Indian Oil Corporation Limited-IOCL has published Tender For Statutory Inspection Of 2X110 Mts Above Ground Lpg Storage Vessels. Submission Date for this Tender is 03-03-2023. Bottles Tenders in ajmer Rajasthan. Bidders can get complete Tender details and download the document.
| Sl. No. | Item Description |
| 1 | Degassing and cleaning of Storage vessel with IOCL suppliedwaterafter making necessary connections for in and out flow with suitable pipelines/hoses arrangement (all arrangements to be made by contractor) asdirected by the site-in-charge. The water used for degassing has to be used for de-gassing the consecutive bullet by making necessary hose/ pipe/ siphon arrangement for the transfer 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 directionoftheengineerin-chargeforavoidingignitionofpyro-phoriciron Compounds, if any. If required a sample of sludge shall be submitted to the plant. |
| 2 | Disconnecting the inlet, outlet of the Storage vessel LPG liquid & vapour lines, SRV, Manhole, drain line, globe valves, ROV, HLA, Servo gauges, radar gauges and other fittings and disconnections of electrical cables wherever required to enable easy approach to all the areas inside the entire Storage vessel. Any damage during de-box up / box up, the same shall be made good by the contractor at his own cost. |
| 3 | Providing MS tubular ladder / scaffolding inside of the Storagevessel 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 all allied jobs as directed. Contractor has to arrange all equipments and consumables required for carrying out the job. Suitablearrangementbywayofprovidingblower/exhaustfanandbreathing apparatus,safety belts forworking personnel is tobe madeby thecontractor 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 three bullets testing and the same scaffolding to be used in the other bullets by turn. |
| 4 | Dismantling the blind flanges, pipe joints of LPG Bullets 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. |
| 5 | 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. |
| 6 | Thorough Cleaning of inner surface of Storagevessel 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 thorough 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. |
| 7 | Ultrasonic thickness measurement 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 Metal 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. |
| 8 | Ultrasonic Thickness Gauging (UTG) As per relevant code to be done around and on each nozzle-neck at four quadrants. Including LPG Pipelines upto 1st flange. |
| 9 | 100% UFD (Ultrasonic flaw detection) to check any internal defects of weld Joints, 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 & OISD as per direction of third party Inspecting Agency / IOC Site Engineer. |
| 10 | WFMPI( Wet fluorescentMagneticparticleInspection) ofweld jointsof storage vessels including nozzle joints to check any surface /sub surface defects or linear typeofindicationsovertheweldscoveringHAZon100%circumferential and longitudinal weld joints from inside and on outside portion exposed encompassing the nozzleweldsetcandonweld jointsof allnozzles,manholes,RFpadsto 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. |
| 11 | 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. |
| 12 | Hardnesstesting tocheckhardnessvalueofwelds,parentmetalsandHAZon selected spots on welds, HAZ and parent metal in each accessible area as per applicable codes and standard and meeting all requirements of PESO. |
| 13 | 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 applicable codes and as instructed by third party inspecting agency. (12 inch exposure). |
| 14 | Testing & Calibration of radar, rochester gauge and other gauges after fixing the second valve for each of the storage vessels. |
| 15 | 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 hydro testing has to be used for the hydro testing of the consecutive bullet by making necessary hose/ pipe/ siphon arrangement for the transfer of water and draining the water after completion of Hydro testing. Work also includes checking of settlement using total station equipment and dumpy level at various levels of water filling & decanting viz. 0%, 25%, 50%, 75% and 100% levels. Hydro testing of each of the vessels has to be witnessed by the competent person duly authorised by PESO, no other representative shall be allowed to witness the same on their behalf. The contractor shall have to make prior planning for such witness so that the whole process of each vessel doesn’t take more than one month. |
| 16 | Third party inspection services for statutory testing of 2*110 MT storage bullets including the scope of jobs of (i) Visual inspection of bullets (ii) Internal & External inspection (nozzles etc.) of the entire bullet surface to detect to deterioration (iii) Witnessing, guiding, supervising, interpretation and analysis of NDT as per scope of work given in schedule (iv) Witnessing and supervision of HPT & all tests (V) Preparation of detail reports containing observation, recommendation and certification as per SMPV rules & OISD. (Vi) Certifying Hydro test of each storage Bullet. An inspection engineer having engineering degree with adequate field experience should be posted at site for supervision of the works all the time till the completion of work. The parties hired shall be reputed and are dealing/having past experience in inspection and certifications of hydro testing of LPG vessels.Should have PESO approval certificate in the name of certifying person as competent person for above ground Storage vessel. |
| 17 | A. Arrangement of approciate scaffolding around the bullets. PAINTING a) surface Preparation: Clean to St-3 (Power tool cleaning) b) Paint system: Applying one coat primer(red oxide zinc phosphate primer) DFT-30-35 micron Two coats aluminium finish(DFT-30-40 micron, 2 coat of 15-20 micron) paint as per standard specification. Total DFT -60-70 micron. Painting of ladder, Plateform, saddle, support of bullet , 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. Writing and painting of IOCL logo along with storage capacity as per look book will also under the scope of contractor. |
| 18 | Fixing back all the liquid and vapour lines.after servicing the valves, EFCV and fixing all removed fittings like HLA, SRV, Pressure/Rochester/Temperature/Radar gauges, Manhole covers etc. After completing the testing, Purging to be carried out with assistance under supervision of third party agency. Hydro test of each vessel shall be conducted as per standard of SMPV (U) rules and OISD. 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 rochester gauge, HLA etc. fitted to the vessel and complete all suchjobs inall respects to makethe LPG Storage vesselsready 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. |
| 19 | 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. |
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