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| 1 | Degassing of650 MT LPG Hortonsphere withIOCL suppliedwater aftermakingnecessaryconnectionsfor inandoutflowwithsuitable pipelines/hosearrangements as directed on site. The water used for degassing should be disposed off safelyin the drainageand the sludgeif any comingalong with the watershouldbe carefullyremovedand disposed/keptin safe place as directedat site. The sludge shouldbe buried if necessary aspersitedirections.Asampleofallsludgecollectedshouldbe handed over to the site engineers.The contractorhas to provide all equipments and consumables for carrying out the degassing jobs as per the SOP provided by theIOCL Engineer In charge. Thisitemincludestheexcavationandrefillingofsoil/earthfor burying the pyrophoric sludge as per instructions. |
| 2 | Disconnectingtheinlet,outletoftheLPGliquidandvapourline, SRV,MeasuringGauges(Servo type LevelGauge,Radar type level Gauge, Level switch , Pressure gauge), Manhole, Water drain line, globe valves, ROVandotherfittingsofthe Horton sphere ,disconnectionofelectrical cableswithoutanydamageetcasperdirectionofSiteEngineer. Any damage during de-box up / box up, the same shall be made good by the contractor at his own cost. Job includes all required materials Shiftingtostoresandbackforservicing. All the disconnected pipelines and manifold valves and nozzles etc., should be positively segregated by blind flanges of 300 class rating with nut bolts which have to be supplied by the contractor on returnable basis. |
| 3 | Providing& fixing MS tubular ladder / scaffolding system (Cup lock type or as approved by EIC) inside and outsideof the Horton Sphere to enableeasy approachto all the areasinside and outside theentireHortonSphere for carrying out various activities and inspection at all required points. Scaffolding arrangement should be with 40 mm dia M.S. tube 1.5 m centre to centre, horizontal & vertical tubes joining with cup & lock system with M.S. tubes, M.S. tube challies, M.S. clamps and M.S. staircase system in the scaffolding for working platform etc. and maintaining it in a serviceable condition for the required duration as approved and removing it there after .The scaffolding system shall be stiffened with bracings, runners, connection with the building etc wherever required for inspection of work at required locations with essential safety features for the workmen etc. complete as per directions and approval of the IOCL Engineer- in-charge. Whereever tubular pipe touches the shell plate suitable rubber pads to be provided to avoid damages to the shell . All the activities like NDT,Cleaning ,Painting, Repairing job, Sprinkler nozzle replacement jobetc to be done using the same scaffolding.The scaffolding shall be retained by IOCL till the completion of the Testing, Painting, Repairing job, Sprinkler nozzle replacement job and handing over of the Horton Sphere (Approx 45 days/vessel) |
| 4 | Providing FLP Blower/exhaust fan/ventilator fan for circulation of air and Flameproof lighting arrangement (CMRI/CIMFR/CCOE approve)along with required junction box, cables, FLP Glands , 30 mA rating ELCB etc inside the Horton Sphere as an aid forcarryingoutnecessaryinspection,cleaningandNDT Tests. Electricity will be provided by IOCL on chargeable basis. |
| 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 suitable means (rotary pneumatic/electric or manual 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 to be exposed with 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 necessary equipments 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 | OVERALL VISUAL INSPECTION :To conduct thorough “Visual Inspection\" of outer andinner surface of pressure vessel, its nozzles and leg support pads etc. for observation of any surface defects, weld defects, corrosion, pittings or otherwise physical / material defects etc. as per ASME Sec V , Subsection A & B and meeting all requirements the PESO standards. |
| 7 | Servicing and Overhauling of Vapour,liquid ROV , other first flange valves and SRV (Each Horton Sphere has Liquid ROV-8\"valve-1nos, Vapor- ROV 6\"valve-1nos, 8\"valve-2 nos, 6\"valve-2nos,ROV actuator - 2nos , SRV-02 nos). Work includes changing of fire safe seatings with OEM spares if damaged, servicing of actuators,gland packing changing with OEM spares , smooth and free operation of valve and hydrotesting and leakage testing of serviced valves at max working pressure of the Horton sphere witnessed by IOCL site incharge. This leak testing records shall also to be made available with ST documentation. Operational fittnes testing of emergency shutoff valves, ROVs using nitrogen gas for observing operational fittness as per SMPV / CCOE norms and issuing certificates. |
| 8 | Hydrotest/Stretch Testing of the HortonVesseland LPG pipe lines after completionof all NDT as per SMPV Rules, ASME-Sec. VIII Div 1andrevelentcodesusingtheIOCL suppliedwaterforspecifiedtest pressure, using motorised reciprocatingpumpandbuildinguppressurein stagesandretainingthesametoaspecifiedperiodanddraining thewateringradualstagesaftercompletionofthetesting. The contractor has to make his own arrangements for motorised pressure testing equipment with calibrated pressure gauge (0-60 KG/cm2).(The max hydrostatic test pressure upto30 Kg/cm2)Work also includes checking of settlement using dumpy level or theodolite during slow and gradual water filling operation in LPG Storage vessels. |
| 9 | Fixingbackall theliquid andvapourlines ,water drain lines afterservicingthevalves , EFCVandfixingall removed fittings like level switch, SRV, Pressure / Temp/Servo/Radar gauges, manhole covers etc., including supplying and fixing of New metallicspiralwoundgaskets,Studs&nutsandasper specifications/codes. Replacing all studs& nuts with new studs& nutsin all first flanges in 650MT Horton sphere .GasketusedshallconformtoASMEB16.20or equivalent.ThestudsusedshallconformtoASTMA194Gr2 H/ASTM A 193 Gr B7 or equivalent. The studs&nuts should have proper test certificate and to be certified by third party before in use.Finally, correctnessof level gauges , pressure , Temparature gauges / transmitters to be established by the successful tenderer.If required , correctness checking of the instruments are to be done through liasoning with the existing AMC holder of the instrument as per direction of EIC. Job also includes purging the vessel aftercompletion of all testingand carry out leak test of all the flanges before the commissionning .This includes all the works pertaining to commissioning the Horton sphere after inspection and testingand subsequent clearing of all debris and removing of scaffholding materials at site. |
| 10 | Dismantling Steel work in built up sections in angles, tees, flats channels etc. including all gusset plates, bolts nuts, cutting rivets welding etc. including dismembering and stacking within premises . This job is required for repair ofStructural like Ladder Staircase leading up to the top of the Horton Sphere, Valve operating Platforms, Hand Railing, Approach Ladders and Platforms, Work Structures and any other Structural items inside the kerb wall area and around the Horton Sphere. |
| 11 | Fabrication & Erection of IOC supplied structural steel work riveted, bolted or welded in single/ built up sections,trusses & framed work hoisting, fixing in position and applying a priming coat of approved steel primer all including cutting, complete - This job is required for repair ofStructural like Ladder Staircase leading up to the top of the Horton Sphere, Valve operating Platforms, Hand Railing, Approach Ladders and Platforms, Work Structures and any other Structural items inside the kerb wall area and around the Horton Sphere. |
| 12 | Structural steel work in built up sections/ framed work in gratings, frames, guard bar, ladder, railings, brackets, gates and similar works including cutting,hoisting,fixing in position & applying a priming coat of approved steel primer etc. as required. This job is required for repair ofStructural like Ladder Staircase leading up to the top of the Horton Sphere, Valve operating Platforms, Hand Railing, Approach Ladders and Platforms, Work Structures and any other Structural items inside the kerb wall area and around the Horton Sphere. |
| 13 | Cleaning of Medium velocity water sprinkler system (Sprinkler line of various dia ) and Security air line of various diaaround the Horton sphere and at the valve manifold section of Horton sphere , check for blockage & any leakage in the sprinkler system and security air line system. |
| 14 | Dismantling of old Sprinkler nozzles and supply & fixing of new sprinkler nozzles for total sprinkler system of Horton Spheres including valve manifolds of HS. Job includes supply and fixing of tag plate with SS grade wire for each sprinkler nozzle of size 4\" X 3\". Painting and numbering of the tag plates is included in the rate. ( Approx 170 nos sprinkler nozzlesin each Horton sphere).Specification of spray nozzle:1) Sprinkler K factor - 41, 120D2) MOC - SS 3163) Approvals - Manufacturer test / quality certificate to be provided (UL listed) |
| 15 | Calibration of the Horton sphere to be performed as per the latest SMPV / PESO guidelines using standard equipment and the standard equipment for the same to be arranged by the tenderer. Water for the calibration to be supplied by IOCL. Calibration certificate (duly certified & stamped )to be provided with 4 copies duly mentioning the data of dip, corresponding volume percentage , volume of water litres at each dip and weight of LPG at each dip. |
| 16 | PaintingofexternalsurfacesofLPGlines,productlines,water sprinklerpipelines,Airpipelinesofvariosdiameters ,SRVincluding surfacepreparationtoSSPCSP2byhandcleaningwirebrushing applyingone coat of Zinc phosphateprimer(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 necessaryworksforcompletionoftheworkincludingsupplyof paint, labours, materials, numbering of nozzles complete as per the approved colouranddirectionsatsite.Paymentwillbemade based on area painted. |
| 17 | Painting the MS structure of catwalks, Connected platforms,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 SP2 by 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. Payment will be made based on area painted. |
| 18 | Paintingofexternalsurfacesofsphereincludingsurface preparationtoSSPCSP3handcleaningwirebrushing,onecoat Zincphosphateprimer(P3)of30-35micronDFTand2coatsof AluminiumFinishpaint(F2)of15-20micronseachcoatasper technicalspecification(TotalDFT60micron).Theitemincludes all necessary works for completion of the work including supply of paint, labour , materials, lettering on the Horton sphere with paint of approved colour and brand for stencilling of brand name \"Indane\" in english & hindi with IOCL logo as per colour coding specified in Indane lookbook. Complete asperthedirectionsatsite.Thedetailed paintspecifications are mentioned in Scope of Work, Clause No. 19. |
| 19 | Paintingof Spherelegswithtwocoatsof TWO PACKALIPHATIC ACRYLIC POLYURETHANE FINISH PAINT from approvedmanufacturer.TheworksincludingsurfacepreparationtoSSPC SP2by handcleaningwirebrushing,applyingputtitomakeeven surface,fillingofgapbyputtiatspherelegjoiningplacesand applying twocoatsofTWOPACK ALIPHATIC ACRYLIC POLYURETHANE FINISH PAINT as per approved colour and manufacturer’s specifications.Payment will be made based on area painted. |
| 20 | WetfluorescentMAGNETICPARTICLETEST: WFMPI ( Wet fluorescent Magnetic particle Inspection) of weld joints of Horton spheres, 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. |
| 21 | ULTRASONIC TESTS: To conduct 100% \"Ultrasonic Thickness Test\"onshellofvesselasperSMPVrule,ASTM -A-435,ASTM -A-578, ASTM -E-797 or equivalent codes and meeting all requirements of PESO. Mapping of each plate section to cover the whole plate - say six to seven readings to be taken between each consecutiveweldseam(Horizontal&Vertical),Nozzle,Manhole, Pipingaroundinstallationuptofirstisolationvalve. |
| 22 | DYE-PENETRATIONTEST:Toconduct“Dye-PenetrationTest”of Nozzles , manholes , support pads and any otherinaccessibleareas for defects like porosity , cracks etc as per ASTM-E -165-80 and meeting all requirements of PESO. |
| 23 | UltrasonicFlaw Detection Test to check any internal defects of Horton sphere weld joints on(a)T-Weld joint,Internal:100%,(b)Middlecircumferentialandlongitudinal Seam,dishendswelds-Internal: 100%,(c)Nozzleweld —neckto shell, Internal: 100%, as per as per ASTM E – 164 , ASME Sec V & Sec VIIIand meeting all requirements of PESO. |
| 24 | HardnessTestasperASTM-E-110 and meeting all requirements of PESOusingmicroprocessorbased (polditypenottobeused)portablehardnesstesteratrandom, preferably below the equator oncumferential/longitudinal weld,T-joint& alsonozzleweld,HAZ: Left & right,parentmetal: Left & right i.e. at 5 position on 25 locations. Approximate quantity per vessel : 125 nos. |
| 25 | Radiographytest for weld jointsat selectedlocations based on problem defect/flawsobservedduring other tests subject to a maximumof 10% oftotalweld lengthas per ASTM-E-94applicablecode . This is an OPTIONALitem and same is to be conductedwhere defect / flaws are observed. |
| 26 | Certificationanddocumentation: Inspection services for statutory testing of 4 X 650 MT sphere including the scope of jobs of (1) Visual inspection of sphere, (2) Internal /external inspection of the entire surface of the sphere to detect for deterioration. (3) Witnessing, Guiding, Supervising, interpretation and analysis of NDT as per scope of work given in the schedule (4) Witnessing Hydrostatic test and witnessing of sphere settlement with fixed point during progressive water filling (4)Preparation of detailed report containing observations, recommendations and certification as per SMPV rules and OISD, including submission of certificate of control and uploading in online to comply with PESO .Submit5setsofTestingandInspection certificates/reportsanddocumentsforalltestsandinspection coveredinthescopeofworkasperSMPVRuleNo.19(‘Issueof onlinecertificateoftestalong withannexuregivingthedetailsof NDTinspection’).SubmissionofstatutorytestreportSMPV(U) Rules1981 formatduly certifiedby competentinspectionagency havinghavingauthorization/approvalofCCOE,Nagpurtoissue such certificate. |
