Indian Oil Corporation Limited Tender

Providing M.S. Tubular ladder / scaffolding inside and outside of the degassed pressure vessels for the cleaning of inner surface and for suitably carrying out all statutory NDT testing / inspection like UFD, UTG, MPI, Hardness, DPT, etc. as required under SMPV(U) rules, surface preparation, application of paint, etc, complete as per BS 1139, 4074 and other relevant codes and all other allied jobs as directed. Only one pressure vessel will be handed over at a time. Contrator shall retain the same scaffholding till the completion of all the pressure vessels and the same scaffholding may be used for the providing in the other bullets, if required by turn. Hence the contractor is advised to quote accordingly. Contractor has to arrange all the equipment and comsumables required for the carrying of the job. Suitable arrangements by way of providing blower, exhaust fan and breathing appratus, safety belts for the working personnel is to be made by the contractor as required. Scaffholding shall be property of the contractor after completion of the job. Permits of confined entry, cold work and height work to be taken before the commencement of job in each shift.

Providing the flameproof lighting arrangement inside the pressure vessel for carrying out the necessary inspection, cleaning and NDT tests. Required materials like the supply of the flameproof light fittings, junction boxes, required cables, etc. will be arrranged by the contractor. Since only one storage vessel will be handed over for the testing purpose at a time, hence, the same lighting arrangement may be used in the other bullets by turn. (Electricity if required shall be provided by IOCL, however, all arrangements including supply of fittings, cables, etc. for connections and cables etc. to be done by the contractor).

Dismantling & Re-fixing all the LPG liquid line and Vapour line valves present in the bullet manifold area. List of valves/vessel are as under : a) 4" dia Plug valve ROV with actuator - 1Nos, b) 4” Globe valve/Gate Valve - 3 No c) 4" dia NRV - 1 No d) 3” globe valve/Gate Valve/Ball Valve - 3 Nos e) 2" globe valve/Gate Valve/Ball Valve - 3 Nos After completion of all the tests, fresh gas has to be taken in as directed by IOCL. Carry out the leak tests of all the flanges before the commissioning. Finally establishing correctness of level gauges, pressure/temperature gauges & testing of the emergency shut off valves such as all EFCVs in bullet manifold area corresponding to each bullet, ROVs, using nitrogen gas for observing operational fitness as per SMPV/CCOE norms and relevant standards and issuing certificates. Certificates for correctness also required for all gauges. Job including internal inspection of EFCV and leak test for ROV. After completion of the work, the work site to be cleared of all the debris to enable free and easy movement of the operating personnel as per the instructions of the site in charge.

Servicing of Gate Valve/Globe Valve/Ball valve as per IOCL procedure mentioned in Tender document by supplying & replacing Sealkits, Sealants, Gland Packing, Body Seats PTFE/Teflon, Graphite/PTFE O-ring etc required for servicing of Valves. Hydrotesting of Valves before installation.

4" dia Plug valve ROV with actuator

4” Globe valve/Gate Valve

4" dia NRV

3” globe valve/Gate Valve/Ball Valve

2" globe valve/Gate Valve/Ball Valve

Supplying of Metallic Gaskets(MATL. SP.WND SS 316 + GRAFIL, DIM. STD. ASME B- 16.20 TO SUIT ASME B 16.5 RF FLANGES, 300#, Grade B1A

4" Dia Metallic Gaskets

3" Dia Metallic Gaskets

2" Dia Metallic Gaskets

1.5" Dia Metallic Gaskets

Supplying of Stud Bolts and Nuts(STUD BOLT WITH TWO HVY HEXAGONAL NUTS / STUD BOLT MATL. A 193 GR. B7 , NUT : A194 GR. 2H DIM STD . ASME B 18.2 .1, Grade B1A)

Stud Bolt & Nuts Suitable for 4in Dia 300# Valve

Stud Bolt & Nuts Suitable for 3in Dia 300# Valve

Stud Bolt & Nuts Suitable for 2in Dia 300# Valve

Calibration jobs for Bullet 1, 2 and 3. Capacity 72 Cubic meters, weight of LPG at approx 85% is 33.3 MT. Contractor to calibrate the bullets as per the latest gudelines of the SMPV/PESO guidelines. Using standard equipment for calibration & standard equipment for the same to be arranged by the contractor. Water for the same to be supplied by IOCL. Calibration certificate (duly certified and stamped) to be provided with 4 copies duly mentioning the data of dip, corresponding volume percentage, volume of water in litres at each dip and weight of LPG at each dip.

Visual Examination: 100% Visual Examination on internal and external Surfaces for observation of any surface defects, weld defects, corrosion, pittings, dents, erosion, cracking, scaling, deposits or otherwise physical / material defects etc. as per ASME Sec V / Sub section A&B and meeting all requirements of the PESO standards.

To Conduct Ultrasonic thickness measurement of weld on shell plates, dished end plates, LPG pipelines, manholes, nozzles, and T -joints, etc. as per SMPV rule & ASTM A-578, ASTM - E- 797, or equivalent code and meeting all the PESO requirements. Mapping of each petal plate to cover the whole plate say 6 to 7 readings to be taken between each consecutive weld seam (horizontal & vertical & LPG pipelines and nozzles and 25% on T-joints as per standards.

Ultrasonic Thickness Gauging (UTG). As per ASTM-E-797 around and on each nozzle-neck at four quadrants. Including LPG Pipelines upto 1st flange.

UFD (Ultrasonic flaw detection) to check any internal defects of Bullet weld joints on a) 100 % "T" joints from inside b) middle circumferential seam, Longitudinal seam weld, bottom and 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.

Wet fluorescent Magnetic Particle test of 100% internal and 10% for outside portion of weld joints including Nozzle weld, cleat weld, all RF pads to shell wherever applicable, using AC Yoke – magnaflux / tiede / Y6 black light and white washable distemper as background as per ASTM-E- 709-89 / ASME SEC V and as per applicable codes and standards of PESO. WFMPI to be done for the folowings:- a) circumferential joint and long seam joint internal 100 % and external more than10% b) nozzle weld (neck to shell) internal 100 % c) Nozzle weld (RF pad to shell)- external 100% d) Fillet weld of supporting column - RF pad to shell and legs to RF pad- external- 100%

Hardness testing with potable hardness tester to check hardness value of welds, parent metals and HAZ on selected spots on welds, HAZ and parent metal, equatorial polar petal & any site cleat weld areasetc. in each accessible area as per ASTM E - 110 and meeting all requirements of PESO

Dye-Penetrant Test to check any surface defects over welds. Covering HAZ (heat affected zone) of all nozzles, leg support pads & any other in accessible areas manholes etc. for defects like porosity, cracks etc as per ASTM E-165-80 / IS 3658 or equivalent code and meeting all requirements of PESO. a) nozzle attachment weld: 100% b) Supporting column RF pad to shell : 100%

Radiography test for weld joints as supporting test in case of defects observed if any in WFMPI as per ASTM-E-94 or applicable codes. (12 inch exposure). (Approximately 20 sot per vessel if required)

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 supplied water and draining the water after completion of Hydro testing. Work also includes checking of settlement using dumpy level or theodolite during slow and gradual water filling operation in LPG Storage vessels. Job also includes purging of Bullet with LPG vapour. Tenderer has to arrange their own equipments for the job.

Certification and Documentation as per SMPV rules 19. Reports, Certificates of testing and inspection of all tests/inspection covered in the scope of works in four sets to be submitted.

PAINTING of pipeline and structurals:Bullets, Bullet Area LPG pipeline, Compressed air pipeline, security air line, water sprinkler lines and adjacent water lines structurals as per Indane Look Book:- Surface Preparation as per St-2 / St-3ii. Primer : P3- Red Oxide Zinc Phosphate Primer - Single Coat, DFT 30-35µiii. Finish Coat : F2- Aluminium Finish Paint - Two Coats (15-20µ each),DFT 30-40µTotal Min DFT 60µ . The Bullets, LPG pipelines, Compressed air line, Security air line, Water line, Pipeline valves, SRVs, PAV vent lines, Pipeline structural supports, etc shall be painted as per the IOCL Indane Look Book, tender document, recent guidelines and as per the instructions of the site in charge. Rates is also inclusive of providing IOC logo with tank writing works as per standard drawing.. Note : 1. Application for External / Internal painting for all product tanks shall be carried out by means of AIRLESS SPRAY PAINTING SYSTEM only.

Lettering with paint of approved colour and brand. Painting includes painting of the background color and lettering with the foreground color as per the color scheme. The lettering of Bullets, LPG pipelines, Compressed air line, Security air line, Water line, Pipeline valves, sprinkler nozzles, test dates of vessels, SRVs, PAVs, etc shall be painted as per the IOCL Indane Look Book, tender document, recent guidelines and as per the instructions of the site in charge. Lettering jobs will also include lettering over the bands over the LPG and Air and water pipleines and lettering as per procedure in tender document and lettering of the test & due dates over the tested vessels and SRVs and PAVs, etc. Payment Will done on Per Unit/Letter/cm Height.