Indian Oil Corporation Limited-IOCL has published Tender For Statutory Testing, Inspection, Cleaning, Calibration,Re-Certification,Tpi & Other Allied / Miscellaneous Works In 1X600mt Capacity Horton Sphere & 3X150mt Capacity Bullets Including Suppy/Installation,Testing & Commissioning Of 6 Liquid Rov At. Submission Date for this Tender is 19-08-2020. ISO Consultancy Tenders in MALDA BP West Bengal. Bidders can get complete Tender details and download the document.
| Name of Work: Statutory Testing, Inspection, Cleaning, Calibration,re-certification,TPI & other allied / miscellaneous works in 1X600MT Capacity Horton Sphere & 3X150MT Capacity Bullets including suppy/installation,testing & commissioning of 6" liquid ROV at LPG BP Malda”. The sizes of the various product lines for the purpose of tender is : Horton sphere : HS(L) 200NB,HS(V) 100NB;Bullets : B1(L) 150NB,B1(V) 100NB;B2(L) 150NB,B2(V) 100NB;B3(L) 150NB,B3(V) 100NB respectively. | |||||
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| Sl. No. | Item Description | Item Code / Make | Quantity | Units | |
| 1 | 1 | Degassing and cleaning of vessel with IOCL supplied water after making necessary connections for in and out flow with suitable pipelines/hose arrangements as directed on site , for safe removal and disposal of sludge within the Plant premises as per instructions of the site-in-charge, cleaning upto 3 cm on either side of the circumferential seams and longitudinal seams of the vessels with buffing tool if required, providing platform to enable inspection of the vessel as per the instructions of the site in-charge. 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. The tenderer to arrange for the pumping facility of the water and also supply blind flanges as and when required all complete as per the directions of site in charge. 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 cleaning with brass/nylon wire brush to expose the metal surface and thorough buffing of the weld and weld joints and 60 mm on either side of the heat effected zone for MPI test of bullet. Minimum 60 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. Localized grinding of the welds to be done if required as directed by IOC Site in charge. \nBullet- Capacity 150MT | 3 | EA | |
| 2 | 2 | Degassing and cleaning of vessel with IOCL supplied water after making necessary connections for in and out flow with suitable pipelines/hose arrangements as directed on site , for safe removal and disposal of sludge within the Plant premises as per instructions of the site-in-charge, cleaning upto 3 cm on either side of the circumferential seams and longitudinal seams of the vessels with buffing tool if required, providing platform to enable inspection of the vessel as per the instructions of the site in-charge. 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. The tenderer to arrange for the pumping facility of the water and also supply blind flanges as and when required all complete as per the directions of site in charge. 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 cleaning with brass/nylon wire brush to expose the metal surface and thorough buffing of the weld and weld joints and 60 mm on either side of the heat effected zone for MPI test of bullet. Minimum 60 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. Localized grinding of the welds to be done if required as directed by IOC Site in charge. \nHorton- Capacity 600 MT | 1 | EA | |
| 3 | 3 | Disconnecting the inlet, outlet of the LPG liquid and vapor line, blind flanges,SRV, Manhole, drain line, globe valves, ROV, HLA, Rochester Gauge/Fixed tube level gauge, Manhole, Water drain line, pressure transmitter, pressure/temperature gauges and other fitting and disconnections of electrical cables wherever required to enable easy approach to all the areas inside the entire vessels. Any damage during de- box up/ box up, the same shall be made good by contractor at his own cost. Bullet 150 MT | 3 | EA | |
| 4 | 4 | Disconnecting the inlet, outlet of the LPG liquid and vapor line, blind flanges,SRV, Manhole, drain line, globe valves, ROV, HLA, Rochester Gauge/Fixed tube level gauge, Manhole, Water drain line, pressure transmitter, pressure/temperature gauges and other fitting and disconnections of electrical cables wherever required to enable easy approach to all the areas inside the entire vessels. Any damage during de- box up/ box up, the same shall be made good by contractor at his own cost.HORTON 600 MT | 1 | EA | |
| 5 | 5 | Providing MS tubular ladder/scaffolding (MS tubular ladder can be used for Bullet but for Horton scaffolding should be used to do allied job) inside the vessels suitable for cleaning of inner surface and suitable for carrying out all inspections like NDT Testing ultrasonic testing, UTG, MPI Hardness Test, DPT etc. as required under SMPV (U) Rules and all allied jobs as directed. Contractor has to arrange all Equipments and consumables required for carrying out the job and Suitable arrangement by way of providing blower /exhaust fan and breathing apparatus, safety belts for working personnel is to be made by contractor as required.Permits of confined space entry, cold work and height work to be taken before the commencement of job in each shift.The job also includes providing fire screen on top of horton for safe completion of hot work involving modification of top crown for fixing the radar gauge nozzle/pipe/stilling well. Bullet- Capacity 150MT\n | 3 | EA | |
| 6 | 6 | Providing MS tubular ladder/scaffolding (MS tubular ladder can be used for Bullet but for Horton scaffolding should be used to do allied job) inside the vessels suitable for cleaning of inner surface and suitable for carrying out all inspections like NDT Testing ultrasonic testing, UTG, MPI Hardness Test, DPT etc. as required under SMPV (U) Rules and all allied jobs as directed. Contractor has to arrange all Equipments and consumables required for carrying out the job and Suitable arrangement by way of providing blower /exhaust fan and breathing apparatus, safety belts for working personnel is to be made by contractor as required.Permits of confined space entry, cold work and height work to be taken before the commencement of job in each shift.The job also includes providing fire screen on top of horton for safe completion of hot work involving modification of top crown for fixing the radar gauge nozzle/pipe/stilling well. HORTON-600 MT | 1 | EA | |
| 7 | 7 | Providing the flameproof lighting (CMRI/CIMFR/CCOE approved) arrangement inside the pressure vessel for carrying out the necessary inspection, cleaning and NDT tests. Required materials like the supply of the flameproof light fittings, junction boxes, required cables, etc. will be arrranged by the contractor. Since only one storage vessel will be handed over for the testing purpose at a time, hence, the same lighting arrangement may be used in the other bullets by turn. Electricity if required shall be provided by IOCL, however, all arrangements including supply of fittings, cables,junction boxes,exhaust fans for ventilation etc. to be done by the contractor as directed at site.Bullet- Capacity 150MT | 3 | EA | |
| 8 | 8 | Providing the flameproof lighting (CMRI/CIMFR/CCOE approved) arrangement inside the pressure vessel for carrying out the necessary inspection, cleaning and NDT tests. Required materials like the supply of the flameproof light fittings, junction boxes, required cables, etc. will be arrranged by the contractor. Since only one storage vessel will be handed over for the testing purpose at a time, hence, the same lighting arrangement may be used in the other bullets by turn. Electricity if required shall be provided by IOCL, however, all arrangements including supply of fittings, cables,junction boxes,exhaust fans for ventilation etc. to be done by the contractor as directed at site.Horton- Capacity 600 MT | 1 | EA | |
| 9 | 9 | Fitting back and other allied miscellaneous jobs. Item is inclusive of supply of all required consumables as per the tender document, Metallic Gaskets(MATL. SP.WND SS 316 + GRAFIL, DIM. STD. ASME B- 16.20 TO SUIT ASME B 16.5 RF FLANGES, 300#, Grade B1A), Stud Bolts and Nuts(STUD BOLT WITH TWO HVY HEXAGONAL NUTS / STUD BOLT MATL. A 193 GR. B7 , NUT : A194 GR. 2H DIM STD . ASME B 18.2 .1, Grade B1A) a.Job including supply and fixing of new hi-tension studs and nuts and metallic gaskets. b. Job including fit-up of all removed fittings like HLA, SRV, Pressure / Temp/Rochester gauges, fixed tube gauges, pressure transmitter, manhole covers, magnetic level guages, Differential press guage(for Horton) all electrical cable terminations and FLP re-glanding of the corresponding bullet etc., all other 50 NB/25NB/15NB ball valves including supply and fixing of newly supplied metallic gaskets as per appropriate sizes, Stud-bolts & nuts as per specifications/codes. c. After completion of all the tests, fresh gas has to be taken in as directed by IOCL. Carry out the leak tests of all the flanges before the commissioning. d. Finally establishing correctness of level gauges /pressure/temperature gauges/transmitters which is to be conducted through the existing AMC holder of plant & to be liasoned by successful tenderer, testing of the emergency shut off valves such as all EFCVs in bullet/horton manifold area corresponding to each bullet, ROVs, using nitrogen gas for observing operational fitness as per SMPV/CCOE norms and relevant standards and issuing certificates. Certificates for correctness also required for all gauges including internal inspection of EFCV and leak test for ROVs.Servicing & operational fitness of ROVs is to be conducted through the existing AMC holder of plant & to be liasoned by successful tenderer. All such costs shall be borne by the successful bidder. e. Job including supply and fixing of the new metallic gaskets and new studs and bolts for fixing the Rochester / Servo gauges, ROVs, EFCVs, Globe valves, ball valves, etc, as per relevant code. After completion of the work, the work site to be cleared of all the debris to enable free and easy movement of the operating personnel as per the instructions of the site in charge.Any damage for the fitting or any Equipments during removal & fixing of the connection has to be rectified by the vendor itself at her. His own risk and cost. f. (Code for Studs and Metallic Gasket: The flange joints of these valves shall either have spiral wound metallic gasket or ring joints. plain asbestos sheet/reinforced gaskets shall not be used. Gasket used shall conform to ASME B16.20 or equivalent. The studs shall conform to ASTM A194Gr 2H/ASTM A193 Gr B7 or equivalent)Bullet- Capacity 150MT | 3 | EA | |
| 10 | 10 | Fitting back and other allied miscellaneous jobs. Item is inclusive of supply of all required consumables as per the tender document, Metallic Gaskets(MATL. SP.WND SS 316 + GRAFIL, DIM. STD. ASME B- 16.20 TO SUIT ASME B 16.5 RF FLANGES, 300#, Grade B1A), Stud Bolts and Nuts(STUD BOLT WITH TWO HVY HEXAGONAL NUTS / STUD BOLT MATL. A 193 GR. B7 , NUT : A194 GR. 2H DIM STD . ASME B 18.2 .1, Grade B1A) a.Job including supply and fixing of new hi-tension studs and nuts and metallic gaskets. b. Job including fit-up of all removed fittings like HLA, SRV, Pressure / Temp/Rochester gauges, fixed tube gauges, pressure transmitter, manhole covers, magnetic level guages, Differential press guage(for Horton) all electrical cable terminations and FLP re-glanding of the corresponding bullet etc., all other 50 NB/25NB/15NB ball valves including supply and fixing of newly supplied metallic gaskets as per appropriate sizes, Stud-bolts & nuts as per specifications/codes. c. After completion of all the tests, fresh gas has to be taken in as directed by IOCL. Carry out the leak tests of all the flanges before the commissioning. d. Finally establishing correctness of level gauges /pressure/temperature gauges/transmitters which is to be conducted through the existing AMC holder of plant & to be liasoned by successful tenderer, testing of the emergency shut off valves such as all EFCVs in bullet/horton manifold area corresponding to each bullet, ROVs, using nitrogen gas for observing operational fitness as per SMPV/CCOE norms and relevant standards and issuing certificates. Certificates for correctness also required for all gauges including internal inspection of EFCV and leak test for ROVs.Servicing & operational fitness of ROVs is to be conducted through the existing AMC holder of plant & to be liasoned by successful tenderer. All such costs shall be borne by the successful bidder. e. Job including supply and fixing of the new metallic gaskets and new studs and bolts for fixing the Rochester / Servo gauges, ROVs, EFCVs, Globe valves, ball valves, etc, as per relevant code. After completion of the work, the work site to be cleared of all the debris to enable free and easy movement of the operating personnel as per the instructions of the site in charge.Any damage for the fitting or any Equipments during removal & fixing of the connection has to be rectified by the vendor itself at her. His own risk and cost. f. (Code for Studs and Metallic Gasket: The flange joints of these valves shall either have spiral wound metallic gasket or ring joints. plain asbestos sheet/reinforced gaskets shall not be used. Gasket used shall conform to ASME B16.20 or equivalent. The studs shall conform to ASTM A194Gr 2H/ASTM A193 Gr B7 or equivalent)Horton- Capacity 600 MT | 1 | EA | |
| 11 | 11 | Visual Examination: 100% Visual Examination on internal and external Surfaces for observation of any surface defects, weld defects, corrosion, pittings, dents, erosion, cracking, scaling, deposits or otherwise physical / material defects etc. as per ASME Sec V / Sub section A&B and meeting all requirements of the PESO standards. Bullet- Capacity 150MT | 3 | EA | |
| 12 | 12 | Visual Examination: 100% Visual Examination on internal and external Surfaces for observation of any surface defects, weld defects, corrosion, pittings, dents, erosion, cracking, scaling, deposits or otherwise physical / material defects etc. as per ASME Sec V / Sub section A&B and meeting all requirements of the PESO standards. Horton- Capacity 600 MT | 1 | EA | |
| 13 | 13 | Ultrasonic thickness measurement of weld on shell & dished end plates as per SMPV Rule & ASTM A577-88 or equivalent code. Mapping of each petal plate to cover the whole plate 6to 7 reading to be taken b/w each consecutive weld seam (horizontal &LPG pipeline and nozzles and 25 % on T Joints as per ASTM _A -578 or applicable code.Bullet- Capacity 150MT | 3 | EA | |
| 14 | 14 | Ultrasonic thickness measurement of weld on shell & dished end plates as per SMPV Rule & ASTM A577-88 or equivalent code. Mapping of each petal plate to cover the whole plate 6to 7 reading to be taken b/w each consecutive weld seam (horizontal &LPG pipeline and nozzles and 25 % on T Joints as per ASTM _A -578 or applicable code.Horton- Capacity 600 MTT | 1 | EA | |
| 15 | 15 | Ultrasonic Thickness Gauging (UTG). As per ASTM-E-797 around and on each nozzle-neck at four quadrants. Including LPG Pipelines upto 1st flange.Bullet- Capacity 150MT | 3 | EA | |
| 16 | 16 | Ultrasonic Thickness Gauging (UTG). As per ASTM-E-797 around and on each nozzle-neck at four quadrants. Including LPG Pipelines upto 1st flange.HORTON-600MT | 1 | EA | |
| 17 | 17 | UFD (Ultrasonic flaw detection) to check any internal defects of storage vessels weld joints on a) 100 % "T" joints from inside b) Middle circumferential seam, bottom,& Crown weld, Internal 100%, c) Nozzle weld – neck to shell, Internal: 100% as per ASTM E – 577, Sec V Art. 4,5,23, Sec VIII Div 1 & 2 not less than 25 % covering and as applicable codes and meeting all requirements of PESO. Bullet- Capacity 150MT | 3 | EA | |
| 18 | 18 | UFD (Ultrasonic flaw detection) to check any internal defects of storage vessels weld joints on a) 100 % "T" joints from inside b) Middle circumferential seam, bottom,& Crown weld, Internal 100%, c) Nozzle weld – neck to shell, Internal: 100% as per ASTM E – 577, Sec V Art. 4,5,23, Sec VIII Div 1 & 2 not less than 25 % covering and as applicable codes and meeting all requirements of PESO.HORTON-600MT | 1 | EA | |
| 19 | 19 | WFMPI ( Wet fluorescent Magnetic particle Inspection) Weld joints of storage vessels , including nozzle joints to check any surface /sub surface defects or linear type of indications over the welds covering HAZ on 100 % circumferential and longitudinal weld joints from inside and on outside portion exposed encompassing the nozzle welds etc. and on weld joints of all nozzles, manholes, RF pads to shell wherever applicable (externally exposed weld) as per ASTM-E-709 and meeting all requirements of PESO. BULLET-150 MT | 3 | EA | |
| 20 | 20 | WFMPI ( Wet fluorescent Magnetic particle Inspection) Weld joints of storage vessels , including nozzle joints to check any surface /sub surface defects or linear type of indications over the welds covering HAZ on 100 % circumferential and longitudinal weld joints from inside and on outside portion exposed encompassing the nozzle welds etc. and on weld joints of all nozzles, manholes, RF pads to shell wherever applicable (externally exposed weld) as per ASTM-E-709 and meeting all requirements of PESO. HORTON-600 MT | 1 | EA | |
| 21 | 21 | Dye-Penetrant Test To check any surface defects over welds. Covering HAZ (heat affected zone) of all nozzles, manholes etc. for defects like porosity, cracks etc. as per ASTM E-165-80 and meeting all requirements of PESO. BULLET-150 MT | 3 | EA | |
| 22 | 22 | Dye-Penetrant Test To check any surface defects over welds. Covering HAZ (heat affected zone) of all nozzles, manholes etc. for defects like porosity, cracks etc. as per ASTM E-165-80 and meeting all requirements of PESO. HORTON-600 MT | 1 | EA | |
| 23 | 23 | Hardness testing To check hardness value of welds, parent metals and HAZ on selected spots on welds, HAZ and parent metal in each accessible area as per ASTM E - 110 and meeting all requirements of PESO BULLET-150 MT | 3 | EA | |
| 24 | 24 | Hardness testing To check hardness value of welds, parent metals and HAZ on selected spots on welds, HAZ and parent metal in each accessible area as per ASTM E - 110 and meeting all requirements of PESO HORTON-600 MT | 1 | EA | |
| 25 | 25 | Radiography test For weld joints as supporting test (If Required) in case of defects observed if any in WFMPI as per ASTM-E-94 or applicable codes. (12 inch exposure). BULLET-150 MT | 3 | EA | |
| 26 | 26 | Radiography test For weld joints as supporting test (If Required) in case of defects observed if any in WFMPI as per ASTM-E-94 or applicable codes. (12 inch exposure). HORTON-600 MT | 1 | EA | |
| 27 | 27 | Hydro testing/ Stretch test Storage vessels at a specified test pressure for specified holding time as per design code up to first isolation valve as per ASME Sec VIII, Div I and relevant code after successful completion of all NDT as per SMPV Rules, using the IOCL supplied water and draining the water after completion of Hydro testing.The hydrostatic test pressure shall be 28.857Kgf/cm2.Bullet- Capacity 150MT | 3 | EA | |
| 28 | 28 | Hydro testing/ Stretch test Storage vessels at a specified test pressure for specified holding time as per design code up to first isolation valve as per ASME Sec VIII, Div I and relevant code after successful completion of all NDT as per SMPV Rules, using the IOCL supplied water and draining the water after completion of Hydro testing.The hydrostatic test pressure shall be 28.857Kgf/cm2.HORTON-600 MT | 1 | EA | |
| 29 | 29 | 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 or as applicable. BULLET-150 MT | 3 | EA | |
| 30 | 30 | 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 or as applicable. HORTON 600 MT | 1 | EA | |
| 31 | 31 | Calibration jobs for Bullets & HS : HS water capacity of 1433281 Ltrs & each bullet water capacity of 333119 Ltrs, weight of LPG at 85% is approx 657 MT & bullets is 150 MT each. Contractor to calibrate the bullets as per the latest guidelines of the SMPV/PESO guidelines. Using standard equipment for calibration & standard equipment for the same to be arranged by the contractor. Water for the same to be supplied by IOCL. Calibration certificate (duly certified and stamped) to be provided with 4 copies duly mentioning the data of dip, corresponding volume percentage, volume of water in litres at each dip and weight of LPG at each dip.Bullet- Capacity 150MT | 3 | EA | |
| 32 | 32 | Calibration jobs for Bullets & HS : HS water capacity of 1433281 Ltrs & each bullet water capacity of 333119 Ltrs, weight of LPG at 85% is approx 657 MT & bullets is 150 MT each. Contractor to calibrate the bullets as per the latest guidelines of the SMPV/PESO guidelines. Using standard equipment for calibration & standard equipment for the same to be arranged by the contractor. Water for the same to be supplied by IOCL. Calibration certificate (duly certified and stamped) to be provided with 4 copies duly mentioning the data of dip, corresponding volume percentage, volume of water in litres at each dip and weight of LPG at each dip.HORTON 600 MT | 1 | EA | |
| 33 | 33 | ROV: (PART B) Supply and Installation of 6" ROV Ball valve(FB & FIRESAFE) in Bullet1 liquid line including Testing, TPI, Certification and approval including limit switch & solenoid valve specifications/requirement as per technical data mentioned in tender document with Inspection shall be in accodance with - API 598, Hydrostatic test in accordance with ANSI B 16.34 , Fire Safe Valve as per API607 or API-RP-6F. The Flange to flange dimensions to be taken as per the site requirements so as to replace the one that is found unserviceable during the replacement/servicing of valve(s). | 1 | EA |
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