Indian Oil Corporation Limited Tender

SURVEY, REPAIR & MONITORING STEAM TRAPS

Unit EA means Survey of 13 no's of traps in any of the mentioned units. 25% SURVEY OF THE TOTAL CONTRACTED STEAM TRAP POPULATION 25% survey of total steam trap population are to be carried out as and when required by Digboi Refinery as per the set route decided randomly by Digboi Refinery and report to be submitted within one month as per instruction and entire satisfaction of Engineer-In-Charge. MODUS OPERANDI 1) 25% of Total Contracted steam traps = 0.25 X 3326 = 832 traps. 2) Survey shall be conducted in four sessions in a year and a cumulative total of 832 traps shall survey eah year. 3) Minimum lot for one session shall be 5% which will be uniformly distributed in the following units. A) AVU B) CRU C) DCU D) DCU TF E) MSQ F) SDU G) SDU TF H) WHFU I) WHFU TF J) TF K) PPH L) WPU M) WRDS Survey of steam trap will includes following activities: 1) Steam traps/piping system of all the units and offsite areas including power plant shall be identified and a permanent metallic tag should be provided with allocation of a unique tag number. The metallic tag,SS wire etc will be arranged by the Vendor. 2) Data required like trap type, size, type of connection, operating pressure and working condition (say red for passing, blue for water-logging, green for okay etc) are to be stored against each tag in the data base. 3) A survey/inspection route to be set in advance and sequencing of traps to be done. 4) A comprehensive report is to be generated for all the installed steam trap and piping network with both before and after repair data like trap passing, water logged, flange/gland leakage, okay etc with quantifing the leakages.

CONTINUOUS MONITORING, RECTIIFICATION & SUPERVISION OF REPAIRING OF TRAPS FOR DIFFERENT UNITS/AREAS. Steam Trap network continuous monitoring & repairing includes following activities: 1)Continuous monitoring and repair of the entire steam trap network system. 2) Any leak in the steam network like flange leak, v/v gland leak, thread joint leak etc are to be rectified by the Vendor. 3) Jobs to be carried out under the supervision of expert from the Vendor and the Vendor supervisor should be present on continuous basis at DR site. 4)In case of steam trap beyond repair, replacement of steam traps to be done by the Vendor with consent from DR personnel. 5)Welding job, if any, will be carried out by DR, but the detection and information shall be provided by the Vendor at least 1 day in advance. 6)Data of repair/replacement for each tag is to be mentioned in the report. 7)Installation of new traps for 'No trap Location' will be in the scope of the Vendor. DETAILED SCOPE OF WORK: 1)STEAM SYSTEM STUDY: a)Vendor will carry out the monitoring of all steam traps modules in all units of DR. b)The CHT and UNFCCC methodology will be used to assess the total steam leakage quantity. c)Vendor will do a root cause analysis of steam trap failure and leakage based on the selection/installation/sizing of the steam traps and type of failure and recommend improvements to avoid recurrence of the same. d)The steam loss will be computed for steam traps and the supporting system inclusive of the drip leg and the isolation valves. e)Each steam trap to be tagged by aluminum tags and SS wire with a colour code displaying trap operating status and indicating (1)Area/Location code,(2)Recommended Traptype for the particular location,(3) steam trap serial no. if not done. f)The locations with no Steam Traps installed will be identified. g)Any deficiencies in the support system and leakages in the drip leg and isolation valves will be identified. 2) ANALYSIS OF STUDY FINDINGS: a)The steam system study report will include the Analysis of the steam trap modules findings and preparation Electronic Database for the steam trap modules containing following details for future reference(repeatability) b)Health status of each individual trap c)Steam trap type, size, application and installation d) Steam pressure and temperature at the trap e)Location reference of the trap f)Existing no trap locations & Newly identified steam trap locations. g)Recommendations for each trap h)Unit wise steam loss findings. i)Recommendations for standardization of trap installations and specify latest technology upgradation to minimize maintenance and downtime. j)Identify potential system improvements & benefits to minimize maintenance and downtime. k)Specify latest technology upgrades where steam and condensate is used to ensure best practice methodes and latest technology is applied. l)Development of a "Zero Leak" program for steam system optimization for all the units of DR based on the survey with plan for frequency of ongoing checks based on application, priority and installation. m)Vendor to specify the inventory levels for spares and steam traps to be maintained by DR for future availability.