutting of new tubes to match the required dimension. The new tubes will be about 25 mm
excess in length.
 After insertion of all row tubes, move all new tubes one side to clean other side tube sheet hole
groove cleaning, burr removal, old tube chips removal. Also do chamfering i.e. Edge
preparation (J-Groove) for strength welding. Clean all holes using proper size rotary wire brush
& cleaning agent. Ensure cleaning of all holes of tube sheet. Then adopt same procedure for
the other end of tube sheet. Measured ID of tube sheet holes, ID of tubes (at 10 nos. predefined
locations on each tube sheet).
 Tube to tube sheet welding by TIG process & as per WPS approved by CFCL.
 First pass tube to tube sheet welding from both ends as per the established procedure. Welding
of tubes is to be done in that manner to have uniform heating of tube sheet.
 DP test of root run tube to tube sheet welding is to be done by contractor and interpreted by
CFCL inspection department.
 Pneumatic test at 2 kg/cm2 of root run tube to tube sheet welding to be done by Production
dept.
 Final welding of tube to tube sheet welding to be done by contractor after repair welding, if any.
 DP test of final run tube to tube sheet welding and get checked by CFCL.
 Pneumatic test by CFCL.
 Tube to tube sheet expansion of the tubes (3-5%) with appropriate expansion tools by
contractor.
 After expansion, measurement of tubes ID (at 10 nos. predefined locations on each tube sheet).
This is required for calculation & verification of expansion percentage.
 Repeat pneumatic test of the shell the leaky tubes will be re-expanded and re-tested, if
required.
 Hydro test of shell at 6.6 Kg/cm2 after the complete tube expansion.
 After getting clearance from owner Engineer-in-charge the revamped equipment shall be lifted
with same crane, used for dismantling
 Reconnecting of all pipelines and necessary NDE.
11
9. PROCEDURE FOR REPLACEMENT OF 11V-01& 11C-05

The equipment is situated at an elevation of 5.00 meter on horizontal position, inside a concrete
building. There are two saddles. It is not possible to apply crane directly for dismantling & erection.
Our concept is to fabricate & fix a temporary structure for jacking and lift to an elevation so that the
job saddle is free from foundation bolt. Jacks shall be placed under two numbers newly fabricated
saddle.
As soon as the job lifted same shall be placed over a temporary structure called sliding structure &
as long as that the equipment can be slide over the same outside the building. The sliding structure
length shall be so sufficient that the job can be lifted with the help of main crane. The same
process shall be followed for erection of new equipment also. The detailed structure and Design
calculations shall be provided later.
9.1 DETAILS OF EQUIPMENT
Existing (11V-01/C-05) New (11V-01/C-05)

Total Empty weight 42 ton 42 ton
Maximum diameter 3326 mm/ 813 mm 3332 mm/ 813 mm
Overall length 10.105m /4 m 10.270m /4 m
Elevation above ground level Bottom at 5m Bottom at 5m
Drawing No. 1844/B V-1149/FAD/2017
9.2 FOLLOWING SEQUENCES SHALL BE ADOPTED TO EXECUTE THE JOB

 Dismantling and removal of pipelines
 Removal of instruments. BLIND TO BE PROVIDED IN LOCATIONS
 De-mounting of 11C-05 Sl. Details Size
 Lifting 11-C-05 with the help of suitable 1 V-1 ammonia I/L line 6”X300#
chain block to a certain height 2 C-5 ammonia I/L line 4”x300#
 Placement of temporary saddles and jacks 3 C-5 top vapour line flange 3”x300#
at four corners as mentioned in our scheme 4 P-5A/B recycle line flange 3”x300#
 Lifting 11V-01 with help of jacks 5 P-1 recycle line flange 3”x300#
 Placement of temporary saddles & sliding 6 P-5 jacket recycle line 3”X300#
structure 7 E-9 vapour line 4”x300
 Placement of Steel rollers between saddles 8 PSV-106 U/S flange 4”x300#
and sliding structure.
 Removal of jacks
 Sliding of 11V-01 over temporary structure with the help of chain blocks, which are fixed with
concrete column i.e. K-1 & L-1
 As soon as the equipment moves out of building the main crane CC2000 shall be engaged to
lift & lower the job on ground level.
12
 Now the 11-C-05 shall be lowered on ground level, using same chain block on which it was
hanging.
 New 11-C-05 shall be first lifted and hanged till new 11V-01 enters its position.
 New 11-C-05 shall be erected adopting the same process applied for lowering old one.
 Lowering new 11C-05
 Bolting both the equipment
 Re-fixing of all pipe connection with new gasket
 Removal of all the temporary structures
 For details refer Rigging Scheme
Main Crane : LIEBHERR LTM 1160 160 Mt capacity; Tire Mounted
10. MANPOWER DEPLOYMENT
Pre-shutdown
Sl. Designation Shutdown Remarks
(30 days before S/D)
Staff
1 Site in-charge 1 1
2 Piping Engineer 1 2
3 Piping Supervisor 2 4
4 Structural Supervisor 1 1
5 Welding Engineer 1 1
6 Equipment Engineer 1 1
7 Erection Foreman 2
8 NDT Engineer 1 1
9 QA/QC Engineer / Supervisor 1 2
10 Safety Supervisor 1 3
Labour
1 Fitter 3 8
2 Pipe Welder 3 6
3 Structure Welder 2 2
4 Grinder Man 3 6
5 Gas Cutter 1 3
6 Helper 6 20
7 Rigger 12 40
8 Electrician 1 2
13
11. TOOLS & MACHINERY DEPLOYMENT (Indicating the strength in individual phase)
Sl. Description Unit Pre S/D S/D Remarks
1 Crawler Crane 300 Mt with steel mat plates No 1
2 Tyre Mounted Telescopic Boom Crane 160 Mt No 1
3 Tyre Mounted Telescopic Boom Crane 100 Mt No 1 1
4 Hydra 15 T No 1 2
5 Trailer No 1
6 Welding Rectifier Set 10 15
7 TIG Set Set 2 6
8 Gas Cutting Set Set 2 4
9 Grinder No 6 12
10 Drill Machine No 1 1
11 Chain Block 3 Mt/5 Mt/10 Mt No 3 6/2/1
12 Mechanical Jack 50 T No 8
13 Portable Oven No 2 4
14 Hydro Test Pump Set 1 2
15 Wire Rope Sling Ø50 mm x 10 mtr. Pair 2 2
16 Wire Rope Sling Ø25 x 12 mtr Pair 4 4
17 Wire Rope Sling Ø20 mm x 6 mtr Pair 2 2
18 Lifting Belt 5 Mt Pair 4 6
19 ‘D’ Shackle 50 Mt Pair 2 2
20 ‘D” Shackle 25 Mt Pair 2 2
23 Nylon Rope Ø20 mm Mtrs 100 200
24 Spanner Set Lot Lot Lot
25 Electrician Tools Set 1 2
26 Scaffolding Pipe 6 mtr No 200 200
29 Steel Chali No 100 100
30 Fitter Tool Box with general fabrication tools Set 4 8
31 DP Test Kit Set 6 8
32 RT Source (Approved agency)
33 Purging Tape
34 Welding consumable
35 Grinding consumables
36 Gas Cylinder (O2; DA; Argon)
37 All PPE’s
14
12. ATTACHMENTS
 SGIL - CFCL-ATR19-001 SHEET 1 OF 5

 DEMAG CC – 1800 LOAD CHART
 LIEBHERR LTM 1160 LOAD CHART
15
Making the job Horizontal to Vertical & Vertical to Horizontal
UREA STRIPPE 11 E-1 subsequently during Dismantling and Erection N
MAIN CRANE DEMAG-CC-1800

DIN 75%
CONFIGURATION SSL
TRACKS 7.25 m
SUPERLIFT WEIGHT 80 t
CENTER BALLAST 120 t
MAIN BOOM 54 m
RADIUS 20.0 m
CAPACITY 121.0 t
% OF USE 71.98 % LIFTING TACKLE ARRANGEMENT FOR MAIN CRANE
TOTAL LOAD 87.1 t

* LOAD 80.5 t
* HOOK BLOCK (200Te SWN) 4.6 t
* LIFTING TACKLES 2.0 t
2 x 10m slings double back
at trunnion 50mm S.W.L
36000
UREA STRIPPE 11 E-1 = 50 te (Each)
TAIL 100MT TYRE MOUNTED CRANE

DIN 75%
CONFIGURATION SSL
TRACKS 8.0 m
5400
TAILING TACKLE ARRANGEMENT FOR TAIL CRANE
COUNTERWEIGHT 120 t
CENTER BALLAST - -
0
MAIN BOOM 24 m
BACKMAST 00 m
RADIUS 5.98 m
CAPACITY 47.0 t
%SWL 87.7 % 2 x 10m slings double back
TOS. 22.000
TOTAL LOAD 41.8 t = 50 te (Each)
* LOAD 40.0 t
* HOOK BLOCK (600Te SWN) 0.8 t 2410
Surrounding Structure
12085
0 30-05-2018 ISSUED FOR COMMENTS. RAGHAV G.B. S.G.

REV. DATE REVISION BY CHK. APPROVED REMARKS
CLIENT:-
CHAMBAL FERTILSERS AND CHEMICALS LIMITED
DRAWING TITLE:- RIGGING SCHEME FOR UREA STRIPPER

(11 E-1 ) - SHEET 1
12410
PROJECT :- DISMANTLING AND ERECTION WORK FOR REPLACEMENT OF
20000 13000 FOLLOWING EQUIPMENT: CFCL
CONTRACTOR :-
SATNAM GLOBAL INFRAPROJECT LTD, DELHI
Ground bearing Pressure should be 22 -24Mt/Sqm. ELEVATION VIEW (STAGE-Ist) JOB NO. UNIT SCALE DRAWING NO. SHEET REV.
20mm steel mat plate shall be placed under crawler. - - - SGIL - CFCL-ATR19-001 1 OF 5 01

DIN 75%
CONFIGURATION SSL
TRACKS 7.25 m
(MIN.)
5000
MAIN BOOM 54 m
RADIUS 20.0 m
CAPACITY 121.0 t
6780
TOTAL LOAD 87.1 t
* LOAD 80.5 t
* LIFTING TACKLES 2.0 t The Equipment shall be lifted till
it's bottom comes to an elevation 2 x 10m slings double back
5249
of 26.0 meter, then the main at trunnion 50mm S.W.L
UREA STRIPPE 11 E-1 crane Boom shall be lifted up as = 50 te (Each)
TAIL 100MT TYRE MOUNTED CRANE mentioned in stage-3rd. 4940

DIN 75%
CONFIGURATION SSL
TRACKS 8.0 m
11884
COUNTERWEIGHT 120 t
CENTER BALLAST - -
5400
MAIN BOOM 24 m
BACKMAST 00 m
0
RADIUS 5.98 m
ELV. 26.000
CAPACITY 47.0 t
%SWL 87.7 %
4000
TOTAL LOAD 41.8 t TOS. 22.000 = 50 te (Each)
* LOAD 40.0 t
2410

CLIENT:-

(11 E-1 ) - SHEET-2

12410 FOLLOWING EQUIPMENT: CFCL
20000 13000 CONTRACTOR :-

Ground bearing Pressure should be 22 -24Mt/Sqm.
20mm steel mat plate shall be placed under crawler. ELEVATION VIEW (STAGE-IInd) JOB NO. UNIT SCALE DRAWING NO. SHEET REV.
01
- - - SGIL - CFCL-ATR19-001 2 OF 5

DIN 75%
CONFIGURATION SSL
TRACKS 7.25 m
MAIN BOOM 54 m
RADIUS 20.0 m
CAPACITY 121.0 t
TOTAL LOAD 87.1 t The crane boom shall be lifted up

* LOAD 80.5 t to the extent that the job
* HOOK BLOCK (200Te SWN) 4.6 t During swing of crane boom the job completely comes out of the
* LIFTING TACKLES 2.0 t must be tied with 2 nos. nylon rope to building battery limit, so that the
5249
restrict any type of shock load. crane can be swing in anti-clock
direction safely. at trunnion 50mm S.W.L
2415
BUILDING BATTERY LIMIT

DIN 75%
12131
CONFIGURATION SSL
TRACKS 8.0 m
COUNTERWEIGHT 120 t
CENTER BALLAST - -
MAIN BOOM 24 m
BACKMAST 00 m ELV. 26.000
RADIUS 5.98 m
3750
CAPACITY 47.0 t
%SWL 87.7 % TOS. 22.000 2 x 10m slings double back
* LOAD 40.0 t

CLIENT:-
DRAWING TITLE:-
RIGGING SCHEME FOR UREA STRIPPER
12410 (11 E-1 ) - SHEET-3
12000 13000 PROJECT :- DISMANTLING AND ERECTION WORK FOR REPLACEMENT OF
20000 FOLLOWING EQUIPMENT: CFCL
CONTRACTOR :-
Ground bearing Pressure should be 22 -24Mt/Sqm. ELEVATION VIEW (STAGE-IIIrd) JOB NO. UNIT SCALE DRAWING NO. SHEET REV.

DIN 75%
CONFIGURATION SSL Rested on structural members & these members to dismantled after
TRACKS 7.25 m taking full load on crane during removal & during reinstallation after
lowering the job to required elevation structural members to be
MAIN BOOM 54 m reinstalled at their previous position before final lowering
RADIUS 20.0 m
CAPACITY 121.0 t
TOTAL LOAD 87.1 t

* LOAD 80.5 t
7409
20000
11-R1 at trunnion 50mm S.W.L
UREA STRIPPE 11 E-1
6792 = 50 te (Each)
TAIL 100MT TYRE MOUNTED CRANE 2470

DIN 75%
CONFIGURATION SSL
TRACKS 8.0 m
40
23
COUNTERWEIGHT 120 t
CENTER BALLAST - -
MAIN BOOM 24 m
BACKMAST 00 m
RADIUS 5.98 m
0
00
12
CAPACITY 47.0 t
%SWL 87.7 % 1200
0
12410 at trunnion 50mm S.W.L
* LOAD 40.0 t Final Position of the Job on the Ground

R130
00

CLIENT:-

(11 E-1 ) - SHEET-4

FOLLOWING EQUIPMENT: CFCL
CONTRACTOR :-
PLAN VIEW SATNAM GLOBAL INFRAPROJECT LTD, DELHI
Ground bearing Pressure should be 22 -24Mt/Sqm. JOB NO. UNIT SCALE DRAWING NO. SHEET REV.

DIN 75%
Maximum wind speed for load UREA STRIPPE 11 E-1
CONFIGURATION SSL
TRACKS 7.25 m
The maximum wind speed for working
with this crane configuration is 9.8 m/s
MAIN BOOM 54 m
(MIN.)
5000
RADIUS 20.0 m
CAPACITY 121.0 t
TOTAL LOAD 87.1 t

* LOAD 80.5 t

DIN 75%
CONFIGURATION SSL
TRACKS 8.0 m
COUNTERWEIGHT 120 t
CENTER BALLAST - -
54000
MAIN BOOM 24 m
BACKMAST 00 m
RADIUS 5.98 m
CAPACITY 47.0 t
%SWL 87.7 %
0 ( MAX.) 2 x 10m slings double back
TOTAL LOAD 41.8 t

240 at trunnion 50mm S.W.L
= 50 te (Each)
* LOAD 40.0 t
00
150
Ground bearing Pressure should be 22 -24Mt/Sqm.

20mm steel mat plate shall be placed under crawler.
0 30-05-2018 ISSUED FOR COMMENTS. GURUDEV SINGH G.B. S.G.

CLIENT:-

(11 E-1 ) - SHEET-5

CONTRACTOR :-
14000 SATNAM GLOBAL INFRAPROJECT LTD, DELHI
12410
ELEVATION VIEW JOB NO. UNIT SCALE DRAWING NO. SHEET REV.
- - - SGIL - CFCL-ATR19-001 5 OF 5 01
M.P. CONDENSER 21 E-07
Swinging radius of crane for brining down the EQUIPMENT TAG NO.- 21-E-07 MAIN 300MT CRAWLER CRANE
equipment on ground after dismantling & lifting MAX. DIAMETER - 1.258mtr DIN 75%
LENGTH- 8.166mtr CONFIGURATION SH
the same from ground to erection location TRACKS 7.25 m
EMPTY WEIGHT- 10.0mt COUNTERWEIGHT 140 t
CENTER BALLAST 40 t
MAIN BOOM 78 m
RADIUS 26.0 m
CAPACITY 40.0 t
%of Use 31.25 %
TOTAL LOAD 12.5 t
Old dismantle equipment placement * LOAD 10.0 t
R2
600
0 M.P. CONDENSER 21 E-07
N1
1250
2500
4500
1500 DIN 75%
O1 CONFIGURATION SSL
Plant structural building battery limit

26
TRACKS 8.0 m
00
3000 3000
8243
0
COUNTERWEIGHT 120 t
7800
CENTER BALLAST - -
MAIN BOOM 24 m
0
BACKMAST 24 m
RADIUS 5.98 m
CAPACITY 47.0 t
%SWL 20.0 %
TOTAL LOAD 6.6 t
* LOAD 5.0 t
3188
T.O.S 22.000 PLAN VIEW
0 30-05-2018 ISSUED FOR COMMENTS. RAGHAV S.G. S.G.

CLIENT:-
DRAWING TITLE:-
DISMANTLING & ERECTION SCHEME FOR
M.P. CONDENSER (21 E-07)
PROJECT :- DISMANTLING AND ERECTION WORK FOR
REPLACEMENT OF FOLLOWING EQUIPMENT: CFCL
15000
Ground bearing Pressure should be 14-16Mt/Sqm.

26000
CONTRACTOR :-
ELEVATION VIEW 20mm steel mat plate shall be placed under crawler. JOB NO. UNIT SCALE DRAWING NO. SHEET REV.
01
- - - SGIL - CFCL-ATR19-002 1 OF 1
LIEBHERR LTM 11600 160MT Tyre Mounted
WOODEN BLOCKS
Telescopic Boom Crane
1 x 5m Grommet in concrete
beam 20mm sling
Chain Block capacity 5 ton
1 x 22m Sling of 32mm

Jacking at four corners
9821 9821 9821
3250
3250
3250
Final position of job, from
here crane shall be used
during dismantling & erection.
Temporary Structure for Jacking Temporary Saddle Temporary Saddle
Temporary Structure for Jacking 4mm Steel Rollers Temporary Structure for Sliding
Temporary Structure for Sliding Temporary Structure for Jacking

5000
5000
GROUND LEVEL
K1 L1
CLIENT:-
DRAWING TITLE:-
RIGGING SCHEME FOR AMMONIA RECEIVER
(11V-01) & RECOVERY TOWER ( 11V-05)

CONTRACTOR :-
JOB NO. UNIT SCALE DRAWING NO. SHEET REV.

- - - SGIL - CFCL-ATR19-003 1 OF 2 01
WOODEN BLOCKS WOODEN BLOCKS
1 x 5m Grommet in concrete 1 x 5m Grommet in concrete

beam 20mm sling beam 20mm sling
9821
3250
GROUND LEVEL GROUND LEVEL
LOWERING & LIFTING OF 11-C-05 LOW RING & LIFTING 11-C-05

K1 K1
L1 L1
JOB DETAILS
TAG NO. : 11-V-01 REV. DATE REVISION BY CHK. APPROVED REMARKS
CLIENT:-
MAXIMUM DIAMETER - 3326 CHAMBAL FERTILSERS AND CHEMICALS LIMITED
TOTAL LENGTH - 10.105 MTR DRAWING TITLE:-

RIGGING SCHEME FOR AMMONIA RECEIVER
AT ELEVATION - MTR (11V-01) & RECOVERY TOWER ( 11V-05)
TOTAL WEIGHT - 28.0 MT
TAG NO. - 11-C-05 FOLLOWING EQUIPMENT: CFCL
MAX. DIA - 813mm

CONTRACTOR :-
TOTAL LENGTH 4.0 MTR SATNAM GLOBAL INFRAPROJECT LTD, DELHI
AT ELEVATION - 9.0 MTR APPROXIMATE JOB NO. UNIT SCALE DRAWING NO. SHEET REV.
- - - SGIL - CFCL-ATR19-003 2 OF 2 01
CRANE TYRE MOUNTED 160MT
CRANE CAPACITY 24.00mt
BOOM LENGTH 32.00m
OUTER RIG 26.00m

CRANE RADIUS 8.200m
Job Details
Equipment Tag No. 11-E-17
Main Dia 0.905 mtr
12414
Main Length 12.414 mtr
3200
0
Equipment weight 11.009 Kg.

CLIENT:-
DRAWING TITLE:-
RIGGING SCHEME FOR REMOVAL, RETUBING & FIXING
OF DISTILLATION TOWER OVERHEAD CONDENSER(E-17)
PROJECT :-
DISMANTLING AND ERECTION WORK FOR REPLACEMENT OF
CONTRACTOR :-
JOB NO. UNIT SCALE DRAWING NO. SHEET REV.

8200 - - - SGIL - CFCL-ATR19-004 1 OF 1 01
300t
DEMAG CC 1800
Version:2.6 Dimensions in millimeters

Page: 1 of 10 For reference only.
300t
DEMAG CC 1800 (SH/SSL)
Version:2.6 Dimensions in meters

300t
DEMAG CC 1800 (SH)
Crawler width : 7.25m
Ballast : 120t
Mainboom
Boom length
Radius
5 6 7 8 9 10 11 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 54 58 62 66 70 74 78
18 273 254 239 227 203 170 149 128 102 84 72
24 276 260 244 202 169 148 127 101 83 70 61 54
30 252 243 202 169 147 126 100 82 70 60 53 47 42 38
36 242 201 168 146 125 99 81 69 59 52 46 41 37 33
42 240 200 167 145 124 98 81 68 58 51 45 40 36 32 29 27 25 23
48 200 167 145 124 98 80 67 58 50 44 39 35 31 28 26 24 22 20 19
54 140 166 146 127 100 83 70 60 52 46 41 37 34 31 28 26 24 22 20 19 18
60 140 131 123 100 82 69 60 52 46 41 37 33 30 27 25 23 21 20 18 17 16 15 13
66 102 107 112 96 80 69 59 52 46 41 37 33 30 27 25 23 21 20 18 17 15 14 13 11
72 94 89 78 65 59 51 45 40 36 33 30 27 24 22 20 19 17 16 15 14 12 10 9
78 80 74 69 64 58 51 45 40 36 32 29 27 24 22 20 19 17 16 15 14 12 10 8 7.3 6
84 70 69 67 65 58 51 45 40 35 32 29 26 24 22 20 18 16 15 14 13 11 9 8 6.6 5 4
90 56 54 52 50 49 44 39 35 32 29 26 24 22 20 18 16 15 14 13 11 9 7 6.3 5 4 3
96 41 39 37 36 34 33 32 31 30 27 25 23 21 19 17 15 14 13 12 10 8 7 5.6 4 3
Configuration for 21 E07

Replacement work
Version:2.6 Weights and capacities in metric tonnes, dimensions in meters.

300t
DEMAG CC 1800 (SSL)
Crawler width : 7.25m
Configuration of crane for Urea Stripper Ballast : 120t
Superlift radius : 13m
Reversal Work
Mainboom with superlift

Superlift ballast
Boom length
Radius
6 7 8 9 10 11 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 54 58 62 66 70 74 78 82 86 90 94
0 221 210 200 189 170 152 135 108 89 75 65 57 51 46 41
40 281 281 281 262 236 212 189 154 128 109 95 83 74 67 61
80 300 300 272 250 228 193 163 141 124 110 98 89 81
30 120 289 273 258 221 193 169 149 133 120 109 100
160 248 217 192 173 155 140 128 116
180 256 228 203 182 165 150 134 116
200 300 300 300 300 291 282 274 256 228 203 182 165 150 134 116
0 229 210 187 169 152 135 107 88 74 64 56 50 44 40 36
40 288 288 260 235 212 189 153 127 108 94 82 73 66 60 55
80 288 288 271 248 226 193 163 141 123 109 97 88 80 73
36 120 288 272 257 220 192 169 149 133 119 108 99 91
160 280 246 215 191 171 155 140 127 116 107
180 260 227 201 181 164 150 136 125 115
200 288 288 288 288 284 280 260 227 201 181 164 150 136 125 115
0 238 209 186 168 151 134 106 87 73 63 55 49 44 39 36 30 25
40 250 250 250 234 211 189 153 126 107 93 82 73 65 59 54 46 39
80 274 274 270 247 225 193 163 141 122 108 96 87 79 72 62 54
42 120 274 265 256 219 191 169 148 132 119 108 99 91 78 68
160 279 245 214 190 170 154 139 127 116 107 92 81
180 259 226 200 180 163 149 136 125 115 99 87
200 279 279 279 279 279 279 259 226 200 180 163 149 136 125 115 99 87
0 209 186 167 150 133 105 87 73 63 55 48 43 39 35 29 24 22 21
40 232 232 232 211 190 152 126 107 92 81 72 65 58 53 45 39 36 34
80 242 242 233 224 192 163 140 122 107 96 86 78 72 61 53 49 46
48 120 242 218 190 168 149 132 119 108 98 90 77 67 63 59
160 242 213 189 169 153 139 127 116 107 92 80 75 71
180 225 199 179 162 148 136 124 115 99 86 81 76
200 242 242 242 242 242 242 225 199 179 162 148 136 124 115 99 86 81 76
0 185 166 149 133 105 86 72 62 54 47 42 38 34 28 24 22 20 18 17
40 200 196 193 190 152 125 106 92 80 71 64 58 52 44 38 35 33 31 29
80 209 209 209 191 163 140 121 107 95 86 78 71 60 52 48 45 42 40
54 120 213 209 189 167 148 132 119 107 97 89 76 66 62 58 55 52
160 194 185 168 152 139 126 115 106 91 79 74 70 66 63
180 176 161 147 135 124 114 98 86 81 76 72 68
200 218 218 215 213 203 194 185 176 161 147 135 124 114 98 86 81 76 72 68
0 167 167 149 132 104 85 72 61 53 47 42 37 33 27 23 21 19 17 16 15 14 13 12
40 169 169 169 169 151 125 106 91 80 71 63 57 52 43 37 34 32 30 28 26 25 23 22
80 181 181 163 139 121 106 95 85 77 70 59 51 48 45 42 39 37 35 33 32
60 120 184 181 167 149 132 118 107 97 89 75 65 61 57 54 51 48 46 43 41
160 181 168 152 138 126 115 106 91 79 74 70 66 62 59 56 53 51
180 172 160 146 134 123 114 98 85 80 75 71 67 64 61 58 55
200 201 201 201 201 201 191 181 172 160 146 134 123 114 98 85 80 75 71 67 64 61 58 55
0 141 136 132 104 85 71 61 53 46 41 37 33 27 22 20 19 17 16 14 13 12 11 9
40 144 144 144 141 124 105 91 79 70 63 57 51 43 36 33 31 29 27 25 24 22 21 19
80 151 151 151 139 120 106 94 84 76 70 59 51 47 44 41 39 36 34 32 31 28
66 120 156 148 142 132 118 106 96 88 75 65 61 57 53 50 47 45 42 40 37
160 149 143 137 126 115 106 91 79 74 69 65 62 58 55 52 50 46
180 138 133 123 114 98 85 80 75 71 67 63 60 57 55 50
200 158 158 158 158 158 155 149 143 138 133 123 114 98 85 80 75 71 67 63 60 57 55 50
0 121 121 121 104 85 71 60 52 46 41 36 32 26 22 20 18 16 15 13 12 11 10 8 7
40 124 124 124 124 121 105 90 79 70 62 56 51 42 36 33 31 29 27 25 23 21 20 18 16
80 131 131 131 120 105 94 84 76 69 58 50 46 43 40 38 36 34 32 30 27 24
72 120 134 129 123 117 106 96 88 74 64 60 56 53 50 47 44 42 40 36 33
160 133 129 125 115 106 90 78 73 69 65 61 58 55 52 49 45 41
180 125 121 113 97 85 80 75 71 67 63 60 57 54 49 45
200 141 141 141 141 141 141 137 133 129 125 121 113 97 85 80 75 71 67 63 60 57 54 49 45
Version:2.6 Weights and capacities in metric tonnes, dimensions in meters.

Satnam Global Infraprojects Limited
Project: COMPOSITE ERECTION Work at CFCL, Gadepan
PRELIMINARY SCHEDULE FOR ATR'2019
ID Task Name Duration Start Finish PredecessorsResource Feb 17, '19 Feb 24, '19 Mar 3, '19 Mar 10, '19 Mar 17, '19 Mar 24, '19
Names 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 T W T F S S M T W T F
1 Pre Shutdown 639 hrs Fri 2/15/19 8:00 AM Wed 3/13/19 11:00 PM
2 Sub & app of docs 4 days Fri 2/15/19 8:00 AM Tue 2/19/19 4:00 AM
3 Site Mob 2 days Fri 2/15/19 8:00 AM Sun 2/17/19 6:00 AM
4 Welder qualification 3 days Mon 2/18/19 8:00 AM Thu 2/21/19 5:00 AM
5 Pre fab of temp str 10 days Sun 2/17/19 6:00 AM Tue 2/26/19 8:00 PM 3
6 Pre fab of piping 15 days Thu 2/21/19 5:00 AM Thu 3/7/19 2:00 PM 4
7 Scaffolding work in all required area 10 days Mon 3/4/19 8:00 AM Wed 3/13/19 10:00 PM
8 Placement of temp str 14 days Tue 2/26/19 8:00 PM Tue 3/12/19 6:00 AM 5
9 Transportation of main crane 10 days Wed 2/27/19 8:00 AM Fri 3/8/19 10:00 PM
10 Assembly of main crane 5 days Fri 3/8/19 10:00 PM Wed 3/13/19 5:00 PM 9
11 Main crane Load Test 6 hrs Wed 3/13/19 5:00 PM Wed 3/13/19 11:00 PM 10
12 Tail crane mob & load test 0 days Wed 3/13/19 8:00 AM Wed 3/13/19 8:00 AM 3/13
13 Removal of insulation 0 days Fri 3/15/19 8:00 AM Fri 3/15/19 8:00 AM 3/15
14 Shutdown 345 hrs Fri 3/15/19 8:00 AM Fri 3/29/19 5:00 PM
15 Recpt of necessary permissions 0 days Fri 3/15/19 8:00 AM Fri 3/15/19 8:00 AM 3/15
16 11 E-1 184 hrs Fri 3/15/19 9:00 AM Sat 3/23/19 1:00 AM
17 Removal of piping connection 8 hrs Fri 3/15/19 9:00 AM Fri 3/15/19 5:00 PM 15FS+1 hr Crane 300 Mt Crane 300 Mt
(Cutting /debolting)
18 Top & bottom manhole opening 8 hrs Fri 3/15/19 9:00 AM Fri 3/15/19 5:00 PM 15FS+1 hr
19 Removal of thermocouple 1 hr Fri 3/15/19 9:00 AM Fri 3/15/19 10:00 AM 15FS+1 hr
20 Wooden scaffolding erec for 6 hrs Fri 3/15/19 10:00 AM Fri 3/15/19 4:00 PM 19
ECT of tubes
21 Performance of ECT 30 hrs Fri 3/15/19 5:00 PM Sat 3/16/19 11:00 PM 18,19,20
22 Removal of internals 6 hrs Sat 3/16/19 11:00 PM Sun 3/17/19 5:00 AM 21
23 Removal of str. Gratings 16 hrs Fri 3/15/19 4:00 PM Sat 3/16/19 8:00 AM 15FS+8 hrs
24 Dismant & lowering 11E1 4 hrs Sat 3/16/19 11:00 PM Sun 3/17/19 3:00 AM 23,21 Crane 300 Mt Crane 300 Mt
on saddle at ground
25 Cleaning of Flanges 6 hrs Sun 3/17/19 4:00 AM Sun 3/17/19 10:00 AM 24FS+1 hr
26 Provision of blind to the nozzles 12 hrs Sun 3/17/19 10:00 AM Sun 3/17/19 10:00 PM 25
spare in new mode of operation
27 Lifting & erec of E - 1 (Revalsal) 6 hrs Mon 3/18/19 12:00 AM Mon 3/18/19 6:00 AM 26FS+2 hrs,11
Crane 300 Mt Crane 300 Mt
28 Re-installation of structures 16 hrs Mon 3/18/19 1:00 AM Mon 3/18/19 5:00 PM 27SS+1 hr
29 Re-installation of internals 6 hrs Mon 3/18/19 7:00 AM Mon 3/18/19 1:00 PM 27FS+1 hr
30 Manhole closing 16 hrs Mon 3/18/19 1:00 PM Tue 3/19/19 5:00 AM 29
31 Fixing of thermocouple 2 hrs Mon 3/18/19 1:00 PM Mon 3/18/19 3:00 PM 29
32 Recon of pipelines after suitable 108 hrs Mon 3/18/19 1:00 PM Sat 3/23/19 1:00 AM 29
modification, torquing
33 Main crane readyness for 21 E 07 112 hrs Mon 3/18/19 5:00 PM Sat 3/23/19 9:00 AM
34 Dismant of crane 36 hrs Mon 3/18/19 5:00 PM Wed 3/20/19 5:00 AM 28
35 Placement for 21 E07 16 hrs Wed 3/20/19 5:00 AM Wed 3/20/19 9:00 PM 34
36 Assembly of crane 60 hrs Wed 3/20/19 9:00 PM Sat 3/23/19 9:00 AM 35
37 11 E-17 344 hrs Fri 3/15/19 9:00 AM Fri 3/29/19 5:00 PM
38 Dismant of pipes 12 hrs Fri 3/15/19 9:00 AM Fri 3/15/19 9:00 PM 15FS+1 hr Crane 150 Mt Crane 150 Mt
39 Dismant & lowering of 11 E-17 4 hrs Fri 3/15/19 9:00 PM Sat 3/16/19 1:00 AM 38 Crane 150 Mt Crane 150 Mt
on support
40 Opening of end covers 4 hrs Sun 3/17/19 3:00 AM Sun 3/17/19 7:00 AM 39,24
41 Cleaning of tube sheets & 4 hrs Sun 3/17/19 7:00 AM Sun 3/17/19 11:00 AM 40
removal of tapper plugs
42 Removal of welds by chamfering 36 hrs Sun 3/17/19 11:00 AM Mon 3/18/19 11:00 PM 41
/ bevelling/ drilling
43 Removal of expanded portion of tubes 24 hrs Mon 3/18/19 11:00 PM Tue 3/19/19 11:00 PM 42
44 Removal of tubes by hydraulic 10 hrs Tue 3/19/19 11:00 PM Wed 3/20/19 9:00 AM 43
pulling mechanism
45 Insertion of new tubes/edge preparation 80 hrs Wed 3/20/19 9:00 AM Sat 3/23/19 5:00 PM 44
/ welding/ DP test as per sequence
46 Final welding of tube to tube sheet 60 hrs Sat 3/23/19 5:00 PM Tue 3/26/19 5:00 AM 45
47 Final DP 2 hrs Tue 3/26/19 5:00 AM Tue 3/26/19 7:00 AM 46
48 Pneumatic Test of shell side 2 hrs Tue 3/26/19 7:00 AM Tue 3/26/19 9:00 AM 47
49 Expansion of tubes & measurement 24 hrs Tue 3/26/19 9:00 AM Wed 3/27/19 9:00 AM 48
50 Pneumatic Test of shell side 2 hrs Wed 3/27/19 9:00 AM Wed 3/27/19 11:00 AM 49
Project: MSProj11 Task Progress Summary External Tasks Deadline

Date: Thu 5/31/18 6:22 PM Split Milestone Project Summary External Milestone
Page 1
Satnam Global Infraprojects Limited
Project: COMPOSITE ERECTION Work at CFCL, Gadepan
PRELIMINARY SCHEDULE FOR ATR'2019
ID Task Name Duration Start Finish PredecessorsResource Feb 17, '19 Feb 24, '19 Mar 3, '19 Mar 10, '19 Mar 17, '19 Mar 24, '19
Names 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 T W T F S S M T W T F
51 Hydroteting & boxup 8 hrs Wed 3/27/19 11:00 AM Wed 3/27/19 7:00 PM 50
52 Lifting & re-erection 6 hrs Wed 3/27/19 7:00 PM Thu 3/28/19 1:00 AM 51 Crane 150 Mt Cran
53 Connection of piplines 36 hrs Thu 3/28/19 1:00 AM Fri 3/29/19 1:00 PM 52
54 Removal of scffolding 4 hrs Fri 3/29/19 1:00 PM Fri 3/29/19 5:00 PM 53
55 11V-01& 11C-05 135 hrs Fri 3/15/19 9:00 AM Thu 3/21/19 12:00 AM
56 Removal of pipeline connection 8 hrs Fri 3/15/19 9:00 AM Fri 3/15/19 5:00 PM 15FS+1 hr
57 Debolting & hanging of 11C-05 6 hrs Fri 3/15/19 5:00 PM Fri 3/15/19 11:00 PM 56
58 Lifting 11 V-01 by jacking 8 hrs Fri 3/15/19 11:00 PM Sat 3/16/19 7:00 AM 57
59 Complete placement of sliding str 4 hrs Sat 3/16/19 7:00 AM Sat 3/16/19 11:00 AM 58
60 Sliding 11 V - 01 to outside building 10 hrs Sat 3/16/19 11:00 AM Sat 3/16/19 9:00 PM 59
61 Removal & lowering on ground 2 hrs Sat 3/16/19 9:00 PM Sat 3/16/19 11:00 PM 60 Crane 150 Mt Crane 150 Mt
V-01 from temp str
62 Lowering C-05 on gr level 6 hrs Sat 3/16/19 1:00 PM Sat 3/16/19 7:00 PM 60SS+2 hrs
63 Lifting & hanging of new C-05 8 hrs Sat 3/16/19 7:00 PM Sun 3/17/19 3:00 AM 62
64 Lifting new V-01 on sliding str 2 hrs Sun 3/17/19 6:00 AM Sun 3/17/19 8:00 AM 63FS+3 hrs Crane 150 Mt Crane 150 Mt
65 Slding V-01 to foundation 10 hrs Sun 3/17/19 8:00 AM Sun 3/17/19 6:00 PM 64
66 Placement of V-01 onfoundation 4 hrs Sun 3/17/19 6:00 PM Sun 3/17/19 10:00 PM 65
by jacking
67 Lowering C-05 & assembly with V-01 6 hrs Sun 3/17/19 10:00 PM Mon 3/18/19 4:00 AM 66
68 Reconnection of all pipeline 60 hrs Mon 3/18/19 4:00 AM Wed 3/20/19 4:00 PM 67
69 Removal of temp str & scaffolding 8 hrs Wed 3/20/19 4:00 PM Thu 3/21/19 12:00 AM 68
70 21 E-07 222 hrs Sun 3/17/19 11:00 AM Tue 3/26/19 5:00 PM
71 Dismantling of pipelines 16 hrs Sun 3/17/19 11:00 AM Mon 3/18/19 3:00 AM 64FS+3 hrs
72 Removal of structure 4 hrs Mon 3/18/19 3:00 AM Mon 3/18/19 7:00 AM 71
73 Lifting & lowering of old E-07 6 hrs Sat 3/23/19 10:00 AM Sat 3/23/19 4:00 PM 36FS+1 hr Crane 300 Mt Crane 300 Mt
74 Lifting & erec of new E-07 6 hrs Sat 3/23/19 5:00 PM Sat 3/23/19 11:00 PM 73FS+1 hr Crane 300 Mt Crane 300 Mt
75 Erec of dismantled str 8 hrs Sat 3/23/19 11:00 PM Sun 3/24/19 7:00 AM 74
76 Reconnection of pipelines 60 hrs Sun 3/24/19 1:00 AM Tue 3/26/19 1:00 PM 74FS+2 hrs
77 Removal of scaffolding 4 hrs Tue 3/26/19 1:00 PM Tue 3/26/19 5:00 PM 76
Project: MSProj11 Task Progress Summary External Tasks Deadline

Date: Thu 5/31/18 6:22 PM Split Milestone Project Summary External Milestone
Page 2

CFCL - ATR'19 Revised - 25.05.2018

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CFCL - ATR'19 Revised - 25.05.2018

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Project Execution Methodology

Project : Dismantling, Erection of Equipments & Piping Work.

No Title Page No.

1. Replacement of M.P. Condenser (21 E-07)

Shutdown of G-1 Plant is proposed in Feb/March 2019; however, actual dates

Period of shutdown is for 15 days.

 Easier assembly and erection

Area of Unloading, Assembly & Load Testing of Crane

4.1 Crane Mobilization Schedule

4.2 Main Crane Assembly Schedule

a. Crane Load charts (attached here with).

6.1 PROCEDURE FOR REVARSAL OF UREA STRIPPER 11E1

 Performance of ECT of tubes.

Tailing Crane : Tadano 100 Ton Capacity Tire Mounted.

‘D’ Shackles : 50 Mt Capacities (100% Tested with TPI Certification

6.2 LIST OF NOZZLE CONNECTIONS

For details please see Rigging Scheme no. SGIL-CFCL-ATR19-001 (1 OF 5 TO 1 OF 5)

7. PROCEDURE FOR REPLACEMENT OF M.P. CONDENSER (21 E-07)

 Removal of piping connection ( de-bolting or cutting) as mentioned below

Sl. Services Size & Rating MOC

Tailing Crane : Tadano 100 Ton Capacity Tire Mounted.

‘D’ Shackles : 12 Mt Capacities (100% Tested with TPI Certification)

8. CONDENSER (21 E-17) REMOVAL, PARTIAL RETUBING & REFIXING

Total Empty (Dry) weight 11009

8.2 MAIN PIPING CONNECTIONS TO DISMANTLE & RE-ERECT

Sl. Services Size & Rating Pipe Thickness MOC

Main Crane : LIEBHERR LTM 1160 160 Mt capacity; Tire Mounted

Tailing Crane : Hydra 14 Mt Capacity.

‘D’ Shackles : 12 Mt Capacities (100% Tested with TPI Certification)

8.3 SEQUENCES TO EXECUTE THE JOB 11 E-17

 Dismounting of connected pipeline after match marking

 Cleaning of tube sheet by wire brushes to remove loose scale.

9. PROCEDURE FOR REPLACEMENT OF 11V-01& 11C-05

9.1 DETAILS OF EQUIPMENT

Existing (11V-01/C-05) New (11V-01/C-05)

9.2 FOLLOWING SEQUENCES SHALL BE ADOPTED TO EXECUTE THE JOB

10. MANPOWER DEPLOYMENT

 SGIL - CFCL-ATR19-001 SHEET 1 OF 5

MAIN CRANE DEMAG-CC-1800

TOTAL LOAD 87.1 t

TAIL 100MT TYRE MOUNTED CRANE

0 30-05-2018 ISSUED FOR COMMENTS. RAGHAV G.B. S.G.

DRAWING TITLE:- RIGGING SCHEME FOR UREA STRIPPER

MAIN CRANE DEMAG-CC-1800

TAIL 100MT TYRE MOUNTED CRANE mentioned in stage-3rd. 4940

0 30-05-2018 ISSUED FOR COMMENTS. RAGHAV G.B. S.G.

DRAWING TITLE:- RIGGING SCHEME FOR UREA STRIPPER

PROJECT :- DISMANTLING AND ERECTION WORK FOR REPLACEMENT OF

20000 13000 CONTRACTOR :-

MAIN CRANE DEMAG-CC-1800

TOTAL LOAD 87.1 t The crane boom shall be lifted up

TAIL 100MT TYRE MOUNTED CRANE

BUILDING BATTERY LIMIT

0 30-05-2018 ISSUED FOR COMMENTS. RAGHAV G.B. S.G.

MAIN CRANE DEMAG-CC-1800

TOTAL LOAD 87.1 t

TAIL 100MT TYRE MOUNTED CRANE 2470

* LOAD 40.0 t Final Position of the Job on the Ground

0 30-05-2018 ISSUED FOR COMMENTS. RAGHAV G.B. S.G.

DRAWING TITLE:- RIGGING SCHEME FOR UREA STRIPPER

PROJECT :- DISMANTLING AND ERECTION WORK FOR REPLACEMENT OF

MAIN CRANE DEMAG-CC-1800

TOTAL LOAD 87.1 t