MALIK POLYCHEM LTD.

JOB NO.

S. No. PARTICULARS
PARTICULARS
1 SHELL
TOP DISHEND
BOTTOM DISHEND

2 LIMPET COIL ON SHELL

LIMPET COIL ON DISH

2.1 INTERNAL COUPLING

BUSH
FLANGE
NUT & BOLT
LOCK NUT

3 AGITATOR ASSY.
AGITATOR SHAFT
BEARING HOUSING
HOUSING FLANGE
COVER PLATE
BEARING -32317
BEARING-32318
OIL SEAL-90x115x13
OIL SEAL-75x95x12
COUPLING- B6
CHUCK NUT

4 LENTON
BUCKET SHELL
B/H SUPPORT FLANGE
B/H SUPPORT FLANGE
NUT & BOLT- M12
NUT & BOLT-M15
NUT & BOLT

5 MOTOR & GEAR BOX BASE

BASE PLATE
CLADDING
SANDWITCH PLATE
CLADDING
LENTON RIB SPRT. ANGLE
MOTOR ALINGNMENT ANGLE
MOTOR NUT & BOLT
GEAR BOX NUT & BOLT
6.00 PITCH BLADE TYPE
ANCHOR BLADE
PITCH BLADE
TEE
TRIPAD STAND
TEFLON BUSH
BLADE BUSH
BUSH FOR TEFLON

7 BAFFLE ASSY.
BAFFLE PLATE
SUPPORT CLEATS FOR BAFFLE
NUT & BOLT

8 NOZZLES
NOZZLE - 450 NB
PIPE 450 NB; SCH 40
FLANGE 450 NB
CLADDING
PAD PLATE
COVER PLATE
CLADDING
DISH
NUT & BOLT

NOZZLE - 300 NB
PIPE 300 NB; SCH 40
FLANGE 300 NB
CLADDING
PAD PLATE
RIB PLATE
NUT & BOLT

NOZZLE - 150 NB
PIPE 150 NB; SCH 40
FLANGE 150 NB
CLADDING
PAD PLATE

SIGHT GLASS - 100 NB

PIPE 100 NB; SCH 40
FLANGE 100 NB
COVER PLATE
NUT & BOLT
GLASS

NOZZLE - 100 NB
PIPE 100 NB; SCH 40
 FLANGE 100 NB
CLADDING
PAD PLATE

NOZZLE - 80 NB
PIPE 80 NB; SCH 40
FLANGE 80 NB
PAD PLATE

NOZZLE - 65 NB
PIPE 65 NB; SCH 40
FLANGE 65 NB
PAD PLATE

NOZZLE - 50 NB
PIPE 50 NB; SCH 40
FLANGE 50 NB

NOZZLE - 40 NB
PIPE 40 NB; SCH 40
FLANGE 40 NB
PAD PLATE

NOZZLE - 25 NB
PIPE 25 NB; SCH 40
FLANGE 25 NB
PAD PLATE

LUG SUPPORT
PAD PLATE
RIBS
BASE PLATE

S.S. FABRICATION CHARGES

M.S. FABRICATION CHARGES

POLISHING CHARGES

DISHING CHARGES

DOUBLE MECHANICAL SEAL

MOTOR FLP 20 H.P FLANGED
GEAR BOX - AS-80
 Job activities job code-AV-166
1 TOP DISH & BOTTOM DISH
a Material Procurement
b Blank Dia Cutting
c Grinding
d Polishing
e Nozzle Marking on top dish
f Nozzle Marking on bottom dish
2 SHELL
a Material Procurment
b Plate marking and cutting
c ROLLING
d Plate to plate Joining and TACKING
e Welding
f Top Dish Fit up
g Bottom Dish Fit
h Both Dish end welding
b square bar welding on shell.
3 Jacket shell
a Raw material procurment
b Shell marking & cutting
c Plate to plate Joining & welding
d Rolling
e Long Seam joint Welding
4 Nozzles
a Raw material procurement
b Pipe Cutting
c Pipe fit
d weilding
e Polishing the welding JOINT

5 Dishend Nozzles Assembly

a Nozzles Marking and cutting .
b On Dish Nozzles fit-up.
c Nozzles welding on dish end.
d R f pad cutting and welding .
7 LEGS & LEG TIKKI
a Raw material procurement
b Leg pad plate marking & cutting
b Pipe cutting
c Machining & grinding
6 Lifting Hooks
a Raw material procurement
b Lifting marking & cutting
c lifting hook pad plate marking cutting.
d lifting hook machining
e lifting hook tacking & welding with pad plate
7 Buffing
a Top Dishend
b Bottom D'end
c Shell
d Nozzle welding joint
8 Insulation Jacket
a Material Procurement
b Insulation shell marking & cutting
c Insulation Bottom marking & cutting
d Fitting the insulation jkt or Bttom end
e welding ,
9 Hydrotesting
a Hydrotesting of shell.
b Hydrotesting of Jacket.
11 Name Plate
12 Dispatch
code-AV-166
Dispatch date-
7 8 9
 Job activities

1 PROCUREMENT TIME unit

a Bottom Dishend Material

b Top Dishend Material days
c Shell Material
d SPIRAL/LIMPET
e Jacket shell
f Jacket Dishend
g Main Shell Nozzles Pipes & Flange
7
h Jacket Shell Nozzles Pipes & Flange
i SHAFT
j BLADE
k Lantern Support
l Bloom Pipe
m Gland Housing
n Chuck Nut
o Motor
p Gear Box 40 days
Bearing
Nut & Bolt
2 FABRICATION
2.1 Dishend
Bottom dishend Plate Marking,Cutting & Fitup 6 hour
Bottom Dishend Plate Welding 6 hour
Bottom Dishend Forming 12 hour

Top Dishend Plate Marking,Cutting & Fitup 6 hour

Top Dishend Plate Welding 6 hour
Top Dishend Forming 12 hour

2.2 Main Shell

Main shell 1 plate marking cutting,fitting & tacking 6 hour
Main shell 1 welding 6 hour
Main shell 1 rolling 4 hour
Main shell 2 plate marking cutting,fitting & tacking 6 hour
Main shell 2 welding 6 hour
Main shell 2 rolling 4 hour
Both Shell Fitting & Welding 6 hour
Bottom Dish Fit 3 hour
Top Dish Fit up 3 hour
Both Dish end to Shell welding 16 hour

2.3 Spiral /Limpet

Spiral rolling, fitting 16 hour
Tacking & Welding 4 hour
2.4 Jacket
Dishend Material marking,cutting & fitting 6 hour
Dishend Welding 6 hour
Dishend Forming 12 hour

Main Jacket Shell 1 plate marking cutting,fitting & tacking 6 hour

Main Jacket Shell 1 welding 6 hour
Main Shell 1 rolling 4 hour
Main Shell 2 plate marking cutting,fitting & tacking 6 hour
Main Shell 2 welding 6 hour
Main Shell 2 rolling 4 hour
Both Shell Fitting & Welding 6 hour
Dishend to Shell Fit up 3 hour
Dishend to Shell Welding 8 hour
2.5 Nozzles
a Nozzles Making for Main Shell 12 hour
b Nozzle Making for Jacket Shell 8 hour
c Nozzle Fitup to Main Shell & Dishend 3 hour
d weilding 4 hour
e Nozzle Fitup to Jacket Shell & Dishend
f weilding
g Polishing the welding JOINT

2.6 Agitator
Shaft Machining 32 hour
blade Marking Cutting & welding
Tripod Bush Machining 24 hour
Agitator Assembly 16 hour

2.7 Lug Support 4 hour

2.8 Lifting Hooks 2 hour
2.9 Buffing 16 hour
a Top Dishend
b Bottom D'end
c Shell
d Nozzle welding joint
2.1 Hydrotesting
a Hydrotesting of shell. 6 hour
b Hydrotesting of Jacket. 6 hour

2.11 Painting & Acid Pickling 8 hour

11 Name Plate
12 Dispatch
Total Time Required for Making Reactor 25 days
 job code-R-313
Man Power Name Machine
Involvment

2 Fitter & Helper

2 Fitter & Helper
3 dish man & 2 Helper

2 Fitter & Helper

2 Fitter & Helper
3 dish man & 2 Helper

3 Fitter & 2 Helper

2 Welder & Helper
4 Fitter,Welder & 2 Helper
2 Fitter & 2 Helper
2 Welder & Helper
4 Fitter,Welder & 2 Helper
3 Fitter,Welder & 1 Helper
3 Fitter,Welder & 1 Helper
3 Fitter,Welder & 1 Helper
3 Fitter,Welder & 1 Helper

2 Fitter & Helper

2 Welder & Helper
2 Fitter & Helper
2 Fitter & Helper
3 dish man & 2 Helper

3 Fitter & 2 Helper

2 Welder & Helper
4 Fitter,Welder & 2 Helper
2 Fitter & 2 Helper
2 Welder & Helper
4 Fitter,Welder & 2 Helper
3 Fitter,Welder & 1 Helper
3 Fitter,Welder & 1 Helper
3 Fitter,Welder & 1 Helper

2 Fitter & Helper

2 Fitter & Helper
2 Fitter & Helper
2 Fitter & Helper

2
2 Formen & Helper

2
2

1
1
3
Dispatch date-
7 8 9
 Condenser Fabrication (C-268) Dispatch -

1 Tube plate and baffles

a Material procurement
b Marking tube plate and baffles
d Machining of tube plate and baffles
f Drilling of baffles with tube plate
g Drilling of baffles for tie rods

2 Shell
a Material procurement
b Marking & cutting plate for shell
c Fit up of joining plate
d Welding of joint plate
e Rolling of plate for shell
f Welding of long seam joint
g Gauging of shell

3 Header flanges
a Material procurement
b Machining of flanges
c Drilling of flanges
d Cladding cutting, fitting & welding.

4 Nozzle
a Pipe cutting
b Fit up of flanges and pipe
c Welding of flanges and Pipe
d Machining of nozzles

5 Header
a Bland Dia cutting for dish.
b Dish procurement
c Rolling of neck shell
d V-making at D/end & Neck shell
e Fit-up of neck and dish
f Fitup of neck and flange
g Welding of Flanges and Neck
h Facing of flange
i Fit up of Dish end and neck
j Welding

5 Tube Assembly
 a Marking and cutting
b Tie rod fit up
c Tube plate and tubes welding.

6 Hydrotesting
a Shell side
b Tube side
7 Red Oxide & Acid wash
8 Name plate
9 Dispatch
 LIST OF MACHINE MPL FAB
LATH MACHINE 16' 1
12' 1

DRILL MACHINE
RADIAL 40 mm. 3
PEDESTAL 20 mm. 1

SHAPER MACHINE 3 H.P. 1

PRESS MACHINE 15 H.P 1

PRESS MACHINE 10 H.P 1
SHELL ROLLING MACHINE 10 H.P 2
PIPE ROLLING MACHINE 10 H.P 1
COMPRESSURE 7.5 H.P 2
HYDRAULIC PRESSURE MACHINE 2 H.P 1
PIPE CUTTING MACHINE 2
MAGNET DRILL MACHINE 2
HAND DRILL MACHINE 2
TUBE EXPANDER MACHINE 2
BENCH GRINDER 2
MONO BLOCK PUMP 2
RECTIFIER MACHINE 400 A 5
RECTIFIER MACHINE 400 A 1
INVERTER TYPE WELDING MACHINE 400 A 7
AIR COOLED MACHINE 600 A 1
INVERTER TYPE WELDING MACHINE 250 A 2
PLASMA MACHINE 400 A 2
SL.NO TEAM MANPOWER
1 PANCHULAL MUNNA FITTER
PUSHPENDRA HELPER
HAREKRISHNA HELPER
PAWAN SHARMA HELPER
DHARMENDER HELPER
DEV MAN YADAV ARGON WELDER
SURESH SHARMA ARGON WELDER
SANJAY HELPER
SASHIKANT ARC WELDER
2 NAGENDAR RAMBABU CUTTER/ARC WELDER
RATAN DAS HELPER
AMIT ARGON WELDER
VIMAL SHARMA HELPER
KANHIYA HELPER
3 BAHADUR ANIL ARGON / ARC WELDER
PAPPU RAM FITTER/ARC WELDER
SUNIL HELPER
SUMANTH HELPER
AJAY SINGH HELPER
ABDUL KHAN
MACHINE SHOP
1 DRILL MACHINE-1 GARIB DRILL MAN
AMIT HELPER

2 DRILL MACHINE-2 SISHUPAL DRILL MAN

HELPER REQUIREMENT
3 LATHE M/C 1 JNARDHAN
4 LATHE M/C 2 RAKESH
5 PRESS M/C VRINDER
ASHISH OPERATOR
GHANSHAYAM HELPER
6 BUFFING MAN 1 SHAMBHU
7 BUFFING MAN 2 TILAK SINGH
8 BUFFING MAN 3 AJAY
9 BUFFING MAN 4 SUSHIL.
10 HELPER REQUIREMENT-2