| 1 | 1 | ALIGARH 4X150 MT LPG BULLETS | | | |
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| 2 | 1.01 | Degassing and cleaning of storage vessal :- with IOCL supplied 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 water should be carefully removed and disposed / kept in safe place as directed at site. The sludge shall be handled wet and should be buried if necessary as per directions of PLANT MANAGER or his representative for avoiding ignition of pro- phoric iron compounds, if any if required, A sample of all sludge collected should be handed over to the Plant Manager / Site Engineer. \nThorough cleaning of the inner surface with water jet and clearing the sludge / rust materials followed by thorough cleaning of inner surface to remove the scales, oil and dust by wire brushes to expose the metal surfaces and thorough buffing of weld joints. The contractor has to provide all equipments and consumables items for carrying out the job. localised grinding of the welds to be done if required as directed by IOC Site incharge/ Third Party inspecting Authority. | | 4 | No |
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| 3 | 1.02 | Disconnecting the inlet, outlet of the LPG liquid and vapour line, SRV, Manhole, drain line, globe valves, ROV, HLA, gauges and other fitting and disconnections of electrical cables wherever required to enable easy approach to all the areas inside the entire vessals. Any damage during de- box up/ box up, the same shall be made good by contractor at his own cost. | | 4 | No |
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| 4 | 1.03 | Providing MS tubular ladder/scaffolding 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 /exaust fan and breathing apparatus, safety belts for working personnel is to be made by contractor as required | | 4 | No |
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| 5 | 1.04 | Providing flameproof lighting arrangement inside the bullet for carrying out necessary inspection, cleaning and NDT Tests. Contractor to supply the flameproof light fittings, Junction boxes, required cables, exhaust fans for proper ventilation etc, as directed at site. | | 4 | No |
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| 6 | 1.05 | Dismantling the blind flanges, pipe joints ofLPG Horton Sphere as required and thorough cleaning of the joints, fixing new supplied gaskets, studs and nuts and fixing back all the connected line valves including excess flow check valves, safety valves after testing and other instruments like gauges, HLA etc. fitted to the vessel and complete all such jobs in all respects to make the LPG Bullets ready for commissioning after completion of inspection and testing of LPG storage vessels duly certified by CCE approved parties. All tools, tackles and consumables required for the job is to be provided by the contractor. After commissioning of the LPG storage vessels, the work site is to be cleared of all debris to enable free and easy movement of operating personnel as per the instruction at site. Carry out leak testing of all flanges before commissioning. Finally correctness of level gauges has to be established. All studs/ gasketc etc to be supplied by contractor for complete replacement.. | | 4 | No |
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| 7 | 1.07 | To conduct 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. | | 4 | No |
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| 8 | 1.08 | WFMPI ( Wet fluorescent Magnetic particle Inspection) of weld joints of storage vessals , 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. \n | | 4 | No |
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| 9 | 1.09 | UFD (Ultrasonic flaw detection) to check any internal defects of storage vessals weld joints on a) 100 % \"T\" joints from inside b) Middle circumferencial seam, bottom,&\nCrown 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.\n | | 4 | No |
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| 10 | 1.1 | 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\nASTM E-165-80 and meeting all requirements of PESO.\n | | 4 | No |
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| 11 | 1.11 | 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\n | | 4 | No |
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| 12 | 1.12 | 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 or as per applicable codes and as instructed by third party inspecting agency. \n | | 4 | No |
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| 13 | 1.13 | Carrying out hydro testing/ Stretch test of LPG BUllets at a specified test pressure 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. \n | | 4 | No |
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| 14 | 1.14 | A. Arrangement of approciate scaffolding around the Bullets.\nPAINTING\na) surface Preparation: Clean to St-3 (Power tool cleaning)\nb) Paint system: Applying one coat primer(red oxide zinc phosphate primer) DFT-30-35 micron \nTwo coats aluminium finish(DFT-30-40 micron, 2 coat of 15-20 micron) paint as per standard specification. \nTotal DFT -60-70 micron.\nPainting of ladder, Plateform, saddle, support of vessel , one coat of primer & two coat paint. Painting of pipeline upto ROV - one coat primer and two coat paint including all material and labours will be in scope of contractor. | | 4 | No |
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| 15 | 1.15 | Testing and calibration of both the level guages after fixing the second valve for Bullets. | | 4 | No |
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| 16 | 1.16 | Certification and documentation :- to submit 5 sets of testing and inpection certificates/ reports and documents for all tests and inspection covered in the scope of work as per SMPV Rule no. 19 or as applicale. | | 4 | No |
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| 17 | 2 | Shahjahanpur 2X1400 MT LPG HORTON SPHERE | | | |
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| 18 | 2.01 | Degassing and cleaning of storage vessal :- with IOCL supplied 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 water should be carefully removed and disposed / kept in safe place as directed at site. The sludge shall be handled wet and should be buried if necessary as per directions of PLANT MANAGER or his representative for avoiding ignition of pro- phoric iron compounds, if any if required, A sample of all sludge collected should be handed over to the Plant Manager / Site Engineer. \nThorough cleaning of the inner surface with water jet and clearing the sludge / rust materials followed by thorough cleaning of inner surface to remove the scales, oil and dust by wire brushes to expose the metal surfaces and thorough buffing of weld joints. The contractor has to provide all equipments and consumables items for carrying out the job. localised grinding of the welds to be done if required as directed by IOC Site incharge/ Third Party inspecting Authority. | | 2 | No |
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| 19 | 2.02 | Disconnecting the inlet, outlet of the LPG liquid and vapour line, SRV, Manhole, drain line, globe valves, ROV, HLA, gauges and other fitting and disconnections of electrical cables wherever required to enable easy approach to all the areas inside the entire vessals. Any damage during de- box up/ box up, the same shall be made good by contractor at his own cost. | | 2 | No |
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| 20 | 2.03 | Providing MS tubular ladder/scaffolding 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 /exaust fan and breathing apparatus, safety belts for working personnel is to be made by contractor as required | | 2 | No |
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| 21 | 2.04 | Providing flameproof lighting arrangement inside the bullet for carrying out necessary inspection, cleaning and NDT Tests. Contractor to supply the flameproof light fittings, Junction boxes, required cables, exhaust fans for proper ventilation etc, as directed at site. | | 2 | No |
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| 22 | 2.05 | Dismantling the blind flanges, pipe joints ofLPG Horton Sphere as required and thorough cleaning of the joints, fixing new supplied gaskets, studs and nuts and fixing back all the connected line valves including excess flow check valves, safety valves after testing and other instruments like gauges, HLA etc. fitted to the vessel and complete all such jobs in all respects to make the LPG Horton Sphere ready for commissioning after completion of inspection and testing of LPG storage vessels duly certified by CCE approved parties. All tools, tackles and consumables required for the job is to be provided by the contractor. After commissioning of the LPG storage vessels, the work site is to be cleared of all debris to enable free and easy movement of operating personnel as per the instruction at site. Carry out leak testing of all flanges before commissioning. Finally correctness of level gauges has to be established. All studs/ gasketc etc to be supplied by contractor for complete replacement.. | | 2 | No |
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| 23 | 2.06 | Visual Examination :- 100% Visual Examination on internal and external surfaces\nfor observation of any surface defects, weld defects, corrosion, pitting or\notherwise physical/ material defects etc. | | 2 | No |
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| 24 | 2.07 | To conduct 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. | | 2 | No |
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| 25 | 2.08 | WFMPI ( Wet fluorescent Magnetic particle Inspection) of weld joints of storage vessals , 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. \n | | 2 | No |
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| 26 | 2.09 | UFD (Ultrasonic flaw detection) to check any internal defects of storage vessals weld joints on a) 100 % \"T\" joints from inside b) Middle circumferencial seam, bottom,&\nCrown 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.\n | | 2 | No |
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| 27 | 2.1 | 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\nASTM E-165-80 and meeting all requirements of PESO.\n | | 2 | No |
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| 28 | 2.11 | 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\n | | 2 | No |
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| 29 | 2.12 | 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 or as per applicable codes and as instructed by third party inspecting agency. \n | | 80 | m |
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| 30 | 2.13 | Carrying out hydro testing/ Stretch test of LPG horton sphere at a specified test pressure 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. \n | | 2 | No |
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| 31 | 2.14 | A. Arrangement of approciate scaffolding around the horton.\nPAINTING\na) surface Preparation: Clean to St-3 (Power tool cleaning)\nb) Paint system: Applying one coat primer(red oxide zinc phosphate primer) DFT-30-35 micron \nTwo coats aluminium finish(DFT-30-40 micron, 2 coat of 15-20 micron) paint as per standard specification. \nTotal DFT -60-70 micron.\nPainting of ladder, Plateform, saddle, support of vessel , one coat of primer & two coat paint. Painting of pipeline upto ROV - one coat primer and two coat paint including all material and labours will be in scope of contractor. | | 2 | No |
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| 32 | 2.15 | Testing and calibration of both the level guages after fixing the second valve for Horton sphere. | | 2 | No |
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| 33 | 2.16 | Certification and documentation :- to submit 5 sets of testing and inpection certificates/ reports and documents for all tests and inspection covered in the scope of work as per SMPV Rule no. 19 or as applicale. | | 2 | No |
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| 34 | 3 | HARDWAR 2 X 900 MT LPG MOUNDED STORAGE VESSEL | | | |
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| 35 | 3.01 | Degassing and cleaning of Storage vessel with IOCL supplied water after making necessary connections for in and out flow with suitable pipelines/hoses arrangement (all arrangements to be made by contractor) as directed by the site-in-charge. The water used for degassing has to be used for de-gassing the consecutive vessel by making necessary hose/ pipe/ siphon arrangment for the tranfer of water. Sludge if any shall be carefully removed and disposed off/kept in a safe place as directed by the site-in-charge. The sludge shall be handled wet and buried as per the direction of the engineer in-charge for avoiding ignition of pyro-phoric iron Compounds, if any. If required a sample of sludge shall be submitted to the plant. | | 2 | No |
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| 36 | 3.02 | Disconnecting the inlet, outlet of the Storage vessel LPG liquid & vapour lines, SRV, Manhole, drain line, globe valves, ROV, HLA, Servo gauges and other fittings and disconnections of electrical cables wherever required to enable easy approach to all the areas inside the entire the Storage vessel. Any damage during the disconnection of the above mentioned fittings or the boxing up shall be made good by the contractor at his own cost. | | 2 | No |
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| 37 | 3.03 | Providing MS tubular ladder / scaffolding inside of the Storage vessel suitably for cleaning of inner surface and for suitably carrying out all Statutory NDT testing like UFD, UTG, MPI, Hardness, DPT etc. as required under SMPV (U) Rules and as per OISD-150. Contractor has to arrange all equipments and consumables required for carrying out the job. Suitable arrangement by way of providing blower / exhaust fan and breathing apparatus, safety belts for working personnel is to be made by the contractor as required. (a) All the weld joints of the vessel shall be examined through Non-Destructive Testing (NDT) techniques e.g., radiography, Wet Magnetic Particle Test (WPT), Dye Penetration Test (DPT), ultrasonic flaw detection to ensure the integrity of the joints and other test as per requirement. b) The wall thickness of the vessel shall be measured ultrasonically. Scaffoldings shall have to be retained at site till the completion of all the vessel testing and the same scaffolding may be used for providing in the other bullets by turn. | | 2 | No |
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| 38 | 3.04 | Providing flameproof lighting arrangement inside the Storage vessel for -carrying out necessary inspection, cleaning, NDT and other Tests. Contractor to supply the flameproof light fittings, junction boxes, required cables etc., as directed at site. Lighting arrangements shall have to be kept at site till completion of the testing of all the bullets. | | 2 | No |
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| 39 | 3.05 | Thorough Cleaning of inner surface of Storage vessel with water jets and clearing the sludge/rust material followed by thorough cleaning of the inner surface to remove the scales, oil & dust by suitable means (wire brush, buffing machine etc.) to expose the metal surface and thorough buffing of weld joints. Cleaning of minimum 10 mm on both side of each weld joint including nozzle welds by through cleaning using rotary brushes to expose bear metal (shining surface) with care to entire weld joints of nozzles and weld area of support legs & all other weld joint of open area of vessel outer side. The contractor has to provide all equipments and consumables for carrying out the cleaning jobs. Localised grinding of the welds to be done if required as directed by third party Inspecting Agency / IOC Site Engineer. | | 2 | No |
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| 40 | 3.06 | Ultrasonic thickness measurement of the entire vessel i.e. the shells and the dish ends (Crown & Petal Plates), LPG pipe lines and nozzles as per ASTM-A-578, ASTM-E-797 or other applicable codes and meeting all requirements of PESO and as per instruction of third party Inspection Agency & IOC Site Engineer.(One UT test {reading} per 6*6 square inch of the surface area is to be taken, The dimensions of the vessel are as follows :- Dia 7.0 mtrs, Length 79.162 mtrs) | | 2 | No |
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| 41 | 3.07 | Ultrasonic Thickness Gauging (UTG) As per relevent code around and on each nozzle-neck at four quadrants. Including LPG Pipelines upto 1st flange. | | 2 | No |
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| 42 | 3.08 | 100% UFD (Ultrasonic flaw detection) to check any internal defects of weld Joints, 100 % \"T\" joints from inside b) Middle circumferencial 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 & OISD as per direction of third party Inspecting Agency / IOC Site Engineer. | | 2 | No |
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| 43 | 3.09 | WFMPI ( Wet fluorescent Magnetic particle Inspection) of weld joints of Mounded bullets 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. Test to be done by using AC Yoke-magniflux tiede / Y6 black light and white washable distemper as background and as per applicable code as instructed by third party Inspecting Agency / IOC Site Engineer. | | 2 | No |
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| 44 | 3.1 | 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 or applicable codes and meeting all requirements of PESO. | | 2 | No |
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| 45 | 3.11 | 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 or applicable codes and as instructed by third party inspecting agency. | | 80 | m |
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| 46 | 3.12 | Testing & Calibration of radar, Servo and other gauges after fixing the second valve for each of the mounded bullets. | | 2 | No |
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| 47 | 3.13 | Hydro Testing: Carrying out hydro testing/ Stretch test of LPG Storage vessels at a specified test pressure 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 .The water used for hydrotesting has to be used for the hydrotesting of the consecutive bullet by making necessary hose/ pipe/ siphon arrangment for the tranfer of water. Work also includes checking of settlement using total station equipment and dumpy level at various levesl of water filling & decanting viz. 0%, 25%, 50%, 75% and 100% levels. | | 2 | No |
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| 48 | 3.14 | Visual Examination :- 100% Visual Examination on internal and external surfaces\nfor observation of any surface defects, weld defects, corrosion, pitting or\notherwise physical/ material defects etc. | | 2 | No |
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| 49 | 3.15 | Fixing back all the liquid and vapour lines after servicing the valves, EFCV and fixing all removed fittings like HLA, SRV, Pressure/Servo/Temparature/Radar gauges, Manhole covers etc. After completing the testing, Purging / fresh air in it to be carried out with assistance under supervision of third party agency. Hydro test of each vessel shall be conducted as per standard of OISD-150. Fixing new supplied gaskets, new studs and nuts and fixing back all the connected line valves including excess flow check valves, safety valves after testing and other instruments like servo gauge, HLA etc. fitted to the vessel and complete all such jobs in all respects to make the LPG Storage vessels ready for commissioning after completion of inspection and testing of LPG storage vessels duly certified by CCE approved parties. All tools, tackles and consumables required for the job is to be provided by the contractor. After commissioning of the LPG storage vessels, the work site is to be cleared of all debris to enable free and easy movement of operating personnel as per the instruction at site. Carry out leak testing of all flanges before commissioning. Finally correctness of level gauges has to be established. Required all gaskets and new studs will be supplied by contractor. | | 2 | No |
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| 50 | 3.16 | 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. | | 2 | No |
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| 51 | 3.17 | Submission of Detailed NDT Report & Certification of Vessel under SMPV (U) Rules by a competent 3rd party agency authorised by PESO in five copies. | | 2 | No |
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