Indian Oil Corporation Limited-IOCL has published Statutory Testing , Inspection , Cleaning , Calibration And Certification Of 3X1400mt Capacity Horton Sphere At Indane Bottling Plant , Jaipur. Submission Date for this Tender is 04-05-2020. Machinery Repairs Tenders in INDANE BOTTLING PLANT Rajasthan. Bidders can get complete Tender details and download the document.
| Name of Work: Statutory Testing, Inspection, Cleaning, Calibration and Certification of 3X1400MT Capacity Horton Sphere at Indane Bottling Plant, Jaipur | |||||
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| Sl. No. | Item Description | Item Code / Make | Quantity | Units | |
| 1 | 1 | Degassing and cleaning of 1400MT Horton Sphere (18 Meter Diameter) with water after making necessary connections for in and out flow with suitable pipelines/hose arrangements as directed on site. The water used for degassing should be disposed off safely in the drainage and the sludge if any coming along with the water should be carefully removed and disposed/kept in safe place as directed at site. The sludge should be buried if necessary as per site directions. A sample of all sludge collected should be handed over to the site engineers. Cleaning :'Thorough cleaning of the inner surface with water jet and cleaning the sludge/rust materials followed by thorough cleaning of inner surface to remove the scale, oil and dust by pneumatic wire brushes to expose the metal surfaces and thorough buffing of weld joints. Minimum 10 mm on both sides of each weld joint including nozzle welds by thorough cleaning using rotary brushes to expose bare metal (shinning surface) with care to entire weld joints of nozzles and other areas as directed at site. The contractor has to provide all equipments and consumables for carrying out the cleaning jobs. This item includes the excavation and refilling of soil/earth for burying the sludge as per instructions. | 1 | 3 | Nos |
| 2 | 2 | Disconnecting the inlet, outlet of the LPG liquid and vapour line, SRV, HLA, Measuring Gauges (Magnetic Level Gauge, Rochester Gauge, Fixed tube Gauge), Manhole, Water drain line, globe valves, ROV and other fittings of the Horton Sphere, disconnection of electrical cables without any damage etc as per direction of Site Engineer. Shifting to stores and back for servicing.\nRefixing-Fixing back all the Liquid and vapor lines after servicing the valves, EFCV, and fixing all removed fittings like SRV, HLA, Measuring Gauges (Magnetic Level Gauge, Rochester Gauge, Fixed tube Gauge), Manhole, Water drain line, globe valves, ROV and other fittings of the Horton Sphere. Refixing of the same including supplying and fixing of new metallic spiral wound gaskets and stud-bolts as per specification and codes with proper tightness as per instructions at site etc. complete. Test certificates to be provided for the material supplied. Any damage for the fittings or any equipments during removal & fixing of the connection has to be rectified by the vendor itself. Finally correctness of level gauges has to be established.\nTesting shall be carried out for Emergency Shut off valves, EFCV / ROV /Rochester Gauges etc using N2 Gas for observing operational fitness per SMPV / CCE norms / relevant codes. job also includes purging the vessel after testing and connection of pipelines. | 2 | 3 | Nos |
| 3 | 3 | Providing MS tubular ladder/scaffolding inside the horton sphere to enable easy approach to all the areas inside and outside the entire Horton Sphere for cleaning of inner surface and suitable for carrying out all inspection like ultrasonic testing, MPI and all allied jobs. The job of scaffolding erection shall be done as per BS 11, ASME Sec. V/ Sub Sec. A/B and other relevent codes. The work is to be carried out as per instructions of Site engineer / Plant Manager. | 3 | 3 | Nos |
| 4 | 4 | Providing Flameproof lighting arrangement inside the Horton Sphere for carrying out necessary inspection, cleaning and NDT Tests. Contractor to supply the flameproof light fittings, junction boxes, required cables etc. | 4 | 3 | Nos |
| 5 | 5 | 'OVERALL VISUAL INSPECTION : To conduct thorough “Visual Inspection” of outer and inner surface of pressure vessel, its nozzles and leg support pads etc. | 5 | 3 | Nos |
| 6 | 6 | Blinding of LPG Horton Sphere : 'Fixing back all the liquid and vapour lines after servicing the valves , EFCV and fixing all removed fittings like HLA, SRV, Pressure / Temp/Servo/Rochester gauges, manhole covers etc., including supplying and fixing of New spiral wound gaskets, Studs & nuts and as per specifications/codes. Finally, correctness of level gauges has to be established. Testing shall be carried out for Emergency Shut off valves, EFCV / ROV /Rochester Gauges etc using N2 Gas for observing operational fitness per SMPV / CCE norms / relevant codes.job also includes purging the vessel after testing and connection of pipelines. | 6 | 3 | Nos |
| 7 | 7 | Wet flourescent MAGNETIC PARTICLE TEST : To conduct “100% Magnetic Particle test” dry and wet of all weld joints including cleat welds, nozzles, man-holes at top and bottom and external reinforcing pad-welds at the support leg height, as per ASTM E –709-89. NOTE: Dry Magnetic Particle Test to be conducted below the equator and wet magnetic particle test above the equator line. | 7 | 3 | Nos |
| 8 | 8 | ULTRASONIC TESTS: To conduct 100% “Ultrasonic Thickness Test” on shell of Horton Spheres as per SMPV rule, ASTM A–577-88 or equivalent codes. Mapping of each plate section to cover the whole plate - say six to seven readings to be taken between each consecutive weld seam (Horizontal & Vertical), Nozzle, Manhole, Piping around installation upto first isolation valve. | 8 | 3 | Nos |
| 9 | 9 | DYE-PENETRATION TEST : To conduct “ Dye-Penetrant Test” of Nozzles and support pads and any other inaccessible areas, as per ASTM E – 165-80. | 9 | 3 | Nos |
| 10 | 10 | Ultrasonic Flaw Detection Test of Welds as per ASME Sec V Art. 4,5 , ASME Sec VIII Div 1&2 not less than 25% covering (a) T-Weld joint, Internal: 100%, (b) Middle circumferential and longitudinal Seam, dish ends welds-Internal: 100%, (c) Nozzle weld – neck to shell, Internal: 100%, as per the instruction of Third Party Inspecting Agency. Approximate quantity per vessel : 150 R.M. | 10 | 3 | Nos |
| 11 | 11 | HYDROTEST & STRETCH TEST : To witness, supervise and certify “Hydrotest” of vessel after successful completion of all N.D. tests as per SMPV rules and relevant codes. The differential settlement of supports for Horton Spheres to be observed while filling water using Theodolite. | 11 | 3 | Nos |
| 12 | 12 | Hardness Test as per ASTM-E-110 using microprocessor based (poldi type not to be used) portable hardness tester. at random preferably below the equator on circumferential/longitudinal weld, T-joint & also nozzle weld, HAZ: Left & right, parent metal: Left & right i.e. at 5 position on 25 locations as per the instruction of Third Party Inspecting Agency. Approximate quantity for vessel : 125 nos. | 12 | 3 | Nos |
| 13 | 13 | Hydrotest/Strech Testing of the Horton Sphere and LPG pipe lines after completion of all NDT as per SMPV Rules, ASME-Sec. VIII Div 1 and revelent codes using the supplied water for specified test pressure , using reciprocating pump and building up pressure in stages and retaining the same to a specified period and draining the water in gradual stages after completion of the testing. The differential settlement of supports for Horton Spheres to be observed while filling water using Theodolite. | 13 | 3 | Nos |
| 14 | 14 | Radiography test for weld joints at selected locations as problem defect/flaws observed during other tests subject to a maximum of 10% of total weld length as per ASTM-E-94 applicable code . This is an OPTIONAL item and same is to be conducted where defect / flaws are observed. | 14 | 3 | Nos |
| 15 | 15 | Certification and documentation: To submit 5 sets of Testing and Inspection certificates/reports and documents for all tests and inspection covered in the scope of work as per SMPV Rule No.19 | 15 | 3 | Nos |
| 16 | 16 | Supply of Water for Horton sphere hydrotest and cleaning | 16 | 21000 | KL |
| 17 | 17 | Calibration of Horton Sphere | 17 | 3 | Nos |
| 18 | 18 | HORTON SPHERE PAINTING : \nSupply of Paints and Painting work of 18 M dia LPG Horton Sphere + LPG Vapour Line + LPG Liquid Line upto ROV+Tie Roads of HS, after Surface Preparation /cleaing conforming to SSPC ST3 Specification - cleaning external surface complete free from mill, scale rust etc. repainting the prepared surface with 1 coat (30-35 Micron DFT each coat) of Zinc Phosphate Primer (P3) and followed by 2 coats (25 micron DFT each coat) of Aluminium finish paint (F2) as per the specifications given in IOC Painting Specification. Primer, Paints and Thinners etc used will be of IOCL Approved Paint Manufacturers. \nThe work includes all painting of all accessaries/ instruments pipelines and also all colour coding markings etc on them . 'Letter Writing (Indian Oil /Indane Logo Painting 1 Hindi & 1 English, Test Date etc, Details of Sphere as per drawing) with 2 coats of Synthetic Enamel paint of Shades as per IOCL Standards/instructions. \n | 18 | 3120 | SQM |
| 19 | 19 | STRUCTURAL PAINTING \nSupply of Paints and Painting work of STEEL STRUCTURES mounted on the Horton Sphere and adjoining the same upto and including the Dyke Walls. The structures include Landing platforms, railings, staircase , calwalks etc.Colour coding /shade will be as per IOCL's standards and instructions. Work includes Surface Preparation /cleaing conforming to SSPC ST3 Specification - cleaning external surface complete free from mill, scale rustr etc. Repainting the prepared surface with 1 coat (30-35 Micron DFT each coat) of Zinc Phosphate Primer (P3) and followed by 2 coats (25 micron DFT each coat) of Synthetic enamel finish paintpainting (F4) as per the specifications given in IOC Painting Specification. Primer, Paints and Thinners etc used will be of IOCL Approved Paint Manufacturers. The work includes all painting of all accessaries/ instruments pipelines and also all colour coding markings etc on them. | 19 | 900 | SQM |
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