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| 1 | PART - A : PRELIMINARY WORKS FOR STATUTORY TESTING OF1400 MT SPHERE AND PAINTING WORKS Degassing of 1400 MT Spherewith supplied water,filling up water gradually and making necessary connections for in and out flow with suitable pipelineas directed at site.The water used for degassing should be disposed off safely in the drainage and the sludge if any coming along the water should be carefully removed and buried at a safe place as directed.A sample of the sludge collected should be handed over to the site engineer.Note:Water Supply will be under IOCL scope, However Contractor has to make all nessasary arrangement for pumping water into Horton sphere. |
| 2 | Disconnecting the inlet, outlet of the LPG liquid and vapour line, SRV, HLA, Manhole, Servogauge, Water drain lines, Globe valve / Gate Valves,ROVs and other fittingsand directions of the site engineer.All the disconnected pipelines and manifold valves and nozzles etc., should be positively segregated by blind flanges of 300class rating with fasterners have to be supplied by the contractor which can be taken by the contractor on completion of the entire work, the fastners dummy used should be as per IS standards.- of 1400 Mt Sphere |
| 3 | Providing MS tubular scaffolding inside and outside the sphere suitable for cleaning of inner surface and suitable for carrying out all inspections like ultrasonic testing, radiographic testing, MPI and other NDT\"s and all allied jobs for inspection at various places and around all welding joints, , On outer surface weld joints shall be cleaned as directed by the third party agency approved by IOC.Scaffolding arrangement should be provided with movable footrest / MS Grill type / pathwayand Safety net etc., for easy movement of personnel and for resting equipments.Whereever tubular pipe touches the shell plate suitable rubber pads to be provided to avoid damages to the shell.The scaffolding shall be retained by IOCL till the completion of the Sphere (Approx 90 days) testing and Painting.Hence, the contractor is requested to quote accodingly. |
| 4 | Pressure testing of Sphere after completion of thermowell remova andall NDT l using the supplied water for the specified hydrostatic test pressure by using motorised pumpand draining the water after competion of testing.The contractor has to make his own arrangements for motorised pressure testing equipment with calibrated pressure gauge (0-60 KG/cm2)which has to be retained till completion of the work. The entire Testing will be witnessed by Third Party Agency. Note:Water Supply will be under IOCL scope, However Contractor has to make all nessasary arrangement for pumping water intoHorton sphere and back to Fire water tank. |
| 5 | Internal/External 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 rust by rotary pneumatic/electric wire brushes to expose the metal surfaces and thorough buffing of welding joints.Minimum 100 mm on both the sides of each welding joints including nozzle welds by thorough cleaning using rotary pneumatic/electric wire brushes to expose bare metal (shining surface) with care to remove rust from both the sides of the weld ripples and under cuts.In addition 200 mm on all the sides of the entire weld joints of the nozzles and weld area of the support legs and other area as directed at site. The contractor has to provide all equipments, necessary FLP light fitting,cables with 30mA ELCB etc., ventilation provision and consumables for carrying out the cleaning job and also facilitate for carrying out NDT tests.Localized grinding of the welds to be done if required. Note : All electrical fittings should be FLP |
| 6 | Servicing of Vapour,liquid ROV and other first flange valves (12\"valve-3nos, 6\"valve-4nos, 4\"valve-2nos, 2\"valve-5nos, 2\" NRV-1no and ROV actuator - 2nos). Work includes changing of fir safe seatings if damaged, servicing of actuators,gland packing changing, smooth and free operation of valve and hydrotesting of serviced valves witnessed by IOCL site incharge. |
| 7 | Fixing back all the liquid and vapour lines after servicing the valves, EFCVs and fixing all removed fittings like HLA, SRVs, Pressure / temperature gauge,Manhole covers etc., including supply of asbestos filled spiral wound metalic gaskets. This includes all the works pertaining to commissioning the sphere after inspection and testing duly approved by PESO approved third party and subsequent clearing of all debris and removing of scaffholding materials at site. |
| 8 | Replacing all studs& nuts with new studs& nuts as per specification (Studs SA320 Grade L7 and nuts SA194 4/7 ) in all first flanges in 1400MT sphere (110mm M16 x 12nos,120mm M18 x 40nos, 140mm M18 x 24nos, 180mm M30 x 32nos and 250mm M40 x 24nos). The studs&nuts should have proper test certificate and to be certified by third party before in use. |
| 9 | Paining of external surfaces of sprinkler GI pipelines, airMS pipelines of diameter ranging from 1 inch to 6 inch beyond deluge valves of Sphere including surface preparation to SSPC SP2by hand cleaning wire brushing applying one coat of Zinc phosphate primer (P3) coating of 30-35 Micron DFT and 2 coats of Synthetic enamel of approved colour of 25 microns each coat (Total DFT 80micron) .The item includes all necessary works for completion of the work including supply of paint, labours, materials, numbering of nozzles complete as per the approved colour and directions at site.(Approx 750 SqM per Sphere). Payment will be made based on area painted. |
| 10 | Painting the MS structural of catwalks, Connectedplatforms, gratings,MS chequered plates at valve manifold area, Catwalk at sphere kerb wall entry, top and side of the sphere etc.including surface preparation to SSPC SP2by hand cleaning wire brushing, applying one coat of Zinc phosphate primer (P3) coating of 30-35 Micron DFT and 2 coats of Synthetic enamel of approved colour of 25 microns each coat (Total DFT 80micron). The item includes supply of paint, labour, materials as per specification and as per approved colour and directions at site.(Approx 600 Sq M )Payment will be made based on area painted. |
| 11 | Painting of external surfaces of sphere including surface preparation to SSPC SP 3 hand cleaning wire brushing, one coat Zinc phosphate primer (P3) of 30-35micron DFT and 2 coats of Aluminium Finish paint (F2) of 15 -20 microns each coat as per technical specification (Total DFT 60 micron). The item includes all necessary works for completion of the work including supply of paint, labour , materials, lettering on the storage vessels. Complete as per the directions at site. ( Approx 1100 SqM ) The detailed paint specification attached as annexure. |
| 12 | Painting of Sphere legs (12nos) with two coats of TWO PACK ALIPHATIC ACRYLIC POLYURETHANE FINISH PAINT from approved manufacturer. The works including surface preparation to SSPC SP2by hand cleaning wire brushing, applying putti to make even surface, filling of gap by putti at sphere leg joining places and applying two coats of TWO PACK ALIPHATIC ACRYLIC POLYURETHANE FINISH PAINT as per approved colour and manufacturer\"s specifications.Payment will be made based on area painted. |
| 13 | PART-B : NON-DESTRUCTIVE TESTING OF 1400MT SPHEREUltrasonic thickness measurement on shell plates and nozzles as per applicable code and as instructed by third party agency.Code: ASTM-A-435. |
| 14 | 100 % Wet flourescent Magnetic Particle Test of all weld joints by using Magnaflux - Y7 yoke type as per third party agency directive. Code: ASTM-E-164 & ASME Sec V & Sec VIII Machine-Magnaflux-Y7-Yoketype. |
| 15 | 100% Ultrasonic flaw detection (width of scanning 50mm) of welds as per applicable codes from inside as directed by our third party agency. Code: ASTM-E-164 & ASME Sec V & Sec VIII Method:Pulse echo. |
| 16 | Radiographical examination of weld joints at selected locations as per third party inspection agency based on detection of flaws or defects during other test subject and as per applicable code. |
| 17 | Hardness test with poratable micro processor based digitalhardness tester as directed by third party inspection agency and as per applicable code. Code: ASTM-E-110. |
| 18 | Dye penetration test at accessible areas as directed by third party inspection agency. |
| 19 | PART-C.REMOVAL OF THERMOWELL IN 1400 MT HORTON SPHERE.Supply of 300 mm NB SA333 Gr6 seamless LPG Pipe with test certificate |
| 20 | Supply of WN RF Flanges pipe class BD :a) 300 mm NB |
| 21 | Preparation of QAP and WPS for thermowell removal work for 1X1400MT above ground LPG bullet liquid nozzle as per TPI recommendation. Same to be approved by IOCL appointed TPIA |
| 22 | Thermowell removal work consisting of hydrogen diffusion treatment, Removal of thermowell section, preparation of edges, fitup works, welding by certified welder, local stress releiving and all NDT tests like DPT/MPT, radiography, hardness test, etc.,in each stage as recommended in M/s PDIL report.Work shall be carried out by CCOE approved Vessel fabricator, Stage wise work and NDT will be witnessed and approved by TPIA. a) 300 mm NB |
| 23 | Handling and welding of supplied forged weld neck rised flanges on the pipelines in above-ground/over-head at all elevation with necessary weld as per specification testing hydrostatically to required pressureas per specification and direction of site engineer etc., complete.a) 300 mm NB |
| 24 | Making flange joints (between two flanges or between flange and bling flange) on LPG pipelines laid as above ground/overhead at all elevation as required including supplying and providing stud bolts and nuts, washers and jointing materials specified like asbestos filled metal wound gasket class 300 of approved quality and also supplying and providing earthing / bonding connection (one for each joint) from bolt head to the nut copper strip 40X3 mm bent to proper shape, checking electrical continuity of the pipeline system as directed at site. a) 300 mm NB |
| 25 | Removing of perforated 100 mm NB ,4.7M HLA pipe by cutting it and leaving samll projection to avoid any furthur welding/grinding on the sphere,Work shall be carried out by CCOE approved Vessel fabricators and TPI recommendation. Same to be approved by IOCL appointed TPIA |
| 26 | Preparation and submission of reports and final drawing (as-built) for TPI and PESO approval along with all test certificates. |
