SCOPE OF WORK

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PROJECT DESCRIPTION
For balance job of Diesel Quality Upgra dation Project (DQUP) at Nu maligarh Re finery requires t h e execution of following jobs. Part: A - Dismantling and erection of Exchanger (04-EE-001) and fabrication & erection of associated piping. Part: B - Installation of Control Valve and fabrication & erection of associated piping Part: C - installation of Air Fin fan Cooler (04-EA -001 A/B/C/D) Contractor to note that work has to be performed during shut down and also in running plant e xc luding prefabrication which has to be done during pre -shutdown period. The sche me of work execut ion shall be approved by Owner/Eng ineer In -charge prior to ta king up these activities in the p lant. Contractor has to ta ke ut mos t care & safety p recaut ions while working in the p lant. Hot work permits / safety permits for wo rking in the p lant shall have to taken fro m the Owner by the Contractor. Contractor shall carry out work only after obtain ing clearance fro m the Owner.

1.0

SCOPE OF WORK FOR TENDER (PIPING)

Generally the scope of work o f contractor shall inc lude the following: 1.1 Transportation of requ ired piping materials (as described in CL.1.2), p ipe support materials (as described in CL.1.4) and a ll other neces sary p iping mate rials fro m EILs /Owne rs storage po int o r Cont ractor's storage po int (in case of Contracto r's scope of supply) to work site/shop includ ing raising store requ isitions for issue of materials in the prescribed format & ma intaining an account of the materials received fro m EILs/Owne rs stores & reconciliation of all EIL/ Owner supplied free issue materials. Piping materials inc lude the fo llowing but is not limited to the sa me : a. b. c. d. e. f. g. h. i. Pipes (A ll sizes and schedules) Flanges (All sizes, types and pressure ratings) Fittings (All sizes, types and schedules) Valves (All sizes, types and ratings) Gaskets (All sizes, types and ratings) Studs, Nuts or M/c Bolts (all types) Springs, Expansion jo int / Bellows (All types) Spec ialty items like sa mp le coolers, stea m/condensate manifold, stea m traps, strainers, spray nozzles, air t raps, hoses, hos e couplings, s ight glass, etc. Online instru ments like control valves, SDVs, orifice flanges, rotameters, res triction o rifice, desuperheaters, safety valves, co rrosion probes, e jectors, silencers, etc .

1.2

1.3

Shop & field fabricat ion and erection of pip ing in accordance with docu ments listed under CL. 2.0 i.e ., 'BASIS OF W ORK' inc lud ing erect ion of all pip ing materia ls enu merated above. Fabrication and erection o f pipe supports like shoes, saddles, guides, du mmy pipes, stops anchors, c lips, crad les, hangers, turn buckles, special support, supporting fixtu res, brac kets, cantilevers, stru ts, tee-posts, includ ing erect ion of spring supports, expansion bellows, steam and condens ate man ifo lds support and sway brac es etc.

1.4

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1.5

Fabrication Works a. b. Fabrication o f pip ing specials like specia l rad ius bends, reduce rs, miters, etc. Fabrication o f pla in and threaded n ipp les fro m p ipes, thread ing of p ipe ends as required du ring erection. Fabrication o f swage nipples as and when required. Fabrication o f odd angle e lbows like 60, 30 or any other ang le fro m 90/45 elbo ws as and when required. Fabrication of flanges, reducing flanges, b lind flanges, spectacle blinds etc. as and when requ ired . Fabrication of s tub in connectio ns with o r without reinforc e ment. Grind ing of edges of pipes, fittings, flanges, etc. to match mat ing edges of uneven/differe nt thickness where ver required as per specifications including beveling of pla in end p ipes & swages. Grinding/fin ishing of uneven surfaces/jo ints after welding. Tapping and drilling of holes in flanges, blind flanges, p ip ing connections for jack screw, if required. Fabrication of special ite ms like weather protection shield, hood etc., if required. Fabrication of steam supply/condensate recovery man ifolds. Any other fabrication work required to co mp lete the job.

c. d.

e.

f. g.

h. i.

j. k. l. 1.6

Erection of control va lve shall be done after flushing/che mical c lean ing, etc. o f the line. For erection of pip ing, te mpo ra ry spool piec es shall be installed in p lace of control va lves along with temporary gas kets (contractor supplied). No separate pay ment sha ll be made on this account. Preparation of iso metrics and bill of materials fo r process and utility lines up to 1.5 size and lines re lated to instrument and pu mp flushing/cooling, sprinkler pip ing over pumps/vess els etc., purg ing, pump c a s ing vents & d rains, pump base p late dra ins, control valve drain/vent to fla re, stea m tracing fro m supply station/header to condensate recovery , supporting details of all Non -IBR lines up to and includ ing 1.5 (in case o f IBR lines 1.5 & below only ind icative supporting shall be p rovided & detailing of such supports is in contractors scope) and lines specified as field routed including subsequent approval fro m Eng ineer In-charge as and when requ ired is in contractor scope o f wo rk. In some cases control valve, pu mps, e xchange rs, instru ments like level gauge etc. are being replaced where existing s mall bore piping to drains/vents, samp le connect ions, auxiliary piping to pu mps may be ava ilable but th is may need to be modified/aug mented in vie w o f the new d imens ions. Such mod ifications/re routing is to be done at site by contractor in consultation with Eng ineer In-charge meeting P&ID require ments fo r wh ich no is o metrics shall be availab le.

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1.9

Pre Shut Down Activity Contracto r shall carry out detailed planning and all back up activities prior to shut down, to minimize work load during shut down.

1.

Pre fabrication work shall be done to the maximu m possible extent and all prefab ricated spools shall be properly tagged fo r easy identification during shut down.. 2. Marking of hook up po int shall be done o f exis t ing piping and e xisting lines getting dis mantle shall be painted fo r identificat ion. 3. All the G A Ds/isometrics shall be verified at site be fore ta king up p refab rication including nozzle flange size/ratin g. Any discrepancies shall be h ighlighted. 4. Scaffo ld ing/te mpo rary supporting work shall be completed for dismantling/ hook up works before shut down. 1.10 Dismantling Works Contracto r shall carry out dis mantling works (cutting, re moval) in HCU & HGU o f the existing piping (bare/ insula ted/trac ed includ ing supports) and transport the sa me to Owners/EI Ls des ignated storage po int and stacking the material (p iping/va lves/structure steel). All the work shall be carried out as per instruction o f Eng ineer In-charge. 1. The d is mant led materia l may be reused as and when requ ired. In case o f reuse materia l shall be transported from dis mantle s torage po int to work site/fab. yard and no separate pay ment shall be made on this account.. 2. Piping shall be dis mantle a long with supports and no separate payment shall be made on this account. 3. Isolat ion o f existing line shall be done before d is mantling and p roper permit shall be taken for disma ntling work. All s afety precautions shall be ta ken befo re carrying out the job. 4. So me of the e xisting lines/structure may have to be dis mantled and rerouted/re installed to avoid fouling with new lines. 5. Any da mage to existing facilities like piping, painting, insulation etc. shall be rectified as per specification and no extra pa y ment shall be made. 6. All dis mantled valves, control valves shall be prope rly stac ked separately at s torage area. 7. All traced lines shall be dis mantled along with trac ers and no sepa rate pay ment shall be made for t race r lines. 1.12 In case e xisting lines requires pres sure testing due to hook up , the existing line shall be tested up to the point of c losest isolation (e.g. flange, valve). Rad iography, dye penetration test, magnetic partic le test, wet fluorescent magnetic partic le test etc. as p e r specificat ion 6946-6-44-0016. Stress relieving as per specification 6946-6-77-0005. Performing PM I using alloy ana lyser as per Standard Specification for Positive Material Identification at Construction Sites, 6-82-0002. Flushing and testing of all piping systems shall be c arried out as per Standard Specif icat ion for Inspection, Flushing and Testing o f Pip ing Systems, 6-44-0013. Accessories required fo r blind ing the line with suitable plate a re to be arranged by contractor. The scope of testing shall be inclusive of opening the flange jo int, prov iding
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neces sary blind, de b linding the sys tem a fter test and re bo xing up includ ing to rque tightening / bolt tension ing as per specification. Any defe cts noticed during hydro testing shall be made good by the contractor. 1.17 Prov iding insert plates in concrete structures / paved floo rs and repair of platfo rm gratings around pipe openings. Making material reconciliat ion state ment and return o f EIL supplied left ove r materials to EIL's storage. Eng ineering, fabrication and erect ion of stea m supply/condensate recovery manifolds and tracer pipes in a ccordance with drawing and s tandard specific ation for s tea m t racing 644-0007. Stea m trac ing shall be carried out for lines specified in P&ID/ Line Lis t/ Piping Drawings. Ste a m tracing o f e xist ing line, if any shall also in contracto r scope. Hydraulic bolt tensioning & torquing shall be performed on flange joints as p e r the require ments specified in Job specification for application of torq ue and hydraulic bolt tension for flange jo int 6946-6-76-0002. Wherever p iping class breaks of high pressure/ low pressure are involved, the highpressure circuit shall be tested upto piping c lass spec. break and the lo w pressure circuit shall be done upto the nea rest flange of high pressure pip ing. In case of high pressure piping certain equip ments will require to be included as a part of piping hydro tes t circuit. Contra ctors scope shall inc lude making necess ary arrange ments their of and equip ment dry ing after hydro testing. The rates for piping shall be inclusive of said equipment testing and no separate pay ment shall be made on this account. In case of any mod ifications required in the piping layout shown in GADs/Isometrics/Pip ing sketches (prepared by EIL), contractor shall have to undertake site survey, modify the routing if necessary as p e r site conditions, prov ide neces sary supports and obtain approval o f Engineer-in-charge/ OWNER without any price imp lication. Prov iding low friction pads as specified in iso metrics/special support sketches. Contracto r shall take all necessary pe rmits required to carry out the job in the plant and ensure all s afety measures during the job . Prov id ing manpower assis tance during p re-co mmission ing/co mmis sioning without any additional cost. Any other incidental/ intermediate/ancillary or any other enabling wo rk not specifically mentioned in any specificat ion but requ ired to co mplete the job. Preparation of As-Built GA Ds & Iso metrics on Appro ved for Construction GADs & Isometrics and get it checked & approved by Engineer In -charge . Preparation & submission of these drawings is in contractors s cope and for wh ich no separate pay ment shall be made & work is to be co mpleted within quoted rate o f p ip ing.

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1.23 1.24

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B ASIS FOR WORK

The co mp lete unit pip ing work shall be carried out in a ccordance with the following: a. Approved for construction' drawings and sketches issued by EIL to the contractorPlans and / or Iso metrics / system iso metrics.
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b.

Draw ings and sketches issued by Pac kage Vendor - Plans and / o r Iso metrics / system iso metrics.

c.

Dra wings, sketches and docu ments prepa red by Contractor duly approved by Engineer-in-charge (such as lines 1.5 & be low, lines requ ired to be field routed etc.) Approved process licensors specifications & standards. EIL specifications / Docu ments as belo w: Piping and Instru mentation Diag ra m (P&ID). Piping Materia l Specif ication (6946-6-44-0005). Piping Support Standards & Special Supports. Line List. Job Specific ation o f Non-Destruct ive Exa mination Require ment of Pip ing (6946-6-44-0016). W eld ing Specificat ion Chart fo r Piping Classes (6946-6-77-0005). W eld ing Specificat ion for fabrication o f Piping (6-77-0001). Job Specification for Shop & Field Painting (6946-0642-PT-E08) Any other EIL or other specification attached with Pip ing Material Specif icat ion or elsewhere and specia l conditio ns of contract. Procedure for storage, preservat ion and positive identification of materials at Contracto rs works / stores. Job specification for app lication of torque and hydraulic bo lt tension for flange joint 6946-6-76-0002. Standard spec ification for steam tracing 6-44-0007. Any other specification attached with the tender.

d. e.

f.

Follo wing Codes, Standards and Regulat ions: ASM E B 31.3 ASM E Se c.VIII IBR Regulations IS:823 Code for Procedure for Manual Meta l Arc We ld ing of Mild Steel (for structural steel). Bo iler and Pressure Vessel Code
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Process Pip ing Code fo r Unfired Pressure Vessel.

A S M E Sec. V

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All the codes referred above shall be o f the lates t ed ition, at the time o f a ward o f cont ract. Note : Specif ication/Standa rds 6-44-0005, 6-44-0016, 6-77-0005, 6-76-0002 mentioned in any standard specification/standard, SOR o r e lsewhere to be read with prefix 6946.

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3.1

SCOPE OF SUPPLY FOR TENDER (PIPING)

EILs/OWNERs SCOPE OF SUPPLY a. b. c. d. e. f. h. Pipes (A ll sizes and schedules) Flanges (All sizes, types and pressure ratings) Fittings (All sizes, types and schedules) Valves (All sizes, types and ratings) Gaskets (All sizes, types and ratings) Studs, Nuts or M/c Bolts (all types) except structural bolting. g. Spring, Expansion jo int/Bellows (All types). Spec ialty ite ms like sa mp le coolers, steam & condensate manifo lds, stea m traps, strainers, spray nozzles, air t raps, hoses, hos e couplings, s ight glass, etc. Online instru ments like control va lve, SDVs , orifice flange , rota meters, restriction orifice, desuperheaters, s afety valve, corrosion probes, ejectors, silencers, etc. All piping material including Pipes / fittings/ flanges/ gasket/ fasteners related to Galvan ized p ip ing . Du mmy pipes and p ipes fo r lo w supports.

i. j. k. 3.2

CONTRACTORS SCOPE OF SUPPLY The procure ment and supply in sequence and at approp riate t ime of all materials and consumab les required for the co mp letion of the works shall be the respons ibility of the contractor and prices quoted shall be dee med to be inclusive of such materials. The supply of these materials shall include but not limited to the following : a. All cutting, fitting, weld ing, b razin g, c lean ing, g rin d ing, th reading tools & tackles and consumab les. All industrial gases such as oxygen, acetylene , inert gases, all types of electrodes, filler wire, flux wire, brushes, etc. Approva l for Ma ker and Brand o f e lect rodes, filler wire shall be taken by Cont ractor before p rocure ment. Shims , wedges, and packing plates (mach ined wherever requ ired ). All materials such as hydraulic pu mps, metallic b linds, gauges, temporary gaskets, bleed/drip rings, etc. and arrange ment required for hydrostatic testing. Arrange ment fo r compressed air, blin ds, g auges, te mporary gaskets etc. and arrangement required for pneu matic pre ssure testing. Supply of MS flats and Chequered plates in ac cordance with relevant standard, if required. All materials and a rrangement required for all types of non-destruct ive tests such as radiog raphy (Cobalt 60 Source) , DP/ M P, UT etc. All materials and arrange ments required for stress relieving.

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h.

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i.

All materials, consumables, tools & tackles required for hydro testing o f exis t ing lines upto the closest flange in case of hook up (if reqd.). Arrange ment and supply o f e xpe rienced manpo wer, che mica ls, consumables, pumps, tanks, te mporary p ip ing, DM water, bo ilers, coupons and other testing

j.

materials & equ ip ments required for che mica l cleanin g , pic kling and passivation of lines.

k. l.

All materials, consu mab les, tools & tac kles required for the d is mantling work. All sealing and protect ing materia ls requ ired fo r protect ing mat erials/equip ments supplied by EIL/Contractor. Oil, grease, graph ite, neoprene rubber, moly kote, sealing tapes, clean ing agents including acids for cleaning of inte rna ls/packing/through/tray etc. Chain pulley b loc k and all other material hand ling equip ments as per requir e ments. Supply o f all items required for erect ion co mpris ing of: Manually operated ground winch. Hoisting rop e . Direct ion p u lley on g round. Gu ide pulle ys. Motor for hoisting rope, a long with fixing bolts and s tructural support me mbe rs, as required. Thimble for fastening hois ting rope to lifting bea m. Supports for g round winch and d irect ion pulley with foundation bolts, as neces sary. W eld ing/fixing of be aring b rackets on the platform and support a rms on the stack. Structural me mbers as necessary for support ing the gu ides for lifting beam during lowering/ho isting. Tip lowering/hoisting gu ides.

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o. p.

q.

All safety equip ments required to conduct the job and avo id acc ident and keep good house keeping and environ ment. fire blanke ts and water hoses for fire and safety protection as required. Supply o f co ld ga lvan izing or zinc coating mate ria l with approva l o f Engineer Incharge.

r.

s.

Grouting mate rial, if required shall be as p e r EIL Specif icat ion, dra wings and instructions of the Eng ineer-in-cha rge. All tools and tackles required for assistance in p re -co mmis sion ing/co mmission ing. Structural steel required for modification/extension of platform, prov iding additiona l platfo rms, ladders, ju mpovers, etc to improve accessibility , where ver required.

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v.

All other materials though not specified above but required for co mpletion of the work as per specification, drawings and instructions of the Eng ineer-in-charge.

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4.1

SCOPE OF WORK FOR TENDER (PAINTING)

PAINTING WORKS The s cope of work broad ly consists of painting of piping, structural steel wo rk for corrosiv e environ ment as detailed in schedule of rates as per drawings, job specification for shop and field paint ing (spec. no. 6946-0642-PT-E08) & instructions of Eng ineer In-charge.

Painting of impu lse p ip ing (erection by others) and field pa inting of p iping (erection/pre fab. by others) e .g. PSA pac kage shall a lso included in scope of wo rk o f Mechan ical Contracto r. The scope of work shall consist of surface p repa ration as requir ed, se lection and app lication of required paints on surfaces o f piping, steel structures etc. including but not limited to: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. All structural steel work in clud ing walk ways, pipe supports, ladders etc. All un insulated p iping and fittings includ ing flanges and valves (inc luding prov id ing identification ma rks). Painting o f surfaces to be insulated as per require ments. Repair & touch up of primer applied (by others) surfaces as deemed neces sary before application of finish pa ints. Repair o f da mage done on e xist ing painting of pip ing/equip ment during hoo k up work. Any other surface as d irected by Engine er In -charge . Identification, colo ur b ands on all painted surface of pip ing. Identification , lettering/numbe ring on a ll pain ted surface of pip ing. Hazardous content ma rking/identification signs on pa inted surface of p iping. Cleaning up the working areas regularly during the cours e of work for purpose of good house keeping as well as clean ing up the site on completion of the wo rk as directed by the Engineer In-cha rge. Prov id ing scaffo ld ing for all he ights, all other incidental/ auxillary/ ancillary/ accessories, labour, material, tools & tackles, consumab les, supervision ,etc or any enabling work not specifically mentioned in the specifications but necessary for the execut ion and co mp letion of wo rk as envisaged in the tender docu ment.

11.

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5.1

SCOPE OF SUPPLY FOR TENDER (PAINTING)

EILS/OWNERS SCOPE OF SUPPLY Painting NIL 5.2 CONTRACTORS SCOPE OF SUPPLY Painting All p rimers and fin ish paints as per requ ire ment All consu mables and equip ments for surface preparation. All equip ments for paint application like brushes, spray , no zzles, spray pu mps/blowers etc. All equ ip ments like dust collector, pro tection shie ld etc. for conduct ing the job. All items/equip ments requ ired to co mplete the job as pe r require ment o f job specification for shop & field painting (spec. n o . 6946-0642-PT -E08)

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6.0
6.1

SCOPE OF WORK FOR TENDER (INSULATION)

INSULATION WORKS The scope of work shall include hot insulation of p iping etc. as detailed in schedule o f rates as per draw ings, standard specificat ion for hot insulation o f vessels, pip ing & equ ipment (6-440002) & instructions of Engineer In-charge. Insulation of pip ing includ ing impu ls e pip ing (erection by others) and pip ing in pac kages e.g. PSA shall a lso included in s cope of work o f Mechan ical Cont ractor.

The work in brief shall include the following but not limited to this only : 1. Supply of all insulation and ancillary materia l like spacer-ring, stays, mill board, lacing and b in d ing wires, screws, bands, studs, flats, support ring c lips, sealant and mas tic, ce ment, glass cloth, a lu minum sheets/ GI sheets, necessary drilling m/c etc. wherever specified and required. All insulation material shall be new and of approved quality with co mplete test certificates and in acco rdance with the spec ifications. Applicat ion o f insulation with weather proofing on p ip ing includ ing valves, flanges etc. as per specification and instructions of Enginee r In-cha rge. Contracto r shall supply material required for repair of exis ting insulatio n. Prov id ing besides all materials and consumab les labour and supervis ion required for carry ing out the insulation work, a ll safety devices, eq u ip ments, apparatuses, instru ments etc. necessary and incidental requ ire ments to perform the work in workmanship and efficient manner within the stipulated t ime period. Co lour coding identification of piping etc. afte r insulation as per relevant specification and ins truction of Enginee r In -charge . Prope r storage and protection of insulation materia l and consu mables brought to site by the contractor at all stages of work. Prov id ing insulation p lugs and windo ws at all locations as per dra wings, specificat ions and instruction of Eng ineer In -charge. Cleaning up the wo rking areas regularly during the cou rs e of work for purpos e of good house keep ing as well as clean ing up the site on completion of the work as directed by the Engineer In-cha rge. Prov id ing scaffo ld ing for all heights, all other incidental/ auxillary/ ancillary/ accessories, labour, material, too ls & tackles, consumab les, supervis ion etc. or any enabling work not specifically mentioned in the specifications but necessary for the execut ion and co mp letion of wo rk as envisaged in the tender docu ment.

2. 3. 4.

5. 6. 7. 8.

9.

7.0
7.1

SCOPE OF SUPPLY FOR TENDER (INSULATION)

EILS/OWNERS SCOP E OF SUPPLY Insulation NIL 7.2 CONTRACTORS SCOPE OF SUPPLY Insulation All ite ms required to comp lete insulation (insulation material, attach ment material, fixing materials, vapour barr ie r material, boltings, screws, inspection window, structu re attach ment etc. All consu mab les and equ ip ments to complete the job at any elevat ion and locat ion.

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8.0
S.No. 1 2 3 4 5 6

LIST OF JOB SPECIFICATIONS

TITLE Piping Mat erial Specifications Job Specification for Non Destructive Examination Requirements of Piping Job Specification for Steam Jacketing Job Specification for Application of Torque and Hydraulic Bolt Tension for Flange Joints Welding Specification Charts for Piping Classes Job Specification for Shop & Field Painting Job Specification for Chemical Cleaning SS Piping Job Specification for Chemical Cleaning and Passivation of Field Welds of SS 300 Seri es Piping SPEC / ST D. No. 6946-6-44-0005 6946-6-44-0016 6946-6-44-0078 6946-6-76-0002 6946-6-77-0005 6946-0642-PT-E08 6676-0642-CC-006-L08 6676-0642-CC-011-L08 Rev. 2 1 0 0 0 0 0 0

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LIST OF APPLICABLE SPECIFICATIONS

TITLE Standard Specification for Hot Insulation of Vessels, Piping & Equipment Standard Specification for Steam Tracing Standard Specification for Fabrication & Erection of Piping Standard Specification for Inspection, Flushing & Testing of Piping System Welding Specification for Fabrication of Piping. Standard Specification for Positive Materi al Identification (PMI) at Construction Sites Standard Specification for Colour Coding of Piping Materi al Inspection & Test Plans (ITPs) for Mechanical Works (Item rate contracts) Inspection & Test Plans for General Works (Item rate contracts) SPEC / ST D. No. 6-44-0002 6-44-0007 6-44-0012 6-44-0013 6-77-0001 6-82-0002 6-82-0003 6-82-1100 6-82-1500 Rev. 4 2 2 3 3 1 0 1 1

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LIST OF APPLICABLE STANDARDS

TITLE Vents & Drains (on lines 1 and below) Vents & Drains (on lines 2 and above) Wells Installation 1.5 Dia Taps SPEC / ST D. No. 7-44-0350 7-44-0351 7-44-0353 Rev. 2 2 2

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