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| 1 | FIVE YEALY STATUTORY NDT INSPECTION, HYDROTESTING AND CERTIFICATION OF 03 NUMBERS × 2026 MT MOUNDED LPG BULLETS AT IPPL, HALDIA TERMINAL |
| 2 | Degassing and cleaning of Storage vessel with IPPL supplied water after making necessary connections for in and out flow with suitable pipelines/hoses arrangement (all arrangements to be made by contractor/party) as directed 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 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. |
| 3 | 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 |
| 4 | 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 with latest amendment 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 three bullets testing and the same scaffolding may be used for providing in the outer bullets by turn. |
| 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 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 / IPPL Site Engineer. |
| 7 | 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 / IPPL Site Engineer.(One UT test {reading}, Ultrasonic Thickness Gauging (UTG) As per relevent code around and on each nozzle-neck at four quadrants. Including LPG Pipelines upto 1st flange. Dimension of the vessel : Dia: 8.0 meter & Length: 81 meter |
| 8 | 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 / IPPL Site Engineer. |
| 9 | 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 & IPPL Site Engineer. |
| 10 | 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 applicable codes and meeting all requirements of PESO. |
| 11 | Testing & Calibration of Radar, Servo and other gauges after fixing the second valve for each of the mounded bullets. |
| 12 | 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 IPPL 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 level of water filling & decanting viz. 0%, 25%, 50%, 75% and 100% levels. (water for hydrotest will be supplied by IPPL) |
| 13 | Third party inspection services for statutory testing of mounded 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 150. (Vi) Certifying Hydro test of each Mounded Bullet. An inspection engineer 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 Mounded Storage vessel. |
| 14 | Fixing back all the liquid and vapour lines after servicing the valves, EFCV (to be checked and refixed after satisfactory checking) and fixing all removed fittings like HLA, SRV, Pressure/Servo/Temparature/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 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 CCOE 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 IPPL |
| 15 | 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. |
| 16 | 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. (Approximate length of weld joint per vessels is 1500 Mtr) |
| 17 | Submission of Detailed NDT Report & Certificates of Vessel under SMPV (U) Rules by a competent 3rd party agency authorised by PESO in three copies. |
| 18 | GST @ 18% |
