DHDS T&I ’09: MAIN CONTRACT Annexure 1: Part IItenders.hpcl.co.in/tenders/tender_prog/TenderFiles/2318/Tender... · DHDS T&I’09: Main Contract Annexure 1 – Part II Part –

DHDS T&I ’09: MAIN CONTRACT

Annexure 1: Part II

UNIT RATE SCOPE OF JOBS

DHDS T&I’09: Main Contract Annexure 1 – Part II

Part – II - UNIT RATES

Annexure 1 – Part II / Page 2 of 40

INDEX

1. PART – II : UNIT RATE JOBS .............................................................................. 4 1.1. INTRODUCTION............................................................................................. 4

1.2. BLINDING AND DE-BLINDING ................................................................... 4

1.3. PIPING REPLACEMENT ............................................................................... 5

1.4. DYE PENETRATE TEST AND WFMPT ...................................................... 8

1.5. RADIOGRAPHY .............................................................................................. 9

1.6. STRESS RELIEVING OF WELD JOINTS ................................................... 9

1.7. ULTRA SONIC FLAW DETECTION TEST .............................................. 10

1.8. DROPPING AND REINSTALLATION OF VALVES ............................... 10

1.9. CS /SS OVERLAY PATCH WORK .............................................................. 10

1.10. CS /SS INLAY PATCH WORK ..................................................................... 11

1.11. WELD BUILD UP JOBS ................................................................................ 11

1.12. WELD RUNS ................................................................................................... 12

1.13. SCAFFOLDING ............................................................................................. 12

1.14. CEMENT LINING OF VESSELS ................................................................. 13

1.15. REFRACTORY REPLACEMENT BY CASTING ..................................... 13

1.16. GUNNITING OF REFRACTORY WITH ANCHOR REPLACEMENT . 13

1.17. FABRICATION AND WELDING OF ANCHORS ..................................... 14

1.18. BRICK LINING .............................................................................................. 14

1.19. CERAMIC FIBRE BLANKET LINING ...................................................... 15

1.20. CERAMIC FIBRE MODULES REPLACEMENT ..................................... 16

1.21. REPLACEMENT OF THERMO COUPLES .............................................. 16

1.22. HYDROTEST OF HEATER TUBE PASSES .............................................. 17

1.23. REPLACEMENT OF REFORMER TUBES. .............................................. 17

1.24. REPLACEMENT OF REFORMER PIGTAILS ......................................... 18

1.25. FABRICATION & INSTALLATION OF BURNER COMPONENTS ..... 18

1.26. REPLACEMENT OF BURNER BLOCK (SET) ......................................... 19

1.27. REPAIR/ REPLACEMENT OF SS PERFORATED SHEETS .................. 19

1.28. ORIFICE PLATE ........................................................................................... 20

1.29. REPLACEMENT OF CEMENT LINED PIPES ......................................... 20

1.30. FABRICATION OF MITERS/REDUCERS ................................................ 21

1.31. CEMENT LINING OF PIPES, FITTINGS, MITRES, BENDS AND

SPECIALS ................................................................................................................... 21

1.32. CS CASING PLATE REPLACEMENT ....................................................... 23

1.33. STRUCTURAL WORKS ............................................................................... 23

1.34. RELIEF VALVES ........................................................................................... 25

1.35. LEVEL GAUGES ........................................................................................... 25

1.36. CIVIL WORKS ............................................................................................... 26

1.37. CHANNEL SECTION PARTITION PLATE REPAIRS ............................ 29

1.38. REPLACEMENT/ REPAIRS OF LINER PLATES .................................... 30

1.39. LINING FOR EXCHANGER COMPONENTS .......................................... 31

1.40. RETUBING OF EXCHANGERS/ COOLERS ............................................ 34




1.41. MACHINING OF GASKET FACES OF CHANNEL SECTIONS

OUTSIDE REFINERY ............................................................................................... 34

1.42. REPEAT SHELL TEST AND TUBE TEST ON EXCHANGERS ............. 35

1.43. HYDROTESTING OF PIPING ..................................................................... 35

1.44. GASKET REPLACEMENT .......................................................................... 35

1.45. SUCTION STRAINERS CLEANING .......................................................... 35

1.46. DROPPING & RE-INSTALLATION OF CONTROL VALVES.............. 36

1.47. TRAY/DOWN COMER/SEAL PAN REPLACEMENT IN COLUMNS .. 36

1.48. VALVE RECONDITIONING ....................................................................... 37

1.49. IN-SITU MACHINING .................................................................................. 39

1.50. POSITIVE MATERIAL IDENTIFICATION .............................................. 39

1.51. JOBS ON EXCHANGER NOT PART OF LUMPSUM SCOPE ................ 39

1.52. JOBS ON MANPOWER SUPPLY BASIS .................................................... 40




1. PART – II : UNIT RATE JOBS

1.1. INTRODUCTION

1.1.1. These unit rates are for carrying out jobs not covered under

the lumpsum scope of work. The scope under this head

includes mobilization and supply of all items including

skilled manpower on round-the-clock basis with

supervision, all required equipment, tools and tackles,

consumables, transportation of all required materials from

HPCL’s warehouse or other designated areas

within/adjacent to the Refinery premises as well as

agency’s material etc required for carrying out the job in

totality unless otherwise specifically mentioned as under

HPCL’s scope. Rates for the jobs are given in PR lines.

1.1.2. For all items where rate payable is on the basis of inch dia,

this shall be on the basis of nominal dia of the pipe. In case

of any ambiguity, agency shall obtain all clarifications

prior to quoting. After placement of order, the

interpretation thereof and decision of HPCL shall be final

and binding on the agency.

1.2. BLINDING AND DE-BLINDING

1.2.1. Isolate various systems as advised by job engineer by

fabricating and installing necessary blinds. All required

blinds should be fabricated by the agency. Initially blinds

are to be installed in spread condition for steaming and

after steaming those are to be made-up fully. Remove

blinds as per job engineer’s advice and make up the flanges

with new gaskets. Approval of Operations and inspection

groups shall also be obtained before making up the flanges

with new gaskets.

1.2.2. Rate payable is per inch dia of blinding & de-blinding done.




1.3. PIPING REPLACEMENT

1.3.1. Job scope includes cutting to size, dismantling, edge

preparation, bending, welding, threading and laying above

ground/below ground/overhead on racks, painting etc at all

elevations. Replacement/repairs/ modification of pipelines

in the unit and all rundown lines in offsite locations for

different pressure and temperature ratings of all sizes &

schedules, flanges, orifice assemblies etc and all types of

fittings like elbows, reducers, tees, stubs, valves, corrosion

pads, RF pads, threaded parts etc as per the specifications,

drawings and instructions of Engineer-in-charge including

providing shoe supports to piping, hydro

testing/inspection of the replaced portion, scaffolding,

blinding, de-blinding and making arrangements for

flushing the lines as required are covered under this

scope and no additional payment shall be made for

these items. Payment for hydrotesting of un replaced

portion will be paid extra.

1.3.2. Cutting and removal of the old pipes and other associated

jobs is part of the job. Agency shall carryout replacement

of IBR piping using IBR approved welder with CS -

6010/7018 electrodes for butt joint and E 7018 for fillet

joint. For provision of piping as per schemes, agency shall

be provided drawings by HPCL. All connected civil works

of excavation, backfilling, dewatering, etc and pypkote

wrap coating shall be additionally payable under applicable

unit rate items.

1.3.3. Agency shall carryout all allocated works using either

electrical operated or diesel operated machines. HPCL

shall provide electrical power for carrying out works within

the unit battery limit but for works outside the unit battery

limit where electrical power source cannot be provided by

HPCL, agency shall mobilize adequate diesel operated

welding generators with source for lighting and grinding

machines. Additional rates are payable for carrying out




works using diesel operated machines which include all

costs towards operator, consumables such as diesel, engine

oils, etc., as per applicable unit rate items given in PR lines.

1.3.4. Agency shall use E-6010 electrodes for root weld, E-7018

for filler/final weld runs for butt-welding for CS pipes. E-

502/ER-502 electrodes shall be used for P5, E-505/ER-505

for P9, E-308/309/309 Mo /316/316L for SS piping.

1.3.5. For CS fillet joint E 7018 electrodes shall be used as per job

Engineer. For NACE piping agency shall use ER 70-S2

electrodes for root run and E 7018 for filler runs.

1.3.6. Suitable electrodes to be used for SS and AS welding in

other areas as per job Engineer. Root welds for all SS,

Alloy steel and Carbon steel NACE piping weld joint shall

be done using TIG welding. Agency shall mobilize TIG

welding set along with Argon gas and other consumables

for all SS & Alloy steel welding jobs.

1.3.7. Carryout wrap coating of 4mm thickness for underground

lines by sandblasting, application one layer of inorganic

zinc silicate primer, @ 65 DFT, subsequently apply 2

layers, each of 2 mm thick, "Pypkote" wrapping material,

as per manufacturer's guidelines. The agency shall carryout

spark testing of both the layers stage-wise and offer for

inspection, carryout repairs, if any, and obtain clearance.

Charges for sandblasting, painting, supply/apply of wrap

coating, spark testing including mobilization of spark

testing equipment, etc are included under this unit rate item

for wrap coating.

1.3.8. Charges towards DP Test, Radiography and stress relieving

will be paid separately on unit rate 1.4, 1.5, 1.6 & 1.7. In

case of any weld failure, the agency shall redo the entire

job at no extra cost.




1.3.9. Rate for provision of Reinforcement pads includes Air

testing of the RF pad after making all necessary

arrangements for the same and obtaining clearance from

Inspection. The rate for RF pads shall be payable for the

NB size of the branch piping. All replaced items shall be

sand blasted and painted as per attached specification for

painting of piping and steel structural items and are payable

as per respective unit rate item.

1.3.10. Agency to carryout sandblasting & one coat of primer paint

( under the inspection of HPCL Corrossion Cell group ) for

all replacements of piping including fittings prior to

installation. All piping and connected materials shall be

sand blasted to SA 2 1/2 of Swedish standard SIS 05-

5900-1967. HPCL Corrosion cell group shall inspect the

Sandblasting job and only on obtaining clearance from

Corrosion cell group, primer coat shall be applied. Offer to

HPCL for DFT checking after drying of Primer. Painting

specification to be followed as per annexure. The payment

for the same shall be made separately on Unit rate basis.

Further coats of paintings shall be applied by separate

agency deputed by HPCL corrosion cell.

1.3.11. For replacement of nozzles on equipment such as columns,

vessels, etc, agency shall gouge out the existing nozzles

with care or puncture the shell in case of provision of new

nozzle as marked by HPCL job engineer. Fabricate nozzle

pipe, offer fit up of the fabricated nozzle pipe to the

equipment obtain inspection clearance, carryout root

welding using E 7018 electrodes and offer DP test,

carryout back gouging and offer DP test, obtain inspection

clearance and carryout final welding.

1.3.12. Offer final welds for visual inspection and carryout box

hydrotest by welding of box inside the equipment. After

hydrotest remove the box and flush grind the burrs and

obtain inspection clearance. The rate payable under this

item covers the entire scope of this work. This item is




applicable only for the nozzle to the shell joint and for the

rest of the nozzle connected piping weld joints are payable

under piping works. Radiography/SR/RF pad for nozzle

shall be payable separately.

1.3.13. IBR PIPING

1.3.13.1. Fabrication, erection, welding, testing and painting of

IBR piping for various schemes in the unit is covered in

this. Scope of work includes all necessary coordination

for obtaining IBR approvals from CIB/DCIB for the

drawings and the job to be carried out as in piping as

applicable. Agency shall carryout replacement of IBR

piping using IBR approved welder with CS - 6010/7018

electrodes for butt joint and E 7018 for fillet joint. For

provision of piping as per schemes, agency shall be

provided drawings by HPCL.

1.3.13.2. Agency shall have a valid boiler repair certificate from

Director of Boilers, Andhra Pradesh.

1.3.13.3. Provide all necessary coordination with the Inspector

of Boilers to execute all jobs as detailed below to

complete the schemes. Obtain IBR approvals from

CIB/DCIB for the drawings and the job.

1.3.14. Rate payable is per inch dia

1.4. DYE PENETRATE TEST AND WFMPT

1.4.1. Carry out DP test and Wet Fluorescent Magnetic Particle

Test of welds as advised by Inspection department. Scope

includes all necessary equipments, materials, skilled

personnel, etc required to execute the work at all elevations

as per instructions of job Engineer. Only “MAGNA

FLUX” or P-MET” DP material is acceptable. Cleaning of

the area to be tested, by buffing, is part of the scope of

work.

1.4.2. Rate payable is per running foot length of DP test/

WFMPT done.




1.5. RADIOGRAPHY

1.5.1. Perform Radiographic inspection on all types

piping/equipment, which includes providing / hiring of all

necessary equipment and facilities to perform the work

safely as per instructions of Engineer. Radiographs shall be

submitted to Engineer-in-charge.

1.5.2. Repeat radiography due to defective technique, defective

films or radiography on repaired joints due to contractor’s

fault or due to poor performance of contractor’s welders

are not payable.

1.5.3. Rate payable is per running foot of film exposed.

1.6. STRESS RELIEVING OF WELD JOINTS

1.6.1. Carry out stress relieving of different weld joints as required

by HPCL. Agency shall provide all necessary equipments,

accessories and qualified personnel required to carry out

the job. Temperature recorders shall be calibrated at HPCL

Instrumentation workshop and record for the same shall be

obtained.

1.6.2. Agency shall start stress relieving jobs within 12hrs of being

informed of the job. Approval from HPCL Inspection shall

be obtained on stress relieving charts at site before starting

the job and after job completion. Agency shall carryout all

allocated works using either electrical operated or diesel

operated machines.

1.6.3. HPCL shall provide electrical power for carrying out works

within the unit battery limit, for works outside the unit

battery limit where electrical power source cannot be

provided by HPCL, agency shall mobilize adequate diesel

operated power source. Additional rates are payable for

carrying out works using diesel operated machines which

include all costs towards operator, consumables such as

diesel, engine oils, etc as per applicable unit rate items

given in PR lines.

1.6.4. Rate payable is for SR Done per Running foot length of

weld joint




1.7. ULTRA SONIC FLAW DETECTION TEST

1.7.1. Carry out Ultra Sonic Flaw Detection Test on equipments as

per Inspection. The scope includes mobilization of

equipment within 12hrs of informing, ASNT level 2

qualified technicians, with certificates, to carry out the job

round the clock, submission of written report on the

findings of the test to our Inspection Dept.

1.7.2. Rate payable is per 8hrs of UFDT job carried out at site

(minimum)

1.8. DROPPING AND REINSTALLATION OF VALVES

1.8.1. Scope includes opening the flanges and dropping of any type

of valves at any elevation, transporting the same to valve

section for servicing, transportation of valves back to the

job site, reinstallation with new gaskets etc. In case existing

valve requires replacement, new valve shall be drawn from

the Warehouse and transported to site apart from the above

activities. Any minor job like freeing up, gland pulling etc

shall be carried by the agency.

1.8.2. Rate payable is per inch diameter of valve

1.9. CS /SS OVERLAY PATCH WORK

1.9.1. Agency to carry out Inlay patch plate fabrication, welding

and testing of 5 to 8 mm thick CS/SS plate on Heater,

reformer, casing plate roof plate, floor plate at all

elevations as per Inspection. Scope of the job for Inlay

patch involves drawing materials from stores, marking,

cutting to size, fabrication to shape by rolling, bending etc

cutting the existing plate from the equipment, edge

preparation, fit up, root weld, DP test, back grinding and

DP test, full welding. Radiography will be paid extra...

1.9.2. Rate payable is Per Square foot of SS/CS overlay patch

for various thicknesses




1.10. CS /SS INLAY PATCH WORK


and testing of 8mm/12mm thick CS/SS plate on any

equipment or any pipe line at all elevations as per

Inspection. Scope of the job for Inlay patch involves

drawing materials from stores, marking, cutting to size,

fabrication to shape by rolling, bending etc cutting the

existing plate from the equipment, edge preparation, fit up,

root weld, DP test, back grinding and DP test, full welding.

Radiography will be paid extra.

1.10.2. Incase of inlay patch work for heater, reformer casing

plates ref item 1.26 for casing plates

1.10.3. Rate payable is per Square foot of inlay patch work

done

1.11. WELD BUILD UP JOBS

1.11.1. Scope of job involves grinding the surface and weld build

up using CS/SS electrodes for 3mm thick deposition after

finish grinding. DP test the weld deposited area after finish

grinding and obtain clearance from inspection. Flange face

rectification also to be carried out, if required.

1.11.2. The agency shall be paid only for 3mm thick weld

deposition. If however it has to be more than 3mm job

engineers approval is necessary before starting the job.

1.11.3. Rate payable is:

1.11.3.1. Per square inch for Carbon Steel with E-7018 /

ER70S2 electrodes.

1.11.3.2. Per square inch for Carbon Steel with E-7018-A1

electrodes.

1.11.3.3. Per square inch for Stainless Steel with E-

308/309/310-15 Electrodes




1.11.3.4. Per square inch for Stainless Steel with E-

309Mo/385/ 316/316L Electrodes.

1.11.3.5. Per square inch with Monel (E-NiCu-7)/90-10

Copper Nickel (E-Cu Ni) Electrodes.

1.12. WELD RUNS

1.12.1. Scope of the job involves grinding the surface and

providing weld runs using CS/SS electrodes/ Equivalent

Tig wire for 3mm thick deposition after finish grinding. DP

test the weld deposited area after finish grinding and obtain

clearance from inspection. Flange face ratification also to

be carried out, if required. Upto 5mm thick (finished) width

will be considered as single run, thereafter proportionate

multiple.


1.12.2.1. Per running foot for CS with E-7018 electrodes.

1.12.2.2. Per running foot of SS with E-308/309/310

electrodes.

1.12.2.3. Per running foot of SS with E-309Mo electrodes.

1.12.2.4. Per running foot of Monel with Monel electrode.

1.13. SCAFFOLDING

1.13.1. Agency shall provide system scaffolding wherever required

at all elevations. Scaffolding shall be erected with 1.5” dia

steel tubular pipe with suitable safe clamping arrangement.

Distance between adjacent vertical members shall not be

more than six feet and distance between adjacent horizontal

members shall not be more than three feet. At one or two

locations of the scaffolding erected, the distance between

horizontal members shall not be more than 1 ½ feet, so that

climbing is safe. Provide sufficient number of iron gratings

and tie with wire at each floor level of scaffolding. Detailed

scaffolding specifications and requirements are given in

annexures on scaffolding and safety which has to be strictly




adhered to. Rate to be inclusive of safety net, fire retardant

cloth wherever required.

1.13.2. Rate payable is per block of scaffolding (3M x 3M x

3M).

1.14. CEMENT LINING OF VESSELS

1.14.1. Carry out lining of vessels as per Job Engineer. Weld nuts

and tie with 2x2x12G mesh as advised. Cement to sand

ratio shall be 1:1. Apply FOSROC compound on the

cement-lined surface.

1.14.2. Rate payable is per sft of cement lining replaced .

1.15. REFRACTORY REPLACEMENT BY CASTING

1.15.1. This covers all jobs required for execution of

repair/replacement of internal refractory lining of Furnaces,

ducts, APH or any other area in the unit. The agency shall

furnish all the resources like skilled personnel, tools &

tackles, equipment and materials including all the

consumables etc except those specified under HPCL scope

of supply and carry out all jobs as per the given scope to

complete all jobs in their entirety.

1.15.2. The scope of job shall be as per the Annexure 4 –

Attachment 4.1 : Standard procedure for jobs on

heaters. Agency to use the approved agencies as per

standard attachment for carrying out the refractory jobs.

1.15.3. Rate payable is per Square meter area .

1.16. GUNNITING OF REFRACTORY WITH ANCHOR

REPLACEMENT

1.16.1. The scope of job shall be as per the Annexure 4 –

Attachment 4.1 : Standard attachment for heaters.




Agency to use the approved agencies as per standard

attachment for carrying out the refractory jobs.

1.16.2. Rate payable is per Square meter area

1.17. FABRICATION AND WELDING OF ANCHORS

1.17.1. Fabricate required number of new anchors for replacing

existing anchors using 3mm dia to 12mm dia SS 304/316

rods supplied by HPCL. Fabrication of anchors shall be

done by cold forming and no heating is permitted.

1.17.1.1. Rate payable is per anchor fabricated.

1.17.2. Grind out the existing damaged anchors and weld new

anchors as per drawing and specification. Chip out slag and

obtain inspection clearance. Install plastic caps supplied

HPCL on individual anchor legs.

1.17.2.1. Rate payable is per anchor welded.

1.17.3. After fabrication of anchors by cold/hot work, agency shall

carry out solution annealing prior to welding.

1.17.3.1. Rate payable is per batch of anchors solution

annealed.

1.18. BRICK LINING

1.18.1. The scope of job involves drawing insulating

bricks/refractory firebricks from warehouse or any other

designated location inside the refinery premises as advised

by the Engineer-in-charge, transportation of these materials

to the work spot. The agency shall ensure that refractory

material issued from HPCL warehouse is stored in a dry

place at the agency’s work shed.




1.18.2. The scope covers removal of insulating bricks /refractory

firebricks from inside Furnaces at all elevations.

Scaffolding required for carrying out the subject job is

included in the agency’s scope of work. While removal of

brick lining the agency shall recover all bricks that are in

good shape for reuse. Clean the surface of the casing plate

thoroughly, free from all scales, deposits etc by sand

blasting/power tool cleaning as advised by HPCL and offer

for inspection. Replacement of anchors if required shall be

carried out by the agency. On obtaining clearance from

HPCL Inspection, re-lay new insulating bricks/ Refractory

firebricks as per the drawing with or without mortar.

Cutting of bricks to shape if required is a part of agency’s

scope. The entire job is subject to stage wise inspection to

avoid any job delays.

1.18.3. Rate payable is per Cubic mtr area of job done for:

1.18.3.1. Brick lining without Mortar

1.18.3.2. Brick lining with Mortar

1.19. CERAMIC FIBRE BLANKET LINING

1.19.1. The scope of job involves drawing cerawool blankets,

hardware, Stainless wire etc from warehouse or any other

designated location inside the refinery premises as advised

by the Engineer-in-charge and transportation of the same to

the work spot. Mobilisation of hand lamps, step down

transformers (24V DC), Switch boards, lighting cables etc

required for carrying out these jobs inside various

equipment.

1.19.2. The agency shall remove all loose/damaged cerawool from

various locations & at all elevations in Furnaces etc as

advised by the Engineer-in-charge. Scaffolding required for

carrying out the job is included in the agency’s scope. On

obtaining inspection clearance fix back new cerawool

blankets in place using speed fix washers or any other

hardware as per the job requirement. Welding of anchors is

covered under the scope of the agency. Pack loose




cerawool wherever required as per the advice of HPCL

Inspection.

1.20. CERAMIC FIBRE MODULES REPLACEMENT

1.20.1. This item covers the replacement of Ceramic Fibre

Modules in the reformer radiant section walls and roof. The

scope of job involves drawing ceramic module. Anchor

studs etc from warehouse or any other designated location

inside the refinery premises as advised by the Engineer-in-

charge and transportation of the same to the work spot.

Mobilisation of hand lamps, step down transformers (24V

DC), Switch boards, lighting cables etc required for

carrying out these jobs inside various equipment.

1.20.2. The agency shall remove all loose/damaged ceramic

modules from various locations & at all elevations in

Furnaces etc as advised by the Engineer-in-charge.

Scaffolding required for carrying out the job is included in

the agency’s scope. On obtaining inspection clearance fix

back new ceramic modules under the guidance of

representative deputed by HPCL. In case of any studs

replacement the welding shall be paid under manpower

rates.

1.20.3. Rate payable will be per square meter area of module

replacement.

1.21. REPLACEMENT OF THERMO COUPLES

1.21.1. Carry out replacement or welding of new Skin Thermo

couples of Heater Tubes in kind as advised after the

inspection. Scope includes scaffolding, grinding and

removal of existing thermocouple carefully, cleaning the

pad by grinding and buffing, welding of new thermo

couple as per Job Engineer. The job shall be carried out

win close coordination with HPCL’s Instrumentation

department. Carry out DP test of the weld and obtain

clearance from Inspection department. Care shall be taken

not to damage the tubes and refractory while carrying out




the job. Inconel electrode & filler wire for TIG welding is

in vendor’s scope.

1.21.2. Rate payable is per Thermocouple replaced.

1.22. HYDROTEST OF HEATER TUBE PASSES

1.22.1. Scope includes all necessary jobs required to carry out

Hydro testing of Heater Tube coils at specified pressure.

This is only for additional hydrotesting of passes after

repair (If damage was observed during the previous

hydrotest and the joint had not been attended by the agency

before that hydrotest)

1.22.2. Rate payable is for hydro testing of

1.22.2.1. One pass of Hydrocarbon coil of any heater

1.22.2.2. One pass of steam coil

1.23. REPLACEMENT OF REFORMER TUBES.

1.23.1. This item covers the replacement of reformer catalyst tubes

as per inspection advice.

1.23.2. Scope involves cutting and removal of damaged tubes,

transportation of new tube assemblies from warehouse to

site, installation of the tube assembly and alignment and

welding to the pigtails.

1.23.3. This rate is applicable only if the tubes have been replaced

with new ones. For any repairs done to the weld joint the

payment shall be made under inch dia of welding done.

1.23.4. Scope of work also includes edge preparation, stage wise

DP test, radiography, pre& post weld heat treatment and

radiography after PWHT.

1.23.5. Remove the roof & related obstructing structures at the

tube location for crane accessibility. Ensure to provide firm

support to the dismantle structural supports by fixing

temporary supports.

1.23.6. Repair the existing weld joints as per Inspection including

grinding out the defect, D.P. testing, weld repairs,

radiography, stress relieving, radiography after S.R. etc





1.23.7.1. Per tube replaced ( inclusive of cutting and welding,

NDT and heat treatment)

1.23.7.2. Per inch dia of the welding repairs carried out for joint

previously not attended by the agency.

1.24. REPLACEMENT OF REFORMER PIGTAILS

1.24.1. Scope involves cutting and replacement of reformer inlet

pigtails located above the roof section and outlet pigtails

located below the floor of the reformer.

1.24.2. The job to be done as per HPCL inspection advice

1.24.3. The job involves cutting and removal of damaged pigtails,

transportation of new pigtails from HPCL warehouse to

site , installation in position and carrying out welding.

1.24.4. Scope of work also includes edge preparation, stage wise

DP test, radiography, pre& post weld heat treatment and

radiography after PWHT.

1.24.5. Rate payable will be :

1.24.5.1. Per inlet pigtail replaced inclusive of welding, NDT

and heat treatment.

1.24.5.2. Per outlet pigtail replaced inclusive of welding &

NDT

1.25. FABRICATION & INSTALLATION OF BURNER

COMPONENTS

1.25.1. Fabricate and replace in kind various components like

primary and secondary barrels, burner bottom plate, Regen

tile casing plate, etc for burners and retainer plates around

Man ways. Scope of the job involves dismantling the

damaged component of the burner, drawing materials from

stores, marking, cutting to size, rolling, bending, mock

assembly, fit up, fabrication and reassembly of various

components. Cut and remove existing damaged

components. Fabricate, weld and install new components

using 3mm thickness stainless steel plate of SS 304 / 316 /

410 metallurgy, to exactly match the original dimensions.




Job shall be carried out with stage wise inspection

clearance.

1.25.2. Rate payable is per sq.ft of plate replaced of the

component.

1.26. REPLACEMENT OF BURNER BLOCK (SET)

1.26.1. The scope of job involves drawing burner tiles from

warehouse or any other designated location inside the

refinery premises as advised by the job engineer,

transportation to the work spot and installation. In case part

or all of the burner block segments have to be re-used,

remove the same carefully and keep in a secure place. The

agency shall ensure that enough care is taken while

handling & transportation of these materials to the work

spot to avoid any damage.

1.26.2. The job scope covers removal of existing damaged burner

blocks without damaging the segments in good condition.

Clean the area thoroughly free from all loose refractory

materials and offer for Inspection. After carrying out

repairs to floor plate if any, obtain clearance from

inspection, fix new burner blocks in position. Carry out

alignment of the assembly and offer to TSD/Inspection

sections and obtain approval. One set comprises of many

tiles in segments forming a complete block per burner.

1.26.3. Rate payable is per burner set

1.27. REPAIR/ REPLACEMENT OF SS PERFORATED

SHEETS

1.27.1. Repair/replace the oxidized and buckled perforated

Stainless steel sheets of Plenum boxes of all burners (each

burner has one panel of perforated sheet on all four sides) .

Grind and remove all the existing damaged perforated

sheets lining the acoustic insulation of the Plenum boxes.




Straighten the removed panels of SS perforated sheet and

offer for inspection. Discard all panels that cannot be

reused. Recover the reusable panels after carrying out

necessary repairs. Replace the damaged panels using new

2mm thick SS316 perforated sheets. Straighten the base

plates of the Plenum boxes made of CS plates primary and

secondary guides. Line the plenum boxes with 25mm thick

Ceramic wool and install the perforated sheet panels. Weld

the perforated sheet panels in place. Obtain stage wise

clearance from HPCL’s inspection.

1.27.2. Rate payable is per sq.ft of perforated plate replaced.

1.28. ORIFICE PLATE

1.28.1. The scope includes dropping of orifice plates as per job

engineer and hand over it to Operations. Agency shall

match mark the plate before opening the bolts. Install the

plates under Maint- Instrumentation guidance with proper

gaskets and ensure proper direction.

1.28.2. Rate payable is 1.5 times the rate for gasket replacement

1.29. REPLACEMENT OF CEMENT LINED PIPES

1.29.1. Scope includes cutting and removal of existing

underground and above ground cement lined piping works

including piping and fittings, trimming of pipe edges after

cutting to size, fabrication of collars, complete welding of

fabricated collars on to the pipe joint after fit up, including

welding of all connected fittings such as flanges, tees,

mitres, reducers, RF pads, etc. Fabrication of collar shall be

as per EIL class J5A and Corolac resin shall be applied on

the inside of the collar and outside surface of the pipe

before welding. While welding the collars, care to be

taken, such that resin (Corolac) is not heated beyond

100deg.c. All associated civil works shall be carried out by

the agency under part III unit rate items for civil works.




Civil works and pypkote wrap coating shall be additionally

payable under respective unit rate items. HPCL shall

provide electrical power for carrying out works within the

unit battery limit, for works outside the unit battery limit

where electrical power source cannot be provided by


power source. Additional rates are payable for carrying out



oils, etc. as per applicable unit rate items given in PR lines.

Cement lined pipes shall be supplied by HPCL.

1.29.2. Rate payable is per inch dia meter (inch dia per meter

length) pipe replaced.

1.30. FABRICATION OF MITERS/REDUCERS

1.30.1. Scope includes fabrication of miters/reducers as per EIL

specification 7-44-33 / 7-44-485/ 487 . HPCL's scope of

supply is limited to piping material only. HPCL shall

provide electrical power for carrying out works within the

unit battery limit, for works outside the unit battery limit

where electrical power source cannot be provided by


power source. Additional rates are payable for carrying out



oils, etc as per applicable unit rate items given in PR lines

1.30.2. Rate payable is

1.30.2.1. Per inch dia of miter joint

1.30.2.2. Per inch dia of bigger end of reducer fabricated

1.31. CEMENT LINING OF PIPES, FITTINGS, MITRES,

BENDS AND SPECIALS

1.31.1. Agency shall collect the bare specials from any designated

location within the refinery and transport to the works for




cement lining within or outside the refinery. Clean the

surface internally free of rust, dust, scales, etc prior to

cement lining by sandblasting or manual means and

carryout cement mortar lining as below.

1.31.2. The cement lining shall be suitable for transporting sea

water, brackish water upto 65degC at 10 kgs/cm2.

1.31.3. The cement mortar material of sand shall confirm to IS

383, cement to IS 1489 and fresh, clean water free from

any foreign materials like oil, acid, alkali, salt or organic

matter.

1.31.4. The density of mortar shall be sufficient not to leave voids

so as to achieve water tightness and also adhere firmly to

the pipe surface. Cement sand ratio shall be 1:1.5 upto 6

mm thick and 1:1 above 6 mm thick. Water cement ratio

shall be between 0.3-0.4.

1.31.5. Finished mortar lining shall be free from any honey

combing, cracks and irregularities.

1.31.6. Pipes, Fittings, mitres, bends, specials, etc shall be properly

lined with cement concrete lining by manual applications /

toweling etc.

1.31.7. For pipe dia meters 8" and above, cement lining of miters,

fittings and specials shall be done after welding of MS nuts

at a pitch as per HPCL recommendations and tying of 16

gauge wire mesh to the nuts all along the area to be lined.

This is for reinforcement and for proper adhesion of

cement lining on to the metal substrate.

1.31.8. Cement lining thickness shall be as given below. 1.31.8.1. Size 2" to 10" NB thickness shall be 6mm with

tolerance of + 3 /- 1.5mm.

1.31.8.2. Size 12" to 22: NB thickness shall be 8mm with

tolerance of + 3 / - 1.5mm.

1.31.8.3. Size 24" to 36" NB thickness shall be 10mm with

tolerance of + 3 / - 1.5mm.

1.31.8.4. Size above 36" NB thickness shall be 13mm with

tolerance of +3 / -1.5mm.




1.31.9. Curing: Water / LP steam curing of cement mortar lining

shall be commenced after lining gets set. Curing shall be

done for a period not less than 14 days. Mortar shall be

allowed to dehydrate.

1.31.10. Finishing: The mortar lining shall be straight smooth,

dense, hard and free from honey combing, cracks,

irregularities etc. Mortar lining shall be inspected and

approved by HPCL. If any defects are found, the same

shall be rectified, removed or replaced by the contractor at

no extra cost.

1.31.11. Rate payable is per

1.31.11.1. Inch dia mtr of cement lining of

pipes/fittings/mitres/specials by water curing

1.31.11.2. Inch dia mtr of cement lining of

pipes/fittings/mitres/specials by steam curing.

1.32. CS CASING PLATE REPLACEMENT


and testing of 5 to 8 mm thick CS plate on Heater,

reformer, casing plate roof plate, floor plate at all

elevations as per Inspection. Scope of the job for Inlay

patch involves drawing materials from stores, marking,

cutting to size, fabrication to shape by cutting the existing

plate from the equipment, edge preparation, fit up, root

weld and DP test, full welding. Radiography will be paid

extra.

1.32.2. Rate payable is per Sq Foot of replacement done

1.33. STRUCTURAL WORKS

1.33.1. Agency shall carry out structural steel plates repair /

replacement works like providing Monorails, additional

ladders, replacing old ladders, staircases, gratings, railings,

platforms, chequered plates, etc as directed by the




engineer-in-charge during the T&I. This includes removal

of the old structural if required, fabrication, erection,

welding of the above mentioned structural using channels,

angles, I beams, flats, chequered plates, rounds, handrailing

pipe & GI / Electro forged gratings etc at all elevations

Agency shall carryout all allocated works using either

electrical operated or diesel operated machines. HPCL

shall provide electrical power for carrying out works within

the unit battery limit, for works outside the unit battery

limit where electrical power source cannot be provided by


welding generators with source for lighting and grinding

machines.

1.33.2. Agency shall also be required to carryout structural works

at various locations as per scope given above including the

supply of material. Agency shall procure and supply

material of quality IS 2062 / IS 226, make SAIL, TISCO,

IISCO, RINL, from reputed vendors, including

transportation to site, handling, etc. Re rolled grade of

material shall not be accepted. This material shall be

procured on written advice by HPCL only. Agency shall

arrange for the material within a maximum of 4 days from

the date of HPCL advice. The material will required to be

weighed in the refinery weighbridge and payment shall be

made against submission of the weighment slip duly

certified by job engineer. Agency shall submit the MTC of

the structural material duly endorsed by the supplier.

1.33.3. Agency to carryout sandblasting & one coat of primer paint

( under the inspection of HPCL Corrossion Cell group ) for

all replacements of structurals prior to installation. All

structurals shall be sand blasted to SA 2 ? of Swedish

standard SIS 05-5900-1967. HPCL Corrosion cell group

shall inspect the Sandblasting job and only on obtaining

clearance from Corrosion cell group, primer coat shall be

applied. Offer to HPCL for DFT checking after drying of

Primer. Painting specification to be followed as per

annexure. The payment for the same shall be made

separately on Unit rate basis. Further coats of paintings




shall be applied by separate agency deputed by HPCL

corrosion cell

1.33.4. Additional rates are payable for carrying out works using

diesel operated machines which include all costs towards

operator, consumables such as diesel, engine oils, etc., as

per applicable unit rate items given in PR lines. Staging

required for the job is to be arranged by the agency.

1.33.5. Rate payable is per

1.33.5.1. Metric Ton of finished structure installed & welded,

with HPCL material supply.

1.33.5.2. Metric Ton of finished structure installed & welded,

with agency material supply.

1.34. RELIEF VALVES

1.34.1. Dropping and reinstallation of relief valves other than 96

nos valves mentioned in the Lumpsum scope, is covered

under this.

1.34.2. The jobs shall be carried out as given in the attachment for

Relief Valves.

1.34.3. Rate payable is per inch diameter of the relief valve

removed & re-installed. Relief valve outlet flange size is

considered for measurement of Inch dia

1.35. LEVEL GAUGES

1.35.1. Carry out Removal, transportation and re-fixing of gauge

glasses other than the 59 nos mentioned in the Lumpsum

scope on various equipments in the unit as per scope of

work given in the attachment for Level Gauges.

1.35.2. The rate payable is:

1.35.2.1. For each level gauge (size < or equal to 2 segments)

1.35.2.2. For each level gauge (size >2 and < or equal to 4

segments)




1.35.2.3. For each level gauge (size >4 and < or equal to 6

segments)

1.36. CIVIL WORKS

1.36.1. Carryout the following civil works in the unit in order to

attend to related mechanical works such as underground

piping replacement, etc:

1.36.2. Excavation: Earth work in excavation below ground levels

for all kinds of works in foundations including trenches,

pavements, footings etc., in all types of soils including all

labour, material, dressing of sides, leveling, grading and

ramming of bottoms, pumping and bailing out rain or sub-

soil water, disposal or stacking of surplus excavated

material within a lead of 50M etc., complete for the line

trenches.

1.36.2.1. Rate payable is per cu.mtr

1.36.3. Backfilling: Back filling after execution of the work to

proper grade and level with selected materials from

available excavated soil from soil heaps within a lead of

50M, including re-excavating the deposited soil excavated

earlier, breaking clods, laying at all depths and heights in

layers of thickness not exceeding 15 cms, watering and

ramming to compaction, dressing etc. complete in

foundation, plinth, trenches etc.


1.36.4. Transportation: Transporting the surplus earth and debris

from construction area beyond the initial lead of 50M

including re-excavating the deposited soil excavated

earlier, transportation, loading, unloading, laying at all

depths and heights, stacking, levelling and dressing both

the areas (viz., from where the earth is transported and

where it is deposited) to the required levels and slopes




complete with all lifts as directed up to a lead of 2.0

KM.from the line trenches.


1.36.5. RCC dismantling: Dismantling of RCC work for all

heights /depths including disposal of unserviceable

material within a lead of 50m and handing over

reinforcement / steel to the scrap yard as directed by the

Engineer-in-charge including all labor, tools for demolition

etc., complete.


1.36.6. Sand filling : Supplying and filling sand of approved

quality under floors, in foundation and plinth etc.,

including the cost of sand, transportation for all leads,

loading, unloading spreading in layers of 15 cm thickness

at all depths, watering, ramming, compacting to required

depth, leveling etc., complete.


1.36.7. RCC works: Supplying and laying Reinforced Cement

Concrete (RCC) 1:11/2:3 (1: cement :11/2 sand : 3 HBG

metal of 20 mm nominal size) including, mixing, placing,

compacting, including neat cement finishing, curing etc.,

complete as per IS:456:1978, in foundations & pits / sumps

for all depths, footings, plinth beams, pavements etc.,

complete including hacking of old concrete surface if any

(excluding shuttering and reinforcement).


1.36.8. HBG metal filling: The scope includes cost of HBG metal,

royalities, transportations to site for all leads and lifts

including loading, unloading spreading in layers all

complete as per job engineer.





1.36.9. Reinforcement steel: Supplying and fixing in position

high yield deformed bars reinforcement conforming to

IS:1786 for RCC works including cost of steel,

transportation, straightening, cutting, bending to the

required shapes as per details, binding with 16 SWG black

soft annealed binding wire, placing with proper cover

blocks, supports, chairs, spacers etc., for all heights and

depths as per the directions of the engineer-in-charge.

1.36.9.1. Rate payable is per MT

1.36.10. Centering and shuttering: Supplying and providing

centering and shuttering with approved plywood / steel

sheets including strutting, propping to the required levels

and sizes and removal of form work etc., complete for

footings, columns, beams, lintels, chajjas, slabs, trenches

etc., all levels.

1.36.10.1. Rate payable is per sq.mtr

1.36.11. Grouting: Providing grouting/repairs to the existing

deteriorated/ improper slope / cracked grouts of base plates

/ anchor bolts on pedestals / columns including the

removal of cracked / deteriorated grouts, cleaning the

surface by removing oil, grease etc and grouting using

non-shrink high strength grout of CONBEXTRA GP1 of

FOSROC mixed with coarse aggregate (HBG metal of

10mm down size) 50% by weight or equivalent approved

by the Engineer-in-charge including shuttering, finishing,

all equipment, skilled manpower, consumable etc.

complete.

1.36.11.1. Rate payable is per cu.mtr.

1.36.12. Shoring: Providing and installing approved type of

"SHORING AND STRUTTING" for all depths to retain

earth including dismantling and removal of the same etc.,




from site after completion of work etc., all complete as

directed by Open Timbering method.

1.36.12.1. Rate payable is per sq.mtr.

1.36.13. Dewatering: Agency shall supply diesel operated

dewatering pumps of capacity 5 HP/10 HP including all

consumables such as diesel, operator, sufficient length of

hoses with foot valve, to facilitate uninterrupted welding

works. The pumps should be fitted flame arrestors.

1.36.13.1. Rate payable for per hour

1.36.14. Fireproofing

1.36.14.1. Agency shall carry out fireproofing of assigned areas

including chipping out of old fireproofing, applying

single coat primer, laying of wire mesh, applying of

vermiculate cementitious compound, curing compound

and application of fire retardant paint.

1.36.14.2. Rate payable per cu m of fireproofing done.

1.37. CHANNEL SECTION PARTITION PLATE REPAIRS

1.37.1. Scope of the job involves drawing material (10/12 mm

thick CS) from stores, marking, cutting to size, cutting the

existing plate to be replaced, edge preparation, fit-up, root

weld, full welding, DP test. Partition plate replacement

may be sectional or full and agency shall be prepared for

the same. Includes removal of existing lining and cleaning,

offering for Inspection. This scope includes sectional

replacement of shell plate (inlay patch). Rolling of

replacement plate to match shell contour is part of the

replacement job.

1.37.2. Stiffeners shall be welded to avoid distortion. and grinding

after completion.

1.37.3. Welding per foot is inclusive of top and bottom welding (

Double "V" welding).




1.37.4. Carry out weld repair on the existing partition plate weld

joints with specified electrodes as instructed by the job

engineer. This shall cover the additional build up on the

existing joints after necessary cleaning, buffing, grinding,

DP testing with all consumable and equipment in agency's

scope.

1.37.5. Weld build up : In case of weld build up of pits, 8 nos of

weld bulid up of pits will be considered as one Rft for

compensation. Flush grinding is part of the scope.

1.37.6. Payment for weld repairs are quantified in terms of Rft of

weld completed in its entirety and not the no. of weld runs

to achieve the quality.

1.37.7. Rate payable:

1.37.7.1. Per running foot of finished weld joint for plate replacement.

1.37.7.2. Per running foot of finished weld joint for weld

repairs.

1.38. REPLACEMENT/ REPAIRS OF LINER PLATES

1.38.1. Scope of the job includes grinding out the defective liner

plate, thorough cleaning the base plate by buffing, drawing

3mm thick new liner plate from ware house, fabrication of

new liner plate to size including rolling, fit-up, welding,

DP test and air test. Liner replacement can be sectional or

total, agency shall be prepared to carry out the same.

1.38.2. Electrodes - Er Cu Ni Al for Nickel Al Bronze

lining

1.38.3. E Ni Cu 7 for monel lining

1.38.4. All replacement and repairs against this scope shall be

carried out by TIG welding only.

1.38.5. As for testing of iron absorption in monel welding,

Potassium ferro cyanide test shall be carried out by the

agency. In case of absorption more than allowable, agency




shall redo the welding at that location after required surface

preparation at no extra cost.

1.38.6. Rate payable is per running foot of finished weld joint

1.39. LINING FOR EXCHANGER COMPONENTS

1.39.1. Carry out FRE or FRP lining (3mm thick) of exchanger

components and tube sheets as per standard specification

and advise of Job Engineer. Area for measuring lining on

tube sheets includes the tube holes

1.39.2. Supply and application of cold compound for protection of

Tube sheets and glass flake epoxy coating on the

components for the specified coolers and Condensers.

Necessary sand blasting / power tool cleaning / sand

blasting for surface preparation of the area to be coated and

application as per the specifications given below. For the

purpose of calculation the area where compound is not

applied, the same shall not be considered for payment, such

as tube holes, etc.

1.39.3. Brushable ceramic coating Specification:

1.39.3.1. The cold compound application shall be done on the

tube sheet locations after the Shell test of the respective

cooler has been completed.

1.39.3.2. Agency to follow surface preparation , base coat

preparation and top coat application as per

manufacturers standard procedure.

1.39.3.3. For surface preparation, agency to carry out sand

blasting.

1.39.3.4. During sand blasting for surface preparation, all

necessary care shall be taken to ensure that work in the

surrounding areas is not affected and sand/grit does not

fly on to other equipments. The whole area shall be

covered using Tarpaulin. Each Tube shall be plugged to

avoid sand getting deposited inside the Tubes. After

sand/grit blasting is completed, the entire area and the

exchanger shall be thoroughly cleaned of all sand and




other debris. In case of power tool cleaning care should

be taken not damage the tube ends projecting from

tubesheets. Compound to be supplied by the agency.

The following are the approved makes for supply and

application of cold compounds along witht eh surface

preparation required.

1.39.3.4.1. ITW Devcon: Surface preparation : Blast cleaning

Base coat : Titanium putty ~ 1.2mm thk.

Top coat ( 2 coats) : Brushable cerami lining ~

0.8mm thk.

1.39.3.4.2. Belzona Surface preparation: Blast cleaning

Base coat: Belzona-1511 ~ 2mm thk

Top coat: Belzona 5891 ~ 0.25mm thk.

1.39.3.4.3. Sentinel

Surface preparation:Blast cleaning

Base coat: Epxylon Titanium reinforced putty- 9104

~ 1.2mm thk.

Top coat: Wear Tuff brushon-9201 ~ 1mm thk.

1.39.3.4.4. Demech Surface preparation: Blast cleaning

Base coat: Koroguard primer- 0.25mm thk

Top coat: Koroguard -GF - 2.0 mm thk.

1.39.3.5. Rate payable is per sq foot of FRE/FRP lining done.

1.39.3.6. For cold compound application rate payable is per Sq.

meter of application done.

1.39.4. Glass flake epoxy coating specification:

1.39.4.1. Surface Preparation: Abrasive Blast Clean to Sa2.5

using non-sparking sieved copper slag of uniform size

conforming to SSPC-SP-10

1.39.4.2. Coating System: One coat of two component glass

flake filled high build self priming epoxy coating of @

100 microns / per coat, followed by 2 coats of two

component solvent free high build glass flake filled




epoxy coating @ 200 microns DFT per coat = 2X 200

microns DFT = 400 microns. Total DFT =500 microns

minimum

1.39.4.3. Recommended manufacturers and paints

Sl.

no.

Manufacturer's

Name

Surface tolerant

polyamine cured self

priming epoxy coating

Solvent free / high build

polyamine cured glass

flake filled epoxy coating

1. M/s. Akzo Nobel

Coatings

Interplus 256 Interzone 505

2. M/s. Sigma Coatings Sigma Cover primer Sigma cover TCP / CSF -

Glass flake

3. M/s. Jotun Paints Jota mastic 87 primer Marathon

4. M/s. Berger Paints

Ltd.

Portectomastic Epilux super build Glass

Flake epoxy

5. M/s. Kirloskar

Brothers

Plasmet ZF Plasmet ZE

6. M/s. Chemtreat India

Ltd. (Atlas Minerals

& Chemicals Corp.

USA)

Chempruf Epoxy

primer

Chempruf 121 primer

7. M/s. Winn & Coales

(Denso) Ltd.,

England

Archo - Rigidon System

1.39.4.4. Guarantee: The agency shall provide guarantee for

trouble free and good performance of the coating for a

period of 3 (three) years. Any damage to the coating

and/or components due to failure of the product shall be

repaired by the agency free of cost.

1.39.4.5. Rate payable is per sq mtr of coating done.

1.39.5. Note: For the purpose of calculating the area under all items of

14, only the area where compound is applied shall be

considered. The area where compound is not applied shall not

be considered for payment, such as tube holes, etc. Further, for

calculating area of the coating, total thickness of the finished

coating shall be considered and not the area of the individual

coats.




1.40. RETUBING OF EXCHANGERS/ COOLERS

1.40.1. RETUBING: Inspection Engineer will mark the tubes that

require replacement. Pull out the marked tubes using Jenny

puller. Cut three sections (both ends and middle) of two

tubes into pieces of one-foot length. Split the tubes axially

into two halves and hand over to Inspection Engineer.

Clean the Tube sheet Holes and the serrations inside them.

Offer for Inspection. Agency shall record and submit the

internal diameters of tube sheet holes using a calibrated

dial gage. The tube shall be identified in the record basis

row and tube number. Insert new tubes of required

specification into the Tube Holes. Roll and expand the tube

ends into the tube sheet grooves as per Job Engineer. Scope

includes supply of all necessary equipments and

accessories to execute the job. New tube will be supplied

by HPCL. In case of requirement for 100% re-tubing of

any bundle, cutting and removal the old tubes, removing

the tube stubs from the tube sheets and baffles, cleaning

and offering the tube sheets and cage for Inspection and re-

tubing etc are part of the job scope.

1.40.2. For welded tubes rates for fillet weld & NDT shall be paid

extra.

1.40.3. Rate payable is per tube replaced by re-tubing.

1.41. MACHINING OF GASKET FACES OF CHANNEL

SECTIONS OUTSIDE REFINERY

1.41.1. Agency shall transport components such as channel

sections/ shell covers of diameter greater than 1 meter,

whose gasket faces are to be machined to a reputed

machine shop, arrange to machine gasket faces and bring

back them. Agency is responsible for safety of the

components. Amount shall be deducted from bills of

agency, in case of any damages to the component.

1.41.2. Rate payable is per gasket face machined for various

dia.




1.42. REPEAT SHELL TEST AND TUBE TEST ON

EXCHANGERS

1.42.1. Repeat Shell test and Tube test on exchangers in case Tube

leak is found during Tube test or during Shell cover test on

any exchanger at the specified test pressure. The procedure

for the tests is given under I.A.1 of lump sum job scope.

1.42.2. Rate payable is per Shell/Tube/Shell Cover repeat test

carried out

1.42.2.1. For exchangers of Shell diameter less than 900mm

1.42.3. For exchangers of Shell diameter more than 900mm

1.43. HYDROTESTING OF PIPING

1.43.1. Carryout hydrotesting of loops (other than loops given in

lumpsum, if any) and other piping sections as advised by

the job engineer. The agency carryout jobs as per the

attachment for Hydrotesting .

1.43.2. Separate rates shall be payable for blinding/deblinding,

scaffolding, valve dropping under the respective unit rate

items for hydrotesting jobs.

1.43.3. Rate payable is per inch dia. meter (inch dia x meter

length).

1.44. GASKET REPLACEMENT

1.44.1. This unit rate is for replacement of all gaskets that does not

form a part of the Lumpsum scope like jobs as per HPCL-

Operations etc.

1.44.2. Replace gaskets of various flanges as per instruction of job

Engineer. Open the existing flange joint by removing the

bolts, wedge gap between the flanges, clean the flange

gasket face free of all foreign particles, offer new gasket to

Inspection and obtain approval, insert new gasket between

the flanges and make up the flange after obtaining approval

from Inspection and Operation Engineers.

1.44.3. Rate payable is per inch dia of piping

1.45. SUCTION STRAINERS CLEANING




1.45.1. The job involves removal of strainer, cleaning thoroughly,

carry out minor repairs, if any and after clearance from job

engineer fix back the strainer along with gasket

replacement.

1.45.2. Rate payable is per inch dia (Pipe NB Dia)

1.46. DROPPING & RE-INSTALLATION OF CONTROL

VALVES

1.46.1. : Drop control valves on Hydro test loops before

pressurizing the system. Coordinate with HPCL’s

Instrumentation department for disconnection of cables,

Copper tubing etc. All the control valves shall be dropped

and transported to Instrumentation section & back to site

under the Maint-Instrumentation supervision. Reinstall the

control valves after Hydro test. Care shall be taken not to

damage any components during dropping, transportation

and re-fixing of control valves. This entire job to be done

under HPCL instrumentation including certification of

challans.

1.46.2. Rate payable per Inch Dia of Control Valve

1.47. TRAY/DOWN COMER/SEAL PAN REPLACEMENT IN

COLUMNS

1.47.1. Scope of work covers jobs to be executed for re-

fixing/replacement of any dislodged/damaged segment of

tray/ down comer/seal pan.

1.47.2. Number the tray segments and down comers for

identification as per drawing. Remove all fallen, displaced,

distorted tray segments. Open all the clamps of the tray

segments, weir angles etc to be repaired/ replaced. Remove

the segments and bring them to ground level, if required,

for repairs.

1.47.3. Service all tray clamps wherever the tray segments, down

comers are removed and replace the damaged ones.




Recover all the tray valves that can be reused. Fix new tray

valves that are missing.

1.47.4. Straighten tray segments, down comer plates, angles etc. if

they can be reused as per Inspection. In case the distorted

segments cannot be repaired, draw new segments from

warehouse and bring to site.

1.47.5. Assemble the down comer plates, seal pans, tray segments

etc. in position along with the overflow weir angle and

clamps as per drawing. Minor modifications that may have

to be carried out to make the new tray segments to suit the

field conditions shall be carried out by the agency at no

additional cost. Agency shall mobilize required drilling

machines for modification of mismatched bolt holes while

assembling new and old tray segments, to suit to field

conditions

1.47.6. Ensure proper overlap and alignment is maintained as per

drawing on segment- to-segment joint while fixing.

Agency shall co-ordinate with Operations and Inspection

departments for obtaining necessary stage wise approvals.

1.47.7. Tray segments adjacent to damaged/ fallen trays which

have to be removed and re-fixed to facilitate removal and

reinstallation of the damaged trays will also be considered

for payment under this category. No additional payments

shall be made for removing, repairing and re-fixing weir

angles and support angles of trays.

1.47.8. Rate payable is per square meter of tray removed, repaired/

replaced and reinstalled.

1.48. VALVE RECONDITIONING

1.48.1. The scope of the job involves servicing of the valves of

different sizes and ratings in the DHDS unit insitu or at a

servicing yard by the agency.

1.48.2. The agency shall mobilise adequate manpower along with

all tools & tackles, equipment like lapping machine, test

bench along with supervision to execute the jobs.




1.48.3. In case of non availability of spares alternate spares like

hand wheels, etc shall be recovered from other valves

available at site and replaced.

1.48.4. The job is subject to stage wise inspection by HPCL.

Agency shall maintain a book for all the valves

reconditioned with a record of the valve size, rating, type

of repair attended duly endorsed by HPCL representative.

All repaired valves shall be tagged by agency with a metal

strip with date and company name.

1.48.5. Valve servicing without opening bonnet.

1.48.5.1. Dismantling of the gland follower, removal of entire

old existing packing. Thorough cleaning/polishing of

the spindle and inspection. Replacement of total gland

packing by cutting rings from packing material. Re-

assembly of gland. Free-up the valve as required.

1.48.6. Valve servicing opening the bonnet

1.48.6.1. Opening of the valve bonnet, dismantling of gland

follower, removal of entire old existing packing.

Thorough cleaning of all internals like spindle, yoke

bush, sleeve, etc, servicing of all bolts and inspection.

All repairs like lapping and blue matching, weld build

up at grooved/pitted locations, grinding and servicing of

bonnet gasket surface, gate, seat.

1.48.6.2. Replacement of total gland packing. Re-assembly of

valve, after replacing the bonnet gasket. Free-up the

valve as required. Agency shall mobilize the required

gaskets for the bonnets.

1.48.6.3. Agency on dismantling the valve shall immediately

indicate to HPCL the dimensions of the bonnet gasket

and make arrangements to procure the same within 72

hrs. the same has to be procured from approved gasket

manufacturers only. It may be noted that these are non

standard gaskets and their dimension and MOC shall be

obtained and sketch made only after opening the

bonnets. To ensure close co-ordination and availability




of gaskets in time, the agency shall station a person at

the gasket manufacturer’s factory.

1.48.7. Rate payable is

1.48.7.1. Per each valve of various sizes (all ratings)

serviced without bonnet opening.

1.48.7.2. Per each valve of various sizes (all ratings) serviced

with bonnet opening and bonnet gasket replacement.

1.48.8. Other miscellaneous jobs on valves which are not covered

under the above scope such as valves freeing up, cleaning

of valve spindle / bushes free of sand and foreign matter &

greasing, replacement of damaged hand wheels in the

location, replacement of damaged gland follower eye bolts,

etc as advised by the job engineer etc shall be

compensated on manpower basis.

1.49. IN-SITU MACHINING

1.49.1. This covers the machining of the flange faces Insitu using

flange facers. Rate is inclusive of mobilization of necessary

flange facers and manpower.

1.49.2. Rate payable is per inch dia of flange machined.

1.50. POSITIVE MATERIAL IDENTIFICATION

1.50.1. Scope involves usage of portable alloy analyser for

checking metallurgy of pipes, plates tubes etc. The PMI

portable alloy analyzer instrument shall measure alloy

compositions of common elements like Silicon,

Manganese, Chromium, Nickel, Molybdenum, Iron,

Tungsten, Vanadium, Niobium, Tantalum, Titanium,

Copper, Aluminum, Zinc, Tin, Antimony, Sulfur,

Phosphorus, and Cobalt among others.

1.50.2. Rate payable is per shift of PMI carried out.

1.51. JOBS ON EXCHANGER NOT PART OF LUMPSUM

SCOPE




1.51.1. Scope of job involves jobs on the exchangers which are not

part of Lumpsum scope.

1.51.2. Carry out all the jobs on the exchanger as per Annexure 4

– Attachment 4.2: Standard procedure for jobs on

exchangers.

1.51.3. Box up after inspection clearance and make up flanges.

1.51.4. Rate payable is lumpsum per exchanger for different

range of diameter.

1.52. JOBS ON MANPOWER SUPPLY BASIS

1.52.1. This covers manpower to be utilized for executing any

additional work, which is not covered under any of the unit

rate items mentioned above. Agency shall mobilize

manpower with all tools, equipment, consumables,

electrical services, supervision etc. and execute the job.

1.52.2. Rate payable is per head per 8hrs Hrs shift. Rate payable

for 12hrs shift shall be double of the rate payable for 8hrs

shift

Documents

DHDS T&I ’09: MAIN CONTRACT Annexure 1: Part IItenders.hpcl.co.in/tenders/tender_prog/TenderFiles/2318/Tender... · DHDS T&I’09: Main Contract Annexure 1 – Part II Part –