BPCL Volume III

ATTACHMENT 11 SECTION A
WORK PACKAGE FOR PACKAGE NO. 3
NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE

STOCK UNIT ( NHGU / LOBS) - COLUMNS
Carry out jobs on following columns as per general guide line given in Appendix A
attachment 2 and specific scope as detailed below.
NHGU
Naphtha
EQUIPMENT NO 133-C-301 SERVICE Deaerator / Surge
drum
PM ORDER NO. NA NO. OF TRAYS NA
Column Dia (mm) 2500 HEIGHT (mm) 6400
NO. OF BEDS 2 BED SIZE 0.8 X 2 M
DEMISTER YES DRAWING 133-ME-2-25-1
NO. OF SIZE( In) 24 X 150 /
2 + 1( Dome)
MANWAYS /RATING(lbs) 32 X 150
Sr. SIZE RATING
LOCATION
No. (inch) (lbs)
1. NAPHTHA I/L TO DEAERATOR 4 150
2. PROCESS GAS,N2, CRU OFF
GAS COMMON LINE TO
DEAERATOR 4 150
3. LP STEAM I/L LINE 2 150
4. C-310 O/L TO P-301 A/B LINE 4 150
1
5. P-301 A/B BALANCING LINE TO
C-301 2 300
6. P-301 A/B ARC LINE TO C-301 2 150
7. PUMP DISCHARGE RV'S LINE
TO C-301 3 150
SPADE LIST
8. COMMON DRAIN LINE TO
CBD/OWS 3 150
9. NAPHTHA FROM V-313 TO C-
301 2 150
10. SAMPLE POINT RSC1471 LINE
FLANGE 2 150
11. COMMON O/L LINE TO F-301
AND RV'S 4 150
12. GAUGE GLASS DRAIN LINE ( 4
NOS. ) 2 150
13. LEVEL SWITCH 402 A/B/C
DRAIN LINE( 3 NOS.) 2 150
14. RPDT-402 DRAIN LINE 3/4" 300
Page 1 of 10
SR NO DESCRIPTION OF WORK
1 Carry out spading as per spade list
2 Erect external scaffolding wherever required.
3 Open all hand holes on column and man ways of surge drum.
4 Unload pal rings from both the beds through hand holes.
5 Open top flange of column.
6 Remove demister. Demister shall be replaced with new one.
7 Remove Naphtha and Gas inlet distributors, clean and check
8 Dismantle the column in three sections by opening intermediate shell flanges and
lower the section on ground floor and clean the individual section.
9 Enter inside the surge drum
10 Carry out internal cleaning of surge drum including surge drum boot.
11 Service all first isolation valves
12 Remove service and fix back all the gauge glasses.
13 Clean all the nozzles.
14 Fix naphtha inlet distributor.
15 Assemble bottom section of the column.
16 Box up hand hole and load the pal ring in bottom bed.
17 Assemble middle section of the column.
18 Box up hand hole and load the new pal ring in top bed.
19 Fix back the gas inlet distributor, demister and box up the end flange third (top most)
section of column.
20 Assemble back the top section of column.
21 Box up surge drum man ways
22 Carry out de-spading
23 Remove external scaffolding except that required for hot bolting of flanges.
Process
EQUIPMENT NO 133-C-302 SERVICE condensate
Stripper
NO. OF BEDS 1 BED VOLUME -
DEMISTER YES DRAWING 133-ME-1-52-1
NO. OF SIZE( In)
1 20 X 600
MANWAYS /RATING(lbs)
2 Sr. SIZE RATING
LOCATION
No. (inch) (lbs)
1. CONDENSATE I/L TO C-302 2 600
2. MORPHOLINE INJECTION LINE 2 600
3. HP STEAM I/L LINE TO C-302 4 600
SPADE LIST 4. C-302 COMMON CONDENSATE 3
O/L LINE TO E-314 A/B/C AND
OWS 600
5. RPDT-659 AND RPDT-661 2 600
6. COMMON STEAM O/L LINE TO 3
MIXING POINT AND RV'S 600
Page 2 of 10
3 Open top dome cover flange bolts and lower the dome. Open the shell flanges
(manhole 1& 2 ) and remove the shell portion
4 Remove demister from top dome end. Demister shall be replaced with new one.
5 Open bottom man way and enter inside the bottom section of the column.
6 Unload pal rings from both the beds through hand holes. and load new pal rings after
box up of hand holes
7 Provide ladder inside the bottom section for cleaning and inspection.
8 Carry out internal cleaning in bottom section.
10 Remove service and fix back all the gauge glasses.
11 Remove insulation around all the manways, nozzles up to the first flange of nozzle or
250 mm from the column shell for UT gauging / assessing the CUI. Make insulation
pockets at all the platform level on all the four compass direction for UT gauging. The
removed insulation shall be restored back to original shape and contour matching
with the surface and sealing compound shall be applied to avoid water ingress as per
BPCL standard.
12 Open the skirt access and erect scaffolding inside the skit for inspection of bottom
nozzles.
13 Assemble top dome cover of the column and the shell.
14 Remove ladders from the bottom section
15 Box up man ways
Remove external scaffolding except that required for hot bolting of flanges.
LOBS
FPU Vacuum
EQUIPMENT NO 132-C-221 SERVICE
Column
Column Dia (mm) 2000 / 6500 HEIGHT (mm) 42245
NO. OF BEDS 6 BED VOLUME
DEMISTER NO DRAWING 132-ME-1-152/11
6+2
Sr. SIZE RATING
LOCATION
1 No. (inch) (lbs)
1. TRANSFER LINE TO FLASH
34 300
ZONE
2. STRIPPING STEAM 4 300
3. FPU COLUMN START UP VENT 2 150
SPADE LIST
4. FPU COLUMN STEAM OUT
2 300
STEAM SUPPLY
5. OVER FLASH FROM COLUMN 8 300
6. OVER FLASH TO COLUMN 8 300
7. OVER FLASH DRAIN TO CFBD 2 50
8. OVER FLASH DRAIN TO OWS 2 50
Page 3 of 10
9. FPU COLUMN OVER HEAD 30 150
10. FPU O/H TO RELIEF AND PSV'S 6 150
11. VACCUM COLUMN TOP
12 150
SIDECUT DRAW
12. VACCUM COLUMN TOP
6 150
REFLUX
13. VACCUM COLUMN TOP P/B TO
6 150
C OLUMN
14. W 100 N DRAW OFF 8 300
15. W 100 N VAPOR EX C-222 E/S 18 300
16. W 100 N VAPOR EX C-222 W/S 18 300
17. W 100 N P/B TO COLUMN 6 300
18. W 150 N DRAW OFF 10 300
19. W 150 N P/B TO COLUMN 6 300
20. W 150 N P/A TO COLUMN 6 300
21. W 150 N VAPOR EX C-223 E/S 18 300
3 Open all shell man ways
4 Enter inside the column
5 Erect scaffolding inside the column in bottom dish end area (approximately 3 meter
height)
6 Remove all the distributors located above each bed and below bottom packing, clean
and check. Replace 37 nos spray nozzles each above bed #3 and bed #6.
7 Clean all the weld seams of top dish end and top shell course carry out buffing of 6
inches on both sides of weld seams to carry out WFMPI.
8 Carry out internal cleaning including strainer around the vortex breaker. All Structure
packing bed shall be inspected in situ.
9 Remove insulation of top dish end and top shell course, clean and offer to inspection
to check CUI.Remove insulation around all the manways, nozzles up to the first
flange of nozzle or 250 mm from the column shell for UT gauging / assessing the
CUI. Make insulation pockets at all the platform level on all the four compass
direction for UT gauging. The removed insulation shall be restored back to original
shape and contour matching with the surface and sealing compound shall be applied
to avoid water ingress as per BPCL standard.
11 Clean all the nozzles
12 Open skirt access, and Provide scaffolding inside the skirt for inspection of bottom
elbow.
13 Fix back all the distributors, isolation valves.
14 Remove internal scaffolding
15 Box up all shell manways
2 Waxy 100N side

cut striper
Page 4 of 10
NO. OF SIZE( In)
2 24 X 300
Sr. SIZE RATING
LOCATION
No. (inch) (lbs)
1. C-222 S/C STRIPPER VAPOR
36 300
RETURN
2. S/C STRIPPER VENT TO
2 150
ATMOSPHERE
SPADE LIST 3. W100 N FEED TO C-222 4 300
4. MP STRIPPING STEAM TO C-
1-1/2 300
222
5. STEAM OUT STEAM SUPPLY 2 300
6. STR BOTTOMS TO P-255 A/B 6 300
7. BLT711 DRAIN TO OWS 300
8. P-255A/B MINI CIRCULATION 1 150
5 Erect scaffolding inside the column in bottom dish end area (approximately 2.5 meter
height)
6 Remove all the distributors located above and below packing bed, clean and check.
7 Carry out internal cleaning including strainer around the vortex breaker. Structure
BPCL standard.
10 Remove and service gauge glasses.
elbow.
13 Fix back all the distributors, isolation valves, gauge glasses.
15 Box up all shell man ways
Page 5 of 10
Waxy 150N side
cut striper
NO. OF SIZE( In)
2 24 X 300
Sr. SIZE RATING
LOCATION
3 No. (inch) (lbs)
42 300
RETURN
2. S/C STRIPPER VENT TO
2 150
ATMOSPHERE
SPADE LIST
3. W150 N FEED TO C-223 8 300
2 300
223
5. STEAM OUT STEAM SUPPLY 2 300
7. BLT712 DRAIN TO OWS 3/4 150
5 Erect scaffolding inside the column in bottom dish end area (approximately 2.5 meter
height)
6 Remove the distributor located below packing bed, clean and check.
BPCL standard.
elbow.
Page 6 of 10
DW product
stripper
PM ORDER NO. NA NO. OF TRAYS 10
NO. OF BEDS NA BED VOLUME NA
DEMISTER NO DRAWING 132-ME-1-209-1
1+1
Sr. SIZE RATING
LOCATION
No. (inch) (lbs)
4 1. FEED INLET 4 300
2. MP STRIPPING STEAM 3 300
3. STRIPPER O/H VAPOR 4 300
4. STEAM OUT STEAM INLET 1-1/2 300
5. STRIPPER LIQUID O/L 4 300
SPADE LIST
6. STRIPPER LIQUID O/L DRAIN
2 150
TO OWS
7. STRIPPER O/H TO RELIEF AND
4 300
PSV'S
8. STRIPPER VENT TO
1 150
ATMOSPHERE
height)
6 Remove the distributor located above tray no. 1 and below tray no 10, clean and
check.
7 Open all tray man ways.
8 Carry out internal cleaning including strainer around the vortex breaker.
BPCL standard.
13 Replace missing tray valves. (Total SS Valves: AC 5U (LIGHT) 90 nos. Material:
SA 240 Tp 410s, 1.62 mm thk. & AC 5U (HEAVY) 90 nos., Material: SA 240 Tp
410s, 2.0 mm thk. )
elbow.
16 Box up tray man ways
Page 7 of 10
DW Vacuum
Column
DEMISTER NA DRAWING 132-ME-1-151/10
4+3
Sr. SIZE RATING
LOCATION
No. (inch) (lbs)
1. TRANSFER LINE TO FLASH
18 300
ZONE
2. STRIPPING STEAM 6 300
3. DW COLUMN START UP VENT 2 150
4. DW COLUMN STEAM OUT
2 300
STEAM SUPPLY
5. OVER FLASH FROM COLUMN 8 300
6. OVER FLASH TO COLUMN 8 300
5 7. OVER FLASH DRAIN TO CFBD 2 150
8. OVER FLASH DRAIN TO OWS 2 150
9. DW COLUMN OVER HEAD 18 150
10. DW O/H TO RELIEF AND PSV'S 8 300
11. P-265 A/B MIN CIRCULATION
SPADE LIST 4 300
TO C-221
12. P-265 A/B START UP VENT 2 150
13. BYPRODUCT DRAW OFF 8 150
14. BYPRODUCT REFLUX 6 150
15. BYPRODUCT P/B 4 150
16. LT LUBE S/C STRIPPER VAPOR 8 150
17. LT LUBE DRAW OFF 4 150
18. LT LUBE P/B 3 150
19. C-225 BOTTOMS 6 300
20. C-225 BOTTOMS DRAIN TO
2 150
CFBD
21. C-225 BOTTOMS DRAIN TO
2 150
OWS
22. BLT727 DRAIN TO OWS 150
Page 8 of 10
height)
6 Remove the distributor located above each packing bed and below bottom packing
bed, clean and check. Replace 07 nos spray nozzles above bed #6.
8 Remove insulation from top dish end upto bed no 3 outlet for checking CUI.Remove
insulation around all the manways, nozzles up to the first flange of nozzle or 250 mm
from the column shell for UT gauging / assessing the CUI. Make insulation pockets at
all the platform level on all the four compass direction for UT gauging. The removed
insulation shall be restored back to original shape and contour matching with the
surface and sealing compound shall be applied to avoid water ingress as per BPCL
standard.
elbow.
14 Box up all shell midways
DWLT Lube side

cut stripper
DEMISTER NA DRAWING 132-ME-1-210-1
NO. OF SIZE( In)
TOP COVER 24 X 300
Sr. SIZE RATING
LOCATION
6 No. (inch) (lbs)
8 150
RETURN
2. LT LUBE STRIPPER VENT TO
1-1/2 300
ATMOSPHERE
SPADE LIST
3. LT LUBE TO C-226 3 150
1-1/2 300
226
5. STEAM OUT STEAM SUPPLY 1-1/2 300
Page 9 of 10
3 Open column top cover and hand holes
4 Remove the distributor located above and below Packing bed, clean and check.
Carry out replacement of total packing along with bed limiter.
BPCL standard.
9 Provide external scaffolding outside the skirt for inspection of bottom elbow.
11 Box up top cover.
12 Box up all shell hand holes.
Page 10 of 10
ATTACHMENT 11 SECTION B

STOCK UNIT ( NHGU / LOBS) HEATERS
NHGU
Carry out jobs on following heaters as per general guide line given in Appendix A
1 EQUIPMENT NO 133-F-301 Service Reformer Heater

GENERAL
3 Open all the duct man ways
4 Carry out jobs on burner assemblies (240 nos) as per our general scope.
5 Carry out smoke bomb testing before opening and after box up of the heater to
check the duct / casing leakages
RADIATION
1 Erect internal scaffolding in both the cells internally upto the top to carry out OD
measurement and Insitu metallography of reformer tubes.
2 Carry out external cleaning of all the tubes by mopping with DM water to remove
the refractory / ceramic wool material stuck on the tube surface.
3 Carry out OD measurement of all the tubes.
4 De-lag weld joints of all the 184 hair pins tubes and inlet header, clean and carry
out DP test. On completion of the DP testing, carry out insulation of the weld joints
using calcium silicate blocks, ceramic wool, SS foil & cladding.
5 Provide necessary scaffolding arrangement to access the inlet header. Make
insulation pockets on the inlet header at few locations which shall be marked
during shutdown and carry out DP test.
6 Carry out replacement of the all broken hair pin springs.
7 Open the top cover of all the 184 nos. catalyst tubes for catalyst replacement.
Kindly note that catalyst replacement (loading and unloading shall be carried
out by another agency).Top cover opening shall require delinking the spring
support mechanism from the cover.
Carry out cleaning of catalyst tubes from inside and offer it for inspection.
On completion of the catalyst loading by another agency, fix back all the covers
& restore the spring support connection.
8 Carry out insulation of the joints at the cold collector end.
9 Carry out repair to the telescopic inspection blankets provided on the top of the
duct where catalyst tubes come out of the heater shell. Carry out insulation
stitching between sleeves and tubes.
10 Based on inspection finding replacement of few catalyst tubes may be required.
The payment for replacement of the catalyst tube shall be made as per
applicable SOR.
Page 1 of 11
COLD COLLECTOR
1 Open the cold collector man ways. Opening of man way shall require breaking of
the refractory sleeve at the man way.
2 Take entry inside the cold collector, clean and offer for inspection.
3 Carry out internal refractory repair of approx 5 m2 as per drawing no 133-CE-3-
111.
4 Carry out external shot blasting and painting of cold collector using Thermo
indicative paint as per BPCL AES 5430 System 27.
5 On completion of internal inspection, make the refractory sleeve at man ways and
box up man ways.
STACK
1 Open the access door and offer the stack for internal inspection. Provide
necessary Bosun chair arrangement.
2 Carry out Castable refractory repairs of approx 5 m2.
PRE REFORMER COIL 133-E-301& 302
1 Replacement of both the exchanger shall be carried out by other agency.
AIR PRE HEATER (133-AP-301 /302 / 303)
1 Open man ways of the duct and erect scaffolding inside the duct to access all
coils. Provide scaffolding / ladder arrangement wherever required.
2 Clean all tubes externally free of scales by water washing and blowing with High
pressure air jet and offer for inspection.
3 Remove insulation of the following permanently. After repairs, carryout scrap
cleaning and painting as per company specification.
a) APH 301,
b) Duct between APH 301 and APH 302.
c) APH 302 bypass duct.
4 Fabricate and carry out the replacement of duct from FD301A/B discharge damper
immediate flange to elbow flange near APH301 as existing (Drg no 133-ME-4-63)
Fabricate and carryout entire replacement of APH 302 BYPASS duct as existing
(133-ME-4-66)
5 Carry out cutting of the finned tubes of APH 301 from inside the duct and spade
inlet and outlet flanges (steam side) of APH 301 (Refer Drg no 133-ME-4-16-2 for
APH 301)
6 Remove insulation of the duct between APH303 and reformer and check for
repairs. After repairs, carryout scrap cleaning, painting and insulation as per
company specification.
DAMPERS
1 Carry out servicing of all the following multi louver dampers.
1) FD fan suction dampers: 2 nos.

2) FD fan common discharge damper: 1 no.
Page 2 of 11
3) ID fan suction dampers: 4 nos.
4) ID fan discharge dampers: 2 nos.
5) APH 302 by pass damper: 1 no.
6) Combustion air to burner duct dampers: 16 nos.
2 Remove both the multi louver ID discharge dampers and guillotines of ID301A/B.
The position of guillotines and ID discharge dampers shall be swapped. The
necessary modification shall be carried out. as per MOC-NHGU-11-1194 &
Drawing no 133-CE-3-30,Rev.E).
Also replace the adjoining fabric bellow of discharge of both ID fan, if required.
3 Carry out servicing of all air damper assemblies of 133-F-301 burners.
(Each burner has small air damper to control combustion air flow.)
AIR / FLUE GAS DUCTING
1 Open man way covers, clean and offer for internal inspection.
2 Open all access doors and provide necessary ladder/ scaffolding/ hand lamps for
internal inspection.
3 Carry out insulation removal at select location for carrying out CUI assessment..
4 Based on the observations, patch work may be recommended using 3 mm thk
Alloy steel. Payment for patch plating shall be made as per applicable SOR.
5 133-FD-301A/B FD fan discharge duct is patched at 4-5 locations. Carry out
replacement of the same (Approx. 4m X 2m) area using 5mm thk IS 2062 Gr A
plate.
6 133-AP-302 combustion air pre-heater II bypass duct to be delagged completely
and offer for inspection. Same duct is already having leaks at 2 locations on west
of stack. Carry out replacement/patch work for Approx. 6m X 2m area using 5mm
thk IS 2062 Gr A plate.
7 Scrap clean and paint the FD suction duct and suction stack internally with 2
coats of CTE. Scrap clean and paint the FD discharge duct up to steam air heater
internally with 2 coats of zinc dust graphite.
8 Carry out replacement of the FD fan suction silencer baffles as per Annexure I
9 All diverter plates wherever found damaged shall be repaired and fitted back.
REFRACTORY / INSULATION WORK
1 Carry out replacement of approx. 15 m2 ceramic fiber modules, blankets, clips and
SS foils of side walls & roof in both cells of radiation section as per drawing no.
133-CE-3-11 (roof) & 133-CE-3-5 (side walls).
SS foils of floor as per drawing no. 133-CE-3-12.
SS foils of taper duct as per drawing no. 133-CE-3-27.
4 Carry out replacement of Castable for an area of 5 m2 as per drawing no. 133-CE-
3-109 for convection section
5 Carry out replacement of Castable for an area of 10 m2 as per drawing no. 133-
CE-3-113 for Flue gas duct section and APH.
6 Fill/pack ceramic blanket/ pumpable ceramic fiber in the expansion joints/gaps in
ceramic modules
7 Carry out replacement of Clamp nuts and ceramic caps at approx. 400 locations
GUILLOTINE DAMPERS
1 Carry out servicing of all the guillotine dampers and offer dampers for inspection.
2 Carry out replacement of the sealing strips of the guillotines as per inspection
finding during shutdown. The payment for replacement of the sealing strips of
Page 3 of 11
the guillotines shall be made as per applicable SOR
MISC JOBS
1 Renew complete 2 nos. leaky fuel Naphtha lines along with their jacket
piping (1B and 2A) of Reformer as their jackets are leaking. Offer hydro test
of both jacket and inner pipe of entire fuel circuit from Naphtha fuel
vaporizer 133-E-312 to 133-V-304 and 16 nos naphtha jacketed lines going
to burners.
2 Fabricate and carry out replacement of approximately 35 nos. of steam trap
assemblies of 133-F-301 jacketed piping fuel gas lines.
Spade List for 133-F-301
Sr No. Location Size Rating

FUEL NAPHTHA LINE BLOCK VALVES U/S FLANGE
DOWNSTREAM OF RSDV 576
1. A SIDE FIRST ROW BURNER MAIN NAPHTHA BLOCK VALVE 1.5 150
2. A SIDE SECOND ROW BURNER MAIN NAPHTHA BLOCK
2 150
VALVE
3. A SIDE THIRD AND FOURTH ROW BURNER MAIN NAPHTHA
3 150
BLOCK VALVE
4. A SIDE FIFTH ROW BURNER MAIN NAPHTHA BLOCK VALVE 2 150
5. B SIDE FIRST ROW BURNER MAIN NAPHTHA BLOCK VALVE 1.5 150
6. B SIDE SECOND ROW BURNER MAIN NAPHTHA BLOCK
2 150
VALVE
7. B SIDE THIRD AND FOURTH ROW BURNER MAIN NAPHTHA
3 150
BLOCK VALVE
8. B SIDE FIFTH ROW BURNER MAIN NAPHTHA BLOCK VALVE 2 150
9. C SIDE FIRST ROW BURNER MAIN NAPHTHA BLOCK VALVE 1.5 150
10. C SIDE SECOND ROW BURNER MAIN NAPHTHA BLOCK
2 150
VALVE
11. C SIDE THIRD AND FOURTH ROW BURNER MAIN NAPHTHA
3 150
BLOCK VALVE
12. C SIDE FIFTH ROW BURNER MAIN NAPHTHA BLOCK VALVE 2 150
13. D SIDE FIRST ROW BURNER MAIN NAPHTHA BLOCK VALVE 1.5 150
14. D SIDE SECOND ROW BURNER MAIN NAPHTHA BLOCK
2 150
VALVE
15. D SIDE THIRD AND FOURTH ROW BURNER MAIN NAPHTHA
3 150
BLOCK VALVE
16. D SIDE FIFTH ROW BURNER MAIN NAPHTHA BLOCK VALVE 2 150
OFFGAS LINE BLOCK VALVE DOWNSTREAM OF RPC 574
17. A SIDE FIRST ROW BURNER MAIN OFF GAS BLOCK VALVE 6 150
18. A SIDE SECOND ROW BURNER MAIN OFF GAS BLOCK
8 150
VALVE
19. A SIDE THIRD AND FOURTH ROW BURNER MAIN OFF GAS
12 150
BLOCK VALVE
20. A SIDE FIFTH ROW BURNER MAIN OFF GAS BLOCK VALVE 8 150
21. B SIDE FIRST ROW BURNER MAIN OFF GAS BLOCK VALVE 6 150
22. B SIDE SECOND ROW BURNER MAIN OFF GAS BLOCK
8 150
VALVE
Page 4 of 11
23. B SIDE THIRD AND FOURTH ROW OFF GAS MAIN NAPHTHA
12 150
BLOCK VALVE
24. B SIDE FIFTH ROW BURNER MAIN OFF GAS BLOCK VALVE 8 150
25. C SIDE FIRST ROW BURNER MAIN OFF GAS BLOCK VALVE 6 150
26. C SIDE SECOND ROW BURNER MAIN OFF GAS BLOCK
8 150
VALVE
27. C SIDE THIRD AND FOURTH ROW BURNER MAIN OFF GAS
12 150
BLOCK VALVE
28. C SIDE FIFTH ROW BURNER MAIN OFF GAS BLOCK VALVE 8 150
29. D SIDE FIRST ROW BURNER MAIN OFF GAS BLOCK VALVE 6 150
30. D SIDE SECOND ROW BURNER MAIN OFF GAS BLOCK
8 150
VALVE
31. D SIDE THIRD AND FOURTH ROW BURNER MAIN OFF GAS
12 150
BLOCK VALVE
32. D SIDE FIFTH ROW BURNER MAIN OFF GAS BLOCK VALVE 8 150
33. R 303 O/L LINE TO BE SPADED 16 900
34. EJECTOR I/L PROCESS GAS FLANGE TO BE SPADED 10 900
35. EW 301 O/L LINE FLANGE 18 300
36. EW 301 RISERS TO V 301 12 600
37. EW 301 DOWNCOMERS TO V 301 12 600
38. EW 301 BLOWDOWN LINE 2 150
39. EW 301 Steam Inlet valve upsteam Flange 1.5 150
40. STEAM JACKETING TO REFORMER AREA 2 600
41. R 303 RPDT 564 I/L BLOCK VALVE D/S FLANGE LINE TO BE
3/4 150
SPADED
LOBS
Carry out jobs on following heaters as per general guide line given in Appendix A
1 EQUIPMENT NO 132-F-204 Service FPU Feed Heater

GENERAL
2 Erect external scaffolding wherever required
3 Remove all 18 burners assemblies and service.
4 Open all man ways / header boxes.
5 Carry out smoke bomb testing before opening and after box up of the heater to
check the duct / casing leakages. Duct / Casing repair if any shall be carried out
by the contractor and payment for the Duct / Casing repair shall be made as per
applicable SOR.
RADIATION
1 Erect internal scaffolding in both the cells.
2 Carry out external Passivation of all the tubes by external spraying or mopping
with soda ash as per procedure approved by Inspection/Technology.
Page 5 of 11
3 Carry out external cleaning of tubes. Use SS wire brush for cleaning & spot
making.
4 Make around 700 nos. 2 diameter spot on tubes and all U bends for UT gauging.
5 Clean all the weld joints of tubes size 8 / 6 / 4 for fluorescent DP testing.
6 Clean 8 nos. thermocouple weld joint and offer for DP testing
7 Open all the temperature indicator flanges at inlet end of each stream for
assessing internal condition of the tubes
CONVECTION
1 Open convection coil panels
2 Clean the entire convection coil bend, make approximately 250 nos. 2 diameter
spot on bends and on first row of plain tubes. Use SS wire brush for cleaning &
spot making.
3 Provide scaffolding for accessing bottom row of convection coil.
4 Provide scaffolding in the bridge section of the convection bank and breech
section below stack.
5 Clean all the welds of 3 dia U bends in convection section and offer for DP test.
8 Carry water washing of all the tubes in convection section. (Dry Ice blasting?). The
tubes of convection zones shall be thoroughly water washed; in order to clean
them externally free of deposits (ensure that chloride is less than 50 ppm).
Suitable arrangement shall be made for draining water so that the refractory inside
the heater does not get affected
9 Carry out replacement /repairs to approx 12 m2 header box plate.
HYDRO TESTING
1 Carry out hydro testing of all the 4 passes using DM water at 34.5 Kg / cm2.
CROSS OVER PIPING
1 Offer the entire cross over piping for inspection.
2 Open insulation pockets at all elbow locations and few straight sections of all 4
crossover pipe lines connecting convection outlet to radiation inlet. Provide
necessary scaffolding for thickness measurement at these locations.
STACK
necessary Bosun chair arrangement//scaffolding.
2 Carry out insulating castable refractory repairs of approx 5 m2 as per drawing no
132-CE-3-247
DAMPERS
1 Carry out servicing of all the dampers , louvers & Pee hole doors.
APH AND AIR / FLUE GAS DUCTING
1 Open man way / access door covers of APH modules, Cold air ducts, hot air
ducts and flue gas ducts. Clean the ducts internally and APH tubes (internally /
externally) free of all deposits and offer for inspection.
2 Provide necessary ladder/ scaffolding/ hand lamps for internal inspection.
3 Take necessary precautions while erecting scaffolding below Glass APH module
and while cleaning the glass tubes.
4 Based on inspection findings, carry out renewal of 100 nos damaged glass tubes
size 32 mm OD x 2.0 mm thk. Borosilicate glass tubes. Removal of insulation,
cutting of duct , rewelding of duct plates and fixing back insulation for carrying out
replacement of glass tubes shall be in Contractors scope.
Page 6 of 11
5 Carry out water wash cleaning of the Glass and the Cast air pre heater modules.
6 Scrap clean and paint the FD suction duct and suction stack internally with 2
coats of CTE. Scrap clean and paint the FD discharge duct and GAPH bypass
duct up to GAPH module internally with 2 coats of zinc dust graphite.
7 Carry out insulation removal of flue / air duct for inspection
8 Carry out patch plating of the duct using 6 to 8 mm thick SA 515 / 516 Gr 60 / 70
plates. The payment for patch plating shall be made as per applicable SOR.
1 Carry out replacement of 8 nos. burner muffle blocks. For remaining 8 nos burner
muffle block carry out repairs. Offer all the cup throats for inspection of internal
lining and carry out refractory repair if any.
2 Carry out repairs of refractory wall and roof ceramic modules (approx area 15
m2) as per drawing no. 132-CE-3-253 & 132-CE-3-254.
3 Carry out repair of insulating Castable (approx. 5 m2) along with anchors of
furnace floor as per drawing no. 132-CE-3-243.
4 Carry out touch up / minor refractory repairs of peep holes and area around it in
standard manner.
5 Carry out insulating Castable repair (approx. 10 m2) along with anchors of
convection section as per drawing no. 132-CE-3-246-2.
6 Carry out insulating Castable repair (approx. 10 m2) along with anchors of header
box covers as per drawing no. 132-CE-3-246-2.
7 Carry out replacement/repair of Ceramic fiber modules (approx. 5 m2) along with
anchors of ID flue gas ducts as per drawing no. 132-CE-3-251.
8 Carry out insulating Castable repair (approx. 10 m2) along with anchors of APH
section as per drawing no. 132-CE-3-255-2
9 Pack ceramic insulation material in the expansion joint gaps.
GUILLOTINE
1 Carry out servicing of all the guillotine dampers and offer dampers for inspection.
2 Carry out replacement of the sealing strips of the other guillotines as per
inspection finding during shutdown. The payment for replacement of the sealing
strips of the guillotines shall be made as per applicable SOR.
Size Rating
Sr no. Location
( In) (Lbs)
1. PASS 1 FURNACE INLET 3 300
5. PASS 1 FURNACE OUTLET 8 300
9. PASS 1 FURNACE OUTLET TO CFBD 2 150
Page 7 of 11
13. ATOMIZING STEAM 2 300
14. FO SUPPLY 2 300
15. FO RETURN 2 300
16. MAIN FG SUPPLY 4 150
17. PILOTS FG SUPPLY 2 150
18. OFF GAS EX FPU COLUMN 8 150
19. OFF GAS EX FPU COLUMN 8 150
20. OFF GAS EX DW COLUMN 6 150
21. OFF GAS EX DW COLUMN 6 150
22. STEAM TO SOOT BLOWER 3 300
23. SNUFFING STEAM TO FIRE BOX 8 150
2 EQUIPMENT NO 132-F-205 Service DW Reactor Feed

Heater
GENERAL
RADIATION
1 Erect internal scaffolding in the cell.
2 Carry out external Passivation of all the tubes.
3 Carry out external cleaning of tubes. Use SS wire brush for cleaning & spot
making.
5 Clean all the weld joints of tubes size 5 for fluorescent DP testing.
CONVECTION
spot on bends and on first row of plain tubes. Use SS wire brush for cleaning &
spot making.
4 Provide scaffolding in the bridge section of the convection bank.
5 Clean all the welds of 3 dia U bends in convection section and offer for DP test.
7 Clean and offer Economizer and steam super heater coil in convection section for
inspection.
8 Carry water washing of all the tubes in convection section.
HYDRO TESTING
1 Carry out pneumatic testing of all the passes using nitrogen at 7.0 Kg / cm2.
2 Carry out hydrostatic test of Economizer & steam super heater coil at 56.4
Kg/cm2 and 39.2 Kg/cm2 respectively for BPCL Inspection and at 31.5 kg/cm2g
along with other equipment of LOBS Waste heat boiler MR-13892 to GBI.
Page 8 of 11
STACK
necessary Bosun chair arrangement/scaffolding
132-CE-3-272
DAMPERS
1 Carry out servicing of all the dampers , louvers & Pee hole doors.
1 Offer all the 16 nos. cup throats for inspection and carry out refractory repair if
any. Carry out repair of all the muffle blocks. Carry out replacement of 8 nos.
burner muffle blocks. For remaining 8 nos burner muffle block carry out repairs.
2 Carry out repair/replacement of refractory wall and roof ceramic modules during
shutdown (approx area 15 m2) as per drawing no. 132-CE-3-274-1 & 132-CE-3-
274-2.
furnace floor as per drawing no. 132-CE-3-265
standard manner.
convection section as per drawing no. 132-CE-3-266-1.
6 Carryout insulating Castable repair (approx. 10 m2) along with anchors of header
box covers as per drawing no. 132-CE-3-266-2.
Size Rating
Sr no. Location
( In) (Lbs)
1. PROCESS INLET 8 1500 RTJ
2. PROCESS OUTLET 8 1500 RTJ
3. PROCESS O/L DRAIN TO CFBD 2 150
3 EQUIPMENT NO 132-F-206 Service DW Vacuum Column

Feed Heater
GENERAL
RADIATION
1 Erect internal scaffolding in both cells.
2 Carry out external cleaning of tubes.
4 Clean 20 nos. weld joints of tubes size 4 for DP testing.
Page 9 of 11
CONVECTION
spot on bends and on first row of plain tubes.
4 Provide scaffolding in the bridge section of the convection bank.
5 Clean all the welds of 3 / 4 dia U bends in convection section and offer for DP
test.
6 Clean and offer 2 nos. thermocouple weld joint of the coils for DP test.
8 Clean and offer Economizer and steam super heater coil in convection section for
inspection.
9 Carry water washing of all the tubes in convection section.
CROSS OVER PIPING
1 Offer all cross over piping for inspection.
2 Open insulation pockets at all elbow locations and few straight sections of both the
crossover pipe lines connecting convection outlet to radiation inlet.
HYDRO TESTING
1 Carry out hydro testing of all the passes at 11.5 Kg / cm2.
2 Carry out hydrostatic test of Economizer & steam super heater coil at 56.4
Kg/cm2 and 40.3 Kg/cm2 respectively for BPCL Inspection and at 31.5 kg/cm2g
along with other equipment of LOBS Waste heat boiler MR-13892 to GBI.
STACK
necessary Bosun chair arrangement//scaffolding.
132-CE-3-264.
DAMPERS
1 Carry out servicing of all the dampers, louvers & Pee hole doors.
1 Offer all the 4 nos. cup throats for inspection and carry out refractory repair if any.
Carry out renewal of 2 nos muffle block and repair remaining muffle blocks.
2 Carry out repair/replacement of refractory wall and roof ceramic modules during
shutdown (approx area 15 m2) as per drawing no. 132-CE-3-264
furnace floor as per drawing no. 132-CE-3-257
standard manner.
convection section as per drawing no. 132-CE-3-258-1& 2.
6 Carry out insulating Castable repair (approx. 10 m2) along with anchors of header
box covers as per drawing no. 132-CE-3-258-1 & 2.
Page 10 of 11
Size Rating
Sr no. Location
( In) (Lbs)
9. SNUFFING STEAM TO FIRE BOX 4 150
ANNEXURE I
Procedure and scope of work for replacement of 133-F-301 FD fan suction silencer
baffles.
1. Erect metal scaffolding.
2. Open all the connected duct flange bolts.
3. Make necessary rigging arrangement and remove the silencer piece (i.e. Section
between connecting piece for stack and transition piece as per BPCL drawing no.
133-CE-3-29).
4. If any connected duct / structure required to be removed for completion of the job,
then removal and restoration of the same is included in your scope.
5. Carry out replacement of all the baffles (part no. 17.1) inside the silencer. New
baffles shall be provided by BPCL.
6. For dismantling and assembly of baffles following procedure shall be followed,
a. Remove the stopper of any one side of the baffle by gas cutting. Stopper
is nothing but the small piece of angle welded to silencer housing.
b. Remove the baffle.
c. Insert the new baffle.
d. Weld the stopper as earlier.
e. Repeat the above steps to replace the other baffles.
7. On completion of the baffle assembly, the silencer assembly shall be fitted back.
8. Remove the scaffolding on completion of the job.
9. Old baffles metal part after removal of the insulation shall be disposed in scrap
yard.
Page 11 of 11

STOCK UNIT ( NHGU / LOBS) HEAT EXCHANGER / AIR
FIN COOLERS
Part A: For the following exchangers carry out the entire jobs as
per general scope of work detailed in Appendix A attachment 4
including opening and pulling out of exchanger bundle and
specific job as detailed against individual exchangers.
General RFET & ECT requirement for this package is given in the
inspection scope under section-Q
NHGU
Note: For the entire data sheet, the unit of measurement shall be , tube
length in mm, Pressure in kg/cm2, weight in Kg. The no of tubes
mentioned are for each bundle.
TAG NO 133-E-306 TYPE BHU(H)

SERVICE 2ND BFW PREHEATER LOCATION HGU
SHELL AND TUBE DETAILS
TUBE OD 20 MM TUBE LENGTH U-TUBE
TUBE THICK 2.3 MM TUBE MAT SA 213M T12
NO OF TUBES 269 BUNDLE WEIGHT 5900
SHELL ID 0.875 meter AREA 198
SHELL HYD 37.10 TUBE HYD 104
NOZZLE AND GASKET DETAILS
LOCATION DESCRIPTION QTY MESC
SHELL INLET 14-300# 2
SHELL OUTLET 14-300# 2
TUBE INLET 6-600# 1
TUBE OUTLET 6-600# 1
VENT 2-300# 1
DRAIN 2-300# 1
802 GSKT,SS410SSPWND,945X875X4.5,PN:802,W/P 1 85.41.12.911.5
803 GSKT,SS410SSPWND,945X875X4.5,PN:803,W/OP 1 85.41.12.912.5
INSERT NA -- NA
DRG NO 133-ME-3-22
1 Carry out bundle replacement with new bundle.
2 Offer shell test at 37.10 kg/cm2.
3 Offer tube test at 104 kg/cm2
4 Open insulation for CUI including insulation rings and UT gauging.
TAG NO 133-E-309 A/B TYPE NHN

SERVICE Water Cooler LOCATION HGU
Page 1 of 26
TUBE OD 25 MM TUBE LENGTH 8000
TUBE THICK 2 MM TUBE MAT SB163 UNS4400
SHELL HYD 37.1 TUBE HYD 24.7
TUBE INLET 8-150# 1
801 LHS GSKT,CAF,810x836x2,PN:801 LHS,W/P 1 85.31.10.810.5
803 RHS GSKT,CAF,803x829x2,PN:801 RHS,W/P 1 85.31.10.803.5
INSERT PTFE 392 43.53.98.332.5
DRG NO 133-ME-3-40
1 Carry out ECT of 100% of the tubes. Carry out replacement of 25% of
tubes of both coolers at site (including seal welding)
2 Carry out internal CTE painting of wet part of the exchanger
component on cooling water side including both tube sheets as per
BPCL painting specification AES 5430
4 Offer tube test at 24.7 kg/cm2
5 Open insulation for CUI including insulation rings and UT gauging
TAG NO 133-E-311 A/B TYPE BEM(V)

SERVICE FEED PREHEATER LOCATION HGU
TUBE OD 25 MM TUBE LENGTH 9000MM
TUBE THICK 2.5 MM TUBE MAT SA 213 T12
TUBE INLET 6-600# 1
DRAIN 2-600# 1
INSERT NA -- NA
DRG NO 133-ME-3-59
3 Open insulation for CUI excluding insulation rings and UT gauging
TAG NO 133-E-312 A/B TYPE BEU

SERVICE NAPHTHA FUEL VAPORISER LOCATION HGU
TUBE OD 20 MM TUBE LENGTH STRAIGHT LENGTH 3750
TUBE THICK 2.3 MM TUBE MAT SA 179M
Page 2 of 26
TUBE INLET 3-600# 1
802 GSKT,IJA,393x413x3,PN:802,W/P 1 85.37.05.322.5
803 GSKT,IJA,393X413X3,PN:803,W/OP 85.37.05.314.5
INSERT NA -- NA
DRG NO 133-ME-3-64
1 Carry out RFET of 20% of tubes.
TAG NO 133-E-313 TYPE NEN

SERVICE BOILER BLOW DOWN COOLER LOCATION HGU
TUBE OD 25MM TUBE LENGTH 4500MM
TUBE THICK 2MM TUBE MAT SB 163 UNS No.4400
TUBE INLET 3-150# 1
VENT 2-150# 1
DRAIN 2-150# 1
801 GSKT,CAF,231x251x2,PN:801 RHS,W/P, 1 85.31.10.231.5
801 GSKT,CAF,231x251x2,PN:801 LHS,W/OP 1 85.31.10.232.5
INSERT PTFE 22 43.53.98.332.5
DRG NO 133-ME-3-70
1 Carry out replacement of 100% of tubes at site.
TAG NO 133-E-314 A/B/C TYPE BEM(H)

SERVICE PROCESS COND. FEED/EFFLUENT EXCHANGE LOCATION HGU
TUBE OD 20 MM TUBE LENGTH 11000 MM
TUBE THICK 1.6 MM TUBE MAT SA 213M F304L
SHELL ID 0.25747 meter AREA 45.4
Page 3 of 26
TUBE INLET 2-600# 1
VENT 2-600# 1
DRAIN 2-600# 1
INSERT NA -- NA
DRG NO 133-ME-3-76
1 Carry out ECT of 20% of the tubes
2 Carry out repairs to leaky channel box
TAG NO 133-E-316 TYPE NEN

SERVICE N2 COOLER FOR REFORMING AND SHIFT LOCATION HGU
SELECTION
TUBE 2MM TUBE MAT SB163UNS No.4400
THICK
NO OF 331 BUNDLE WEIGHT 6650
TUBES
SHELL 13.7 TUBE HYD 9.1
HYD
TUBE INLET 6-150# 1
DRAIN 2-150# 1
VENT 2-150# 1
801 GSKT,CAF,759x785x2,PN:801 RHS,W/P 1 85.31.10.759.5
801 GSKT,CAF,759x785x2,PN:801 LHS,W/P 1 85.31.10.760.5
INSERT PTFE 331 43.53.98.332.5
DRG NO 133-ME-3-88
TAG NO 133-E-317 TYPE NJ21N(H)

SERVICE N2 COOLER FOR SHUTDOWN LOCATION HGU
TUBE 2MM TUBE MAT SB 163 UNS No.4400
THICK
NO OF 170 BUNDLE WEIGHT 3900
TUBES
Page 4 of 26
SHELL 13.7 TUBE HYD 9.1
HYD
SHELL 8-150# 2
INLET
SHELL 10-150# 1
OUTLET
TUBE 4-150# 1
INLET
TUBE 4-150# 1
OUTLET
VENT 2-150# 1
DRAIN 2-150# 1
801 GSKT,CAF,590x610x2,PN:801 RHS,W/P 1 85.31.10.588.5
801 GSKT,CAF,590x610x2,PN:801 LHS,W/P 1 85.31.10.589.5
INSERT PTFE 170 43.53.98.332.5
DRG NO 133-ME-3-95
2 Carry out internal CTE painting of wet part of the exchanger component
on cooling water side including both tube sheets as per BPCL painting
specification AES 5430
TAG NO 133-E-331 TYPE

SERVICE LUBE OIL COOLER FOR 133K304 A LOCATION HGU
TUBE OD 10mm TUBE LENGTH 1000mm
TUBE THICK 2mm TUBE MAT NA
NO OF TUBES 66 BUNDLE WEIGHT
SHELL ID 0.127 meter AREA NA
SHELL INLET 1.5-150# 1
SHELL OUTLET 1.5-150# 1
TUBE INLET -- 1
TUBE OUTLET -- 1
802 GSKT,CAF,126.5x145x2,PN:802,W/OP 1 85.31.10.126.5
INSERT NA -- NA
DRG NO 133-ME-3-
BPCL painting specification AE-DEP-C03.

SERVICE LUBE OIL COOLER FOR 133K304 B LOCATION HGU
TUBE OD NA TUBE LENGTH NA
TUBE THICK NA TUBE MAT NA
NO OF TUBES NA BUNDLE WEIGHT
SHELL ID 0.127 meter AREA NA
Page 5 of 26
TUBE INLET -- 1
TUBE OUTLET -- 1
802 GSKT,CAF,126.5x145x2,PN:802,W/OP 1 85.31.10.126.5
INSERT NA -- NA
TAG NO 133-E-333 A/B TYPE AES

SERVICE WATER COOLER OF 133K 304 A/B LOCATION HGU
TUBE THICK 2 MM TUBE MAT SA 516M GR 485
TUBE INLET 4-150# 2
GASKET
803 GSKT,IJA,438X458X3,PN:803,W/OP 1 85.38.10.276.5
804 GSKT,IJA,546X566X3,PN:804,W/OP 1 85.38.10.380.5
802 GSKT,CUJA,438X458X3,PN:802,W/P 1 85.44.03.440.5
801 GSKT,CUJA,464X484X3,PN:801,W/P 1 85.44.03.460.5
INSERT NA -- NA
GASKET MAT NA
DRG NO 133-ME-3-129
TAG NO 133-E-335 TYPE AES

SERVICE INTERSTAGE COOLER FOR 133K304A LOCATION HGU
TUBE THICK 1.6MM TUBE MAT SA 789M UNS No.
32760
Page 6 of 26
TUBE INLET 3-300# 1
GASKET
802 GSKT,SW,255X309X4.5,PN:802,W/OP 1 85.41.10.135.5

804 GSKT,SW,344X398X4.5,PN:804,W/OP 1 85.41.10.223.5
805 GSKT,SW,221X249X4.5,PN:805,W/OP 805 1 85.41.10.084.5
INSERT PTFE 42 43.53.98.329.5
GASKET MAT NA
DRG NO 133-ME-3-108
1 Carry out Glass flake coating (800-1000 microns thick) of both the Tube
sheets on cooling water side..

SERVICE INTERSTAGE COOLER FOR 133K304B LOCATION HGU
TUBE THICK 1.6MM TUBE MAT SA 789M UNS No. 32760
TUBE INLET 3-300# 1
GASKET
805 GSKT,SW,221X249X4.5,PN:805,W/OP 805 1 85.41.10.084.5
802 GSKT,SW,255X309X4.5,PN:802,W/OP 1 85.41.10.135.5
804 GSKT,SW,344X398X4.5,PN:804,W/OP 1 85.41.10.223.5
INSERT PTFE 42 43.53.98.329.5
GASKET MAT NA
DRG NO 133-ME-3-108
sheets on cooling water side.

SERVICE SPILL BACK COOLER FOR 133K304A/B LOCATION HGU
TUBE THICK 2MM TUBE MAT SA 789M UNS No.
32760
Page 7 of 26
TUBE INLET 2-300# 1
GASKET
805 GSKT,SW,270X298X4.5,PN:805,W/P 1 85.41.33.123.5
802 GSKT,SW,304X358X4.5,PN:802,W/OP 1 85.41.33.200.5
804 GSKT,SW,393X447X4.5,PN:804,W/OP 1 85.41.33.276.5
INSERT PTFE 31 43.53.98.332.5
GASKET MAT NA
DRG NO 133-ME-3-115

SERVICE INTERSTAGE COOLER FOR 133K306(TUBE LOCATION HGU
IN TUBE)
SHELL HYD 11 TUBE HYD 330
TAG NO 133-EA-301 TYPE AFC

SERVICE N2 AIR COOLER FOR HDS(AFC) LOCATION HGU
TUBE THICK 2.5MM TUBE MAT SA 213 TP GR T12
FINNED
SHELL ID NA AREA 2476
SHELL HYD NA TUBE HYD 23.2
TUBE INLET 6-300# 2
VENT 2-300# 1
DRAIN 2-300# 1
GASKET PLUG GSKT,SS316L,37X42X2,PLUG GSKT,W/OP 85.41.11.037.5
PLUG SA182F12CL2 76.99.99.509.8
INSERT NA -- NA
GASKET MAT SS316 SPWD WITH GRAFITE FILLER
DRG NO 133-ME-3-136
1 Carry out opening of 20% plugs and carry out ECT for these tubes
2 Carry out external cleaning of the air fin cooler using foam method.
Page 8 of 26
TAG NO 133-EA-302A/B TYPE AFC
SERVICE PROCESS GAS AIR COOLER(AFC) LOCATION HGU
TUBE THICK 2MM TUBE MAT SA 213 TP 304L +
SB209
NO OF TUBES 230 BUNDLE WEIGHT ~6000
TUBE INLET 8-300# 2
VENT 2-300# 1
DRAIN 2-300# 1
GASKET PLUG GSKT,SS316L,43X48X2,PLUG GSKT,W/OP 85.41.11.043.5
PLUG SA182F304L 76.99.99.510.8
INSERT NA -- NA
GASKET MAT SS316L SPWD WITH GRAFITE FILLER
DRG NO 133-ME-3-137
2 Carry out opening of 20% plugs and carry out ECT for these tubes
3 Carry out tube test at 37.10 kg/cm2
LOBS
TAG NO 132-E-253 A/B/C/D TYPE AES(H)

SERVICE DW FEED/VACUUM COLUMN BOTTOM LOCATION LOBS
EXCHANGER
TUBE THICK 2.5MM TUBE MAT SA-179
TUBE INLET 4-300# 1
VENT 1-300# 1
DRAIN 1-300# 1
Inst Connection 3/4-300# 4
801 GSKT,SPWD,SS304,845X853X4.5 MM, PN:801/2 85.41.11.600.5
802 GSKT,SPWD,SS304,845X853X4.5 MM, PN:801/2 85.41.11.600.5
803 GSKT,SPWD,SS304,845X853X4.5 MM, PN:803 85.41.11.599.5
804 GSKT,IJA,926X952X3 MM THK, W/OP 85.37.05.741.5
805 GSKT,IJA,715X741X3 MM THK, W/P, PN:805 85.37.05.555.5
INSERT NA -- NA
DRG NO. 132-ME-3-79-1
1 Carry out RFET for 50% tubes
2 Carry out shell test at 31.20 kg/cm2
4 Open insulation for CUI excluding insulation rings and UT gauging.
Page 9 of 26
TAG NO 132-E-258 TYPE AEM
SERVICE DW VACUUM BOTTOMS COOLER LOCATION LOBS
TUBE THICK 2MM TUBE MAT SB-338 (SEAM LESS)
GRD2
TUBE INLET 6-150# 1
DRAIN 1
2-150#
VENT 1
2-150#
PG Connection 1
-300#
801 GSKT,MONEL,602X628X3 MM
THK,PN:801/2,W/P 1 85.43.96.602.5
802 GSKT,MONEL,602X628X3 MM
THK,PN:801/2,W/P 1 85.43.96.602.5
804 1
GSKT,MONEL,602X628X3 MM THK,PN:804 ,W/P 85.43.96.603.5
INSERT NR - --
DRG NO. 132-ME-3-84
BPCL painting specification AES 5430.
TAG NO 132-E-259 TYPE AEM(H)

SERVICE LT TUBE SIDE CUT COOLER LOCATION LOBS
TUBE THICK 2MM TUBE MAT SB-338 (SEAM LESS)
GRD2
SHELL HYD 20 TUBE HYD 26
TUBE INLET 2-150# 1
DRAIN 1
2-150#
VENT 1
2-150#
PG Connection 2
-300#
801 GSKT,MONEL,344X370X3MM THK,PN:801, W/P 1 85.43.96.605.5
802 GSKT,MONEL,359X385X3MM THK,PN:802,W/P 1 85.43.96.604.5
804 GSKT,MONEL,359X385X3MM THK,PN:804, W/P 1 85.43.96.606.5
INSERT NR - --
Page 10 of 26
DRG NO. 132-ME-3-85
BPCL painting specification AES 5430.
3 Carry out shell test at 20 kg/cm2
4 Carry out tube test at 26 kg/cm2

SERVICE BFW PRE HEAT EXCHANGER LOCATION LOBS
TUBE THICK 2MM TUBE MAT SA-179
SHELL ID NA AREA 40.4
TUBE INLET 8-300# 1
DRAIN 1-300# 1
VENT 1-300# 1
PG Connection 2
3/4-300#
801 1
GSKT,IJA,449X475X3MM THK,PN:801/2LHS,W/P 85.37.02.448.5
802 GSKT,IJA,449X475X3MM THK,PN:801/2LHS,W/P 85.37.02.448.5,
; 85.37.02.449.5
GSKT,IJA,449X475X3MM THK,PN:802RHS,W/OP 1
INSERT NA -- NA
DRG NO. 132-ME-3-81-1
3 Open insulation for CUI and UT gauging.Carry out removal of insulation
support rings of channel for inspection and carryout insulation in
standard manner after inspection
4 Carry out RFET for 50% tubes
AG NO 132-E-271 A TYPE AXS H

SERVICE 1ST STAGE INTER CONDENSER LOCATION LOBS
TUBE THICK 2MM TUBE MAT SA-789 M UNS N-32750
NO OF TUBES 838 BUNDLE WEIGHT 19500/9000
WT.UNIT/BUNDLE
SHELL INLET 28-150#(SERIES-) 1
SHELL OUTLET 28-150#(SERIES--) 1
TUBE INLET 18-150# 1
Page 11 of 26
801 1
GSKT,INC,1162x1188x3MM THK,PN:801/2, W/P 85.43.59.116.5
802 1
GSKT,INC,1162x1188x3MM THK,PN:801/2, W/P 85.43.59.116.5
803 1
GSKT,IRON,1162X1188X3MM THK,PN:803, W/OP 85.38.12.116.5
804 1
GSKT,IRON,1247X1273X3MM THK,PN:804, W/OP 85.38.12.124.5
805 1
GSKT,INC,1116x1142x3MM THK,PN:805, W/OP 85.43.59.111.5
INSERT PTFE 838 43.53.98.332.5
DRG NO. 132-ME-3-73
GASKET SS 304 SW GRAPHITE FILLED
1 Remove channel box, channel cover, float head cover and channel
cover and sent to machine shop for repair.
5 Carry out ECT for 100% tubes
TAG NO 132-E-271 B TYPE AES H

SERVICE 2ND STAGE INTER CONDENSER LOCATION LOBS
WT.UNIT/BUNDLE
801 1
GSKT,INC,837X863X3 MM THK,PN:801, W/P 85.43.59.837.5
802 1
GSKT,INC,812x838x3 MM THK,PN:802, W/P 85.43.59.812.5
803 1
GSKT,IRON,812X838X 3MM THK,PN:803, W/OP 85.38.12.812.5
804 GSKT,IRON, 925X951X 3MM THK,PN:804,
W/OP 1 85.38.12.925.5
805 1
GSKT,INC,768X794X3 MM THK,PN:805, W/OP 85.43.59.768.5
INSERT PTFE 838 43.53.98.332.5
DRG NO. 132-ME-3-74
1 Remove float head cover, channel box and send to machine shop for
repair.
3 Send the bundle to BPCL shop for re-tubing
Page 12 of 26
TAG NO 132-E-271 C TYPE AES H
SERVICE AFTER CONDENSER LOCATION LOBS
TUBE THICK 2MM TUBE MAT SA-789 M UNS N-
32750
NO OF TUBES 838 BUNDLE WEIGHT 3700/100 WT.UNIT
/BUNDLE
801 1
GSKT,INC,462X488X3 MM THK,PN:801/2,W/P 85.43.59.462.5
802 1
GSKT,INC,462X488X3 MM THK,PN:801/2,W/P 85.43.59.462.5
803 1
GSKT,IRON,462X488X3 MM THK,PN:803, W/OP 85.38.12.462.5
804 1
805 1
GSKT,INC,421x447x3 MM THK,PN:805, W/OP 85.43.59.421.5
INSERT PTFE 838 43.53.98.332.5
DRG NO. 132-ME-3-69
TAG NO 132-E-275 A TYPE AES H

SERVICE PRECONDENSOR LOCATION LOBS
32750
NO OF TUBES 280 BUNDLE WEIGHT 8200/3000 WT.UNIT
/BUNDLE
SHELLVAPOUR 12-150# 1
OUTLET
SHELL LIQUID 4-150# 1
OUTLET
801 GSKT,INC,689X715X3 MM THK,PN:801/2, W/P 1 85.43.59.689.5
802 GSKT,INC,689X715X3 MM THK,PN:801/2, W/P 1 85.43.59.689.5
Page 13 of 26
803 1
804 1
805 1
INSERT PTFE 280 43.53.98.332.5
DRG NO. 132-ME-3-70
5 Open insulation for CUI and UT gauging. Carryout removal of insulation
support rings of shell for inspection and carryout insulation in
standard manner after inspection.
TAG NO 132-E-275 B TYPE AES H

SERVICE INTER CONDENSOR LOCATION LOBS
WT.UNIT/BUNDLE
OUTLET
OUTLET
801 1
GSKT,INC,562X588X3 MM THK,PN:801/2, W/P 85.43.59.562.5
802 1
GSKT,INC,562X588X3 MM THK,PN:801/2, W/P 85.43.59.562.5
803 1
804 1
805 1
INSERT PTFE 280 43.53.98.332.5
DRG NO. 132-ME-3-71
Page 14 of 26
TAG NO 132-E-275 C TYPE AES H

SERVICE AFTER CONDENSOR LOCATION LOBS
32750
NO OF TUBES 280 BUNDLE WEIGHT 2900/900 WT. UNIT /
BUNDLE
OUTLET
OUTLET
TUBE INLET 8-150# 1
801 1
GSKT,INC, 399X425X3 MM THK,PN801/2, W/P 85.43.59.399.5
802 1
GSKT,INC, 399X425X3 MM THK,PN801/2, W/P 85.43.59.399.5
803 1
GSKT,IRON,399X431X 3 MM THK,PN:803, W/OP 85.38.12.399.5
804 1
GSKT,IRON,489X 515X3 MM THK,PN:804, W/OP 85.38.12.489.5
805 1
GSKT,INC, 358X 384 X 3 MM , PN: 805,W/OP 85.43.59.358.5
INSERT PTFE 280 43.53.98.332.5
DRG NO. 132-ME-3-72

SERVICE DW LUBE BYPRODUCT AIR COOLER LOCATION LOBS
TUBE INLET 6-300# 2
Page 15 of 26
VENT 2-300# 1
DRAIN 2-300# 1
GASKET MAT SS 304 SPWD WITH FLEXIBLE GRAPHITE FILLER
GASKET PLUG
GASKET,PLUG,SOFT IRON,30X35X2 MM, W/OP 85.37.27.010.5
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-23
2 Carry out opening of 20% plugs and carry out for RFET for the tubes.

SERVICE DW VACUUM BOTTOMS AIR COOLERS LOCATION LOBS
TUBE INLET 3-300# 2
VENT 2-300# 1
DRAIN 2-300# 1
GASKET PLUG
PLUG SA105 76.99.99.503.8
INSERT NA -- NA
DRG NO. 132-ME-3-25
2 Carry out opening of 20% plugs and carry out for RFET for the tubes.
Part B: For the following exchanges there is no requirement for opening of the
exchanger & removal of tube bundles. Scope shall include only following activities,
1. Spading on shell and tube side including utilities connection.

2. Opening insulation for UT gauging.
3. Hydro testing of the exchanger on shell and tube side at specified pressure
and holding the pressure for 30 minutes.
4. Despading on completion of the hydrotest.
5. In case of AFC carry out external cleaning of tube bundle by Foam cleaning
method.
6. Insulation & Cladding as per general scope.
7. In case, exchanger requires opening and removal of the tube bundle then all
the jobs as per general scope of work shall be carried out and payment for
the same shall be made as per applicable SOR.
Page 16 of 26
NHGU:
TAG NO 133-E-305 A/B TYPE BHU(H)
SERVICE 1ST BFW PREHEATER LOCATION HGU
TUBE INLET 4-600# 1
VENT 2-300# 1
DRAIN 2-300# 1
802 1
GSKT,SS410SSPWND,841X775X4.5,PN:802,W/P 85.41.12.833.5
INSERT NA -- NA
DRG NO 133-ME-3-16
TAG NO 133-E-307 A/B TYPE BHU

SERVICE 3RD BFW PREHEATER LOCATION HGU
TUBE OD 20 MM TUBE U-TUBE
LENGTH
TUBE 2.3 MM TUBE MAT SA 213M TP 304L
THICK
NO OF 198 BUNDLE 4600
TUBES WEIGHT
SHELL 14-600# 2
INLET
SHELL 14-600# 2
OUTLET
TUBE INLET 6-600# 1
TUBE 6-600# 1
OUTLET
VENT 2-600# 1
DRAIN 2-600# 1
802 GSKT,SS304SSPWND,862X800X4.5,PN:802,W/P 1 85.41.12.858.5
INSERT NA -- NA
DRG NO 133-ME-3-28
Page 17 of 26
TAG NO 133-E-308 TYPE BEM
SERVICE DMW PREHEATER LOCATION HGU
TUBE THICK 1.6 MM TUBE MAT SA 213M TP 304L
VENT 2-300# 1
DRAIN 2-150# 1
INSERT NA NA
DRG NO 133-ME-3-34
TAG NO 133-E-315 TYPE BJ21U

SERVICE N2 HEATER FOR SHIFT REACTION LOCATION HGU
TUBE THICK 2.3 MM TUBE MAT SA 179M
TUBE INLET 3-600# 1
VENT 2-150# 1
DRAIN 2-150# 1
802 GSKT,IJA,531x551x3,PN:802,W/P 1 85.37.05.423.5
803 GSKT,IJA,531x551x3,PN:803,W/OP 1 85.37.05.424.5
INSERT NA -- NA
DRG NO 133-ME-3-82
TAG NO 133-E-318 TYPE BJ21U

SERVICE N2 HEATER FOR HDS LOCATION HGU
TUBE INLET 2-600# 1
Page 18 of 26
802 GSKT,IJA,393x413x3,PN:802,W/P 1 85.37.05.319.5
803 GSKT,IJA,393X413X3,PN:803,W/OP 1 85.37.05.314.5
INSERT NA -- NA
GASKET MAT SS316 SPWD WITH CA FILLER
DRG NO 133-ME-3-102

SERVICE AFTER COOLER FOR 133K306(TUBE IN LOCATION HGU
TUBE)
1 Offer for UT gauging only. No hydro test is required.
LOBS:
TAG NO 132-E-257 A/B TYPE AES(H)

SERVICE DW PRD STRIPPER FEED/VAC COLUMN LOCATION LOBS
BTM EXCHANGER
TUBE THICK 2MM TUBE MAT SA-213 T22
TUBE INLET 4-300# 1
SHELL DRAIN 2-300# 1
SHELL VENT 2-300# 1
PG Connection x300# 3
801 GSKT,SS304,546X549X4.5MM THK,801/2 W/P 1 85.41.11.567.5
802 GSKT,SS304,546X549X4.5MM THK,801/2 W/P 1 85.41.11.567.5
803 GSKT,SS304,546X549X4.5MM THK,803 W/OP 1 85.41.11.568.5
804 GSKT,SS304,646X649X4.5 MM THK,804 W/OP 1 85.41.11.569.5
805 GSKT,SS304,469X495X3 MM THK, 805 W/P 1 85.41.11.570.5
INSERT NA NA NA
DRG NO. 132-ME-3-76-1 & 2 -- NA
TAG NO 132-E-263 TYPE AEM H

SERVICE BW HHPS VAPOUR WATER COOLER LOCATION LOBS
Page 19 of 26
TUBE THICK 2MM TUBE MAT SB-338(SEAM LESS)
GRD 2
NO OF TUBES 242 BUNDLE WEIGHT 1400/200 WT.
UNIT/BUNDLE
SHELL HYD 24 TUBE HYD 31.1
TUBE INLET 3-150# 1
DRAIN 1-300# 1
VENT 1-300# 1
PG Connection 2
3/4-300#
801 1
GSKT,MONEL JKT,676X702X3 MM,PN:801/2,W/ 85.43.96.676.5
802 1
GSKT,MONEL JKT,676X702X3 MM,PN:801/2,W/ 85.43.96.676.5
804 GSKT,MONEL JKT,681X707X3 MM,PN:804,W/P 1 85.43.96.681.5
INSERT NR 242 --
DRG NO. 132-ME-3-83-2
TAG NO 132-EA-221 A/B/C/D TYPE AFC

SERVICE VACUUM COLUMN TOP SIDE REFLEX AIR LOCATION LOBS
COOLER
TUBE INLET 3-300# 1
CHANNEL 2-300# 1
DRAIN
CHANNE VENT 2-300# 1
GASKET PLUG
PLUG
SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-17
TAG NO 132-EA-221 ST A/B/C/D TYPE AFC

SERVICE STEAM COIL LOCATION LOBS
Page 20 of 26
TUBE INLET 3-150# 1
DRAIN 2-150# 1
VENT 2-150# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-18

SERVICE WAXY 150N SIDE CUT AIR COOLER LOCATION LOBS
TUBE INLET 3-300# 1
VENT 2-300# 1
DRAIN 2-300# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-19
TAG NO 132-EA-222 ST TYPE AFC

TUBE INLET 4-150# 1
VENT 2-150# 1
DRAIN 2-150# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-20
Page 21 of 26
SERVICE WAXY 500N PRODUCT AIR COOLER LOCATION LOBS
TUBE INLET 4-300# 1
VENT 2-300# 1
DRAIN 2-300# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-21

TUBE INLET 6-150# 2
VENT 2-150# 1
DRAIN 2-150# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-22

SERVICE LT LUBE SIDE CUT AIR COOLER LOCATION LOBS
TUBE OD 25MM TUBE LENGTH 4000mm
TUBE INLET 2-300# 1
Page 22 of 26
VENT 2-300# 1
DEAIN 2-300# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-24

SERVICE WAXY 100N SC AIR COOLER LOCATION LOBS
TUBE INLET 3-300# 1
VENT 2-300# 1
DRAIN 2-300# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-26

TUBE INLET 3-150# 1
VENT 2-150# 1
DRAIN 2-150# 1
GASKET PLUG
PLUG SA105 76.99.99.502.8
INSERT NA -- NA
DRG NO. 132-ME-3-27
Page 23 of 26
SERVICE DW HHPS VAPOUR AIR COOLER LOCATION LOBS
TUBE THICK 2.5MM TUBE MAT SA-213 T11
TUBE INLET 6-300#RTJ 2
TUBE OUTLET 6-300#RTJ 2
VENT 2-300#RTJ 1
DRAIN 2-300#RTJ 1
GASKET PLUG GASKET,PLUG,SOFT,SS316L,37x42x2 MM,
W/OP 85.37.27.008.5
PLUG 76.99.99.504.8
SA182F11 76.99.99.505.8
GASKET MAT NA
INSERT NA -- NA
DRG NO. 132-ME-3-28
PART C: For Part C, only carry out external scaffolding wherever required
and carry out insulation job as per general scope.
TAG NO 132-E-254A/B/C/D TYPE DFU H

SERVICE REACTOR FEED/EFFLUENT EXCHANGER LOCATION LOBS
TUBE OD 25.4MM TUBE LENGTH U-TUBE
TUBE THICK 2.8MM TUBE MAT SA-213 TP321
SHELL HYD ---- TUBE HYD ----
SHELL INLET 6 BW 2
SHELL OUTLET 6 BW 2
TUBE INLET 6 BW 2
TUBE OUTLET 6 BW- 2
801 GSKT,321,720X747X3 MM THK,PN:801,W/OP 85.41.11.721.5
802 GSKT,321,667.8X690X1.6 THK,PN:802,W/P 85.41.11.854.5
803 GSKT,321,682X690X4.5 THK,PN:803,W/OP 85.41.11.683.5
SPECIAL GSKT GSKT,NON ASB ARAMIDE FIBRE,3MM,FIG:40 85.32.10.106.5
INSERT NA -- NA
DRG NO. 132-ME-3-15-1
GASKET SW 4.5 THK SS 321 GRAPH. FILLER 3.2 THK
MATERIAL SS321 OUTER RING
*** ALL NOZZLES ARE BUT WELDED
Page 24 of 26
TAG NO 132-E-255 TYPE NEN H
SERVICE DW MAKEUP HYDROGEN COOLER LOCATION LOBS
TUBE OD 25MM TUBE 5500MM
LENGTH
TUBE 3.7MM TUBE MAT SB622 UNS-10276
THICK
NO OF 224 BUNDLE 15450
TUBES WEIGHT
SHELL ---- TUBE HYD ----
HYD
SHELL BUT WELDED
INLET
SHELL BUT WELDED
OUTLET
TUBE 8-1500#RTJ 1
INLET
TUBE 8-1500#RTJ 1
OUTLET
DRAIN 2-1500# RTJ 1
VENT 2-1500# RTJ 1
801 GSKT,MSW,760X768X4.5 MM,PN:801 RHS,W/OP 85.43.96.761.5
801 GSKT,MSW,760X768X4.5 MM,PN:801 LHS,W/P 85.43.96.762.5
INSERT NA -- NA
DRG NO. 132-ME-3-14-1
TAG NO 132-E-256 A/B TYPE DFU H

SERVICE DW HHPS VAPOUR / MAKEUP HYDROGEN LOCATION LOBS
EXCHANGER
TUBE OD 25.4MM TUBE LENGTH U TUBE
TUBE THICK 3.4MM TUBE MAT SA-213 T11
SHELL HYD --- TUBE HYD ----
SHELL INLET 6 1
SHELL OUTLET 6 1
TUBE INLET 4 1
TUBE OUTLET 4 1
801 GSKT,SA240 1
GRSS321,476X501.4X3MM,801W/OP 85.41.11.851.5
802 GSKT,SA240 GRSS321,423.8X446X1.6, 802 WP 1 85.41.11.852.5
803 GSKT,SS321, 438X446X4.5MM THK, 803 W/OP 1 85.41.11.853.5
SPECIAL 1
GASKET GSKT,NON ASB ARAMIDE FIBRE,3MM,FIG:37 85.32.10.104.5
INSERT NA -- NA
DRG NO. 132-ME-3-13-1
*** ALL NOZZLES ARE BUT WELDED
Page 25 of 26
Configuration details based on Heat Exchanger type
Page 26 of 26
ATTACHMENT 11 SECTION D
NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE STOCK

UNIT (NHGU / LOBS) STEAM GENERATORS
Carry out jobs on following steam generator as per the scope detailed below
NHGU:-
WASTE HEAT BOILERS
HYDROGEN UNIT WASTE HEAT BOILER (MR12883)
a) Remove complete insulation of all pressure components of Boiler

including steam generators, steam drum, risers, down comers and
connected pipings as per GBI requirements as part of bare inspection of
boiler and offer to BPCL inspection and GBI in clean condition.
b) Carry out RLA study through GBI approved RLA agency and submit
report to BPCL inspection and GBI. Offer NDTs and testing to BPCL / GBI
during RLA study at site as per GBI requirements. The contractor should
take permission from GBI for carrying out RLA. It may be noted that
cutting of samples and their destructive testing as per IBR rules
shall be included in the contractor scope. Also supply of new
tubes/plugs including welding for replacing/plugging the sample
drawn locations shall be in the contractor scope.
I. General:
Erect external scaffolding wherever required.

Carry out spading as per blind list.
II. PROCESS WASTE HEAT BOILER (133-EW-301)
a) Open the man ways and clean the tubes internally / externally free of
scales/ muck and offer for inspection. Ensure that the refractory in the
west side tube sheet / cold collector outlet does not get wet.
b) Open 6 dia 600 # hand hole blind flanges of the shell , clean the
accessible tubes externally and offer for visual inspection.
Page 1 of 9
III. STEAM DRUMS (133-V-301)
a) Open all man ways of steam drum.
b) Remove all drum internals including primary and secondary cyclones ,

demisters / separators and mounting viz. first isolation valves, gauge
glass & pressure gauge etc.
c) Cary out servicing of gauge glass as per procedure.
d) Thoroughly clean the drum internally to bare metal, after removing all the
internal fittings.
e) Offer all fermanited flanges for inspection of the flange faces.
f) Clean and offer all drum internals for inspection.
g) Drop all first isolation valves and offer hydro test of seat and body as per
flange rating.
h) Offer NRV on main steam line for inspection after providing proper
scaffolding arrangement.
i) Open insulation of all 4 and less size nozzles. Remove insulation to

expose MR number of the boiler on drum.
j) After dry inspection of the boiler by GBI, paint the drum internally and all
internals with 2 coats of ferrotol paint as per AES 5430.
k) On completion of the painting, fix back all the internals, box up man ways,
fix back all the drum mountings. The demisters if required shall be
replaced with new one.
IV. FG BOILER COIL (133-E-304)
a) Open man ways and erect scaffolding inside the duct to access all coils of
both modules on either sides and outside the duct to access the top
headers. Provide proper ladder arrangement wherever required.
b) Open complete insulation on top and bottom headers and offer for
inspection.
c) Clean all tubes externally free of scales using heavy duty industrial
vacuum cleaner and offer for inspection.
V. STEAM SUPER HEATER COIL (133-E-303 A/B)
a) Open man ways in the duct and erect scaffolding inside the duct to
access all coils. Open man ways and panels on either side outside the
duct and provide scaffolding to access the headers / coil bends. Remove
Page 2 of 9
insulation in the header box to access the coil bends. Provide proper
ladder arrangement wherever required.
b) Open complete insulation in both inlet and outlet headers and offer for
inspection.
c) Clean all tubes externally free of scales using heavy duty industrial
vacuum cleaner and offer for inspection.
VI. RISERS AND DOWN COMERS
Open complete insulation of down comers and risers and offer for inspection.
Open insulation around vents and drains and offer for inspection. Provide
necessary scaffolding / ladder arrangement to carry out inspection of these
lines.
VII. HYDROSTATIC TEST OF THE BOILER
a) Offer hydrostatic test of the entire boiler at 75.0 kg/cm2g with all first isolation
valves in the circuit to BPCL inspection / GBI. After completion of hydro test of
the boiler circuit, carry out scrape cleaning and painting as per AES-5430 Rev 1.
Carry out the insulation of the entire piping/equipment as per BPCL Standard.
VIII. BLOW DOWN LINES
a) Delag the entire blow down lines fully and offer for inspection. Offer the
hydro test of the same as per flange ratings.
b) Paint the lines with 2 coats of zinc dust graphite and relag in standard
manner.
c) Overhaul the entire blow down valves of the boiler system.
IX. GBI SCOPE
With respect GBI inspection your scope includes, arrangement of following,
a) Submission of Dry test/Bare Inspection and Hydro test request letter

following addressed GBI office l
THE DIRECTOR,
The Directorate of Steam Boilers,
Kamgar Bhavan, 7th floor,
C-20, E Block,
Opp. Reserve Bank, BKC,
Bandra (E), Mumbai-400051
Page 3 of 9
b) Obtaining visits from GBI office for Dry test/Bare Inspection and Hydro
testing.
c) Arrangement of AC Car for to and fro transportation of GBI official on full
day basis.
d) Collection of all the inspection reports and certificate from GBI office.
e) All statutory fees shall be settled by BPCL.
X. JOB COMPLETION
a) After completion of the hydro test inspection by GBI, box up all the duct /
boiler duct manways, remove all spades and scaffolding.
EQUIPMENT DETAILS
TAG NO 133-V-301 LOCATION HGU

SERVICE STEAM DRUM DRG NO.
DEMISTER YES
VESSEL ID 2.870 meter HEIGHT/LENGTH 12.03 meter

HYD TEST 75
PR.(Kg/cm2)
Sr. No. X RATING
No. LOCATION SIZE (lbs)
(inch)
1. BFW I/L line 6 600
2. riser from E-304 to steam drum 12 600
5. riser from E-304 to steam drum 6" 600
6. down comer to E-304 line 12 600
1 9. down comer to E-304 line 6" 600
10. riser from EW-301 to steam drum 12 600
SPADE LIST
14. down comer to EW-301steam drum 12 600
18. o/l saturated HP steam 14 600
19. sample point RSC-1601 600
20. RPSV 1607A line to relief 4" 600
21. RPSV 1607B line to relief 4" 600
22. RPSV 1607C line to relief 4" 600
23. RPSV 1607D line to relief 4" 600
24. 2" line to silencer 2" 600
25. drain line to OWS 2" 600
26. phosphate dosing line 1.5 600
27. BLOW DOWN LINE TO V-303 2" 600
Page 4 of 9
LOBS :-
Steam generator MR No. 13892 consist of
1. Boiler feed water (Economizer) and Steam Generator(Superheater ) coil

located in convection section of 132-F-205 & 206.
2. 132-E-251, 132-E-252, 132-E-260 Steam generators
Remove insulation of the waste heat boiler (MR 13892) and its connected
equipment/piping and offer the boilers for bare inspection to BPCL/GBI in
clean condition. After completion of hydro test of the boiler circuit, carry out
scrape cleaning and painting as per AES-5430 Rev 1.
Scope of work:-
b) Erect external scaffolding wherever required.

c) Cary out spading as per blind list.
d) Open all the covers of above mentioned steam generators.
e) Drop all the first isolation valves, remove all dismountable internals and
dismantle all the attached mounting like gauge glass etc.
f) Clean the tubes internally by high pressure water jet. Carry out RFET / ECT as
per scope given in inspection package. (50% RFET of tubes for each of the
exchanger 132 E251/252/260)
g) Flush shell side thoroughly with water.
h) Make complete insulation of the shell.
i) Shell side shall be thoroughly cleaned and offered for Dry Inspection to GBI
along with the cleaned bundle tube
j) Integral Piping: Open complete insulation of the integral piping (Inlet piping of
Economizer, Inlet piping of steam generators from Economizer, Outlet piping of
steam generators to super heater coils and outlet lines of main super heater).
Provide necessary scaffolding / ladder arrangement to carry out inspection of
these lines.
k) Blow down Lines: Delag the entire blow down lines fully and offer for
inspection. Offer the hydro test of the same as per flange ratings. Paint the lines
Page 5 of 9
with 2 coats of zinc dust graphite and re-lag in standard manner. Overhaul the
entire blow down valves of the boiler system.
l) Offer entire circuit to GBI for dry inspection.
m) After approval by GBI, the bundles to be inserted in the shell after painting the
internal surface of the shells with 2 coats of ferrotol paint.
n) Prepare the shell test.
o) Service and repack the glands of all the first isolation valves including blow down
lines valves.
p) Service all the gauge glasses as per procedure.
q) Carry out hydrostatic test of the steam generators per the following test pressure.
SR. NO. STEAM DESCRIPTION SHELL SIDE TUBE SIDE

GENERATOR NO. Kg/cm2g Kg/cm2g
1 132-E-251 WAXY 150N 31.50 23.40
SIDECUT STEAM
GENERATOR
2 132-E-252 WAXY 500N STEAM 31.50 33.93
GENERATOR
3 132-E-260 WAXY 150N 31.50 21.06
SIDECUT PUMP
AROUND STEAM
GENERATOR
4 ECONOMIZER ECONOMIZER 56.4
COILS IN COILS ( Hydro
CONVECTION - testing at
SECTION OF 132- 56.4 kg/cm2
F-205 & 132-F- is covered
206. in heater
scope)
5 ECONOMIZER SUPERHEATER 40.3
COILS IN COILS ( Hydro
CONVECTION - testing at
SECTION OF 132- 40.3 kg/cm2
F-205 & 132-F- is covered
206. in heater
scope)
r) GBI will witness the COMBINED HYDROTEST including shell side of steam
generator, Economizer and super heater coils located in convection zone of 132-
F-205 & 206. Offer hydro test to GBI at 31.5 kg/cm2g with out covers. All the first
isolation valves shall be included in the test.
Page 6 of 9
s) After completion of hydro test of the boiler circuit, carry out scrape cleaning and
painting as per AES-5430 Rev 1. Carry out the insulation of the entire
piping/equipment as per BPCL Standard.
t) With respect GBI inspection your scope includes , arrangement of following,
Submission of Dry test/Bare Inspection and Hydro test request letter to

following addressed GBI office
THE DIRECTOR,
C-20, E Block,
Obtaining visits from GBI office for Dry test/Bare Inspection and Hydro
testing.
Arrangement of AC Car for to and fro transportation of GBI official on full
day basis.
Collection of all the inspection reports and certificate from GBI office.
All statutory fees shall be settled by BPCL.
u) After completion of the hydro test by GBI fix back all the cover and prepare tube
test.
v) After completion of the tube test remove all spades and scaffolding.
DETAILS FOR STEAM GENERATOR
TAG NO 132-E-251 TYPE BKM(H,IBR)

SERVICE WAXY 150N SIDE CUT STEAM GENERATOR LOCATION LOBS
LENGTH
NO OF TUBES 82 BUNDLE 1225 kg
WEIGHT
SHELL ID 0.65meter AREA 15 m2
SHELL HYD 23.4 kg/cm2 TUBE HYD 31.5
Page 7 of 9
TUBE INLET 3-300# 1
IBD 1-300# 1
CBD 1-300# 1
DRAIN 1-300# 2
INST CONNECT 2-300# 6
INST CONNECT 1.5-300# 2
INST CONNECT 3/4-300# 2
VENT 1-300# 1
802 GSKT,IJA,384x410x3 THK W/P, PN:802 LHS 85.37.02.384.5
802 GSKT,IJA,384x410x3 THK W/P, PN:802 RHS 85.37.02.385.5
INSERT NA -- NA
DRG NO. 132-ME-3-77-1
TAG NO 132-E-252 TYPE BKM(H,IBR)

SERVICE WAXY 500N STEAM GENERATOR LOCATION LOBS
LENGTH
WEIGHT
SHELL ID 0.8 meter AREA 47.8 m2
TUBE INLET 3-300# 1
IBD 1-300# 1
CBD 1-300# 1
DRAIN 1-300# 2
INST CONNECT 2-300# 6
INST CONNECT 1.5-300# 2
INST CONNECT 3/4-300# 2
VENT 1-300# 1
802 GSKT,SS304,569x577x4.5MM THK W/P,802 LHS 85.41.11.571.5
802 GSKT,SS304,569x577x4.5MM THK W/P,802 RHS 85.41.11.572.5
INSERT NA -- NA
DRG NO. 132-ME-3-78-1

SERVICE WAXY 150N SIDE CUT PUMP AROUND STEAM LOCATION LOBS
GENERATOR
LENGTH
WEIGHT
SHELL ID 1.1 meter AREA 154 m2
TUBE INLET 8-300# 1
Page 8 of 9
DRAIN 1-300# 1
VENT 1-300# 1
PG Connection 3/4-300# 2
802 GSKT,SS304,769X777X4.5MM THK W/P,802LHS 1 85.41.11.581.5
802 GSKT,SS304,769X777X4.5MM THK W/P,802RHS 1 85.41.11.582.5
INSERT NA -- NA
DRG NO. 132-ME-3-80-1
Page 9 of 9
ATTACHMENT 11 SECTION E

UNIT ( NHGU / LOBS) : VESSELS / REACTORS
NHGU:-
Part A : Carry out all the jobs on the vessels as per scope of work
detailed in Appendix A attachment 5 including opening of the vessel
and specific jobs detailed against each equipment

SERVICE PROCESS DRG NO. 133-ME-2-23-1
CONDENSATE
SEPARATOR
DEMISTER YES DEM DRAWING 133-ME-2-23 SH 2
VESSEL ID 1.65 meter HEIGHT 3.4 meter
HYD TEST 37.45
PR.(Kg/cm2)
Sr. No. X RATING
1
(inch)
1. process condensate from E-309 A/B
to V-302 16 300
SPADE LIST 2. RPSV-1634 A /B common line to
relief 4" 300
3. P-303A/B seal leak off line to V302 3" 300
4. P-303A/B ARC line to V303 1.5 300
5. process condensate o/l to P-303 A/B 3" 300
6. process gas o/l to PSA 14 300
1 Remove and replace the demister assembly.
2 Carry out hydro testing at 37.45 kg/cm2.
3 Remove and service the gauge glasses

SERVICE FUEL NAPHTHA DRG NO. 133-ME-2-12
KOD
2 DEMISTER Yes DEM DRAWING 133-ME-2-12 SH 1
HYD TEST 7.8
PR.(Kg/cm2)
SPADE LIST Sr. LOCATION No. X RATING
Page 1 of 31
No. SIZE (lbs)
(inch)
1. naphtha i/l line to V-304 6" 150
2. LP steam line to V-304 2" 150
3. drain to CBD/OWS common line 1. 150
4. fuel naphtha o/l line to reformer 6" 150
5. gauge glass drain line 300
6. level switch drain line (2 Nos.) 300
7. jacketing steam line 300
8. naphtha i/l line to V-304 6" 150
4 Carry out insulation removal for inspection including insulation rings as per general scope and
carry out insulation in standard manner.

SERVICE BFW DRG NO. 133-ME-2-26-1
DEAERATOR
VESSEL ID 2.8 meter LENGTH 9 meter

HYD TEST 4.55
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. DM water + condensate common i/l
line to V-305 6" 150
3 2. condensate line from E-314 to v-305 2' 150
3. pump discharge arc line to v-305 3" 150
4. LP steam condensate from v-306 6" 150
5. vent to atmosphere 2" 150
SPADE LIST 6. o/l to RV common line 10 150
7. LP steam for deaeration 10 150
8. LP steam for purging 8" 150
9. vent line from top of deaerator 2" 300
10. o/l to P-302A/B 8" 150
11. hydrazine to v-305 2" 300
12. amine to v-305 2" 300
13. P-302 A/B balance leak off line 2" 300
14. drain line to OWS 2" 300
15. jacketed line from bottom 2" 300
1 Carry out power brushing of all the weld joints 6 on either side of the weld and carry out
WFMPI testing
2 Remove rasching ring in the de-aeration section and load the same after inspection work
3 Carry out internal scrape cleaning and painting with two coats of Ferrotol paint as per painting
specification AES 5430. (System 21)
Page 2 of 31
SERVICE DMDS DRUM DRG NO. 133-ME-2-14-1

HYD TEST NA QTY NA
PR.(Kg/cm2)
Sr. No. X RATING
4
(inch)
1. naphtha i/l to vessel 1" 150
2. nitrogen i/l line to vessel 2" 300
SPADE LIST 3. LP steam line to vessel 1. 150
4. o/l line to P-314 suction 2" 150
5. P-314 spill back/ RV o/l line to vessel 2" 150
6. DMDS i/l line from barrel 2" 150
7. drain line flange 2" 150
8. gauge glass drain line to CBD 3/4 300
1 Carry out water fill up test.

SERVICE N2 SU DRG NO. 133-ME-2-15-1
SEPARATOR FOR
SHIFT SECTION
DEMISTER YES DEM DRAWING 133-ME-2-15-1&2 SH
1
HYD TEST 13.65
5
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. recycle nitrogen from v-302 common
SPADE LIST
i/l to v-308 10 150
2. o/l line to RPSV-2050 A/B 2" 150
3. top o/l line to k-303 10 150
4. bottom drain line to OWS 2" 150
Page 3 of 31
SERVICE FUEL GAS KOD DRG NO. 133-ME-2-16-1
DEMISTER YES DEM DRAWING 133-2-ME-16-1&2 SH
1
HYD TEST 7.8
PR.(Kg/cm2)
Sr. No. X RATING
6
(inch)
1. i/l fuel gas line from C-301 to vessel 4" 150
2. LP staem to V-309 2" 300
3. common o/l line to reformer and
SPADE LIST
RV'S 4" 150
4. drain to OWS/CBD common line 2" 300
5. gauge glass LP and HP steam
tapping 2" 300
6. level switch drain line (2 Nos.) 3/ 300
7. i/l fuel gas line from C-301 to vessel 4" 150
WFMPI testing
3 Carry out internal scrape cleaning and painting of Bottom half of the vessel with two coat of
CTE paint as per painting specification AES 5430.

SERVICE EMERGENCY DRG NO. 133-ME-2-24-1
HYDROGEN
DRUM

7
HYD TEST 276.16
PR.(Kg/cm2)
Sr. No. X RATING
SPADE LIST (inch)
1. common i/l and o/l line to v-311 2" 1500
2. top o/l common line to RV'S 2" 1500
1 Carry out hydro testing at 276.16kg/cm2.
WFMPI testing
Page 4 of 31
SERVICE N2 SU DRG NO. 133-ME-2-19-1
SEPARATOR FOR
HDS
DEMISTER YES DEM DRAWING 133-ME-2-19-1 SH 1
HYD TEST 20.66
PR.(Kg/cm2)
Sr. No. X RATING
8 (inch)
1. nitrogen i/l line 2" 300
2. i/l line from EA 301A/B 6" 300
3. LP steam i/l line 2" 150
4. top o/l to K-307 and RV'S common
SPADE LIST
line 6" 300
5. bottom o/l line to c-301 and
CBD/OWS 2" 300
6. gauge glass drain line to CBD/OWS
(2 Nos.) 300
7. level switch to drain line 3/4 300
8. nitrogen i/l line 2" 300

SERVICE CLOSED BLOW DRG NO. 133-ME-2-20-1
DOWN DRUM
(BURIED VESSEL)
VESSEL ID 1.8 meter LENGTH 6.5 meter

HYD TEST 4.55
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. cooling water supply line block valve
9 d/s flange 3" 150
2. cooling water return line block valve
u/s flange from V-314 3" 150
3. LP steam line block valve d/s flange 2" 300
4. FLARE LINE BLOCK VALVE
SPADE LIST
(REVERSE SPECTACLE) 3" 300
5. P-320 DISCHARGE TO SLOP HDR
2nd block valve u/s flange 4" 300
6. P-320 DISCHARGE LINE DRAIN TO
OWS 2" 150
7. VENT LINE BLOCK VALVE d/s
flange 2" 0
8. CBD HDR FROM HCU 2nd block
valve u/s flange 6" 150
Page 5 of 31
9. CBD HDR FROM HGU 2nd block
valve u/s flange 8" 150
10. cooling water return line to RV U/S
valve u/s flange 3/ 150
1 Carry out internal shot blasting and EPOXY painting System 22 as per painting specification
AES 5430.
WFMPI testing
3 Carry out repair/ replacement of leaky cooling water coil.

SERVICE FLARE KOD DRG NO. 133-ME-2-21-1
VESSEL ID 3 meter HEIGHT 4.85 meter

HYD TEST 17.48
PR.(Kg/cm2)
10 Sr. No. X RATING
(inch)
1. I/L HDR TO V-315 28 300
SPADE LIST
2. O/L LINE TO MAIN FLARE
SYSTEM 28 150
3. O/L COMMON LINE TO CBD AND
RSDV 699 8" 300
WFMPI testing
2 Carry out internal scrape cleaning and painting of bottom half of the vessel with two coat of
CTE paint as per painting specification AES 5430.

SERVICE COND. DRG NO. 133-ME-2-22-1
COLLECTION
DRUM (BURIED
VESSEL)
VESSEL ID 1.1 meter LENGTH 6.5 meter

HYD TEST 4.55
11
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. NHGU CONDENDATE LINE FIRST
SPADE LIST 4" 150
BLOCK VALVE D/S FLANGE
2. CDU VDU CONDENSATE LINE D/S
3" 150
BLOCK VALVE U/S FLANGE
3. HCU CONDENSATE LINE D/S 3" 150
Page 6 of 31
BLOCK VALVE U/S FLANGE
4. SUSPECT CONDENSATE LINE AT
3" 150
PUMP O/L -2 NOS.
5. VESSEL VENT 2" 150
6. NHGU CONDENDATE LINE FIRST
4" 150
WFMPI testing
TAG NO 133-V-317
SERVICE BEARING CW
SUMP
CONCRETE PIT
Sr. No. X RATING
(inch)
1. CDU VDU BCW LINE REVERSE
8 150
SPADE IN PIT
12
2. CDU VDU NEW BCW LINE SPADE 6 150
3. HCU BCW LINE SPADE REVERSE
8 150
SPADE LIST IN PIT
4. NHGU BCW LINE REVERSE
12 150
SPADE IN PIT
5. PUMP 322 A O/L BLOCK VALVE
8 150
D/S FLANGE
6. PUMP 322 B O/L BLOCK VALVE
8 150
D/S FLANGE
7. VESSEL VENT 4 150
1 Carry out internal cleaning of sump and offer for inspection.
TAG NO 133-V-318
SERVICE CRU OFF GAS
KOD
VESSEL ID
HYD TEST 34.98
PR.(Kg/cm2)
Sr. No. X RATING
13 No. LOCATION SIZE (lbs)
(inch)
1. V 318 INLET LINE VESSEL BODY
6" 300
FLANGE
SPADE LIST 2. V 318 OUTLET LINE VESSEL
6" 300
3. V 318 TOP COMMON LINE TO RV
2" 300
FLANGE
4. DRAIN TO CBD COMMON LINE
2" 300
Page 7 of 31
1 Carry out replacement of the demister assembly.
TAG NO 133-V-
321/322/323/324/3
25/326/327/328/32
9/330
14 SERVICE PSA ADSORBER DRG NO 133-ME-2-38-1
VESSEL ID 2800 VESSEL HEIGHT (T 4470

to T)
HYD TEST -
PR.(Kg/cm2)
1 Opening and box up of manways & catalyst loading and unloading for these vessels shall be
carried out by another agency appointed by BPCL. Carry out all other scope as per general
scope of work.
WFMPI testing
3 Carryout DP of dish to skirt weld externally
TAG NO 133-G-301 LOCATION HGU

SERVICE H2 PRODUCT DRG NO. 133-ME-2-
FILTER

HYD TEST 38.25
15
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
SPADE LIST
1. I/L LINE 8" 300
2. O/L LINE 8' 300
3. DRAIN LINE 2" 300
1 Remove and clean filter element

SERVICE PHOSPHATE DRG NO. 133-ME-2-
TANK
16
HYD TEST WATER FILL
PR.(Kg/cm2)
Sr. No. X RATING
SPADE LIST LOCATION
No. SIZE (lbs)
Page 8 of 31
(inch)
1. DM WATER I/L LINE TO VESSEL 1. 150
2. O/L LINE TO P-351 2" 150
3. PUMP DISCHARGE COMMON
LINE TO V-370 2" 150
4. VENT LINE TO ATMOSPHERE 2" 150
1 Carry out water fill up test

SERVICE HYDRAZINE DRG NO.
TANK

HYD TEST WATER FILL
PR.(Kg/cm2)
17 Sr. No. X RATING
(inch)
SPADE LIST 2. O/L LINE TO P-351 2" 150
LINE TO V-370 2" 150

SERVICE AMINE DOSING DRG NO. 133-ME-2-
TANK

HYD TEST WATER FILL
PR.(Kg/cm2)
18 Sr. No. X RATING
(inch)
LINE TO V-370 2" 150
Page 9 of 31
SERVICE AMINE DOSING DRG NO. 133-ME-2-
TANK

HYD TEST WATER FILL
PR.(Kg/cm2)
19 Sr. No. X RATING
(inch)
LINE TO V-370 2" 150
TAG NO 133-V-384 LOCATION

SERVICE CHLORINE DRG NO. 41127
GUARD BED
VESSEL ID HEIGHT
HYD TEST 35.5
PR.(Kg/cm2)
20 Sr. No. X RATING
(inch)
LINE TO V-370 2" 150
1 Carry out replacement of the entire catalyst. Replace SS wire mesh/screen if found damaged.
WFMPI testing
3 Carry out hydro testing of vessel at 35.5 kg/cm2.
TAG NO 133-T-311 LOCATION HGU

SERVICE CLOSED DRG NO. 133-ME-2-
COOLING WATER
TANK
21
VESSEL ID NA HEIGHT 2.1 meter
HYD TEST 9.36
PR.(Kg/cm2)
Sr. No. X RATING
SPADE LIST LOCATION
No. SIZE (lbs)
Page 10 of 31
(inch)
1. RAW COOLING WATER MAKE UP
LINE I/L VALVE D/S FLANGE 150
2. RECYLE WATER TO TANK I/L
FLANGE TO BE SPADED 2" 150
3. TANK O/L TO P-335 LINE TANK
BODY FLANGE TO BE SPADED 2" 150
4. DRAIN LINE TO OWS 3/4 150
1 Carry out internal scrape cleaning and painting with two coat of CTE paint as per painting
specification AES 5430.
2 Carry out hydro testing of vessel at 9.36 kg/cm2.

SERVICE INTER STAGE KOD OF
133-K-304 A
VESSEL ID 0.403 meter HEIGHT/ 1.527 meter

LENGTH
HYD TEST 56.1
PR.(Kg/cm2)
22
Sr. No. X RATING
(inch)
1. I/L LINE TO VESSEL 4 300
SPADE LIST 2. O/L LINE TO FLARE 1ST BLOCK
VALVE D/S FLANGE 2 300
3. DRAIN LINE BLOCK VALVE D/S
FLANGE 3/4 300
4. O/L LINE FROM VESSEL 4 300
2 Carry out hydro testing at 56.1 Kg/ cm2.

SERVICE INTER STAGE KOD OF
133-K-304 B
VESSEL ID 0.403 meter HEIGHT/ 1.527 meter

LENGTH
HYD TEST 56.1
23 PR.(Kg/cm2)
Sr. No. X RATING
(inch)
SPADE LIST
2. O/L LINE TO FLARE 1ST BLOCK
FLANGE 3/4 300
Page 11 of 31

SERVICE SPILLBACK KOD OF
133-K-304 A/B

HYD TEST 36.70
PR.(Kg/cm2)
24 Sr. No. X RATING
(inch)
SPADE LIST 2. O/L LINE TO FLARE 1ST BLOCK
FLANGE 3/4 300
4 Carryout DP of all weld joints
25 EQUIPMENT NO 133-V-355 Service 1ST STAGE SUCTION

OF 133-K-304 A
1 Erect external scaffolding if required and offer vessel for external UT gauging.
3 Open boot and carry out replacement of demister in the boot

OF 133-K-304 B
1 This vessel does not require opening, Erect external scaffolding if required and offer vessel
for external UT gauging.
3 Open boot and carry out replacement of demister in the boot
Part B: - Following vessels does not require any opening/internal

inspection. Provide external scaffolding wherever required and offer
for external UT gauging. Carryout hydrotest at specified pressure against
each specific vessel.
Page 12 of 31
SERVICE STEAM DRG NO. 133-ME-2-13
CONDENSATE
FLASH DRUM

HYD TEST
1 PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. common i/l to line to V-306 8" 150
SPADE LIST
2. top o/l to LP steam Header 6" 150
3. bottom o/l line to V-305 3" 150
4. o/l to RV'S 8" 150
5. o/l to RV'S 8" 150
3 Carry out insulation removal for inspection including insulation rings as per general scope
and carry out insulation in standard manner.

SERVICE CONDENSATE DRG NO. 133-ME-2-17-1
POT FOR 133E-
310 A/B
VESSEL ID 0.8 meter HEIGHT 3 meter

HYD TEST 75
2 PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. common i/l line from E-310 A/B to
SPADE LIST
vessel 6 600
2. bottom o/l line to E 306 3 600
3. o/l line to RVS 2 600
4. vent and balance common line 2 600
1 Carry out hydro testing at 75 kg/cm2.
3 Carry out insulation removal for inspection excluding insulation rings as per general scope
and carry out insulation in standard manner

SERVICE CONDENSATE DRG NO. 133-ME-2-18
POT FOR 133 E
3 312 A/B

HYD TEST 75.0
PR.(Kg/cm2)
Page 13 of 31
Sr. No. X RATING
(inch)
1. common i/l line from E-312 3" 600
SPADE LIST 2. top o/l to RV'S common line 2" 600
3. top o/l to vent and balance common
line 2" 600
4. bottom o/l line to LP steam
condensate header 2" 600
and carry out insulation in standard manner

SERVICE PSA SURGE DRG NO. 133-ME-2-37-1
DRUM

HYD TEST ----
4 PR.(Kg/cm2)
Sr. No. X RATING
(inch)
SPADE LIST 1. I/L LINE TO VESSEL 24 150
2. O/L LINE TO VESSEL 30 150
FLANGE 2" 150
1 Erect external scaffolding and offer vessel for external UT gauging
5 EQUIPMENT NO 133-V-357 Service 1ST STAGE DISCHARGE

OF 133-K-304 A

OF 133-K-304 B
7 EQUIPMENT NO 133-V-359 Service 2ND STAGE SUCTION

OF 133-K-304 A
Page 14 of 31

OF 133-K-304 B
9 EQUIPMENT NO 133-V-361 Service 2ND STAGE DISCHARGE

OF 133-K-304 A

OF 133-K-304 B
11 EQUIPMENT NO 133-V-365 Service SUCTION PULSATION

OF 133-K-305
12 EQUIPMENT NO 133-V-366 Service DISCHARGE

PULSATION OF 133-K-
305

OF 133-K-306

OF 133-K-306
Page 15 of 31
OF 133-K-306

OF 133-K-306
2 Carry out hydro testing at 294 kg/cm2.
NHGU REACTORS
Part C: -
Following reactors require opening. Carry out spading and
provide external scaffolding wherever required and offer for
external UT gauging. Provide internal scaffolding for internal
visual inspection and repair wherever required. In addition to
the above carry out jobs as mentioned against specific
reactor. (Kindly note that catalyst replacement shall be
carried out by another agency)
The scope of work primarily includes all mechanical work on the

reactors like
1. Spading / De-spading
2. Insulation removal for CUI except insulation ring and UT
gauging. After inspection carry out insulation as per BPCL
standard procedure.
3. Opening / box-up of manways / internals,All normal/RTJ
flanges / gaskets grooves lapping wherever applicable - After
opening flange joints, clean the ring type gasket joints and
offer gasket and ring grooves for DP testing. Contractor shall
Page 16 of 31
mobilize hydraulic torquing machines for measured
tightening of all flanges connected with reactor piping.
4. Minor repairs inside the reactor
5. All mechanical jobs associated with the internal of the
reactor are also included in the scope of work.
TAG NO 133-R-301 LOCATION HGU

SERVICE HYDROGENATOR DRG NO. 133-ME-1-12

CATALYST YES
SPADE LIST
SR NO LOCATION SIZE RATING
1. E-311 A O/L PROCESS LINE TO R-301 6 600
2. E-311 B O/L PROCESS LINE TO R-301 6 600
3. OUTLET LINE TO R-302A 6 600
4. R-302A I/L BLOCK VALVE BYPASS 2 600
VALVE
5. R-302A BYPASS LINE FIRST BLOCK 6 600
VALVE D/S FLANGE
6. 2" N2 STUB LINE AT R-301 O/L TO BE 2 600
SPADED
7. R-301O/L SAMPLE POINT RSC 1483 TO 0.5 600
BE SPADED
8. RPSV 1513A U/S VALVE D/S FLANGE 3 600
9. RPSV 1513B U/S VALVE D/S FLANGE 3 600
10. RV BYPASS LINE U/S OF VALVE 2 600
11. R-301 I/L SAMPLE POINT RSC-1477 TO 0.5 600
BE SPADED
12. SAMPLE POINTS FLARE LINE TO BE 3/4 600
POSITIVELY ISOLATED
13. RPDT 486 TO BE DISCONNECTED 3/4 600
TAG NO 133-R-302 A LOCATION HGU

SERVICE SULPHUR ABSORBER/CHLORINE DRG NO. 133-ME-1-25
GUARD

CATALYST YES
SPADE LIST
1. R-302 A I/L LINE TO BE SPADED 6 600
(REVERSE SPECTACLE)
2. R-302 A I/L LINE B/V BYPASS 2" LINE 2 600
GLOBE VALVE U/S FLANGE TO BE
SPADED,
3. R-302 A O/L LINE TO BE SPADED 6 600
(REVERSE SPECTACLE)
4. R-302 A O/L LINE TO EA 301B TO BE 6 600
Page 17 of 31
SPADED (REVERSE SPECTACLE)
5. R-302A RV BYPASS LINE TO BE 2 600
SPADED (REVERSE SPECTACLE)
6. R-302 A EAST SIDE OF RV'S U/S B/V D/S 3 600
FLANGE TO BE SPADED
7. R-302 A WEST SIDE OF RV'S U/S B/V 3 600
D/S FLANGE TO BE SPADED
8. 3 NOS. SAMPLE POINTS TO BE 2 600
DISCONNECTED AND PROVIDE END
FLANGE
9. 1ST BED O/L SAMPLE POINT ON 2 600
REACTOR BODY TO BE
FLANGE
10. 2nd BED O/L SAMPLE POINT ON 2 600
REACTOR BODY TO BE
FLANGE
11. SAMPLE POINT ON R 302 A O/L LINE 2 600
12. SAMPLE POINTS FLARE LINE TO BE 600
POSITIVELY ISOLATED-3 Nos.
13. 2" N2 STUB LINE AT R-302A O/L TO BE 2 600
SPADED
TAG NO 133-R-302 B LOCATION HGU

SERVICE SULPHUR ABSORBER/CHLORINE DRG NO. 133-ME-1-25
GUARD

CATALYST YES
SPADE LIST
1. I/L TO R-302B PROCESS LINE 2ND 600
BLOCK VALVE U/S FLANGE (REVERSE
SPECTACLE BLIND) 6
2. R-302A BYPASS LINE FIRST BLOCK 600
VALVE D/S FLANGE 6
3. O/L PROCESS LINE TO BE SPADED 6 600
4. 2" N2 LINE AT R-302B O/LTO BE 600
SPADED 2
5. RPSV 1515 A U/S VALVE D/S FLANGE 3 600
6. RPSV 1515 B U/S VALVE D/S FLANGE 3 600
7. RV BYPASS 2ND BLOCK VALVE U/S 600
FLANGE 2
8. FIRST BED O/L SAMPLE POINT RSC- 600
1487 TO BE DISCONNECTED AND
FLARE LINE TO BE SPADED 3/4"-
9. 2ND BED O/L SAMPLE POINT RSC-1488 600
TO BE DISCONNECTED AND FLARE
LINE TO BE SPADED 3/4"-
10. O/L SAMPLE POINT RSC 1489 TO BE 600
DISCONNECTED AND FLARE LINE TO
BE SPADED 3/4"-
11. SAMPLE POINTS FLARE LINE TO BE 3/4" 600
Page 18 of 31
POSITIVELY ISOLATED-3 Nos.
1 Carry out in situ metallography

SERVICE PRE REFORMER DRG NO. 133-ME-1-9
VESSEL ID 2.9 m HEIGHT/LENGTH 7.2 m

CATALYST YES
SPADE LIST
1. RSDV 560A UPSTREAM FLANGE 3"-P-133-1404-
(BLOCK - SHUT ,BLEED - OPEN) D5D-IH
2. JA 301 (Ejector) OUTLET VALVE
UPSTREAM FLANGE 12"/D5D
3. 10" NITROGEN TO MIXING POINT LINE 10"-IG-133-3652-
TO BE SPADED AIA-IH
4. 3" NITROGEN TO MIXING POINT LINE 3"-IG-133-3811-
TO BE SPADED A3A
5. RFV 561A D/S BLOCK VALVE U/S 10"-P-133-3031-
FLANGE D2D-IH
6. RFV 563 D/S BLOCK VALVE U/S 6"-SH-133-1401-
FLANGE D2D-IH
7. RFV 564 D/S BLOCK VALVE U/S 2"-P-133-1453-
FLANGE D5D-IH
8. RFV 564 BYPASS LINE GLOBE VALVE 2"-P-133-1453-
D/S FLANGE D5D-IH
9. RFV 568 D/S BLOCK VALVE U/S 3"-P-133-1454-
FLANGE D5D-IH
10. RFV 568 BYPASS LINE GLOBE VALVE
D/S FLANGE 2"
11. RFV 567 U/S LINE TO BE SPADED 1.5"-ME-133-
(REVERSE SPECTACLE) 4223-D1A
12. 16"-P-133-1430-
R-303 PREREFORMER O/L FLANGE E5E-IH
13. 5 NOS. SAMPLE POINTS TO BE
FLANGE AT BOTH SIDE.
14. R 303 I/L LINE SAMPLE POINT - 1 No.
15. R 303 REACTOR BODY SAMPLE POINT -
4 No.
16. RPDT 564 I/L BLOCK VALVE D/S
FLANGE LINE TO BE SPADED 3/4"
17. EJECTOR JA 301 O/L DRAIN LINE 2"/A3A
18. RSDV 560A D/S DRAIN LINE VALVE 1.5"/D5D
19. SILENCER JU 306 DRAIN LINE 2"/D5D
20. SILENCER JU 306 U/S LINE VALVE 4"/D5D
21. R 303 OUTLET LINE TO NITROGEN
CONNECTION 2"
22. Vent line of R303 2"
23. JENSON DRAIN VALVE TO BE KEPT
TIGHT SHUT - NO COMMON FLANGE
AVAILABLE
Page 19 of 31
SERVICE MEDIUM TEMP SHIFT CONVERTER DRG NO. 133-ME-1-54
VESSEL ID 3m HEIGHT/LENGTH 8.775 m

CATALYST YES
SPADE LIST
1 RSDV 602 UPSTREAM FLANGE TO BE 18"-P-133-1611-
SPADED B5D-IH
2 RSDV 602 BYPASS LINE TO BE SPADED 2"/B5D
3 N2 I/L TO R-304 2ND BLOCK VALVE U/S 10"-IG-133-3651-
FLANGE A1A-IH
4 RPSV-1619 A U/S BLOCK VALVE D/S
FLANGE 3"-B5D
5 RPSV-1619 B U/S BLOCK VALVE D/S
FLANGE
6 RV BYPASS 2ND BLOCK VALVE U/S
FLANGE
7 RPDT 607 - LP AND HP LINE 3/4"
8 R 304 OUTLET LINE IMMEDIATE 18"-p-133-1721-
FLANGE NEAR REACTOR B5D-IH
9 Vent line of R304 2"

SERVICE LOW TEMP SHIFT CONVERTOR DRG NO. 133-ME-1-40
VESSEL ID 3 meter HEIGHT/LENGTH 3.825 meter

CATALYST YES QTY NA
SPADE LIST
1. R-305 I/L BLOCK VALVE U/S FLANGE 18 600
2. R-305 BYPASS LINE 2ND BLOCK VALVE 14
U/S FLANGE 600
3. N2 I/L TO R-304 2ND BLOCK VALVE U/S 10
FLANGE 150
4. RPSV-1620 A U/S BLOCK VALVE D/S 3
FLANGE 300
5. RPSV-1621 B U/S BLOCK VALVE D/S 3
FLANGE 300
6. RV BYPASS 2ND BLOCK VALVE U/S 2
FLANGE 300
7. O/L SAMPLE POINT RSC 1608
8. SAMPLE POINT RSC 1608 TO FLARE
LINE
9. R-305 O/L N2 O/L LINE FIRST BLOCK 10
VALVE D/S FLANGE 150
10. R-305 O/L LINE PROVISION FOR N2 2
HOSE 2"
11. R-305 O/L LINE 1ST BLOCK VALVE D/S 18
FLANGE 300
Page 20 of 31
LOBS
Part A : Carry out all the jobs on the vessels as per scope of work
detailed in Appendix A attachment 5 including opening of the vessel
and specific jobs detailed against each equipment
TAG NO 132-V-251 LOCATION LOBS
SERVICE FPU VACUUM DRG NO. 132-ME-2-154-1
COLUMN OVHD
DRUM
VESSEL ID 2 meter LENGTH 5.2 meter

HYD TEST 4.55
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
8. SERVICE WATER TO HOTWELL 2" 150
9. DIPLEG FROM E-271 A 6" 150
10. DIPLEG FROM E-271 B 3" 150
11. DIPLEG FROM E-271 C
3" 150
(CONDENSATE)
12. DIPLEG FROM E-271 C (VAPORS) 3" 150
13. V-273 DRAIN TO HOTWELL 2" 150
14. HOTWELL VAPORS TO PSV &
1 12 150
OWS LINES
15. HOTWELL TOP VENT 2" 150
16. HOTWELL GASES TO V-273 8" 150
17. STEAM OUT STEAM SUPPLY 2" 150
SPADE LIST 18. HOTWELL WATER SIDE DRAIN TO
3" 150
CBD
19. HOTWELL WATER SIDE DRAIN TO
3" 150
OWS
20. SOUR WATER TO P-252 A/B 3" 150
21. SOUR WATER DRAIN TO OWS 2" 150
22. SLOP OIL TO P-260 A/B 1" 150
23. SLOP OIL DRAIN TO OWS 1" 150
24. HOTWELL OIL SIDE DRAIN TO
3" 150
CBD
25. HOTWELL OIL SIDE DRAIN TO
3" 150
OWS
26. HOTWELL WATER SIDE LG DRAIN
150
TO OWS
27. HOTWELL OIL SIDE LG DRAIN TO
3/4 150
OWS
WFMPI testing
3 Remove and service the gauge glasses.
Page 21 of 31
SERVICE DW VACUUM DRG NO. 132-ME-2-155-1
COLUMN OVHD
DRUM

HYD TEST 4.55
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. SERVICE WATER TO HOTWELL 2" 150
2. DIPLEG FROM E-275 A 3" 150
3. DIPLEG FROM E-275 B 3" 150
4. DIPLEG FROM E-275 C 150
2"
(CONDENSATE)
5. DIPLEG FROM E-275 C (VAPORS) 2" 150
6. V-274 DRAIN TO HOTWELL 2" 150
2 7. HOTWELL VAPORS TO PSV & 150
6"
OWS LINES
8. HOTWELL TOP VENT 2" 150
9. HOTWELL GASES TO V-274 6" 150
SPADE LIST
11. HOTWELL WATER SIDE DRAIN TO 150
3"
CBD
12. HOTWELL WATER SIDE DRAIN TO 150
3"
OWS
13. SOUR WATER TO P-261 A/B 2" 150
14. SOUR WATER DRAIN TO OWS 2" 150
15. SLOP OIL TO P-260 A/B 2" 150
16. HOTWELL OIL SIDE DRAIN TO 150
3"
CBD
17. HOTWELL OIL SIDE DRAIN TO 150
3"
OWS
18. HOTWELL WATER SIDE LG DRAIN 150
3/4
TO OWS
19. HOTWELL OIL SIDE LG DRAIN TO 150
3/4
OWS
WFMPI testing

SERVICE DW HOT HIGH DRG NO. 132-ME-2-156
3 PRESSURE
SEPARATOR
Page 22 of 31
HYD TEST 293.6
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. HHPS FEED INLET 8" 2500 RTJ
SPADE LIST
2. HHPS LIQUID OUTLET 8" 2500 RTJ
3. HHPS VAPOR OUTLET 2" 150
4. HHPS LIQUID OUTLET TO CFBD 2" 150
5. HHPS LIQUID OUTLET TO OWS 1" 150

SERVICE DW HOT LOW DRG NO. 132-ME-2-140
PRESSURE
SEPARATOR

HYD TEST 39.91
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. HLPS FEED INLET 4" 300
2. HLPS LIQUID OUTLET 4" 300
3. HLPS VAPOR OUTLET 1 .5 300 RTJ
SPADE LIST
4. HLPS LIQUID OUTLET TO CFBD 2" 150
5. HLPS LIQUID OUTLET TO OWS 2" 150
6. HLPS VENT TO ATMOSPHERE 1" 150
7. HLPS STEAM OUT STEAM INLET 2" 300
8. HLPS VAPOR TO RELIEF AND
2" 300 RTJ
PSV'S

SERVICE DW HHPS DRG NO. 132-ME-2-178-1
VAPOUR KNOCK
OUT DRUM
5
DEMISTER YES DEM DRAWING 132-ME-2-178-4
HYD TEST 30.03
PR.(Kg/cm2)
Sr. No. X RATING
SPADE LIST No. LOCATION SIZE (lbs)
(inch)
Page 23 of 31
1. HHPS SPILL BACK KOD INLET 6 300
2. KOD LIQUID TO CBD 1.5 300
3. KOD DRAIN TO CBD 1.5 150
4. KOD DRAIN TO OWS 1.5 150
5. STEAM OUT STEAM INLET 2 300
6. VAPOR O/L TO HCU MUG
6 300
SUCTION
7. VENT TO ATM 1.5 150

SERVICE STEAM KO DRUM DRG NO. 132-ME-2-179-1
HYD TEST 34.43
PR.(Kg/cm2)
Sr. No. X RATING
6
(inch)
1. MPS INLET TO KOD 8" 300
SPADE LIST 2. MPS OUTLET FROM KOD 8" 300
3. TOP VENT 2" 150
4. PSV 1730A TO ATMOSPHERE 4" 300
5. PSV 1730B TO ATMOSPHERE 4" 300
6. KOD CONDENSATE LINE 2" 300
2 Carry out internal scrape cleaning and painting with two coat of Ferrotol paint as per painting
specification AES 5430

SERVICE OFF GAS KNOCK DRG NO. 132-ME-2-150-1
OUT POT
HYD TEST 4.55

PR.(Kg/cm2)
7
Sr. No. X RATING
(inch)
1. FPU OFFGAS INLET 8" 150
SPADE LIST
2. KOD DRAIN TO FPU HOTWELL 2" 150
3. TOP VENT 2" 150
4. FPU OFF GAS TO F-204/VENT 8" 150
Page 24 of 31
1 Replace the vessel with the new vessel. Shifting of new vessel from warehouse to site and
shifting of old vessel to scrap yard shall be in contractor scope.
2 All the fittings (valves,gauge glasses,etc ) to be removed from old vessel and fitted to new
vessel.
3 Ladder and platform from old vessel to be removed and fitted to new vessel.

SERVICE OFF GAS KNOCK DRG NO. 132-ME-2-184-1
OUT POT
HYD TEST 4.55

PR.(Kg/cm2)
8
Sr. No. X RATING
(inch)
1. DW OFFGAS INLET 6" 150
SPADE LIST
2. KOD DRAIN TO DW HOTWELL 2" 150
3. TOP VENT 2" 150
4. DW OFF GAS TO F-204/VENT 6" 150
WFMPI testing.
2 Carry out internal scrape cleaning and painting with two coat of CTE paint as per company
painting specification AES 5430
TAG NO 132-V-275 L LOCATION LOBS

SERVICE INSTRUMENT AIR DRG NO. 132-ME-2-135
RECIEVER
HYD TEST 13.65

9
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
SPADE LIST
1. IA INLET 3 150
2. IA OUTLET 3 150
3. TOP LINE TO PSV's 3 150
1 Carry out internal scrape cleaning and painting with two coat of CTE paint as per company
10 TAG NO 132-V-281 LOCATION LOBS

SERVICE FUEL GAS KO DRG NO. 132-ME-2-181-1
Page 25 of 31
DRUM
HYD TEST 10.4
PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. FG KOD O/L 6" 150
SPADE LIST 3. KOD DRAIN TO FLARE LINE 2" 300
4. KOD DRAIN TO CBD 2" 300
5. KOD DRAIN TO OWS 2" 150
6. KOD VENT TO ATMOSPHERE 2" 150
7. FLARE LINE NEAR VESSEL 2" 300
8. FG KOD O/L 2" 300
WFMPI testing.
3 Carry out internal scrape cleaning and painting as with two coat of CTE paint as per company

SERVICE FLARE KO DRUM DRG NO. 132-ME-2-182-1
HYD TEST 4.55

PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. KOD I/L 18 150
SPADE LIST
3. KOD O/L TO FLARE HDR 18 150
4. KOD DRAIN IMMEDIATE FLANGE 4" 150
WFMPI testing.
2 Carry out internal scrape cleaning and painting as with two coats of CTE paint as per
company painting specification AES 5430
Page 26 of 31
SERVICE CLOSED BLOW DRG NO. 132-ME-2-136
DOWN DRUM
HYD TEST 4.55

PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. CBD INLET LINE 6" 150
2. CBD DRUM TOP TO FLARE 4" 150
SPADE LIST 3. CBD DRUM TOP VENT 3" 150
4. P-281A DISCHARGE 2" 300
5. P-281B DISCHARGE 2" 300
6. RAW CW INLET 3" 150
7. RAW CW OUTLET 3" 150
8. LP STEAM FOR PURGING 2" 150
1 Carry out internal shot blasting and Epoxy painting (System 22 as per painting specification
AES 5430.
3 Carry out hydro testing of 3 diameter steam coil inside the vessel at 10.5 Kg/Cm2

SERVICE CONGEALING DRG NO. 132-ME-2-138
FLUID BLOW
DOWN DRUM
HYD TEST 4.55

PR.(Kg/cm2)
Sr. No. X RATING
(inch)
1. CFBD INLET LINE 8" 150
2. CFBD DRUM TOP TO FLARE 2" 150
3. CBD DRUM TOP VENT 3" 150
SPADE LIST
4. P-282A DISCHARGE 2" 300
5. P-282B DISCHARGE 2" 300
6. RAW CW INLET 3" 150
7. RAW CW OUTLET 3" 150
8. LP STEAM TO COILS 3" 150
9. LPS CONDENSATE RETURN 3" 150
1 Carry out internal shot blasting and Epoxy painting(System 22) as per painting specification
AES 5430.
Page 27 of 31
SERVICE CONGEALING DRG NO. 132-ME-2-183-1
RELIEF BREAK
VESSEL
HYD TEST 4.55

PR.(Kg/cm2)
Sr. No. X RATING
14 (inch)
1. KOD I/L 8" 150
3. KOD O/L TO FLARE HDR 8" 150
SPADE LIST 4. KOD DRAIN IMMEDIATE FLANGE 4" 150
8. LPS TO COILS 2" 150
9. LPS CONDENSATE FROM COILS 2" 150
TAG NO 132-STR-6301 LOCATION LOBS

SERVICE B/L STRAINER DRG NO.
HYD TEST 10.55

15 PR.(Kg/cm2)
Sr. No. X RATING
(inch)
SPADE LIST
1. SCW INLET TO STRAINER 26 150
2. SCW OUTLET FROM STRAINER 26 150
3. TOP VENT / BOTTOM DRAIN 3 150
1 Remove and clean filter element
3 Carry out FRP lining repair from inside.
TAG NO 132-G-204A/B LOCATION LOBS

SERVICE DW FEED FILTER DRG NO. 132-ME-8-17-1
16
HYD TEST 23.14
Page 28 of 31
PR.(Kg/cm2)
1 Open top cover, remove and clean filter elements(20 each) by ultrasonic cleaning method
(Refer Annexure I)
2 Fit back the filters after cleaning and box up the top cover.
Part B: - Following vessels does not require any opening/internal

inspection. Provide external scaffolding wherever required and offer
for external UT gauging. Carryout hydrotest at specified pressure against
each specific vessel.

SERVICE DW FEED SURGE DRG NO. 132-ME-2-144-1
DRUM

HYD TEST 7.8
PR.(Kg/cm2)
Sr. No. X RATING
1
(inch)
1. FSD LIQUID INLET 4 300
2. FSD LIQUID OUTLET 6 300
3. FSD O/L DRAIN TO CFBD 2 150
SPADE LIST
4. FSD O/L DRAIN TO OWS 2 150
5. FSD VAPOR OUTLET 1 300
6. STEAM OUT STEAM SUPPLY 2 .5 300
7. FSD TOP VENT 1.5 300
8. FSD VAPOR TO RELIEF AND
6 150
PSVS
1 Carry out N2 testing /hydro testing at 7.8 kg/cm2.
and carry out insulation in standard manner.
REACTORS
For following two nos. reactors in LOBS, all the jobs internal to the reactor
including spading / de-spading catalyst replacement shall be carried out by
another agency as applicable. Your scope includes carrying out the
following
Page 29 of 31
External inspection
1. Remove insulation up to 500 mm from all the nozzle welds and clean the surface,
carry out buffing (6 inches on both sides of weld) and offer for MPT and Phased Array
Ultrasonic Testing (PAUT)
2. Remove insulation up to 500 mm from all circumferential welds and clean the
surface, carry out buffing (6 inches on both sides of weld) and offer for Time of
Flight Diffraction (TOFD).
3. Remove insulation up to 500 mm from all around the skirt attachment weld,
clean the surface, carry out buffing (6 inches on both sides of weld) and offer
for MPT and PAUT.
4. After opening flange joints, clean the ring type gasket joints and offer gasket
and ring grooves for DP testing.
5. Provide scaffolding inside the skirt for inspection of bottom dish end.
TAG NO 132-R-204 LOCATION LOBS

SERVICE DW REACTOR DRG NO. 132-ME-1-181
VESSEL ID 1.676M HEIGHT 30.4M

CATALYST YES NO. OF BED 3
HYD TEST 306.1
PR.(Kg/cm2)
BOTTOM 8-2500# RTJ 1
OUTLET
CATALYST 6-2500# RTJ 1
OUTLET
WITH COVER
FEED INLET 8-2500# RTJ 1
QUENCH 5/2-2500# RTJ 1
QUENCH 5/2-2500# RTJ 1
MANWAY 30-SPECIAL RTJ 1
THERMO 1.5-SPECIAL RTJ 1
WELL
TAG NO 132-R-205 LOCATION LOBS

SERVICE HDF REACTOR DRG NO. 132-ME-1-155
VESSEL ID 1.676M HEIGHT 30 M

CATALYST YES NO. OF BED 3
HYD TEST 278.9
PR.(Kg/cm2)
BOTTOM 8-1500# RTJ 1
OUTLET
CATALYST 6-1500# RTJ 1
OUTLET
Page 30 of 31
WITH COVER
FEED INLET 8-1500# RTJ 1
MANWAY 30-SPECIAL RTJ 1
THERMO 1.5-SPECIAL 5
WELL
Annexure I:
Scope of work for carrying out ultrasonic cleaning of feed filters
The scope of work for cleaning of feed filter through ultrasonic technique comprises of
following points.
1. Filter transportation from refinery to specialized vendor having experience and facility
for ultrasonic cleaning of filters.
2. The cleaning of ultrasonic filters by specified method shall be in your scope.
3. Same shall be brought back to refinery after successful completion of cleaning.
4. The specialized Vendor shall be approved by BPCL technology department.
5. Due care shall be taken for transportation of filter. Shall be transported in wooden
enclosure for support. Utmost care shall be taken for lifting and movement of filter.
6. BPCL OPS/Technology at discretion will witness the filter cleaning if possible and have
right to waive off.
7. BPCL OPS/Technology at discretion may depute the person to carryout visual inspection
of cleaned filters at vendor workplace before dispatch.
Page 31 of 31
ATTACHMENT 11 SECTION F

UNIT ( NHGU / LOBS) EJECTORS
NHGU :-
Carry out jobs on following spindle operated ejector as per scope of work
detailed below.
131-JA-301
1. Erect external scaffolding

2. Carry out spading on steam inlet, process fluid inlet and outlet.
3. Remove the actuator part no 1 as per general arrangement drawing.
4. Open steam nozzle flange bolts.
5. Remove the complete assembly including steam nozzle and spindle.
6. Clean the steam nozzle and spindle assembly and offer for dimensional
checks.
7. Offer entire shell for UT gauging.
8. After completion of inspection, fix back the steam nozzle assembly &
Actuator.
9. Remove scaffolding and de-spade.
Following is the general arrangement drawing for ejector
Page 1 of 3
LOBS:-
Carry out jobs on following ejectors as per scope of work detailed in General
scope of work on ejectors given in Appendix A Attachment 6.
1. 132-JA-252 A/B/C/D/E/F(Drg no 132-ME-8-8)

2. 132-JA-256 A/B/C/D(Drg no 132-ME-8-9)
Following is the general arrangement drawing for ejectors
Page 2 of 3
Page 3 of 3
ATTACHMENT 11 SECTION G

UNIT ( NHGU / LOBS) PROCESS VALVES
Carry out servicing of the isolation valves as per scope of work detailed in Appendix- A
Attachment 7
NHGU:-
SR NO LOCATION SIZE RATING QTY
1 MT I/L RSDV 602 18" 300 1
2 LT BYPASS VALVE 14" 300 2
3 MT LT B/P RSDV 604 14" 300 1
4 STEAM TO MIXING POINT U/S OF NRV 14" 600 1
5 STEAM TO MIXING POINT RFC 561 U/S & D/S B/V 10" 600 2
6 S/U STEAM RFC 563 U/S & D/S B/V 6" 600 2
7 PROCESS GAS TO MIXING POINT RFC 557 U/S & D/S
B/V 6" 600 2
8 S/U PROCESS GAS RFC 569 U/S & D/S B/V 3" 600 2
9 EJECTOR PROCESS GAS I/L B/V 10" 900 1
10 EJECTOR JA 301 STEAM I/L B/V 8" 600 2
11 EJECTOR JA 301 O/L B/V 12" 600 2
12 H2 TO HCU RPC-620 A U/S 10" 300 1
13 RSDV-607 U/S B/V 4" 300 1
14 PSA I/L RSDV 608 D/S B/V 14" 300 1
15 STEAM I/L B/V'S OF E-310 A/B 4" 600 2
16 STEAM O/L B/V'S OF E-310 A/B 6" 300 2
17 STEAM I/L B/V'S OF E-311 A/B 10" 600 2
18 STEAM OL B/V'S OF E 311 A/B 10" 600 2
19 E311A & E311B NAPHTHA SIDE O/L VALVE 6" 600 2
20 E311A & E311B NAPHTHA SIDE I/L VALVE 6" 300 2
21 E311B & E311A RV BYPASS D/S VALVE 2" 600 2
22 STEAM DRUM O/L B/V 14" 300 1
23 CCR OFF GAS BATTERY LIMIT BLOCK VALVES
PASSING 6" 300 2
24 IMPURE H2 HEADER B/L B/V 6" 300 3
25 RFC483 RLNG C/V BOTH THE BLOCK VALVES 6" 300 1
26 RFC405/406 C/V BOTH VALVES AND BYPASS
PASSING 2" 300 5
27 RPC501 C/V BYPASS BLOCK VALVE 3" A5A 1
28 RFC564 C/VBYPASS VALVE 2" D5A 1
29 RFC632 C/V BYPASS BLOCK VALVE 3" 600 1
30 RPC628 C/V BYPASS VALVE 8" D2D 1
31 RFC476 C/V D/S block valve 3" 600 1
Page 1 of 2
32 RFC480 C/V both block valves 4" 300 2
33 RFC480 C/V bypass valve 2" 300 1
34 RFC646 C/V both block valve 6" 300 2
LOBS:-
NO OF
VALVES
1. C-221 col. bottom Common MOV 6" 150 1
2. P-258A Suction Valve (Bottom pump) 6" 150 1
3. P-258B Suction Valve (Bottom pump) 6" 150 1
4. P-266A Suction Valve (Excess waxy) 8" 150 1
5. P-266B Suction Valve (Excess waxy) 8" 150 1
DW Feed Pump P-259A Suction MOV
6. (Welded)
6" 150 1
DW Feed Pump P-259B Suction MOV
7. (Welded)
6" 150 1
DW Col. Bottom pump P-265A /B Common
8. suction valve MOV
6" 150 1
9. DW Col. Bottom pump P-265A suction valve 6" 150 1
10. DW Col. Bottom pump P-265B suction valve 6" 150 1
P-264A Suction valve (C-225 LT LUBE S/C
11. Stripper)
2" 150 1
P-264B Suction valve (C-225 LT LUBE S/C
12. stripper)
2" 150 1
13. Inlet to CBD Vessel V-283 (Underground) 6" 150 1
14. Inlet to CBD Vessel V-283 (Underground) 6" 150 1
15. Inlet to CFBD Vessel V-284 (Underground) 8" 150 1
16. Inlet to CFBD Vessel V-284 (Underground) 8" 150 1
17. Inlet to OWS Vessel AU-282 (Underground) 10" 150 1
18. Inlet to OWS Vessel AU-282 (Underground) 10" 150 1
Page 2 of 2
ATTACHMENT 11 SECTION H

STOCK UNIT ( NHGU / LOBS) RUPTURE DISC / RELIEF
VALVES
Carry out jobs on following relief valves as per scope of work detailed in
Appendix- A Attachment 8
NHGU:-
SR TAG NO Location Size SET PR Back PR

NO (Kg/cm2g) (Kg/cm2g)
1 133RPSV1494 133-E-310A Shell side. 3" X 4 39.39 1.7

2 133RPSV1495 133-E-310B Shell side. 3" X 4" 39.39 1.7
3 133RPSV1496 133-E-311A, Feed Pre Heater 3" X 4 39.78 1.7
4 133RPSV1497 133-E-311B, Feed Pre Heater 3" X 4 39.78 1.7
5 133RPSV1606A PG 133-EW-301 O/L 6" X 8" 28.79 1.7
6 133RPSV1606B PG 133-EW-301 O/L 6" X 8" 28.79 1.7
7 133RPSV1607A Steam Drum 133-V-301 4" X 6" 50 -
8 133RPSV1607B Steam Drum 133-V-301 4" X 6" 50 -
9 133RPSV1607C Steam Drum 133-V-301 4" X 6" 50 -
10 133RPSV1607D Steam Drum 133-V-301 4" X 6" 50 -
11 133RPSV1609 133-E-313 CW O/L 3/4" X 1" 7 -
12 133RPSV1618A 133-E-306 I/L 6" x 8" 29.07 1.7
13 133RPSV1618B 133-E-306 I/L 6" x 8" 29.07 1.7
14 133RPSV1621 133-E-307 A/B O/L 1" X 2" 80.8 -
15 133RPSV1642A PG PSA I/L 6" X 8" 25.5 1.7
16 133RPSV1642B PG PSA I/L 6" X 8" 25.5 1.7
17 133RPSV1643A Off Gas Vent 8" X 10" 3.5 1.7
18 133RPSV1643B Off Gas Vent 8" X 10" 3.5 1.7
19 133RPSV1643C Off Gas Vent 8" X 10" 3.5 1.7
20 133RPSV1644A PG PSA BYP 8" X 10" 3.5 1.7
21 133RPSV1644B PG PSA BYP 8" X 10" 3.5 1.7
22 133RPSV1648A Sup. Stm. 133-E-303B O/L 6" x 8" 48 -
23 133RPSV1648B Sup. Stm. 133-E-303B O/L 6" x 8" 48 -
Page 1 of 5
24 133RPSV1654A MP Steam Import / Export 6" x 10" 21 -
25 133RPSV1654B MP Steam Import / Export 6" x 10" 21 -
26 133RPSV1658A Steam Cond. Flash Drum, 6" x 8" 6.5 -
133-V-306
27 133RPSV1658B Steam Cond. Flash Drum, 6" x 8" 6.5 -
133-V-306
28 133RPSV1673A BFW Dearator, 133-V-305 6" x 8" 3.5 -
29 133RPSV1673B BFW Dearator, 133-V-305 6" x 8" 3.5 -
30 133RPSV2010 133-E-312A to Fuel Naphtha 2" x 3" 6.06 1.7
KOD
31 133RPSV2012 133-E-312B to Fuel Naphtha 2" x 3" 6.06 1.7
KOD
32 133RPSV2030A Emergency H2 Drum, 133-V- 1.5" x 3" 222.2 1.7
311
33 133RPSV2030B Emergency H2 Drum, 133-V- 1.5" x 3" 222.2 1.7
311
34 133RPSV2031A Emergency H2 Drum, 133-V- 1.5" x 3" 50 1.7
311 O/L.
35 133RPSV2031B Emergency H2 Drum, 133-V- 1.5" x 3" 50 1.7
311 O/L.
36 133RPSV2043 Silencer Disch. 3/4"X 1" 7 -
37 133RPSV2052 CWR From 133-E-317 3/4"X 1" 7 -
38 133RPSV2034 2nd Stage Disch. 133-K-304A 1.5" x 2" 43.01 1.7
39 133RPSV2035 2nd Stage Disch. 133-K-304A 1.5" x 2" 43.01 1.7
40 133RPSV2064 Outlet of 133-V-366/367 ( 1" x 2" 14.65 -
Pulse Dampener for 133-K-
304A/B)
41 133RPSV2101 1st Stage Disch. 133-K-304A 1.5" x 3" 37.32 1.7
42 133RPSV2102 1st Stage Diisch. 133-K-304B 1.5" x 3" 37.32 1.7
43 133RPSV2103 1st Stage Diisch. 133-K-304A 1" x 2" 24.2 1.7
44 133RPSV2104 1st Stage Diisch. 133-K-304B 1" x 2" 24.2 1.7
45 133RPSV2105 2nd Stage Disch. 133-K-304A 1" x 2" 38.95 1.7
46 133RPSV2106 2nd Stage Disch. 133-K-304B 1" x 2" 38.95 1.7
47 133RPSV2107 133-K-304A Lube Oil Pump 3/4" X 5.9 -
133-P-333 Disch. 1.5"
48 133RPSV2108 133-K-304B Lube Oil Pump 3/4" X 5.9 -
133-P-333 Disch. 1.5"
49 133RPSV2109 133-K-304A Lube Oil Pump 3/4" X 5.9 -
133-P-331 Disch. 1.5"
Page 2 of 5
50 133RPSV2110 133-K-304B Lube Oil Pump 3/4" X 5.9 -
133-P-332 Disch. 1.5"
51 133RPSV2113 1st Stage Cylinder of 133-K- 3/4" X 1" 7 -
304A
52 133RPSV2114 1st Stage Cylinder 133-K- 3/4" X 1" 7 -
304B
53 133RPSV2117 2nd Stage Cylinder of 133-K- 3/4" X 1" 7 -
304A
54 133RPSV2118 2nd Stage Cylinder of 133-K- 3/4" X 1" 7 -
304B
55 133RPSV2121 Outlet of 133-E-335 (Inter 3/4" X 1" 7 -
stage Cooler for 133-K-304A)
56 133RPSV2122 Outlet of 133-E-336 (Inter 3/4" X 1" 7 -
stage Cooler for 133-K-304B)
57 133RPSV2123 Outlet of 133-E-337 (Spill Back 3/4" X 1" 7 -
Cooler)
58 133RPSV2124 Outlet of 133-E-331 (Oil 3/4" X 1" 7 -
Cooler for K-304A)
59 133RPSV2125 Outlet of 133-E-332 (Oil 3/4" X 1" 7 -
Cooler for 133-K-304B)
60 133RPSV2126 Outlet of 133-E-333A (Water 3/4" X 1" 7 -
Cooler for 133-K-304A)
61 133RPSV2127 Outlet of 133-E-333B (Water 3/4" X 1" 7 -
Cooler for 133-K-304B)
62 133RPSV2128 N2 Purging for Cylinder 1" X 2" 0.71 -
66 133RPSV413 133-K-304A Lube Oil Pump 0.5" x 1" 3.4 -
133-P-333 Disch.
67 133RPSV414 133-K-304B Lube Oil Pump 0.5" x 1" 3.4 -
133-P-334 Disch.
68 133RPSV420 133-K-304A Lube Oil Pump 0.5" x 1" 3.4 -
133-P-331 Disch.
69 133RPSV13 133-V-321 1.5"x 2" 25.76 1.7
70 133RPSV23 133-V-322 1.5"x 2" 25.76 1.7
71 133RPSV33 133-V-323 1.5"x 2" 25.76 1.7
72 133RPSV43 133-V-324 1.5"x 2" 25.76 1.7
73 133RPSV53 133-V-325 1.5"x 2" 25.76 1.7
Page 3 of 5
74 133RPSV63 133-V-326 1.5"x 2" 25.76 1.7
75 133RPSV73 133-V-327 1.5"x 2" 25.76 1.7
76 133RPSV83 133-V-328 1.5"x 2" 25.76 1.7
77 133RPSV93 133-V-329 1.5"x 2" 25.76 1.7
78 133RPSV03 133-V-330 1.5"x 2" 25.76 1.7
LOBS:-
Carry out jobs on following rupture disc as per scope of work detailed in
SR NO TAG NO. LOCATION SIZE

1 132-BPSE-1705A 132-BPSV-1712 A/B 2"
2 132-BPSE-1705B 132-BPSV-1712 A/B 2"
3 132-BPSE-1702A 132-BPSV-1710 A/B 3"
4 132-BPSE-1702B 132-BPSV-1710 A/B 3"
5 132-BPSE-1714A 132-BPSV-1714A/B 3"
6 132-BPSE-1714B 132-BPSV-1714A/B 3"
7 132-BPSE-1701A 132-BPSV-1701A/B 4"
8 132-BPSE-1701B 132-BPSV-1701A/B 4"
9 132-BPSE-1703A 132-BPSV-1715A/B 6"
10 132-BPSE-1703B 132-BPSV-1715A/B 6"
Carry out jobs on following relief valves as per scope of work detailed in
SR. Tag No. LOCATION SIZE Set Back

NO. Pr. Pr.
1 132-BPSV-1701A 132-C-221 4" x 6" 3.6 1.8

2 132-BPSV-1701B 132-C-221 4" x 6" 3.6 1.8
3 132-BPSV-1704 132-E-251SHELL 1" x 2" 21 -
4 132-BPSV-1705 132-E-251SHELL 1" x 2" 21 -
5 132-BPSV-1706 132-E-252 SHELL 1" x 2" 21 -
6 132-BPSV-1707 132-E-252 SHELL 1" x 2" 21 -
7 132-BPSV-1708 132-E-260 SHELL 2 1/2" x 4" 21.6 -
8 132-BPSV-1709 132-E-260 SHELL 2 1/2" x 4" 21.6 -
9 132-BPSV-1712A 132-V-255 2" x 3" 31 1.8
10 132-BPSV-1712B 132-V-255 2" x 3" 31 1.8
11 132-BPSV-1715A 132-C-225 6" x 8" 3.5 1.8
12 132-BPSV-1715B 132-C-225 6" x 8" 3.5 1.8
Page 4 of 5
13 132-BPSV-1720A 132-V-256 4" x 6" 23.1 1.8
14 132-BPSV-1720B 132-V-256 4" x 6" 23.1 1.8
15 132-BPSV-1722A 132-V-254 1 1/2"x2" 182.4 1.8
16 132-BPSV-1722B 132-V-254 1 1/2"x2" 182.4 1.8
17 132-BPSV-1723 132-F-206,BFW LINE 1" x 2" 35.7 -
18 132-BPSV-1724 132-F-206,BFW LINE 1" x 2" 35.7 0
19 132-BPSV-1725 132-F-205,SUPERHEATER 2 1/2"x4" 21.6 -
O/L
20 132-BPSV-1726 132-F-205,SUPERHEATER 2 1/2"x4" 21.6 -
O/L
21 132-BPSV-1727 132-F-206,SUPERHEATER 2 1/2" x 4" 21.6 -
O/L
22 132-BPSV-1728 132-F-206,SUPERHEATER 2 1/2" x 4" 21.6 -
O/L
23 132-BPSV-1730A 132-V-271 2 1/2"x4" 21 -
24 132-BPSV-1730B 132-V-271 2 1/2"x4" 21 -
25 132-BPSV-1731A 132-G-204 A ,FILTER I/L 1" x 2" 17.8 1.8
26 132-BPSV-1731B 132-G-204 A ,FILTER I/L 1" x 2" 17.8 1.8
27 132-BPSV-1734 132-X-253,LP STEAM LINE 4" x 6" 6.5 -
28 132-BPSV-1903 132-X-254, LP STEAM 3" x 4" 6.5 -
29 132-BPSV-1904 132-X-255, LP STEAM 3" x 4" 6.5 -
Page 5 of 5
ATTACHMENT 11 SECTION I

UNIT ( NHGU / LOBS) PROCESS PIPING
NHGU:-
A) PROCESS PIPING LOOPS FOR COMPREHENSIVE INSPECTION & HYDROTESTING
Offer all the following process piping for comprehensive inspection as per scope of work detailed
in Appendix A Attachment 9,
Also carry out the following jobs,
1. Lift the pipe lines at support location and offer for inspection. Carry out welding of support
pads as indicated below. All Cold pads to be removed and replaced with welded pads.
Scope shall include fabrication of the pad , lifting of the line at support location , insertion of
the pad , complete welding , pneumatic testing of the pad weld through tale tell hole and
finally plugging of the holes.
2. Carry out necessary repair as per the inspection finding and offer hydro testing of the line at
specified pressure. Repair of the line shall be paid as per the applicable SOR.
Page 1 of 27
SR LINE DESCRIPTION LINE NOS. Support HYD.
no pads PR.
(Nos.) Kg/cm2
g
1 RLNG feed 8/6-P-133-1131-B5A 4+8 36.0
cold pads
exist
2 Fuel RLNG 4-FG-133-4511-B1A 2 + 4cold 36.0
pads
exist
3 CCR off gas 6-P-133-1103-B5A - 36.0
4 Fuel Vap Naptha 3/4-FG-133-1920-A5A 4 18.0
5 133- EA- 302 process gas 8/12/16-P-133-1821- 4( 8 SS 36.0
outlet B54K pads) (DM
16-P-133-1822-B54K water)
6 10 dia Hydrogen line from 10-P-133-1921-B5A 8 36.0
PSA to HCU up to HGU 10-P-133-1925-B5A
Battery limit. 6-P-133-1923-B5A
3-P-133-1922-B5A
6-P-133-1951-B5A
7 4 FG line from 133-V-309 4-P-133-3403-A29A-IJ _ 18.0
to Reformer Furnace 133-f- 2-P-133-3405-A29A-IJ
301 2-P-133-3406-A29A-IJ
8 6 / 4 / 2 Naphtha lines 6-FG-133-3428-A29A- _ 18.0
from 133-V-304 to IJ
Reformer heater burners. and all connected 4
and 2 dia lines up to
burners.
9 Flare header and 0.5(Pne
connected piping umatic
)
B) PROCESS PIPING LOOPS FOR COMPREHENSIVE INSPECTION:
Offer all the process lines (Insulated / Bare) inside the battery limit for comprehensive inspection.
For column overhead lines, make Bosuns chair arrangement for taking wall thickness
measurements.
Based on the RBI analysis and operating temperature, piping circuits have been
grouped in three tables. Following are the table description:
Table A: Insulated lines whose operating temperature falls in CUI range i.e. below
120 Deg C. For external inspection of these lines, insulation shall be
opened in following manner.
Vertical section: 1 meter Insulation band shall be opened after every 10
meters of straight length. Insulation shall also be opened at all the
Page 2 of 27
branches, support locations, elbows, T sections, reducers, drains and
vents.
Horizontal section: 1 meter insulation band shall be opened at every
support location. Insulation shall also be opened at all the branches,
elbows, T sections, reducers, drains and vents.
Table B:High temperature insulated lines. For external inspection of pipeline,

pockets for UT gauging shall be opened at all elbow locations, Tees and
at every 10 meters in straight sections.
Table C: Bare pipe lines. Lift the pipe line at beam support locations and offer for
inspection.
Table A (Insulated pipelines in CUI range)
Sr.
MR loop Pipe Size Circuit From Circuit To
No
DHDS/NHGU/00
1 9V(Line3"-WB- 3" Pipe 133-E-314 A-C 133-V-305
3228-D1A-IH)
DHDS/NHGU/00
MP STEAM
2 9W(Line1.5"-WB- 1.5" Pipe 133-314 A-C
HEADER
3002-D2A-IH)
DHDS/NHGU/00
Tube-side outlet of Inlet of 133-EA-
3 5B(Line16"-P- 16" Pipe
133-E-308 302
1811-B54K-IH)
DHDS/NHGU/00
DHDS/NHGU/008
4 1D(Line6"-P- 6" Pipe 133-E-310 A/B
H
1102-B5A-IH)
DHDS/NHGU/00
133-E-303
5 5G(Line14"-P- 3" Pipe 133-C-302
QUENCH
1941-B5A-IT )
Table B (Insulated lines operating above CUI range)
Sr.
No
DHDS/NHGU/00
1 1E(Line6"-P- 6" Pipe 133-E-310A/B 133-E-311
1111-B5A-IH)
DHDS/NHGU/00
2 1F(Line6"-P- 6" Pipe 133-E-311 A/B 133-R-301
1121-D5D-IH)
DHDS/NHGU/00
3 2A(Line6"-P- 6" Pipe 133-R-301 133-R-302A/B
1211-D5D-IH)
Page 3 of 27
DHDS/NHGU/00
4 2B(Line6"-P- 6" Pipe 133-R-302A/B 133-E-302
1250-D5D-IH)
DHDS/NHGU/00
5 2C(Line16"-P- 16" Pipe 133-E-302 133-R-303
1411-D5E-IH)
DHDS/NHGU/00
6 2D(Line16"-P- 16" Pipe 133-R-303 133-E-301
1430-D5E-IH)
DHDS/NHGU/00
7 2E(Line16"-P- 16" Pipe 133-E-301 Reformer tubes
1441-F51M-IH)
DHDS/NHGU/00
F-301 reformer Tube-side inlet of
8 3A(Line12"-P- 12" Pipe
tube outlets EW-301
1501-F51M)
DHDS/NHGU/00
9 4A(Line18"-P- 18" Pipe 133-EW-301 133-E-305 A/B
1601-B5D-IH)
DHDS/NHGU/00
DHDS/NHGU/004 DHDS/NHGU/00
10 4B(Line10"-P- 10" Pipe
A 4C
1602-B5D-IH)
DHDS/NHGU/00
11 4C(Line18"-P- 18" Pipe 133-E-305A/B 133-R-304
1611-B5D-IH)
DHDS/NHGU/00
12 4D(Line18"-P- 18" Pipe 133-R-304 133-E-306
1721-B5D-IH)
DHDS/NHGU/00
13 4E(Line10"-P- 10" Pipe
D 4F
1722-B5D-IH)
DHDS/NHGU/00
14 4F(Line18"-P- 18" Pipe 133-E-306 133-R-305
1723-B5D-IH)
DHDS/NHGU/00
15 4G(Line18"-P- 18" Pipe 133-R-305 133-E-307 A/B
1731-B5D-IH)
DHDS/NHGU/00
Shell-side outlet of Tube-side inlet of
16 5A(Line16"-P- 16" Pipe
133-E-307A/B 133-E-308
1741-B54K-IH)
DHDS/NHGU/00
17 5F(Line2"-P- 2" Pipe 133-E-314 A-C 133-C-302
3201-D1K-IH)
DHDS/NHGU/00
18 8I(Line6"-FG- 6" Pipe 133-E-312 A/B 133-V-304
3411-A29A-IJ)
Page 4 of 27
DHDS/NHGU/00
19 8J(Line6"-FG- 6" Pipe 133-V-304 133-F-301
3421-A29A-IJ)
DHDS/NHGU/00
20 8N(Line4"-P- 4" Pipe 133-C-301 133-V-309
3403-A2A-IH f)
DHDS/NHGU/00
21 8O(Line4"-P- 4" Pipe 133-V-309 PSA UNIT
3403-A29A-ij )
DHDS/NHGU/00
22 9B(Line6"-WDM- 6" Pipe 133-E-308 133-V-305
3101-A1K-IH)
DHDS/NHGU/00
23 9C(Line6"-WB- 6" Pipe 133-V-305 133-E-307 A/B
1703-D2A-IH)
DHDS/NHGU/00
24 9D(Line4"-WB- 4" Pipe 133-E-307 A/B 133-E-305 A/B
1603-D2A-IH)
DHDS/NHGU/00
25 9E(Line6"-WB- 6" Pipe 133-E-305 A/B 133-V-301
1612-D2A-IH)
DHDS/NHGU/00
DHDS/NHGU/00
26 9F(Line1.5"-SH- 1.5" Pipe 133-V-301
9G
3011-D2A-IH)
DHDS/NHGU/00
27 9G(Line1.5"-BD- 1.5" Pipe 133-EW-301 133-E-304
1602-D2A-IH)
DHDS/NHGU/00
28 9H(Line1.5"-SH- 1.5" Pipe 133-E-304 133-EW-301
3010-D2A-IH)
DHDS/NHGU/00
DHDS/NHGU/009
29 9I(Line3"-BD- 3" Pipe 133-V-301
H
1302-D2A-IH)
DHDS/NHGU/00
30 9J(Line4"-SH- 4" Pipe 133-V-301 133-C-302
3201-D2A-IH)
DHDS/NHGU/00
31 9K(Line3"-BD- 3" Pipe 133-V-301 133-V-303
1605-D2A-IH)
DHDS/NHGU/00
32 9L(Line1.5"-BD- 1.5" Pipe 133-V-303 133-E-313
1611-A1A-IH)
DHDS/NHGU/00
9M(Line6"-SL- DHDS/NHGU/00
33 6" Pipe 133-V-303
1601-A2A-IH) 9N
Page 5 of 27
DHDS/NHGU/00
LP STEAM
34 9N(Line10"-SL- 10" Pipe 133-V-305
HEADER
3101-A2A-IH)
DHDS/NHGU/00
35 9O(Line6"-CL- 6" Pipe 133-V-306 133-V-305
1302-A1A-IH)
DHDS/NHGU/00
DHDS/NHGU/00
36 9P(Line8"-SL- 8" Pipe 133-V-306
9N
3014-A2A-IH)
DHDS/NHGU/00
37 9Q1(Line6"-CL- 6" Pipe 133-V-310 133-V-306
1101-D2A-IH)
DHDS/NHGU/00
38 9Q2(Line3"-CL- 3" Pipe 133-V-312 133-V-306
3401-A2A-IH)
DHDS/NHGU/00
39 9R1(Line6"-CH- 6" Pipe 133-E-310 A/B 133-V-310
1101-D2A-IH)
DHDS/NHGU/00
40 9R2(Line3"-CH- 3" Pipe 133-E-312 A/B 133-V-312
3401-D2A-IH)
DHDS/NHGU/00
133-E-310 A/B &
41 9S(Line4"-SH- 4" Pipe 133-V-301
312 A/B
1101-D2A-IH)
DHDS/NHGU/00
DHDS/NHGU/009
42 9T(Line12"-SH- 12" Pipe 133-E-303
S
3001-D2A-IH)
DHDS/NHGU/00
43 9U(Line3"-WB- 3" Pipe 133-C-302 133-E-314 A-C
3201-D1A-IH)
DHDS/NHGU/00
MP STEAM
44 9X(Line14"-SH- 14" Pipe 133-E-303
HEADER
1411-D2D-IH)
DHDS/NHGU/00
MP STEAM
45 9Y(Line10"-SH- 10" Pipe 133-E-311 A/B
HEADER
3016-D2D-IH)
DHDS/NHGU/00
46 9Z(Line10"-SH- 10" Pipe 133-E-311 A/B 133-JA-301
1130-D2D-IH)
DHDS/NHGU/01
DHDS/NHGU/00
47 3A(Line6"-P- 6" Pipe 133-E-318
1D
1291-B5A-IH)
DHDS/NHGU/01
133-E- DHDS/NHGU/00
48 3B(Line10"-IG- 10" Pipe
315/317/318 4C
3651-A1A-IH)
Page 6 of 27
Table C (Bare line)
Sr.
No
DHDS/NHGU/00
1 1A(Line2"-P- 2" Pipe B/L (NAT. GAS) 133-V-311
3542-F5A)
DHDS/NHGU/00
DHDS/NHGU/00
2 1B(Line2"-P- 2" Pipe 133-V-311
1D
3561-F5A)
DHDS/NHGU/00
3 1C(2"-P-133- 2" Pipe P-301 Mixing Point
1042-DIA )
DHDS/NHGU/00
Outlet of 133-EA- Shell-side inlet of
4 5C(Line16"-P- 16" Pipe
302 133-E-309A/B
1821-B54K)
DHDS/NHGU/00
Shell-side outlet of
5 5D(Line16"-P- 16" Pipe 133-V-302
133-E-309A/B
1831-B54K)
DHDS/NHGU/00
6 5E(Line2"-P- 2" Pipe 133-V-302 133-E-314 A-C
1875-D1K)
DHDS/NHGU/00
B/L (CRU OFF
7 6A(Line10"-P- 10" Pipe Outlet of PSA
GAS)
1921-B5A)
133-V-
DHDS/NHGU/00
321/322/323/324/
8 6B(Line8"-P- 8" Pipe Piping
325/326/327/328/
2122-B5A)
329/330
D/S of Diverter
valve of
DHDS/NHGU/00
133-V-
9 7A(Line18"-FG- 18" Pipe 133-V-335
321/322/323/324/3
2125-A5A)
25/326/327/328/32
9/330
DHDS/NHGU/00
10 7B(Line30"-FG- 30" Pipe 133-V-335 133-F-301
1911-A5A)
DHDS/NHGU/00
11 8A(Line4"-P- 4" Pipe B/L (SRUN) 133-C-301
1002-A1A)
DHDS/NHGU/00
12 8B(Line4"-P- 4" Pipe B/L (HCLN) 133-C-301
1002-A1A)
Page 7 of 27
DHDS/NHGU/00
13 8C(Line4"-P- 4" Pipe B/L (HCN) 133-C-301
1002-A1A)
DHDS/NHGU/00
14 8D(Line4"-P- 4" Pipe B/L (HAN) 133-C-301
1002-A1A)
DHDS/NHGU/00
15 8E(Line4"-P- 4" Pipe B/L (RAFFINATE) 133-C-301
1002-A1A)
DHDS/NHGU/00
DHDS/NHGU/001
16 8F(Line3"-P- 3" Pipe 133-C-301
A
1002-A1A)
DHDS/NHGU/00
17 8G(Line4"-P- 4" Pipe 133-V-302 133-C-301
1011-A5A)
DHDS/NHGU/00
18 8H(Line2"-P- 2" Pipe 133-C-301 133-E-312 A/B
1033-A1A)
DHDS/NHGU/00
19 8K(Line30"-FG- 30" Pipe PSA UNIT 133-F-301
1522-A5A-IH)
20 4" Pipe 133-E-342 T/S
8L 8H
DHDS/NHGU/00
21 4" Pipe B/L(NAT GAS) 133-E-342 T/S
8M
DHDS/NHGU/00
22 9A(Line6"-WDM- 6" Pipe B/L(DMW) 133-E-308
1801-A1K)
DHDS/NHGU/01
23 0A(Line8"-WCS- 8" Pipe CW HEADER 133-E-309A
3707-A5Y)
DHDS/NHGU/01
24 0B(Line3"-WCS- 3" Pipe CW HEADER 133-E-313
3706-A5Y)
DHDS/NHGU/01
DHDS/NHGU/00
25 2A(Line1"-C- 1" Pipe 133-V-307
1E
1081-B1K)
DHDS/NHGU/01
26 2B(Line1.5"-C- 1.5" Pipe 133-V-372 133-V-305
3101-A1K)
DHDS/NHGU/01
2C(Line1.5"-C-
DHDS/NHGU/00
27 3343-A1K) 1.5" Pipe 133-V-372
9C
Page 8 of 27
DHDS/NHGU/01
28 2D(Line1.5"-C- 1.5" Pipe 133-V-373 133-C-302
3217-D1K)
DHDS/NHGU/01
29 2E(Line1.5"-C- 1.5" Pipe 133-V-371 133-V-305
3102-A1K)
DHDS/NHGU/01
DHDS/NHGU/00
30 2F(Line1"-C- 1" Pipe 133-V-371
9C
3373-A1K)
DHDS/NHGU/01
31 2G(Line1"-C- 1" Pipe 133-V-370 133-V-301
3371-A1K)
C) CARRY OUT PROCESS PIPING REPAIR/RENEWAL AS DETAILED BELOW (Included

in LS scope)
SERVICE WATER LINE

Following sections to be renewed:
1. 3 dia service water line to be replaced as per notification no. 10642936.
RAW WATER LINE

1. 4 dia raw water inlet line of 133-E-333A approx 1m length vertical section
east of exchanger (already wrapped)
2. 4 dia raw water outlet line of 133-E-333A leaking at TG tapping location.
Renew approx 1m length bottom vertical section east of exchanger.
3. 2 dia stub of 10 raw water supply line is leaking at north-west side of 133-
R-304.Renew 10 line 0.5m length on each side of stub including stub.
4. 8 dia 133-P-322 A/B discharge line approx 40m length in overhead rack
west of pump up to north-west corner compressor house.
OTHER LINES
1. Replacement of approximately 6 m of 6 clamped line from V306 outlet to

V305 condensate line as per notification no 1044793.
2. Replacement of 6 plant air line S wrapped done plant air line at CDU3 west
b/l as per notification no. 1048669
3. Fabrication and erection of approximately 6m fire water line near PSA (12
dia).
4. Replacement of approximately 6 m of 3 DM water line. (line from 133V305
deareator to CDU).
Page 9 of 27
D) UNDERGROUND PIPING
In order to assess the condition of coating of under ground lines, excavation at 5
nos selected locations shall be carried out prior to shutdown / during shutdown.
After inspection, carry out back filing and PCC as existing.
E) MISC JOBS
1. Replace the fire affected main vertical column ISMB 500 built up section at
south-west corner of 133-R-302B after providing temporary support for height
about 3.6 m from 1m above fourth floor level .Design and drawing for temporary
support shall be made and submitted to BPCL for approval. Detailed
Methodology for replacement of beam shall be prepared and approved by Area
Incharge /Drawing office prior to carrying out the job.
2. Carry out insitu machining of following flanges (both sides) after groove filling and
opening of the flange/valve. After machining tighten the flange with new gasket.
Description Size Qty Spec

BFW to HCU line flange
8"
fermanated at battery limit 2 B2A
Reformer condensate return b/v
3"
flange 2 A2A
UPC513B u/s flange leak(Globe
8"
Valve) 2 B2A
UPC513A C.V flange clamped 4 2 B2A
UPSV 1511A flange leak(Relief
8
valve) 2 A2A
H.P. to L.P diversion hookup line
4
B/V flg clamped(gate valve) 2 D2A
V310 flanges 2 8
V301 O/l flanges 14 2
LOBS:-
A) PROCESS PIPING LOOPS FOR COMPREHENSIVE INSPECTION & HYDROTESTING
Offer all the following process piping for comprehensive inspection as per scope of work detailed
in Appendix A Attachment 9, carry out necessary repair as per the inspection finding and offer
hydro testing of the line at specified pressure. Repair of the line shall be paid as per the
applicable SOR.
SR. HYD. PR.

LINE DESCRIPTION LINE NO.
NO. (Kg/cm2g)
FUEL GAS
Page 10 of 27
6"/3" dia fuel gas line from battery limit to 6"-FG-132-6550-1A3A 18.0
1
plant header. 3"-FG-132-6550-1A3A
6" line from the 6" plant header to 132-V- 18.0

2 6"-FG-132-6551-1A3A
281.
6" dia line from 132-V-281 to furnace gas 6"-FG-132-6552-1A3A 18.0
3
header (6"-FG-132-6554-1A3A-IT). 6"-FG-132-6554-1A3A-IT
2" dia gas line from 6" dia furnace FG 18.0
2"-FG-132-4750-1A3A-IT
4 header including 1" pilot gas line to 132-F-
1"-FG-132-4751-1EOB-IT
205.
4"-FG-132-4550-1A3A-IT
2"-FG-132-4551-1EOB-IT
204.
2"-FG-132-4950-1A3A-IT
1"-FG-132-4951-1EOB-IT
206.
2"-FG-132-6556-1A3A 18.0
2" dia FG line from 3" header (3"-FG-132-
2"-FG-132-6557-1A3A
7 6550-1A3A) to 132-E-271A and 132-E-
2"-FG-132-1750-1A3A
275A.
2"-FG-132-3950-1A3A
18.0
1" dia FG lines from 3" dia plant header to 1"-FG-132-6753-1A3A
8
flare header. 1"-FG-132-6752-1A3A
2"-FG-132-6555-1A3A 18.0
9 2" dia FG lines of 132-V-281 Safety valves. 2"-FG-132-6558-1A3A
2"-FG-132-6553-1A3A
B) PROCESS PIPING LOOPS FOR COMPREHENSIVE INSPECTION:
Offer all the process lines (Insulated / Bare) inside the battery limit for comprehensive inspection
as per scope of work detailed in Appendix A Attachment 9. For column overhead lines, make
Bosuns chair arrangement for taking wall thickness measurements.
Based on the RBI analysis and operating temperature, piping circuits have been
grouped in three tables. Following are the table description:
Table A: Insulated lines whose operating temperature falls in CUI range i.e. below
120 Deg C. For external inspection of these lines, insulation shall be
opened in following manner.
Vertical section: 1 meter Insulation band shall be opened after every 10
meters of straight length. Insulation shall also be opened at all the
branches, support locations, elbows, T sections, reducers, drains and
vents.
Horizontal section: 1 meter insulation band shall be opened at every
support location. Insulation shall also be opened at all the branches,
elbows, T sections, reducers, drains and vents.
Page 11 of 27
Table B:High temperature insulated lines. For external inspection of pipeline,
pockets for UT gauging shall be opened at all elbow locations, Tees and
at every 10 meters in straight sections.
Table C: Bare pipe lines. Lift the pipe line at beam support locations and offer for
inspection.
Table A Insulated Lines within CUI Range
Sr. No Corrosion Loop Piping Description From and To

1 132-MR-103 30-P-132-1450-1A5B From line 132-C-221
(Vacuum O/H to JA-252A/B
System)
2 132-MR-104 (Top 6-P-132-1456-1A3A-IT. From line 132-G-
side cut pump- 205A/B to 132-C-221
around from FPU above Bed 6.
column (132-C- 6-P-132-1856-1A3A-IT. From Line 132-EA-
221) 221A/B/C/D T/S to
Line 132-C-221.
3 132-MR-105 3-P-132-2154-2A3A-IT From Line 132-E-251
(Waxy 100N T/S to Tankage.
sidecut from FPU
column C-221) 3-P-132-2350-2A3A-IT From Line 132-E-227
T/S to Tankage.
3-P-132-2351-2A3A-IT From Line 2350 to

132-C-221.
3-P-132-2352-2A3A-IT
From Line 2352 to
Slops header
4 132-MR-106 3-P-132-2151-2A3A-IT From line 132-EA-222
(Waxy 150N side T/S to Tankage.
cut from FPU
column C-221) 3-P-132-2152-2A3A-IT From line 2151 to
132-C-221
3-P-132-2153-2A3A-IT From line 2152 to
Slop header
5 132-MR-107 (FPU 3-P-132-2251-2A5A-IT From 132-EA-221 T/S
Vacuum Column to Tankage
Bottom)
3-P-132-2252-2A5A-IT From line 2251 to C-
221
3-P-132-2253-2A3A-IT From line 2251 to

Slop header
Page 12 of 27
6 132-MR-108 4-P132-2550-1A3A-IT From Tankage to 132-
(Waxy Feed to F- G-204
205)
4-P132-2551-1A3A-IT From 132-G-204 to
132-E-253 S/S
7 132-MR-110 (DW 1-P-132-2955-8G1C4-IH From Line 2955 to line
Reactor Feed and 2956/2957
Effluent stream)
3-P-132-2952-8G1C4-IH From Line 2951 to
132-R-204
3-P-132-2954-8G1C4-IH From Line 2953 to line

132-R-204
8 132-MR-111 2-PZ-132-3052-7B3B3-IT From Line 3254
(HDF Rx Feed (From 132-E-255) to
and effluent) Line 3050 (inlet of
132-R-205)
9 132-MR-113 1-P-132-2956-7A3B3-IT From Line 2955 to
(Cold Hydrogen Line 2950
Gas and Quench 1-P-132-2957-7A3B3-IT From Line 2955 to
Gas) Line 2854
1-P-132-2958-7A3B3-IH From Line 2955 to
Line 2952
Line 3053
Line 3051
Line 3050
132-R-205
Line 2952
Line 2954
132-R-204
4-P-132-3251-7A3B3-IH From 132-E-255 S/S
to Line 3252/53
132-E-256 T/S
132-E-255
4-P-132-9325-7A3A3-IH From H2 from HCU to
Line 3255
132-E-255 I/L
Page 13 of 27
10 132-MR-114 (Hot 4-P-132-3252-7A3B3- From 132-E-256 T/S
Hydrogen Gas) IH(Loop-114) to 132-E-254 T/S
11 132-MR-115 1.5-PZ-132-3452-2A3B3- From 132-V-256 to
(HHPS cold IH CBD header and 132-
vapour) 6-P-132-3453-2A3B3-IH V-228
6-PZ-132-3450-2A3B3-IH From 132-EA-228 T/S

to 132-E-263 S/S
6-PZ-132-3451-2A3B3-IH
From 132-E-263 S/S
to 132-V-256
12 132-MR-119 (DW 1.5-P132-4259-2A3A-IT from near Line 4255
Vacuum Column to 132-P-259A/B
Bottoms)
4-P132-2554-2A3A-IT From132-E-253 T/S to
4-P132-4255-2A3A-IT 132-EA-258 T/S via
132-EA-226 T/S
4-P132-4256-2A3A-IT From 132-E-258 to

Tankage
4-P132-4257-2A3A-IT Line 4256 to Tankage

4-P132-4258-2A3A-IT From 132-V-253 to
Line 4254
13 132-MR-120 1.5-P-132-4056-2A3A-IH From line 4055 to slop
(Lube Byproduct header
circuit)
1.5-P-132-4057-2A3A-IH From line 4055 to
132-C-225
2-P-132-4054-2A3A-IH From line 4051 to Line

4055
4-P-132-4051-2A3A-IH From Line 4050 to

4-P-132-4052-1A3A-IH 132-C-225 top via
132-EA-224 T/S
6-P-132-4050-2A3A-IH From 132-P-262A/B to

4-P-132-4053-2A3A-IH Line 4053/4051 and
132-C-225.
8-P-132-3751-1A3A-IH From 132-C-225 Bed

4 to 132-P-262A/B
14 132-MR-121 1.5-P-132-4251/4252- From 132-EA-225 T/S
(Light Lube 2A3A-IH to tankages via 132-E-
product circuit) 259 S/S
Page 14 of 27
From Line 4252 to
1.5-P-132-4254-2A3A-IH 132-C-225 Bottoms
15 4/ 3 / 2
Hydrogen
quench gas line.
16 1.5 dia Startup
hydrogen to
HLPS
17 1.5 dia Cold
warm up oil from
132-E-226.
18 1.5 dia Hot
warm up oil to
132-P-265.
19 1 dia W-500N
sample point/
analyzer.
20 1 dia W-100N
sample point/
analyzer.
21 1 dia W-150N
sample point/
analyzer.
22 2 dia RV inlet Remove insulation
line of 132-G- up to 2 m from both
204A/B DW RVs and RV bypass
Feed filter line.
23 Remove insulation
2 dia RV inlet
from isolation valve
line of 132-V-
up to both RVs and
254 DW HHPS
RV bypass line.
24 Remove insulation
4 dia RV inlet
up to 2 m from both
line of 132-V-
RVs and RV bypass
255 DW HLPS
line.
25 6 dia RV inlet Remove insulation
line of 132-V- up to 2 m from both
256 DW HHPS RVs and RV bypass
Vapour KOD line.
Page 15 of 27
Table B - Insulated Lines Above CUI Range
Sr No Corrosion Loop Piping Description From and To
1 132-MR-101 (FPU 4-P-132-1351-2A5A-IT. From Line 1350 to
Feed) 132-F-204.
4-P-132-1656-2A5A-IT. From 132-P258A/B

to 132-F-204.
6-P-132-1350-2A5A-IT. From Line 1703 to

Line 1351(Piping
from Atmospheric
Fractionator bottom
to FPU feed furnace).
6-P-132-1660-2A3A-IT. From 132-P-266A/B

to 132-F-204
2 132-MR-102 (FPU 16-PZ-132-1352-2G1C- From 132-F-204 to
Feed and Vacuum IH. 132-C-221 and C-
Column) 32-PZ-132-1353-2G1C- 221 Flash zone.
IH.
From Bottom of Bed
2 of C-221 to Top of
8-P-132-1552-2G1C-IT. Bed 1 of C-221.
3 132-MR-104 (Top 10-P-132-1850-2A3A-IT From line 132-P-

side cut pump- 253A/B to Line
around from FPU 1851/1852
column 132-C-
221)
132-MR-104 (Top 12-P-132-1451-1A3A-IT From line 132-C-221
side cut pump- to 132-P-253A/B
around from FPU
column (132-C-
221))
132-MR-104 (Top 2-P-132-1858-2A3A-IT From Line 1856 to
side cut pump- 1859
around from FPU
column (132-C-
221))
side cut pump- Line 1859
around from FPU
column (132-C-
221))
Page 16 of 27
side cut pump- Line 132-P-266A/B
around from FPU
column (132-C-
221))
132-MR-104 (Top 4-P-132-1859-1A3A-IT From Line 1857/1858
side cut pump- to 132-V-253
around from FPU
column (132-C-
221))
132-MR-104 (Top 6-P-132-1457-1A3A-IT From line 132-EA-
side cut pump- 221A/B/C/D TS to
around from FPU 132-G-205A/B
column (132-C-
221))
side cut pump- Line 132-G-206A/B
around from FPU
column (132-C-
221))
side cut pump- Line 1852/1854
around from FPU
column (132-C-
221))
side cut pump- Line E-261
around from FPU
column (132-C-
221))
side cut pump- Line 132-EA-
around from FPU 221A/B/C/D T/S
column (132-C-
221))
4 132-MR-105 8-P-132-1452-2A3A-IT From Line 132-C-221
(Waxy 100N side to 132-P-254A/B.
cut from FPU 6-P-132-1950/1952- From Line 132-P-
column C-221) 2A3A-IT. 254A/B to 132-G-207
A/B.
.
6-P-132-1458-2A3A-IT From Line 132-G-207
A/B to 132-C-221
above Bed 4
4-P-132-1951-2A3A-IT. From Line 132-P-
Page 17 of 27
254A/B
top to 132-C-222
Top.
36-P-132-1953-2A3A-IT. From Line 132-C-222

top to 132-C-221
above Bed 4.
6-P-132-1954-2A3A-IT From Line 132-C-222

Bottom to 132-P-
255A/B
4-P-132-1955-2A3A-IT. From Line 132-P-

3-P-132-1956/1957- 255A/B to EA-227
2A3A-IT. T/S and P-266 A/B.
From Line 1956 to

3-P-132-1958-2A5A-IT. Line 132-E-251 T/S.
From Line 132-P-

3-P-132-1658-2A5A-IT. 258B top to Line
1452
5 132-MR-106 10-P-132-1550-2A5A-IT From line 132-C-221
(Waxy 150N side Below Bed 3 to 132-
cut from FPU P-256A/B.
column C-221)
132-MR-106 3-P-132-1958-2A3A-IT From line 132-P-
(Waxy 150N side 257A/B to line 2057
cut from FPU
column C-221)
(Waxy 150N side 257A/B to 132-E-251
cut from FPU T/S
column C-221)
132-MR-106 3-P-132-2058-2A3A-IT From line 2057 to
(Waxy 150N side line 2059
cut from FPU
column C-221)
132-MR-106 3-P-132-2150-2A3A-IT From line 132-E-251
(Waxy 150N side T/S to 132-EA-222
cut from FPU T/S
column C-221)
132-MR-106 42-P-132-2054-2A5A-IH From line 132-C-223
(Waxy 150N side to 132-C-221
cut from FPU
column C-221)
Page 18 of 27
(Waxy 150N side 132-C-223
cut from FPU
column C-221)
132-MR-106 4-P-132-2053-2A5A-IT From line P-256A/B
(Waxy 150N side to 132-G-209 A/B
cut from FPU
column C-221)
(Waxy 150N side 257A/B to line 2057
cut from FPU
column C-221)
132-MR-106 6-P-132-1558-2A5A-IT From line 132-G-
(Waxy 150N side 208A/B to 132-C-221
cut from FPU above Bed 3
column C-221)
132-MR-106 6-P-132-1559-2A5A-IT From line 132-G-209
(Waxy 150N side A/B to 132-C-221
cut from FPU above Bed 2
column C-221)
132-MR-106 6-P-132-2052-2A5A-IT From line 2051 to E-
(Waxy 150N side 260
cut from FPU
column C-221)
132-MR-106 6-P-132-2055-2A3A-IT From line 132-C-223
(Waxy 150N side to 132-P-257A/B
cut from FPU
column C-221)
132-MR-106 6-P-132-2451-2A5A From line 2052 to
(Waxy 150N side 132-E-260 T/S
cut from FPU
column C-221)
132-MR-106 6-P-132-2452-2A5A-IT From line 132-E-260
(Waxy 150N side T/S to 132-G-208A/B
cut from FPU
column C-221)
(Waxy 150N side line 2452
cut from FPU
column C-221)
(Waxy 150N side 256A/B to line
cut from FPU 2051/2052
column C-221)
Page 19 of 27
6 132-MR-107 (FPU 3-P-132-1655-2A5A-IT From Line 1650 to
Vacuum Column 132-E-252 T/S
Bottom)
132-MR-107 (FPU 3-P-132-1657-2A5A-IT From Line1662 to
Vacuum Column 132-P-256A/B
Bottom)
Bottom)
Bottom)
Vacuum Column 132-C-221
Bottom)
132-MR-107 (FPU 3-P-132-2250-2A5A-IT From 132-E-252 T/S
Vacuum Column to 132-EA-223 T/S
Bottom)
132-MR-107 (FPU 4-P-132-1650-2A5AIT From line 132-P-
Vacuum Column 258A/B to line 1651
Bottom)
132-MR-107 (FPU 4-P-132-1651-2A5AIT From line 1650 to
Vacuum Column line 1652
Bottom)
132-MR-107 (FPU 4-P-132-1652-2A5AIT From line
Vacuum Column 1651/1957/2059 to
Bottom) line 1653
132-MR-107 (FPU 4-P-132-1656-2A5A-IT From Line 132-P-258
Vacuum Column A/B to 132-F-204
Bottom)
132-MR-107 (FPU 4-P-132-1662-2A5A-IT From Line 132-P-
Vacuum Column 258B to Line
Bottom) 1657/1658/1659
132-MR-107 (FPU 6-P-132-1557-2A5A-IT From line 132-C-221
Vacuum Column to 132-P-258A/B
Bottom)
132-MR-107 (FPU 6-P-132-1654-2A3A-IT From 132-P-266A/B
Vacuum Column to Stream going to
Bottom) HCU
Vacuum Column 132-F-204
Bottom)
132-MR-107 (FPU 8-P-132-1653-2A3A-IT From Line 1652/1852
Vacuum Column to line 132-P-266A/B
Bottom)
Page 20 of 27
7 132-MR-108 3-P132-2654-1A3A-IT From Line 2659 to
(Waxy Feed to F- 132-C-221
205)
132-MR-108 3-P132-2655-1A3A-IT From Line 2659 to
(Waxy Feed to F- 132-P-253A/B
205)
205)
132-MR-108 3-P132-2657-1A3A-IT From Line 2659 B/I
(Waxy Feed to F- to HCU to 132-P-
205) 265B
205)
132-MR-108 3-P132-2753-1A3A-IT From 132-P-259A/B
(Waxy Feed to F- to Line 2552 I/L of
205) 132-V-253
132-MR-108 3-P132-3853-2A3A-IT From 132-P-265A to
(Waxy Feed to F- Line 2550 Inlet of
205) 132-G-204
132-MR-108 4-P132-1859-1A3A-IT From 132-EA-221
(Waxy Feed to F- T/S to Line 2653 Inlet
205) of 132-V-253
132-MR-108 4-P132-2552-1A3A-IT From 132-E-253 S/S
(Waxy Feed to F- to 132-V-253
205)
132-MR-108 4-P132-2651-1A3A-IT From line 2650 to
205)
132-MR-108 4-P132-2652-1A3A-IT Line 1859 O/L of
(Waxy Feed to F- 132-E-260 T/S to
205) 132-C-225 to Slops
header
132-MR-108 4-P132-2653-1A3A-IT From Line 1859 O/L
(Waxy Feed to F- of 132-E-260 T/S and
205) I/L of 132-V-253 to
line 2552
(Waxy Feed to F- Line
205) 2654/55/56/57/58
132-MR-108 4-P132-2750-8A3A-IT From 132-P-259A/B
(Waxy Feed to F- to FV-738 Upstream
205) of 132-E-254 T/S
Page 21 of 27
132-MR-108 4-P-132-2850-8B3B3-IT From line 2750 to
(Waxy Feed to F- 132-P-259 o/l
205)
132-MR-108 4-P-132-2855-8B3B3-IT From 132-E-254
(Waxy Feed to F- bypass line to line
205) 2856
132-MR-108 4-P132-5911-1A3A-IT From 132-EA-207
(Waxy Feed to F- T/S B/l to HCU to
205) Line 2653
132-MR-108 4-P132-6108-1A3A-IT From 132-EA-208
(Waxy Feed to F- T/S B/l to HCU to
205) Line 2653
132-MR-108 6-P132-2650-1A3A-IT From 132-V-253 to
205)
8 132-MR-109 (Oil- 4-P-132-2851-8B3B3-IT From line 2850 to
Gas loop) 132-E-254 T/S
9 132-MR-110 (DW 8-PZ-132-2852/2853- From 132-E-254 T/S
Reactor Feed and 8G1C4-IH. to F-205 I/L.
Effluent stream)
8-PZ-132-2854-8G1C4- From Line 132-F-205
IH. to 132-R-204.
From Line 2855 to

4-PZ-132-2856-8G1C4- 2852.
IH.
10 132-MR-111 4-P-132-3852-2B3B3-IH From 132-P-265A/B
(HDF Rx Feed to Line 3153
and effluent) I/L of 132-V-255
6-P-132-3155-7B3B3-IH From 132-V-254 to

132-E-256
6-P-132-3159-7B3B3-IH From Line 3155 132-

V-254 top O/L to
Relief Emergency
pump
6-PZ-132-3156-7B3B3-IH From 132-E-256 S/S

6-PZ-132-3157-7B3B3-IH O/L to 132-EA-
201(HCU B/L) and to
Line 3158 (132-EA-
228 I/L).
Page 22 of 27
8-PZ-132- From 132-E-254D
2857/3050/3051-7B3B3- S/S to 132-V-254 via
IH 132-R-205.
11 132-MR-112 4-PZ-132-3151-7B3B3 From Line 3151
(HLPS liquid and 4--P-132- (132-V-254 O/L) to
Vapour) 3152/3153/3154-7B3B3- 132-E-257 via 132-V-
IT. 255.
4-PZ-132-3350-2B3B3-
IH. From 132-V-255 to
132-EA-202 T/S and
1.5-P-132-3351-2B3B3- Flare Header.
IH.
1.5-P-132-3360-4B3B3-
IH.
12 132-MR-115 6-P-132-3158-7B3B3-IH From Line 3157 to
(HHPS cold 132-EA-228
vapour)
13 132-MR-116 4-PZ-132-3550-2B3B3- From 132-E-257 to
(HLPS liquid feed)
IT. 132-C-224
14 132-MR-117 (DW 4-PZ-132-3551-2A5A-IT. From 132-C-224 to
3-PZ-132-3654-2A5A-IT.
Product Stripper 132-F-206.
Circuit) 3-PZ-132-3650-2A5A-IT.
15 132-MR-118 (DW 10-PZ-132-3651-2A6A- From line 132-F-206
Vacuum Column IT. to 132-C-225.
feed) 18-PZ-132-3652-2A6A-
IT.
3-PZ-132-3650-2A5A-IT.
16 132-MR-119 (DW 4-P-132-3856-2A5A-IT From 132-C-
Vacuum Column 225(bottom) to 132-
Bottoms) P-265A/B.
6-P-132-3753-2A5A-IT. From 132-C-225

bottom of Bed 2 to
132-C-225 Top of
Bed 1
4-P-132-3850. From 132-P-265A/B

3-P-132 3851/3853- to 132-E-257 S/S, F-
2A5A-IT. 206 and G-204.
From Line 3853 to

3-P-132-3855-2A5A-IT. 132-P-262A/B
From 132-E-257 T/S

4-P-132-3553-2A5A-IT. to 132-E-253 T/S.
Page 23 of 27
From Line 3553 to
4-P-132-2553-2A5A-IT. Line 2554.
17 132-MR-120 2-P-132-4055-2A3A-IH From line 4054/4250

(Lube Byproduct to Line 4055
circuit)
18 132-MR-121 4-P-132-3752-1A3A-IH. From 132-C-225 Bed
(Light Lube 3 to 132-P-263 A/B
product circuit) S/S.
3-P-132-4150/4151/4152- From 132-P-263A/B

1A3A-IH. D/S to 132-C-226
and G-212A/B I/L.
3-P-132-3764-1A3A-IH From 132-G-212 A/B

o/l to 132-C-225 Bed
2.
8-P-132-4153-1A3A-IH. From 132-C- 226 top

to 132-C-225 bed 2.
3-P-132-4154-1A3A-IH. From 132-C-226

1.5-P-132-4155-2A3A-IH. bottom to 132-E-225
T/S via 132-P-
264A/B.
1.5-P-132-4250-2A3A-IH. From P-264 A/B D/S

to 132-F-203.
19 132-MR-122A 4-P-132-3552-2A5B From 132-C-224 to
(Product Stripper 132-C-203
overhead)
20 132-MR-124 1.5-WB-132-5155- From Economizer
(BFW/Steam 2A3DS-IH. Section 132-F-
Circuit) 1-WB-132-5154-2A3DS- 205/206 to 132-E-
IH. 252 S/S, E-251S/S
2-WB-132-5156-2A3DS- and E-260 S/S.
IH.
From BFW supply to
BFW return via 132-
3-WB-132- E-261 SS.
1850/18511853-2A3DS-
IH
Page 24 of 27
Table C Bare Lines
Sr No Corrosion Loop Piping Description From and To

1 132-MR-103 132-JA-252A/B/C/D/E/F- FPU Column
(Vacuum Shell. Vacuum ejector to
Overhead 2-P-132-1764/1767- 132-V-273 Via. 132-
System) 1A5BN. E-271A/B/C S/S,
3-P-132-1763-1A5BN. 132-V-251.
6-P-132-1762/1766-
1A5BN.
8-P-132-1765-1A5BN
2 132-MR-106 3-WP-132-1754-1A5BN. From 132-V-251 to
(Waxy 150N side 3-WP-132-1755-1A5BN. Suction of 132-P-252
cut from FPU A/B.
column C-221)
3 132-MR-120 2-P-132-4058-2A3A From line 4052 to
(Lube Byproduct line 4054.
circuit)
4 132-MR-122 12-P-132-3750-1A5BN From 132-C-225 to
(DW Vacuum 132-JA-256A/B/C/D-Shell 132-V-274 via
column overhead 2-P-132-3951/3952-1A5B vacuum ejectors,
system) 1.5-P-132-3953/3954- 132-E-275A/B/C S/S,
1A5B 132-V-252.
3-P-132-3963/3964- From 132-V-251/132-

1A5BN V-252 to Suction of
2-P-132-3965-1A5BN 132-P-260A/B.
4-P-132-3966-1A5BN
6-P-132-3967/3968-
1A5BN From 132-P-260 A/B
discharge to HSD
1-P-132-1750-1A5B. Header.
5 132-MR-123 8-WCR-132-1753/3250- From 132-E-271A/B/
1XOAC. C, E-275A/B/C, E-
6-WCR-132-3450/4250- 255/258/259/263/265
1X0AC. T/S to 6352 return
3-WCR-132-4251/2150- line.
1X0AC.
24-WCR-132-6352-
1XOAC.
14-WCR-132-1752-
1X0AC.
10-WCR-132-
1750/3950/3952-1X0AC.
Page 25 of 27
6 132-MR-123 8-WCS-132-1753/3250- From 132-P-280
1XOAC. 6352 Supply Line to
6-WCS-132-3450/4250- 132-E-271A/B/C, E-
1X0AC. 275A/B/C, E-
3-WCS-132-4251/2150- 255/258/259/263/265
1X0AC. T/S.
24-WCS-132-6352-
1XOAC.
14-WCS-132-1752-
1X0AC.
10-WCS-132-
1750/3950/3952-1X0AC.
7 132-MR-125 1.5-WP-132-3957/3958- From 132-V-252 to
(Sour water) 1A5BN. Suction of 132-P-261
A/B.
2-WP-132-1756/1757- From 132-P-261 A/B

1A5BN. D/S to 132-P-252A/B
D/S and Line 3957.
From 132-P-252 D/S
2-WP-132-3955/3956- to SWS and Line
1A5BN. 1756.
C) CARRY OUT PROCESS PIPING REPAIR/RENEWAL AS DETAILED BELOW (Included

in LS scope)
Sr. No. Line description

1 2" corroded Drain line of 132-E-254 C/D T/S O/L line
2 1.5" Sour water circulation line of 132-V-252 through 132-P-252A/B
(composite repaired section).
3 Shoe support welding of 3" dia 132-F-206 Convection O/L to radiation
section I/L line.
4 Support repair of 132-F-206 transfer line to 132-C-225.
5 Support repair of 3" Dia quench line at reactor 132-R-204, third bed
inlet.
6 6 dia leaky Steam header to Furnace.
7 Replace approx. 8 meters corroded section of instrument air line on
south-east junction of LOBS plant.
8 Replacement of approx. 160 meters section of BCS/BCR lines
varying from sizes 1.5/2/3/4/10.
9 Replacement of approx. 25 meters section of service water line
varying from sizes 1.5/2/3/4.
10 P259A discharge drain to CFBD at header joint point.
11 Weld pads on line at all support locations (Approx 15 nos. pads) on 1.5
Page 26 of 27
line from 132-P-260 A/B discharge to battery limit. After pad welding
carry out hydrotest of the line .
12 132-E-254 A/B outlet line is found having tilted shoes in pipe rack in
plant. Rectify approx 6 nos. tilted shoes
D) UNDER GROUND PIPING:

In order to assess the condition of coating and external surface of underground
lines, excavation at approx. 10 selected locations at soil to air interface shall be
carried out prior to shutdown
Page 27 of 27
ATTACHMENT 11 SECTION J

UNIT (NHGU / LOBS) : COOLING WATER SYSTEM
NHGU:
1. COOLING WATER LINES, ELBOWS, TEES, MANWAYS AND END FLANGES
Erect scaffolding wherever required.

Open end flanges / elbows / tees / man ways at respective locations of cooling
water lines.
Clean the line, end flanges, elbows, and tees internally by water washing and
offer for inspection.
Carry out touch up of cement lining at the flange face area on elbow / Tees /
Branches and pipe line flanges.
Carry out internal cement lining repair as required after cleaning and inspection
of the lines/ elbows / tees / branches. Cement lining of the newly fabricated
section as defined in scope of work and for touch repair at the edges of the
flanges is included in lump sum scope.
Box up the end flanges / elbows / Tees / Branches after inspection and repair.
Remove scaffolding after completion of the job.
Scope includes offering the cooling water line for inspection from the tap off from
main cooling water supply /return header including first isolation valve at battery
limit to complete circuit within the plant.
Excavation / back filling / pavement after completion of the job for inspection and
repair of the underground section of the cooling water line from main supply
header to plant , wherever required , is included in lump sum scope.
For soil to air interfaces, on completion of inspection, carry out external bitumen
wrapping and coating as existing.
Following end flanges / elbows at following locations of cooling water lines shall
be opened during shutdown for inspection. Offer the lines internally in clean
condition
A. 12 / 6 DIA C.W. SUPPLY HEADER:
1. 1 no. 12dia strainer (Near battery limit north of compressor house).

2. 1 no, 12 dia elbow (Near battery limit north of compressor house).
3. 1 no. 12 dia miter elbow (Above 133-E-335 Gas Cooler).
4. 1 no. 12 x 6 header reducer in pump house pipe rack.
5. 1 no. 6 dia blind flange of the header in the pump house pipe rack at west
end.
Page 1 of 9
B. 12 / 6 DIA C.W. RETURN HEADER:
Near battery limit north of compressor house.

1. 1 no, 12 dia elbow (Near battery limit north of compressor house).
2. 1 no. 12 dia miter elbow (Above 133-E-335 Gas Cooler).
3. 1 no. 12 x 6 header reducer in pump house pipe rack.
4. 1 no. 6 dia blind flange of the header in the pump house pipe rack at west
end.
C. 10 DIA C.W. SUPPLY LINE TO 133-E-316:
1. 1 no. 10 dia elbow located in pipe rack near header south of 133-V-308.
2. 1 no. 10 dia miter elbow located above 133-E-306.
D. 10 DIA C.W. RETURN LINE OF 133-E-316:
E. 6 DIA C.W. SUPPLY LINE TO 133-E-317:
2. 1 no. 6 dia elbow located above 133-E-315.
F. 6 DIA C.W. RETURN LINE OF 133-E-317:
G. 10 DIA C.W. SUPPLY LINE TO 133-E-309 A/B:
2. 1 no. 10 dia TEE located above 133-EM-303.
3. 2 nos. 10 dia elbows located above 133-EM-303.
4. 2 nos. 10 x 8 reducer in supply lines of 133-E-309A/B
H. 10 DIA C.W. RETURN LINE OF 133-E-309 A/B:
2. 1 no. 10 dia TEE located above 133-EM-303.
3. 2 nos. 10 dia elbows located above 133-EM-303.
2. RENEWAL OF CW LINES:

1. 3 dia leaky stub of 12 dia CW supply header near B/L of north
compressor house.
2. 3 dia TG stub of 4 dia spool piece of 133-E-317 CW O/L line (approx.
100 mm length)
Page 2 of 9
3. 8 dia 133-E-309A CW O/L immediate elbow spool piece.
4. 4 dia 133-E-313 CW O/L line vertical spool piece on south side of
exchanger ( Approx. 2m length)
3. JOB ON COOLING WATER VALVES
i. Servicing of the CW valves
Following valves in cooling water system shall be serviced as per procedure

detailed in scope of work for valves in cooling water service in Appendix A
Attachment 7.
SR VALVE NO. OF VALVE

LOCATION
NO SIZE VALVES TYPE
Supply header near battery limit north of
1 12 4 Butterfly
compressor house.
Return header near battery limit north of
2 12 1 Butterfly
compressor house.
Supply header near battery limit north of
3 3 5 Gate
compressor house.
Return header near battery limit north of
4 3 1 Gate
compressor house.
Drain valves of 6 dia header in pipe rack at west
5 3 2 Gate
end.
6 Supply line to 133-E-316 10 1 Butterfly
7 Return line of 133-E-316 10 1 Gate
8 Drains of 133-E-316 I/L & O/L lines. 3 2 Gate
9 Supply line to 133-E-317 6 1 Butterfly
10 Return line of 133-E-317 6 1 Gate
11 Drains of 133-E-317 I/L & O/L lines. 3 2 Gate
12 Supply lines to 133-E-309 A/B 10 2 Butterfly
13 Return lines of 133-E-309 A/B. 10 2 Gate
14 Drains / TSVs of 133-E-309 I/L & O/L lines. 4 4 Gate
15 Drains of 133-E-309 I/L lines. 3 2 Gate
16 Interconnection at west end in pipe rack. 3 2 Gate
17 Interconnection at west end in pipe rack. 4 2 Gate
LOBS
1. COOLING WATER LINES, ELBOWS, TEES, MANWAYS AND END FLANGES
Erect scaffolding wherever required.

Open end flanges / elbows / tees / man ways at respective locations of cooling
water lines.
Page 3 of 9
Clean the line, end flanges, elbows, and tees internally by water washing and
offer for inspection.
Carry out touch up of cement lining at the flange face area on elbow / Tees /
Branches and pipe line flanges.
Carry out internal cement lining repair as required after cleaning and inspection
of the lines/ elbows / tees / branches. Cement lining of the newly fabricated
section as defined in scope of work and for touch repair at the edges of the
flanges is included in lump sum scope.
Box up the end flanges / elbows / Tees / Branches after inspection and repair.
Remove scaffolding after completion of the job.
Scope includes offering the cooling water line for inspection from the tap off from
main cooling water supply/return header including first isolation valve at battery
limit to complete circuit within the plant.
Excavation / back filling / pavement after completion of the job for inspection and
repair of the underground section of the cooling water line from main supply
header to plant , wherever required , is included in lump sum scope.
For soil to air interfaces, on completion of inspection, carry out external bitumen
wrapping and coating as existing.
End flanges / elbows at following locations of cooling water lines shall be opened
during shutdown for inspection. Offer the lines internally in clean condition. Also
carry out replacement of line as mentioned
A) 26 LOBS COOLING WATER SUPPLY AND RETURN HEADERS FROM

BATTERY LIMIT
26 DIA /10 DIA C.W SUPPLY HEADER
2. 1 no. 26 dia elbow near battery limit.

3. 2 nos. 3 dia blind flanges with instrument connections (located west
of strainer 132-STR-6301)
4. 1 no 26 X 10 reducer spool piece (app. 1m in length) in pipe rack (
north of 132-E-263)
5. 1 no. 10 blind flange in east west pipe rack (North West of 132-E-
256B in pump house).
6. 4 nos. 3 dia elbows of interconnection line near 10 dia blind flange.
26 DIA / 10 DIA C.W RETURN HEADER
1. 1 no. 26 dia elbow near battery limit.

2. 4 nos. 3 dia blind flanges with instrument connection near battery
limit.
3. 1 no 26 X 10 reducer spool piece (app. 1.5 m in length) in pipe rack
( north of 132-E-263)
4. 1 no. 10 blind flange in east west pipe rack (North West of 132-E-
256B in pump house).
Page 4 of 9
B) TAP OFFS
FROM THE 26 DIA / 10 DIA CW SUPPLY/ RETURN HEADER:
2 NOS. 6 DIA TAPPINGS FROM/TO 10 DIA CW SUPPLY / RETURN

HEADERS TO 132-E-263
1. 2 nos. 6 dia elbows near tap off in pipe rack ( north of 132-E-263)
2. 2 nos. 6 dia elbows near 132-E-263.
3. Replace the 6 dia leaky vertical spool piece for both supply and
return line near 132-E-263 I/L and O/L.
4. Replace the leaky 6 dia elbow spool piece at 132-E-263 I/L and 6
dia spool piece with 3 stub near 132-E-263 O/L.

HEADERS TO 132-E-255
1. 2 nos. 8 dia elbows near tap off in pipe rack (north of 132-E-255).
2. 2 nos. 8 dia elbows near 132-E-255.

HEADERS FORMING SEPARATE HEADERS
24 DIA C.W SUPPLY HEADER
1. 1 nos. 24 dia elbow near tapping in pipe rack (location north of 132-
V-255).
2. 1 no. 24 elbow in pipe rack ( east of 132-P-264A)
3. 1 no. 24 dia equal Tee (bypass line of strainers 6302A/B).
4. Suction (24 x 14) and discharge spool pieces (24 x 12) of 132-P-
280A/B
5. 1 no. 24 dia equal Tee (discharge line of 132-P-280B).
Replace the corroded 3 dia elbow spool piece of bypass line on
west of 132-P-280B and vertical supports on discharge line of 132-P-
280A/B.
6. 1 no. 24 dia elbow in Pipe rack (top of 132-V-263).
7. 1 no. 24 dia blind flange in Pipe rack (west of 132- E-260).
8. 1 no. 6 dia drain stub flange near above referred 24 dia blind flange.
9. 1 no. 8 dia elbow of tapping from 24 dia CW supply header
supplying water to 132-e-265/258/259).
10. 1 no. 8 dia blind flange of the above mentioned 8 dia line ( west of
132- E-260)
24 DIA C.W RETURN HEADER
1 nos. 24 dia elbow near tapping in Pipe rack (location north of 132-
V-255).
1 no. 24 dia blind flange in Pipe rack (west of 132- E-260).
2 nos. 6 dia elbow of interconnection line between 8 dia supply line
and 24 dia CW return header.
Page 5 of 9
2 NOS. 3 DIA TAPPING FROM/TO 8 DIA CW SUPPLY HEADER
AND 24 DIA RETURN HEADER TO 132-E-265
1. 2 nos. 3 dia elbows in Pipe rack near tap off (above 132-P-266B).
2. 2 nos. 3 dia elbows near exchanger.
3. 1 no. dia non standard CS gate valve along with CS nipple to be
replaced with brass valve and brass nipple on the return line.
4. Replace the leaky 3 dia vertical spool piece at 132-E-265 I/L and 3
dia elbow spool piece at 132-E-263 O/L.

1. 2 nos. 6 dia elbows in Pipe rack near tap off (above 132-P-262A).
4. Replace the leaky 6 dia 2nd elbow spool piece at 132-E-258
I/L.

1. 2 nos. 3 dia elbows in Pipe rack near tap off (west of 132-E-259).
4. Replace the leaky 2nos. 3 dia spool pieces on west of 132-E-
259 I/L.
2 NOS. 24 DIA TAPPINGS FROM / TO 24 DIA CW SUPPLY /

RETURN HEADERS TO EJECTOR CONDENSERS
1. 2 nos. 24 dia elbows near tapping in Pipe rack ( west of 132-E-261)

2. 2 nos. 24 dia elbows at 2nd floor level ( west of 132-V-282)
3. 2 nos. 24 blind flange ( 3rd floor level)
In 24 CW Return header of Ejector Condensers (counting from east)
1. 1 no. 10 elbow (O/L of 132-E-271A)

2. 1 no. 10 elbow (O/L of 132-E-271B)
3. 1 no. 8 elbow (O/L of 132-E-271C/275C)
4. 1 no. 10 elbow (O/L of 132-E-275B)
5. 1 no. 10 elbow (O/L of 132-E-275A)
6. 1 no. blind flange of 18 return line from 132-E-271A which forms a
18 header.
7. Replace the leaky 14 dia miter elbow spool piece at 132-E-271O/L
and 6 dia elbow spool piece at 132-E-275A O/L.
Page 6 of 9
In 24 CW Supply header (counting from east)
1. 1 no. 10 elbow to 131-E-275A

2. 1 no. blind flange of 10 return line from 132-E-275A which forms a
10 header.
3. Replace the leaky 6 dia elbow spool piece at 132-E-271C I/L and 6
dia vertical spool piece just below floor crossing of 132-E-271C.
In 10 drain line header (counting from east)
1. 1 nos. 10 elbows (1st tapping)

2. 1 nos. 8 elbows (3rd tapping)
3. 1 nos. 6 elbows (5th tapping)
6. 1 no. 10 blind flange (drain header)
2. Scaffolding:
Erect scaffolding just below the floor crossing of ejector

condensers to access the condition of external pipeline surface CW
Supply/Return/Drain headers.
3. JOB ON COOLING WATER VALVES
i. Servicing of the CW valves
Following valves in cooling water system shall be serviced as per procedure

detailed in scope of work for valves in cooling water service in Appendix A
Attachment 7.
VALVE NO. OF TYPE OF

SR NO LOCATION
SIZE VALVES VALVE
1 CW Return Header (near B/L) 26 1 Butterfly Valve
2 CW Supply Header (near B/L) 26 4 Butterfly Valve
3 CW Return header (near B/L) 3 2 Gate valve
CW Supply header (east of
4 Strainer 6301) 3" 2 Gate Valve
CW Supply header (above Strainer
5 6301) 3" 1 Gate Valve
CW Supply header (west of
6 Strainer 6301) 3" 1 Gate Valve
In 10 CW Header inter connecting
7 line. 3" 1 Gate Valve
Near 10 Supply header blind
8 flange 3" 1 Gate Valve
Page 7 of 9
Near 10 Return header blind
9 flange 3" 1 Gate Valve
In CW supply 24header near 132- Butterfly Valve
10 P-280A/B pumps. 24 7
Between the two 24 Butterfly Gate valve
valves near 132-P-280A/B
11 pumps(drain valve) 3" 1
In CW supply 24header (
12 discharge of 132-P-280B) 24" 1 Gate Valve
In CW supply 24header ( in
discharge line of 132-P-280A/B
13 pumps) 3" 2 Gate Valve
In discharge line of 132-P-
14 280B(drain valve) 3 1 Gate Valve
In bypass line of 132-P-280A/B
15 pumps 3 2 Gate valve
In 24 CW supply header(near top
16 of 132-V-263) 3" 1 Gate Valve
In 6 interconnecting line (South of
17 132-P-263B) 6" 1 Gate Valve
In 6 interconnecting line, drain
18 valve (South of 132-P-263B) 3" 1 Gate valve
In 24 CW supply header, drain
19 valve ( near 24blind flange) 3" 1 Gate Valve
In 24 CW return header, drain
20 valve ( near 24blind flange) 3" 1 Gate Valve
In 24 CW supply header (at 3rd
21 floor level west of 132-V-282) 24" 1 Butterfly Valve
In 24 CW return header (at 3rd
22 floor level west of 132-V-282) 24" 1 Butterfly Valve
In 10 interconnecting line (at 3rd
23 floor level) 10" 1 Butterfly valve
In 24 CW supply header (at 3rd
24 floor level ) near 24 Butterfly valve 3" 1 Gate Valve
In 24 CW supply header, drain
valve ( near 24blind flange at 3rd
25 floor level) 3" 1 Gate Valve
In 24 CW return header, drain
valve ( near 24blind flange at 3rd
26 floor level) 3" 1 Gate Valve
27 CW inlet / outlet of 132-E-275A 10 3 Butterfly Valve
28 CW outlet of 132-E-275A 3" 2 Gate valve
29 CW inlet / outlet of 132-E-275B 10" 2 Butterfly Valve
30 CW drain of 132-E-275B 8" 1 Butterfly Valve
31 CW outlet of 132-E-275B 3" 2 Gate Valve
32 CW inlet / outlet of 132-E-275C 8" 2 Butterfly Valve
33 CW drain of 132-E-275C 6" 1 Butterfly Valve
34 CW outlet of 132-E-275C 3" 2 Gate valve
Page 8 of 9
35 CW inlet of 132-E-271A 18" 1 Butterfly Valve
36 CW outlet of 132-E-271A 10" 1 Butterfly Valve
37 CW drain of 132-E-271A 10" 1 Butterfly Valve
38 CW outlet of 132-E-271A 3" 2 Gate Valve
39 CW inlet of 132-E-271A 3" 1 Gate Valve
40 CW inlet / outlet of 132-E-271B 14" 2 Butterfly Valve
41 CW drain of 132-E-271B 10" 1 Butterfly Valve
42 CW outlet of 132-E-271B 3" 2 Gate Valve
43 CW inlet / outlet of 132-E-271C 8" 2 Butterfly Valve
44 CW drain of 132-E-271C 6" 1 Butterfly Valve
45 CW outlet of 132-E-271C 3" 2 Gate Valve
46 CW inlet of 132-E-259 3" 1 Butterfly Valve
47 CW inlet of 132-E-259 3" 1 Gate Valve
48 CW outlet of 132-E-259 3" 1 Butterfly Valve
49 CW outlet of 132-E-259 3" 2 Gate Valve
62 CW inlet of 132-E-255 8 1 Butterfly Valve
63 CW inlet of 132-E-255 3 1 Gate Valve
64 CW outlet of 132-E-255 8 1 Butterfly Valve
Page 9 of 9
ATTACHMENT 11 SECTION K
NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE STOCK UNIT
(NHGU / LOBS) : CIVIL JOBS
NHGU:-
1) PAINTING WORK: - PAINTING OF THE EQUIPMENT / PLANT
1. Carry out painting of the following equipments including associated

structures like connecting pipelines, structures, ladder, railings, cladded
surfaces, concrete structures goose neck type lighting poles with
applicable coating system as per BPCL painting specification AE-S-5430-
Rev1, related to NHGU complex T/A. Painting of stack shall be carried
out by employing rope access technology only. (Refer attached drawing -
Highlighted Portion).
Lighter shaded area shows the extent upto which pipelines, structures
and other connections of equipments are to be painted.
2. All the quantities against each painting system for every equipments are
indicative, bidders are advised to visit the site, asses exact quantities
before quoting the tender & quote accordingly.
3. Painting works shall be carried out as per BPCL standard & quality
assurance plant and QAP document shall be maintained on regular
basis. Contractor shall stand guarantee for the complete painting quality
job for a period of 2 Years. Any defect arising during above period shall
be made good by the contractor without any cost to the BPCL.
4. All structure to be painted in silver color & other as per BPCL color
coding standards.
5. For better quality control measures contractor shall follow following steps
like:
a. Successful bidder shall be required to obtain approval of paint
manufacturer, before ordering for paint materials. Materials shall
preferably be purchased directly from manufacturers. All coats under
one particular system shall be from single manufacturer.
b. Delivery challan/ cash receipt vouchers issued by the
manufacturers/ dealers shall be used as entry challan at the main
gate of BPCL.
c. Materials challan to be processed based on packing slip of materials
not based on coating system and maintained based on PO.
d. On entry of materials inside the refinery, concerned engineer to be
approached for physical verifications of materials along with entry
challan and entered in respective QAP.
e. For monitoring the consumption, inventory to be maintained on daily
basis for surprise check.
f. Contractor is required to comply attached QAP (quality assurance
plan). Contractor shall maintain all relevant documents and produce
on demand during progress of the work. The contractor is required to
submit the entire QAP document at the time of submission of final
bill as a supporting document
6. All areas indicated below are in M2. Sign writing areas are given in
INM i.e. Inch meter.
7. For painting area mark up, please refer drawing in attachment.
8. All type of scraps including empty drums, bags, brushes, emery papers,
scrapped material generated from work to be disposed outside refinery
on regular basis at no extra cost. Reconciliation statement for paint
drums shall be produced at the time of final bill.
Following table gives the quantity of various painting requirement in NHGU

complex
Painting specification & area of application

System
: 20
System : (Stack
13 Paintin Cladded RCC
System :
(Non g) surface surface
Sr. System :27 19
Equipment insulated (Scrap (Scrap + (Scrap + Sign
No (Cold (Scrap +
Scope of work Pipelines, +2 1 coat primer + writing
. Collector) 2 coats of
Structure, coats of aluminu 2 coats of in INM
M2 HR Al.
Railing & Zinc m paint) enamel
paint) M2
ladder ) Dust M2 paint) M2
M2 Graphit
e Paint)
M2
Hydrogen
Reformer
Heater (133-
F-301), Cold
collector with
associated
structures up
to extreme
platform of
heater
including its
ID duct, FD
motor, APH &
access
platform as
per area
marked in
layout
1 6000 250 3000 6000 1500 450
drawing.
(Painting of
external
surface of
heater +
platform +
hand railing +
cat ladder +
pipelines
+lagged
surfaces
+Concrete
surfaces +sign
writing +color
coding as per
BPCL color
coding
standards.)
Stack ( 133-
X-301) with
associated
structures .
(Painting of
external
surface of
Stack +
platform +
2 hand railing + 1500 550 500 250
cat ladder +
pipelines
+lagged
surfaces
+Concrete
surfaces +sign
writing +color
coding as per
BPCL color
coding
standards.)
Process
Condensate
Stripper
(133-C-302)
with
associated
structures as
per area
marked in
layout
drawing.
(Painting of
external
surface of
3 1000 250 120 50
heater +
platform +
hand railing +
cat ladder +
pipelines
+lagged
surfaces
+Concrete
surfaces +sign
writing +color
coding as per
BPCL color
coding
standards.)
PAINTING SYSTEM SHALL BE FOLLOWED AS GIVEN BELOW
A. Steel surfaces (columns, exchangers, vessels, staircases, pipelines, structures,

pumps, motors, panels and all other steel surface.)
Scrape clean the surface thoroughly (to quality grade st.2) so as to make the
surface free of loose mills scales, oil, grease, dirt and dust as per specifications &
as directed by engineer in charge.
System 13
Apply primer of one coat of Self Priming surface tolerant Epoxy Mastic Paint (1*125
brush)
Then apply intermediate coat of High build two pack polyamide cured epoxy (1*125
brush)
And final coat of Aliphatic acrylic modified high solids weather resistant recoatable
two pack polyurethane (1*40 roller or brush)
TOTAL DFT : 290 micron
B. External thermal indicative paint for cold collector vessels of reformer furnaces
(NHGU regenerator ): abrasive cu slag shot blasting to sa 2.5 as per direction of
engineer in charge.
System 27
Apply primer of one coat of Inorganic Zinc Ethyl Silicate Primer (1*65 Air Spray/
Airless)
Then apply two coats of single pack, temperature indicating paint based upon a
modified silicone (2*25 Air Spray)
C. Steel surfaces (hot un-insulated surfaces like heaters, hot pipelines, vessels,
columns)
Scrape clean the surface thoroughly (to quality grade st. 2) so as to make the
surface free of loose mill scales, oil grease, dirt and dust.
System 19
Apply two coats of Silicon Based Heat Resistant Aluminum Paint (Temperature
Resistance : 250 540 degree cel.) - (2 x 20 brush)
TOTAL DFT: 40 micron

D. Steel surfaces (hot un-insulated surfaces like exchangers, stacks)
System 20
Apply two coats of Zinc Dust Graphite paint (Temperature Resistance : 450 degree
Cel.)- (2 x 40 brush)
E. R.C.C structures / fireproofing / masonry structures.
Clean the surface free of oil, grease, dirt, dust etc.

Paint with one coat of compatible primer and two coats of synthetic enamel paint
2 x 25 brush as directed by engineer in charge.
F. Lagged pipelines / surfaces
Aluminum cladding of lagged pipelines/surfaces should be cleaned of oil, grease,

and dirt etc.
Paint the lagged surface with one coat of oil based aluminum paint 1 x 20 brushes
2) COVERING OF DRAIN PITS/FUNNELS
Scope includes covering of total 23 nos. of SWS pit opening over the gratings
with bricks & cement sand mortar. The vent shall be provided in the
covering for release of gases as per the direction of Engineer-in-Charge.
Removal of pit covering and cleaning of SWS pits for removal of any
accumulated sludge/silt during start up of the plant & disposal of the
debris outside the refinery. The scope also includes covering of OWS funnels
using asbestos cloth & removal of the same after the shutdown activities.
3) REFRACTORY WORK
Scope includes refractory work at various Furnaces, APH, Stack, Ducts etc.
for replacement/repairs of muffle blocks, castable lining, brick lining,
ceramic modules, ceramic blankets, calcium silicate boards as per
inspection recommendation. The refractory work includes dismantling of
existing refractory/ceramic modules/refractory brick lining, welding of
anchors/chain link, application of zinc dust graphite paint on the shell
surfaces, covering of anchor tip with insulating tape & application of
refractory lining using gunniting technique or hand application as per
inspection recommendation. All refractory debris shall be disposed outside
the refinery on daily basis.
4) EXCAVATION WORK
Scope includes excavation work for various activities associated & included
in LSTK scope like inspection/repair/replacement of underground pipelines,
underground vessels, and structural foundations. The excavation work
includes breaking of concrete/bitumen pavement, excavation using
JCB/Manually, disposal of unserviceable material, dewatering of excavated
trenches, backfilling with sand/stone dust for a cushion of 300mm &
balance backfilling of excavated areas using excavated earth and paving of
the area. with RCC/ PCC of desired thickness as directed by BPCL.
5) MISC. CIVIL WORKS
Scope includes misc. civil work for various activities associated & included
in LSTK scope. It includes cement lining, breaking of concrete supports,
breaking of foundations, breaking of steps, dismantling of brickwork,
chipping of concrete/plaster, grouting of foundation bolts, dewatering of
existing valve pits/underground vessels/drain channels and construction of
the same to facilitate maintenance activities of mechanical, electrical &
instrument works.
6) SCAFFOLDING
Scope includes scaffolding for various activities such as painting, refractory

works, barricading of excavated trenches and other miscellaneous civil
works which are associated & included in LSTK scope.
LOBS:-
1) PAINTING WORK: - PAINTING OF THE EQUIPMENT / PLANT
1. Carry out painting of the following equipments including associated

structures like connecting pipelines, structures, ladder, railings, cladded
surfaces, concrete structures with applicable coating system as per BPCL
painting specification AE-S-5430-Rev1, related to LOBS complex T/A.
Painting of stack shall be carried out by employing rope access
technology only. (Refer attached drawing - Highlighted Portion) Lighter
shaded area shows the extent upto which pipelines, structures and other
connections of equipments are to be painted.
2. All the quantities against each painting system for every equipments are
indicative, bidders are advised to visit the site, asses exact quantities
before quoting the tender & quote accordingly.
3. Painting works shall be carried out as per BPCL standard & quality
assurance plant and QAP document shall be maintained on regular
basis. Contractor shall stand guarantee for the complete painting quality
job for a period of 2 Years. Any defect arising during above period shall
be made good by the contractor without any cost to the BPCL.
4. All structure to be painted in silver color & other as per BPCL color
coding standards.
5. For better quality control measures contractor shall follow following steps
like:
a. For better quality control measures contractor shall follow following

steps like: Successful bidder shall be required to obtain approval of
paint manufacturer, before ordering for paint materials. Materials
shall preferably be purchased directly from manufacturers. All coats
under one particular system shall be from single manufacturer.
b. Delivery challan/ cash receipt vouchers issued by the
manufacturers/ dealers shall be used as entry challan at the main
gate of BPCL.
c. Materials challan to be processed based on packing slip of materials
not based on coating system and maintained based on PO.
d. On entry of materials inside the refinery, concerned engineer to be
approached for physical verifications of materials along with entry
challan and entered in respective QAP.
e. For monitoring the consumption, inventory to be maintained on daily
basis for surprise check.
f. Contractor is required to comply attached QAP (quality assurance
plan). Contractor shall maintain all relevant documents and produce
on demand during progress of the work. The contractor is required to
submit the entire QAP document at the time of submission of final
bill as a supporting document.
6. All areas indicated below are in M2. Sign writing areas are given in
INM i.e. Inch meter.
7. For painting area mark up, please refer drawing in attachment.
8. All type of scraps including empty drums, bags, brushes, emery papers,
scrapped material generated from work to be disposed outside refinery
on regular basis at no extra cost. Reconciliation statement for paint
drums shall be produced at the time of final bill.
Following table gives the quantity of various painting requirement in LOBS

complex
Painting specification & area of application

System
: 20
System : (Stack
RCC
13 System : Paintin Cladded
Sr. surface
Equipment Scope of (Non 19 g) surface
No (Scrap + Sign
work insulated (Scrap + 2 (Scrap + (Scrap + 1
. primer + 2 writing
Pipelines, coats of 2 coats coat
coats of in INM
Structure, HR Al. of Zinc aluminum
enamel
Railing & paint) M2 Dust paint) M2
paint) M2
ladder ) M2 Graphite
Paint)
M2
FPU FEED
FURNACE (132-F-
204) with
associated
structures up to
extreme platform of
heater including its
Stack, APH &
access platform.
( Painting of
1 2700 850 400 300 600 200
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
coding standards.)
DW REACTOR
FEED FURNACE
(132-F-205) with
associated
structures up to
extreme platform of
Stack, APH &
access platform.
( Painting of
2 1900 400 350 300 130 200
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
coding standards.)
DW VACUUM
COLUMN FEED
FURNACE ( 132-F-
206) with
associated
structures up to
extreme platform of
Stack, APH &
access platform.
3 ( Painting of 2540 500 350 400 250 200
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
coding standards.)
Reactor ( 132-R-
204/205) with
associated
structures up to
extreme platform of
reactor including
its access platform.
4 2000 550 600 100
( Painting of
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
coding standards.)
FPU VACUUM
COLUMN (132-C-
221) with
associated
structures up to
extreme platform of
Column including
( Painting of
5 external surface of 2850 1000 1500 400
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
coding standards.)
WAXY 100N SIDE
CUT STRIPPER
(132-C-222) with
associated
structures up to
extreme platform of
Column including
( Painting of
6 external surface of 225 110 90 50
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
coding standards.)
WAXY 150N SIDE
CUT STRIPPER
(132-C-223) with
associated
structures up to
extreme platform of
7 450 20 600 200 100
Column ncluding
( Painting of
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
coding standards.)
DW PRODUCT
STRIPPER (132-C-
224) with
associated
structures up to
extreme platform of
Column including
( Painting of
8 400 20 450 150 50
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
DW VACUUM
COLUMN (132-C-
225) with
associated
structures up to
extreme platform of
Column including
( Painting of
9 535 350 80 50
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
DWLT LUBE SIDE
CUT STRIPPER
(132-C-226) with
associated
structures up to
10 extreme platform of 200 80 30 50
Column including
( Painting of
external surface of
heater + platform +
hand railing + cat
ladder + pipelines
+lagged surfaces
+Concrete surfaces
+sign writing
+colour coding as
per BPCL color
PAINTING SYSTEM SHALL BE FOLLOWED AS GIVEN BELOW
A. Steel surfaces (columns, exchangers, vessels, staircases, pipelines, structures,

pumps, motors, panels and all other steel surface.)
Scrape clean the surface thoroughly (to quality grade st.2) so as to make the
surface free of loose mills scales, oil, grease, dirt and dust as per specifications &
as directed by engineer in charge.
System 13
Apply primer of one coat of Self Priming surface tolerant Epoxy Mastic Paint (1*125
brush)
Then apply intermediate coat of High build two pack polyamide cured epoxy (1*125
brush)
And final coat of Aliphatic acrylic modified high solids weather resistant recoatable
two pack polyurethane (1*40 roller or brush)
B. Steel surfaces (hot un-insulated surfaces like heaters, hot pipelines, vessels,
columns)
System 19
Apply two coats of Silicon Based Heat Resistant Aluminum Paint (Temperature
Resistance : 250 540 degree cel.) - (2 x 20 brush)

C. Steel surfaces (hot un-insulated surfaces like exchangers, stacks)
System 20
Apply two coats of Zinc Dust Graphite paint (Temperature Resistance : 450 degree
Cel.)- (2 x 40 brush)
D. R.C.C structures / fireproofing / masonry structures.
Clean the surface free of oil, grease, dirt, dust etc.
Paint with one coat of compatible primer and two coats of synthetic enamel paint
2 x 25 brush as directed by engineer in charge.
E. Lagged pipelines / surfaces
Aluminum cladding of lagged pipelines/surfaces should be cleaned of oil, grease,

and dirt etc.
Paint the lagged surface with one coat of oil based aluminum paint 1 x 20 brushes
2) COVERING OF DRAIN PITS/FUNNELS
Scope includes covering of total 32 nos. of SWS pit opening over the gratings
with bricks & cement sand mortar. The vent shall be provided in the
covering for release of gases as per the direction of Engineer-in-Charge.
Removal of pit covering and cleaning of SWS pits for removal of any
accumulated sludge/silt during start up of the plant & disposal of the
debris outside the refinery. The scope also includes covering of OWS funnels
using asbestos cloth & removal of the same after the shutdown activities.
3) REFRACTORY WORK
Scope includes refractory work at various Furnaces, APH, Stack, Ducts etc.
for replacement/repairs of muffle blocks, castable lining, brick lining,
ceramic modules, ceramic blankets, calcium silicate boards as per
inspection recommendation. The refractory work includes dismantling of
existing refractory/ceramic modules/refractory brick lining, welding of
anchors/chain link, application of zinc dust graphite paint on the shell
surfaces, covering of anchor tip with insulating tape & application of
refractory lining using gunniting technique or hand application as per
inspection recommendation. All refractory debris shall be disposed outside
the refinery on daily basis.
4) EXCAVATION WORK
Scope includes excavation work for various activities associated & included
in LSTK scope like inspection/repair/replacement of underground pipelines,
underground vessels, and structural foundations. The excavation work
includes breaking of concrete/bitumen pavement, excavation using
JCB/Manually, disposal of unserviceable material, dewatering of excavated
trenches, backfilling with sand/stone dust for a cushion of 300mm &
balance backfilling of excavated areas using excavated earth and paving of
the area with RCC/ PCC of desired thickness as directed by BPCL.
5) MISC. CIVIL WORKS
Scope includes misc. civil work for various activities associated & included
in LSTK scope. It includes cement lining, breaking of concrete supports,
breaking of foundations, breaking of steps, dismantling of brickwork,
chipping of concrete/plaster, grouting of foundation bolts, dewatering of
existing valve pits/underground vessels/drain channels and construction of
the same to facilitate maintenance activities of mechanical, electrical &
instrument works.
6) SCAFFOLDING
Scope includes scaffolding for various activities such as painting, refractory

works, barricading of excavated trenches and other miscellaneous civil
works which are associated & included in LSTK scope.
ATTACHMENT 11 SECTION L

STOCK UNIT ( NHGU / LOBS) : MODIFICATION JOBS
SCOPE OF WORK
1. Scope of work includes fabrication, erection, testing, supporting, shot blasting

and painting of pipes and structure, insulation, internal cement of lining of the
pipe line as per drawing details.
2. Take actual measurement at site and prepare fabrication drawing.
3. Fabricate the line/ structure as per drawing.
4. Comply with all the general notes on the drawing.
5. All fabrication jobs shall follow stage wise inspection.
6. All civil structural work required for modification job like excavation, support,
anchor fastening, foundation for support, refractory breaking / application etc
shall be carried out by contractor. Supply of grating as per drawing wherever
required is included in your scope.
7. Dismantling of any line required to facilitate the fabrication and to avoid site
welding is included in lump sum scope.
8. For IBR job if any, welding shall be carried out by IBR approved welder and
through IBR approved party. With respect to IBR requirement , your scope shall
include
Submission of all documents and obtaining visits for material
identification, Stage wise inspection, hydro testing etc.
Obtaining permission of the GBI official for performing the job and waver
letter if any for stage wise inspection.
Arrangement of AC Car for to and fro transportation of GBI official on full
day basis.
Submission and collection of all the inspection reports and certificate
from GBI office.
All statutory fees shall be settled by Clients.
All liasoning for GBI shall be carried out on following address.
THE DIRECTOR,
Page 1 of 3
C-20, E Block,
9. After fabrication erect the lines at site.

10. Carry out hydro testing after erection including spading. Remove all spades after
completion of the hydro test. All the water shall be drained from the line after
hydro test and carry out card board blasting if water removal is not possible by
draining.
11. Carry out painting of lines as per BPCL painting specification.
12. For modification job on pumps if any, after completion of the job, alignment of the
equipment shall be carried out by contractor using laser alignment equipment.
List of modification job and drawing details are as follows
NHGU:
SR.
MOC NO. JOB DESCRIPTION DRAWINGS
NO
NHGU-13- Providing platform connecting AFC floor
1 133-SE-3-208
1733 with E311A/B top floor
The guillotine dampers of ID301A/B to be 133-CE-3-
NHGU-11-
2 shifted above/downstream the discharge 30,Rev.E,133-CE-3-
1194
dampers. 29)
NHGU-15- Provision of DP indication across the PSA
3 133-P-1-145
2322 instrument air filter
Provision of block and bleed valves on
NHGU-15- 133-P-1-147 Sheet 1
4 reformer jacketing steam supply and
2123 &2
condensate return lines
MAGNETIC FILTER AND DUAL
REDUNDANCY AIR FILTER TO BE
NHGU-16-
5 PROVIDED ON INSTRUMENT AIR LINE 133-P-1-150
2565
(INLET OF PSA) AS PER ATTACHED
SCHEME
TO PROVIDE TWO Nos. OF NEW 4"
NOZZLE WITH ISOLATION VALVE AND
NHGU-16- 133-SE-3-145 R5,
6 FLANGE TO STACK F-301 FOR FLUE
2595 133-SE-3-148 R4,
GAS SPM ANALYSER AND MANUAL
FSK-2672
SAMPLINGS PURPOSE.
Page 2 of 3
LOBS:
SR.NO MOC NO. JOB DESCRIPTION DRAWINGS

To provide 1" nitrogen line with common
1 LOBS-11-1222 132-P-1-187
PCV to Lube Oil tanks of P259A/B
Diversion of Waxy 65N ex LOBS unit to Tk
132-P-1-205,
2 LOBS-13-1783 1209 through offspec header during FPU
Rev.1
on 250N mode (outside B/L)
To provide sample point across UCO to
3 LOBS-13-1776 132-P-1-216
feed control valve 132-BPC-725.
Fuel gas vent line of all LOBS furnaces F-
204/5/6 orientation to be changed from
4 LOBS-16-2572 132-P-1-224
vertically upward to angled one at the top
portion.
Provision of isolation valve at U/S of SDV-
5 LOBS-16-2573 132-P-1-223
735 on F-205 steam vent line.
Selective diversion of
W65N/W100N/W150N of FPU to
6 LOBS-14-2053 132-P-1-211
FCCU/CCU as feed (Via HOT UCO
Header)
To provide two nos. of new 4" nozzle with 132-SE-3-129/1,2

LOBS-16- isolation valve and flange at stack F-205 / 132-SE-3-
7
2592/2603 206 for flue gas SPM analyser and manual 145/1/,2, 132-SE-
samplings purpose. 3-157/1,2
FSK-2672
To provide one nos. of new 4" nozzle with 132-SE-3-
isolation valve and flange stack F-204 for 129/1,2,
flue gas SPM analyser and manual 132-SE-3-
8 LOBS-16-2591
samplings purpose. Also,2 nos of available 145/1/,2,
stubs length to be reduced of F-204 for 132-SE-3-157/1,2
SOX/NOX/CO/PM10 FSK-2672
Diverting BFW draining ex F205/206 to
9 LOBS-16-2582
OWS via blow down cooler E-265 132-P-1-230
Page 3 of 3
ATTACHMENT 11 SECTION M

STOCK UNIT ( NHGU / LOBS) : STRAINER
Carry out cleaning suction strainer of the following equipment.
Follow following procedure
1. Open the end flange of Y type strainer / top cover of the basket strainer.
2. Pull out the element out of the shell / body.
3. Provide metal tag on the element indicating location of the same.
4. Clean the strainer element and body.
5. If strainer element mesh is damaged, then sent it to owners construction shop
for repair.
6. If no damaged is there to element mesh, then offer the element in clean condition
to operations and assemble the same.
7. In case of repair, after rectification of the element by owner, transport the
element back to equipment location and assemble the same.
8. After assembly of element tighten the end flange / top cover.
9. Metal tag shall be removed while installation of the element.
NHGU:-
NHGU:-
SR NO EQUIPMENT SERVICE LINE SIZE
1 133P301A 133P301A-NAPTHA FEED PUMP 4 x 300
2 133P301B 133P301B-NAPTHA FEED PUMP 4 x 300
3 133P302A 133P302A-BFW PUMP 8 x 600
4 133P302B 133P302B-BFW PUMP 8 x 600
5 133P303A 133P303A-PROCESS CONDENSATE PUMP 3 x 600
6 133P303B 133P303B-PROCESS CONDENSATE PUMP 3 x 600
7 PSA instrument air filter 1 x 150
8 PSA instrument air filter 1 x 150
9 Pure Hydrogen basket filter 8 x 300
10 BCW to K304A/B basket filter 2 x 150
11 P335A BCW pump suction strainer 2 x 150
12 P335B BCW pump suction strainer 2 x 150
13 P332 & P334 lube oil suction strainer 1 x 150
14 G332A lube oil filter of K304B 1 x 150
15 G332B lube oil filter of K304B 1 x 150
16 G331A lube oil filter of K304A 1 x 150
17 G331B lube oil filter of K304A 1 x 150
Page 1 of 3
18 P331 & P333 lube oil suction strainer of K304A 1 x 150
19 V356 of K304B suction strainer 4 x 300
21 V355 of K304A suction strainer 4 x 300
23 V365 of K305 suction strainer 2 x 300
24 P337 & P338 lube oil suction strainer of K305 x 150
25 G333A lube oil filter of K305 1 x 150
26 G333B lube oil filter of K305 1 x 150
LOBS:-
SR NO EQUIPMENT SERVICE LINE SIZE

1 132P252A 132P252A-FPU VAC COLMN WATER PUMP FPU 3 x 150
2 132P252B 132P252B-FPU VAC COLMN WATER PUMP FPU 3 x 150
132P253A-VAC COLMN TOP SIDECUT PUMP
3 132P253A 12 x 50
FPU
132P253B-VAC COLMN TOP SIDECUT PUMP
4 132P253B 12 x 150
FPU
5 132P254A 132P254A-WAXY 100N SIDECUT PUMP 8 x 150
6 132P254B 132P254B-WAXY 100N SIDECUT PUMP 8 x 150
132P255A- 132P255A-LOBS-WAXY 100N SIDECUT STR.
7 6 X 150
LOBS FPU
132P255B-
8 132P255B-LOBS-LWAXY 100N SIDECUT FPU 6 X 150
LOBS
9 132P256A 132P256A-WAXY 150N SIDECUT PUMP FPU 10 X 50
10 132P256B 132P256B-WAXY 150N SIDECUT PUMP FPU 10 X 150
132P257A-WAXY 150N SIDECUT STR.PUMP
11 132P257A 6 X 150
FPU
132P257B-WAXY 150N SIDECUT STR.PUMP
12 132P257B 6 X 150
FPU
13 132P258A 132P258A-VAC COLMN BOT PUMP FPU 6 X 150
14 132P258B 132P258B-VAC COLMN BOT PUMP FPU 6 X 150
15 132P259A 132P259A-DW FEED PUMP (REACT) 6 X 150
16 132P259B 132P259B-DW FEED PUMP (REACT) 6 X 150
17 132P260A 132P260A-DW VACUUM COLMN OIL PUMPS 2 X 150
18 132P260B 132P260B-DW VACUUM COLMN OIL PUMPS 2 X 150
132P261A- 132P261A-LOBS-DW VAC COLMN WATER
19 2 X 150
LOBS (FRACT)
132P261B- 132P261B-LOBS-DW VAC COLMN WATER
20 2 X 150
LOBS (FRACT)
132P262A- 132P262A -LOBS-DW LUBE BYPRODUCT
21 8 x 150
LOBS (FRACT)
132P262B- 132P262B -LOBS-DW LUBE BYPRODUCT
22 8 x 150
LOBS (FRACT)
23 132P263A 132P263A-DW LT LUBE PDT PUMP (FRACT) 4 x 150
24 132P263B 132P263B-DW LT LUBE PDT PUMP (FRACT) 4 x 150
Page 2 of 3
25 132P264A 132P264A-DW LT LUBE S/C STRIPPER PUMPS 2 X 150
26 132P264B 132P264B-DW LT LUBE S/C STRIPPER PUMPS 2 X 150
27 132P265A 132P265A-VAC COLMN BOT PUMP (FRACT) 6 X 150
28 132P265B 132P265B-VAC COLMN BOT PUMP (FRACT) 6 X 150
132P266A-VAC COLUMN.EXCESS WAXY PDT
29 132P266A 8 x 150
PUMP
132P266B-VAC COLUMN EXCESS WAXY PDT
30 132P266B 8 x 150
PUMP
31 132P280A 132P280A-COOLING WATER BOOSTER PUMP 24 x 150
32 132P280B 132P280B-COOLING WATER BOOSTER PUMP 24 x 150
41 132P286A 132P286A-WAXY FEED PUMP 8 X 150
42 132P286B 132P286B-WAXY FEED PUMP 8 X 150
43 132P288A 132P288A-150N PRODUCT PUMP 10 X 150
44 132P288B 132P288B-150N PRODUCT PUMP 10 X 150
45 132P289A 132P289A-500N PRODUCT PUMP 12 X 150
46 132P289B 132P289B-500N PRODUCT PUMP 12 X 150
47 132P290A 132P290A-OFF SPEC PRODUCT PUMP 6 X 150
48 132P290B 132P290B-OFF SPEC PRODUCT PUMP 6 X 150
49 132P281A CBD PUMP (SUBMERSIBLE) 6 X 150
50 132P281B CBD PUMP (SUBMERSIBLE) 6 X 150
51 132P282A CFBD PUMP (SUBMERSIBLE) 2 X 150
52 132P282B CFBD PUMP (SUBMERSIBLE) 2 X 150
53 132P284A OWS PUMP (SUBMERSIBLE) 2 X 150
54 132P284B OWS PUMP (SUBMERSIBLE) 2 X 150
BEARING COOLING WATER PUMP
55 132P285A 6 X 150
(SUBMERSIBLE)
BEARING COOLING WATER PUMP
56 132P285B 6 X 150
(SUBMERSIBLE)
57 132P06A OPTISPERSE DOSING PUMP X 150
58 132P06B OPTISPERSE DOSING PUMP X 150
59 132P291A PIPELINE TRANSFER PUMP 14 X 150
60 132P291B PIPELINE TRANSFER PUMP 14 X 150
Page 3 of 3
ATTACHMENT 11 SECTION N
NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE STOCK UNIT
(NHGU / LOBS): BATTERY LIMIT SPADE
For positive isolation of the unit, carry out spading / de-spading at following battery limit
locations of NHGU / LOBS.
Note: For flare line spading, adequate size working platform with double escape route
shall be provided using scaffolding pipes and planks. Escape route shall have stairs
made of scaffolding planks.
NHGU
SR NO LINE DESCRIPTION STARTING FROM GOING TO SIZE RATING
START UP H2(IMP/EXP
1 OLD H2 B/L NHGU 6" 300
TO OLD H2)
2 HCN FEED TO NHGU HCU B/L NHGU 3" 150
3 SRLN FEED TO NHGU ARU SPHERE NHGU 3" 150
4 O/G EX CRU CRU B/L NHGU 8" 300
RAW COOLING WATER
5 NCDU NHGU 6" 150
(EX NCDU)
6 MEOH EX ARU ARU NHGU 1.5" 300
7 MEOH TO ARU NHGU ARU 1.5" 300
8 RAFFINATE FEED EX NSU NSU B/L NHGU 2" 150
9 HIGH AR NAPTH FEED PH/5 NHGU 4" 150
10 SLOP NGHU P/H-1 4" 300
11 HCLN FEED HCU B/L NHGU 2" 150
12 DRINKING WATER BOILER HOUSE NHGU 1" 150
13 HYDROGEN NHGU HCU 10" 300
14 HYDROGEN NHGU H2 GRID 8 300
15 HYDROGEN ex RFV661 NHGU H2 GRID 6 300
16 RLNG CCU NHGU 8 600
II ND
FLOOR
17 BCW RTN NHGU B/HOUSE 10" 150
18 BCW SUPPLY BOILER HOUSE NHGU 10" 150
19 DM WATER BOILER HOUSE NHGU 6" 150
20 N2 HDR ARU NHGU 6" 150
21 FUEL GAS HDR CCU NHGU 2" 150
22 INST AIR HDR BOILER HOUSE NHGU 3" 150
23 PLANT AIR HDR BOILER HOUSE NHGU 3" 150
24 SERVICE WATER BOILER HOUSE NHGU 3" 150
SUSCEPT CONDENSATE BOILER
25 NHGU 3" 150
HDR HOUSE
WATER SPRAY & SALT WATER
26 NHGU 8" 150
SPRINKLE CURTAIN P/HOUSE
SALT WATER
27 FIRE HYDRANT HDR NHGU 12" 150
P/HOUSE
28 HP STAEM NHGU NCDU 6" 600
29 LP STAEM BOILER HOUSE NHGU 12" 150
30 MP STEAM BOILER HOUSE NHGU 16"
FLARE
NHGU
31 FLARE HDR HDR 28" 150
32 DM WATER NHGU CDU3 4 150
EAST
SIDE
SEA COOLING WATER SALT WATER
33 NHGU 12 150
SUPPLY P/HOUSE
SALT
SEA COOLING WATER
34 NHGU WATER 12" 150
RTN
P/HOUSE
FIRE WATER SUPPLY SALT WATER
35 NHGU 8" 150
LINE P/HOUSE
SALT WATER
36 FIRE WATER RTN LINE NHGU 12" 150
P/HOUSE
SUSPECTED
37 CONDENSATE UNDER HCU NHGU 3"
GROUND EX NCDU 150
38 BCW RTN EX NVDU NCDU NHGU 10" 150
SOUTH
SIDE
39 BCW RTN EX HCU HCU NHGU 8" 150
40 CBD RTN EX HCU HCU NHGU 6" 150
SUSPECTED
CONDENSATE UNDER HCU NHGU
41 GROUND EX HCU 3" 150
LOBS
SR .NO. SERVICE SIZE RATING
1 LOBS FLARE HEADER 18" 150
2 SEA COOLING WATER SUPPLY 26" 150
3 SEA COOLING WATER RETURN 26" 150
4 OWS HEADER 4" 150
5 FLUSHING OIL SUPPLY 4" 150
6 DM WATER SUPPLY 2" 150
7 CFBD TO UCO HDR TO CCU/FOB 3" 300
8 CBD/CFBD TO HCU SLOP HDR 4" 300
9 FUEL GAS 6" 150
10 FUEL OIL RETURN 2" 300
11 FUEL OIL SUPPLY 2" 300
12 MP STEAM 8" 300
13 LP STEAM 6" 150
14 BOILER FEED WATER 4" 300
15 BEARING COOLING WATER SUPPLY 6" 150
16 BEARING COOLING WATER RETURN 6" 150
17 NITROGEN 4" 150
18 PLANT AIR 3" 150
19 INSTRUMENT AIR 3" 150
20 DRIKING WATER 3" 150
21 SERVICE WATER 6" 150
22 OFFSPEC PRODUCT TO TANKS 8" 300
23 WAXY 100N PRODUCT TO TANKS 3" 300
26 WAXY FEED FROM TANK FARM 4" 300
27 LIGHT LUBE TO TANKFARM 2" 300
28 LUBE PRODUCT TO TANK FARM 4" 300
29 SOUR WATER TO SWS-I 3" 150
30 SLOP OIL FROM VACUUM SYSTEM TO 0.05 'S' HSD HEADER 1" 150
31 LUBE BYPRODUCT TO HCU 2" 300
32 DW PRDT. STR. VAPOR TO HCU 4" 300
33 SLOP OIL TO DHDS FROM LOBS 1" 150
34 DW HLPS VAPOR TO HCU 1" 300 RTJ
35 DW HHPS VAPOR (EX V-256) TO HCU 6" 300
36 DW HHPS VAPOR TO HCU 6" 1500 RTJ
37 MAKE UP HYDROGEN EX HCU 4" 1500 RTJ
38 WAXY LIGHT DIESEL FROM HCU 4" 150
39 WAXY HEAVY DIESEL FROM HCU 6" 150
40 EXCESS WAXY PRODUCT TO HCU 4" 300
41 ATM FRACTIONATOR BOTTOM TO F-204 6" 300
42 UNCONVERTED OIL FROM HCU 3" 300
43 LUBE BY PDT, LT. LUBE, LUBE PDT TO 0.05, 0.035 HSD HDR 4 300
44 H2 FROM CCR TO HPCL HYDROGEN LINE 6 300
45 H2 FROM GRID TO HPCL HYDROGEN LINE 8 300
46 BPCL-HPCL HYDROGEN IMPORT-EXPORT LINE (Near P-259) 10 300
TANK FARM
1 INSTRUMENT AIR SUPPLY 2" 150
2 NITROGEN SUPPLY 2" 150
3 LP STEAM 3" 150
4 FLUSHING OIL 3" 150
5 OFF SPEC EX LOBS 8" 300
6 W-100 PRODUCT 3" 300
7 W-150N PRODUCT 3" 300
8 W-500N PRODUCT 3" 300
9 LUBE PRODUCT EX LOBS 4" 300
10 WAXY FEED TO LOBS 4" 300
11 LIGHT LUBE EX LOBS 2" 300
12 OFF SPEC TO HCU 4" 150
ATTACHMENT 11 SECTION O

UNIT ( NHGU / LOBS) : INSTRUMENT & ELECTRICAL JOBS
Carry out following Instrument jobs as per scope of work detailed below,
1. VALVE REMOVAL & FIXING BACK

The CONTRACTOR shall ensure that the valve to be removed has been isolated by the
BPCL Operations.
The CONTRACTOR shall inspect the general condition of the valves before removal and
list all defects observed. This list shall be handed over to the respective BPCL
representative and shall form the reference base to measure work executed by the
CONTRACTOR.
The CONTRACTOR shall inspect the valve stroke indicator to ensure that the indicator
is free from wear, cracks, damage and is not missing. The BPCL supervisor shall be
informed of any such defects.
The CONTRACTOR shall compile a checklist for each valve and submit it to BPCL for
approval.
Make necessary arrangement like erection of scaffolding, rigging arrangement for
removal and installation of valve.
The CONTRACTOR shall remove the valve from the process line.
Provide plate type blind flanges on removal of the valve. Blind flange to be arranged by
contractor.
After repair / testing of the valves which shall be carried out by BPCL and on arrival of
valves at site, inspect the valve and its accessories including the position indicator and
its glass.
Ensure the valve's tag number and name plates are properly fixed to the valve.
Ensure the valve is free of any damage and that there are no missing parts.
Fixing back of CV and SDV back at site and assembling of all the accessories like its
actuator, if any.
Ensure that the control valve or on/off valve is installed according to the flow direction
indicated on the P&ID.
Replace the line gaskets.
Align the valve, gaskets and pipe flanges.
Insert the bolts, nuts and washers.
Tighten nuts and bolts to the correct torque as per specification.
Cary out torque tightening of high pressure ( 1500#) valve flanges, which are removed
and reinstalled.
NHGU
Sr. Tag Service Size (in) Valve type

No. Number
1 RPV501 FG from C-301 to Fl HDR (Passing) 4, 150# Globe
2 RPV488B R-302B Reactor circulation (Passing) 4, 600# Globe
3 RFV561B Ejector steam control valve(Bonnet replacement)
4 RFV561A STEAM TO REFORMER (Overhauling and gland 6 600# GLOBE
leak)
5 RFV563 STEAM TO REFORMER START 4 600# GLOBE
UP(Overhauling)
6 RPC626B HP steam to vent 8" 600# GLOBE
7 RPC628 HP steam to vent 8 600# GLOBE
8 RSDV624 Emergency H2 31500# GLOBE
9 RPV677A Emergency H2 1.51500# GLOBE
10 RPV677B Emergency H2 1.51500 GLOBE
11 RPV660 HP steam to vent (passing) 1.5600# GLOBE
12 RPV669C NG to E-342 3300# GLOBE
13 RFV632 HP steam to C-302 3600# GLOBE
14 RPV581 FG to reformer 3150# Ball
15 RHV482 E-311A/B process steam O/L
8600# Butterfly
16 RSDV572A OFF GAS FROM REFORMER TO PSA 30" 150# BUTTERFLY
17 RSDV611 OFFGAS BLEED 20" 150# BUTTERFLY
18 RSDV572B OFFGAS BLEED TO VENT 2" 150# BALL
19 RSDV575A FUEL NAPTHA FROM V304 6" 150# BALL
20 RSDV575B NAPTHA BLEED TO VENT 2' 150# BALL
21 RSDV576 FUEL NAPTHA FROM V304 6" 150# BALL
22 RSDV577 NAPTHA BLEED TO VENT 2" 150# BALL
23 RSDV578 OFF GAS VENT 2" 150# BALL
24 RSDV699 OUTLET FROM V315 8" 150# BALL
25 RSDV556 LP STEAM TO VENT 1.5" 150# GLOBE
26 RSDV559A PROC FEED TO REFORMER 6" 600# GLOBE
27 RSDV559B VENT VALVE FOR RSDV559A 2" 600# GLOBE
28 RSDV560A PROC FEED TO REFORMER 6" 600# GLOBE
29 RSDV560B VENT VALVE FOR RSDV560A 2" 600# GLOBE
30 RSDV571 STEAM TO JA-301 8" 600# GLOBE
32 RSDV580 LP STEAM TO FUEL NAPTHA VENT 1.5" 150# GLOBE
34 RSDV607 BYPASS TO RPV621 4" 300# GLOBE
35 RSDV610 LP STEAM TO OFFGAS VENT 1.5" 150# GLOBE
36 RSDV626 H2 FOR CAT REGEN 1.5" 300# GLOBE
37 RSDV608 PROCESS GAS FROM 133-V-302 14" 150#
38 RSDV583 FUEL GAS FROM 133-V-309 2" 150#
39 RSDV582A FUEL GAS FROM 133-V-309 4" 150#
40 RSDV582B FUEL GAS FROM 133-V-309 2" 150#
LOBS
Sr.No Tag Number Service Size (in) Valve type
1 132-BHBV-717 V-254 to Flare 6, 1500# BALL

2 132-BLV719A HHPS valve 2X3 1500 Angle
3 132-BLV719B HHPS valve 2X3 1500 Angle
4 132-BFV737 2 1500# Globe
5 132-BSDV-734 Off gas from V-274 to Vent 6, 300# BALL
6 132-BSDV-731 FG Vent F-206 2, 300# BALL
7 132-BTV743B P256B to C221 6, 300# GLOBE
8 132-BTV760A Quench Gas to R204 2, 1500# GLOBE
9 132-BTV760B Quench Gas to R204 1, 1500# GLOBE
12 132-BPV749B V255 Top to Flare 1, 300# GLOBE
13 132-BFV760 Lube Byproduct to C225 3, 300# GLOBE
14 132-BSDV-746 MP Steam TO F-204 4, 300# BALL
15 132-BSDV-738 Vent V-273 8, 300# BALL
16 132-BSDV-739 Off Gas to F-204 8, 300# BALL
17 132-BFBV-714 P-259A/B to E-254D 4, 2500# BALL
18 132-BSDV-737 MP Steam to F-206 4, 300# BALL
19 132-BSDV-733 Off Gas from V-274 to F-204 6, 300# BALL
20 132-BSDV-722A FG to FPU Feed Furnace 4, 300# BALL
21 132-BSDV-722B FG to FPU Feed Furnace 4, 300# BALL
22 132-BSDV-723 FG to Vent 2, 300# BALL
23 132-BSDV-724 Pilot Gas to FPU Feed Furnace 2, 300# BALL
24 132-BSDV-725 Fuel oil to F-204 2, 300# BALL
25 132-BSDV-726 Fuel Oil Return 2, 300# BALL
26 132-BHV-746 Emergency Steam to F204 4, 300# BALL
27 132-BSDV-727A Fuel gas to F-205 2, 300# BALL
28 132-BSDV-727B Fuel gas to F-205 2, 300# BALL
29 132-BSDV-728 Vent gas F-205 2, 300# BALL
30 132-BSDV-729 Pilot Gas to F-205 1, 300# BALL
31 132-BSDV-730A FG to F-206 2, 300# BALL
32 132-BSDV-730B FG to F-206 2, 300# BALL
33 132-BSDV-732 FG Pilot to F-206 1, 300# BALL
34 132-BSDV-735 132-JU-254 6, 300# BALL
35 132-BSDV-736 132-JU-255 6, 300# BALL
36 132-BSDV-903 MP Steam Import Header 8, 300# BALL
37 132-BXV-901 MP Steam to PT-282B 3, 300# BALL
38 132-BXV-902 MP Steam to PT-284B 4, 300# BALL
39 132-BSDV740 Soot Blower Steam to F204 4, 300# BALL
2. TRANSPORTATION OF VALVES
The CONTRACTOR shall transport the valves carefully to avoid any damage, from the
site to the Instrument shop.
Transport the valve from the Instrument Shop to the proper field location.
NHGU
Sr.No Tag Number Service Size (in) / Valve

Rating type
1 RPV501 FG from C-301 to Fl HDR (Passing) 4, 150# Globe
2 RPV488B R-302B Reactor circulation (Passing) 4, 600# Globe
3 RFV561B Ejector steam control valve(Bonnet

replacement)
4 RFV561A STEAM TO REFORMER (Overhauling 6 600# GLOBE
and gland leak)
5 RFV563 STEAM TO REFORMER START 4 600# GLOBE
UP(Overhauling)
6 RPC626B HP steam to vent 8" 600# GLOBE
7 RPC628 HP steam to vent 8 600# GLOBE
8 RSDV624 Emergency H2 31500# GLOBE
9 RPV677A Emergency H2 1.51500# GLOBE
10 RPV677B Emergency H2 1.51500 GLOBE

11 RPV660 HP steam to vent (passing) 1.5600# GLOBE
12 RPV669C NG to E-342 3300# GLOBE
13 RFV632 HP steam to C-302 3600# GLOBE
14 RPV581 FG to reformer 3150# Ball
15 RHV482 E-311A/B process steam O/L

8600# Butterfly
LOBS
Sr.No Tag Number Service Size (in) Valve type
1 132-BHBV-717 V-254 to Flare 6, 1500# BALL

2 132-BSDV-734 Off gas from V-274 to Vent 6, 300# BALL
3 132-BSDV-731 FG Vent F-206 2, 300# BALL
4 132-BTV743B P256B to C221 6, 300# GLOBE
9 132-BPV749B V255 Top to Flare 1, 300# GLOBE
10 132-BFV760 Lube Byproduct to C225 3, 300# GLOBE
11 132-BLV719A HHPS valve 2X3 1500 Angle
12 132-BLV719B HHPS valve 2X3 1500 Angle
13 132-BFV737 2 1500# Globe
3. REPLACEMENT OF ORIFICE PLATES :

Prior to removal check, inspect and issue a report to BPCL on the following:
Element tag number. If it does not have a tag number, allocate a tag number to it
and mark it clearly.
Line number and flanges diameter.
Determine flow direction and mark it clearly,
Determine element position and direction inserted.
Removal of the orifice plates shall be carried out as follows:
Determine the type of taps and disconnect instrument tubing.
Loosen the flanges by unscrewing the bolts and nuts.
When removing the orifice plate, check and determine its original position, (facing
up steam or down steam) and mark accordingly.
Confirm this marking and the original orifice plate marking.
Check the flange gaskets and arrange for new and proper ones from BPCL ,
Check that each orifice plate is free from any damage, scratches and
imperfections that can affect the flow measurement. Record any such blemishes
and issue a report to BPCL.
Inform BPCL Engineer / Supervisor for final inspection.
Re-installation of the orifice plates shall be carried out as follows:
Inspect and ensure that the process line is free of any debris. Clean if required.
Inspect and ensure the flange faces are clean and free of corrosion or oxidation.
Replace the line gaskets. BPCL will supply the gaskets.
Insert orifice plate in the correct direction.
Align pipe flanges, gaskets and orifice plate.
The BPCL Engineer / Supervisor shall inspect the orifice plate installation prior to
the tightening of the nuts and bolts.
Torque nuts and bolts to specified torque settings and sequence.
If any of the instrument tube supports were disturbed during the orifice plate
removal, these shall be re-instituted and made good.
Ensure the orifice plate location is clean and remove all construction tools and
equipment.
Issue final inspection report for BPCL approval.
NHGU
Sr. No. Tag No. SIZE

1 RFE614 10300#
2
3
LOBS
Sr. No. Tag No. SIZE

1 BFE903 4 300#
2 BFE911 8 300#
3 BFE793 8300#
4 BFE910 12 300#
5
4. REPLACEMENT OF SKIN THERMOCOUPLES
Brief scope of job: skin T/C installation in furnace tubes.
Precautions: To work with precautions at height using safety belts and on
scaffoldings.
Remove old faulty skin T/C after disconnecting the cables. with proper tagging
by inst personal
Insert the new skin thermocouples of appropriate size and position to the weld
area.
Bending of the Thermocouple if required can be carried out as per practice
without damage or cracks in sheath in presence of instrument / supplier
supervisor.
Use of bending tools / heat treatment is to be adopted if required for proper
bending in presence of instrument / supplier supervisor. Routing of the
thermocouple and protection Sleeve installations etc. are to be carried out as per
supplier guideline in their presence.
Clamp temporarily the thermocouples, to position the thermocouple / element for
welding.
Temporary support to be removed after the welding.
Welding of the thermocouples and the metal shield is in contractor scope.
Provide permanent supports including heat shields and clamps and remove
temporary supports. The supports are required throughout the length as per
supplier recommendation.
Change of T/C weld location than present location as per M/s Shell guideline and
the recommended route are to be carried out.
Carry out DP Test / Radiography after completion of welding activity.
LOBS
Sr.No Tag Number Service

2 nos. as a
1 provisional
5. Torque tightening of High Pressure Instrument flanges
Carry out torque tightening of following nos. of high pressure joints.
a. Flange size: 10, 1500 /2500#: 3 nos.

b. Flange size: 8, 1500/2500#: 3 nos.
c. Flange size: 6, 1500/2500#: 3 nos.
d. Flange size: 3, 1500/2500#: 3 nos.
e. Flange size: 1, 1500/2500#: 3 nos.
6. MANIFOLDS ISOLATION VALVE (1/2SIZE) REPLACEMENT BY WELDING.
Isolation valves identified and tagged as faulty is to be replaced by welding including

testing as per standard and correct metallurgy. Hydro testing / radiography of the
manifolds / lines to be carried out and offer to BPCL for witnessing.
NHGU
SR. NO. TAG NO.
1 Manifolds Isolation valve replacement
RFT601
by welding
2 RFT605 Manifolds Isolation valve replacement
by welding
3 5 nos. as a provisional
7. MANIFOLDS Fabrication as per Main pipe line Metallurgy By welding and

Installation at site.
New Manifolds to be Fabricated as per Main pipe line metallurgy by welding including
installation at site, testing as per standard and correct metallurgy. Hydro testing /
radiography of the manifolds / lines to be carried out and offer to BPCL for witnessing.
The payment for Fabrication of manifold in addition to the following tags if any shall be
made as per applicable SOR.
SR. NO. Quantity Remarks

Manifold plugged to be portion to be replaced
1 RPDT607 by cutting and welding at site
Manifold plugged to be portion to be
2 RPDT608 replaced by cutting and welding at site
Manifold modification
3 RFT557
Manifold modification
4 RFST558A/B/C
3 nos. as a
5 provisional (legs)
8. Manpower supply
Supply following no. of manpower for entire turnaround period for misc jobs /
as assistance to BPCL instrument crew.
a. 2 no. Fitters
b. 1 no. Rigger
c. 2 no. Helpers
Electrical Jobs :
Carry out following Electrical jobs as per scope of work detailed below,
1. Cleaning of fan covers and cooling tubes for all HT and LT motors. Repairing of fan
covers wherever necessary. Site cleaning will include following job
a) Opening of fan cover
b) Fan and its cover cleaning
c) Repair of fan cover if required by welding, etc
d) Cleaning of cooling tubes/fins of motor using wire brush.
e) Fixing fan cover back to motor.
List of Motors for NHGU(26 nos LT & 6 nos HT Total 32 nos)
Sr
no Motor tag KW Voltage
1 133PM335A 3.7 415V
2 133PM335B 3.7 415V
3 133EAM301A 11 415V
4 133EAM301B 11 415V
5 133EAM302A 11 415V
6 133EAM302B 11 415V
7 133EAM302C 11 415V
8 133EAM302D 11 415V
9 133PM315A 15 415V
10 133PM315B 15 415V
11 133PM303A 30 415V
12 133PM303B 30 415V
13 133KM306 30 415V
14 133PM320A 37 415V
15 133PM320B 37 415V
16 133KM305 45 415V
17 133PM322A 45 415V
18 133PM322B 45 415V
19 133PM301A 90 415V
20 133PM301B 90 415V
21 133PM321A 93 415V
22 133PM321B 93 415V
23 133KM307 160 6600V
24 133KM304A 227 6600V
25 133KM304B 227 6600V
26 133KM303 350 6600V
27 133PM302A 380 6600V
28 133PM302B 380 6600V
29 133FD301A 750 690V
30 133FD301B 750 690V
31 133IDM302A 870 690V
32 133IDM302B 870 690V
List of Motors for LOBS(74 nos LT & 04 nos HT Total 78 nos)
Sr
no Motor tag KW Voltage
132-P-259A-P-
3.7 415
1 01
132-P-259B-P-
3.7 415
2 01
3 132-EM-225A 3.7 415
4 132-EM-225B 3.7 415
5 132-P-263 A 7.5 415
6 132-P-263 B 7.5 415
7 132-P-264 A 7.5 415
8 132-P-264 B 7.5 415
9 132-P-265 A 7.5 415
10 132-P-265 B 7.5 415
11 132-EMV-222A 7.5 415
12 132-EM-222B 7.5 415
13 132-EM-228D 7.5 415
14 132-EMV-223A 9.3 415
15 132-EMV-223B 9.3 415
16 132-EM-223C 9.3 415
17 132-EM-223D 9.3 415
18 132-EM-226A 9.3 415
19 132-EM-226B 9.3 415
20 132-EM-226C 9.3 415
21 132-EM-226D 9.3 415
22 132-P-252 A 11 415
23 132-P-252 B 11 415
24 132-P-260 A 11 415
25 132-P-260 B 11 415
26 132-P-261 A 11 415
27 132-P-261 B 11 415
28 132-P-281 A 15 415
29 132-P-281 B 15 415
30 132-EMV-224A 15 415
31 132-EMV-224B 15 415
32 132-EM-224C 15 415
33 132-EM-224D 15 415
34 132-EMV-227A 15 415
35 132-EM-227C 15 415
36 132-EM-228A 15 415
37 132-EM-228B 15 415
38 132-EM-228C 15 415
39 132-P-290 18.5 415
40 132-P-254A 22 415
41 132-P-254B 22 415
42 132-P-282 A 22 415
43 132-EMV-221A 22 415
132-EMV-
22 415
44 221C
45 132-EM-221B 22 415
46 132-EM-221D 22 415
47 132-P-284 A 30 415
48 132-P-285 A 30 415
49 132-P-285 B 30 415
50 132-FD-251A 37 415
51 132-FD-251B 37 415
52 132-ID-251 37 415
53 132-P-255 A 45 415
54 132-P-255 B 45 415
55 132-P-257 A 55 415
56 132-P-257 B 55 415
57 132-P-258 A 75 415
58 132-P-258 B 75 415
59 132-P-280 A 75 415
60 132-P-280 B 75 415
61 132-P-286 A 75 415
62 132-P-286 B 75 415
63 132-P-288 A 75 415
64 132-P-288 B 75 415
65 132-P-256 A 110 415
66 132-P-256 B 110 415
67 132-P-262 A 110 415
68 132-P-262 B 110 415
69 132-P-289 A 110 415
70 132-P-289 B 110 415
71 132-P-253 A 125 415
72 132-P-253 B 125 415
73 132-P-266 A 125 415
74 132-P-266 B 125 415
75 132-P-291 A 300 6600
76 132-P-291 B 300 6600
77 132-P-259 A 750 6600
78 132-P-259 B 750 6600
ATTACHMENT 11 SECTION P

UNIT ( NHGU / LOBS) : MISC MECH JOBS
A) SILENCER
Erect scaffolding as required and offer the following silencers for inspection:-
a) 133-JU-301
b) 133-JU-302
c) 133-JU-303
d) 133-JU-304
e) 133-JU-305
f) 133-JU-306
B) Manpower Supply
Scope includes supply of following manpower to maintenance / operations

department from three days advance of the feed cut out date till four days after
feed cut in for various activities in the plant during shutdown, engineering
activities and plant start up / stabilization. The manpower shall be utilized by the
owner for all the engineering / cleaning activities in the plant under the direct
supervision of owner representative / employees.
Sr Manpower Day shift Night Shift Department

No Category ( 12 hrs) ( 12 hrs)
1 Rigger 1 1 Mech Maint
2 Helper 4 1 Mech Maint
3 Helper 5 5 Operations
4 Helper 2 2 Elect Maint
5 Helper 4 2 Instrument Maint
6 Helper 3 1 Rotary Maint
ATTACHMENT 11 SECTION Q
NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE STOCK UNIT ( NHGU / LOBS)
: INSPECTION SERVICES
Contractor shall deploy manpower and machines / equipments to complete the

inspection activities as per the scope of work indicated elsewhere in contract including
all the following inspections activities on NHGU / LOBS complex equipments and piping.
1) Inspection of columns, vessels, exchangers and Air Fin Coolers shall be carried out as per
API-510 (Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair and
Alteration) and API-RP-572 (Inspection of Pressure vessels {Towers, Drums, Reactors,
Heat Exchangers and Condensers).
2) Inspection of Fired Heaters and Boilers shall be carried as per API-RP-573.
3) Inspection of piping shall be carried out as per API-570 (Piping inspection code
Inspection, repair, alteration and rerating of In-service piping systems).
4) Inspection practices for piping system components shall be as per API-RP-574.
5) Inspection of Pressure relieving devices shall be carried out as per API-RP-576.
6) Refer API-RP-571 for Damage Mechanisms Affecting Fixed Equipment in the Refinery
Industry.
7) All Non Destructive Examinations shall be carried out as per ASME Section V.
8) Welding Procedure Specification (WPS), Procedure Qualification Record (PQR) AND

Welding Performance Qualification (WPQ) shall be as per ASME Section IX.
9) Welding inspection shall be carried out as per API-RP-577 (Welding Inspection and
Metallurgy).
10) All other design codes like ASME Sec VIII Div 1 & 2, ASME B 31.3 to be followed as
mentioned in the relevant inspection codes.
11) Latest additions of all codes shall be applicable.
12) Refer BPCL Inspection Manual for guidance.
13) The NDT requirements and extent of inspection shall be as per Annexure-1.
14) Contractor to supply Inspection coordinators and Inspectors as per Annexure 2.

15) All inspectors and coordinators shall have total comprehensive Insurance coverage. BPCL
shall be completely indemnified from all kinds of risks, accidents, losses arising out of
working of all these inspectors and coordinators.
The detailed scope of work of contractor with respect to inspection in Train3 HGU/LOBS
shutdown shall be as follows:
1) After thorough internal/external cleaning of equipment / piping, the surface

cleanliness should be thorough to enable proper visual inspection and non-
destructive testing.
2) Contractor overall inspection coordinator shall deploy experienced inspectors for

carrying out visual inspection and collating the results of visual inspections,
ultrasonic thickness readings and other NDTs and issue recommendations for
repairs, box up or hydro testing as the case may be in consultation with BPCL
Inspection Engineer.
3) Contractor shall carry out Ultrasonic thickness measurements as per defined

methodology. Sketches shall be provided by BPCL for recording the readings.
Contractor shall submit the final signed sketches and excel sheet with observed
readings to BPCL. All personnel, consumables and equipment for Ultrasonic
thickness readings shall be in contractors scope of supply.
4) Wherever sketches cannot be provided by BPCL, contractor has to make the

sketches in Auto cad. The number of such sketches shall be limited to 50 A4 size
sketches for each plant. i.e. total 100 nos
5) Contractor shall carry out conventional NDT like Liquid Penetrant testing, Magnetic
Particle Inspection, Ultrasonic Scanning, Eddy current testing, Remote Field
Electromagnetic Testing, Insitu metallography and Long Range Guided Wave
Testing as per the details given in this section as well as during recommended
repairs. Contractor shall submit the final signed observations/results of NDT to
BPCL Inspection. All personnel, consumables and equipment for NDT shall be in
contractors scope of supply. Contractor shall submit details of qualifications and
experience of NDT personnel to BPCL for approval.
6) Contractor shall be responsible for quality control measures during

repair/fabrication works like geometry of weld grooves, weld fit ups, welding
electrodes, name of the BPCL approved welder used for the job, surface
preparation for painting and paint DFT etc. The Quality control measures must be
recorded by the contractor and records submitted to BPCL Inspection.
7) Contractor shall submit the final signed Visual inspection reports / check list to
BPCL Inspection.
8) Based on the records indicated, contractor inspector shall make the required
recommendations for repair or release for hydro testing, box up etc. after approval
of BPCL Inspection. Such recommendations shall be made in Microsoft word
software.
9) Contractor shall be qualifying the welders deployed for repair jobs as per ASME sec
IX.
10) Contractor shall deploy the required NDTs to verify the effectiveness of repairs.
11) Contractor is responsible for the integrity and reliability for the next four years run of
the equipment and piping inspected and inspected during repairs by him. He shall
certify the equipment and piping fit for in service use till 4 more years.
12) Contractor shall liaise with all statutory authorities like GBI and Factory inspectorate
and obtain the Boiler certificates and Form 13 for all equipment and piping
inspected during shutdown. Equipment / piping sketches with thickness readings
duly signed and stamped by competent person authorized by DISH shall be
attached with form-13.
13) Contractor inspectors shall witness RV testing at shop and sign the test records.
14) Separate Large 40 ft long and clean porta cabin with sufficient tables & chairs, AC,
drinking water to be provided by the contractor for the inspectors and inspection
coordinators for both the plant. Adequate number of Laptops/desktops (minimum 6
to 8 nos.) to be provided to the inspectors. Housekeeping of porta cabin to be
maintained.
15) Separate Large 40 ft long and clean porta cabin with sufficient tables & chairs, AC,
drinking water to be provided by the contractor for NDT personnel for both the plant.
Housekeeping of porta cabin to be maintained.
16) All inspection engineers shall be provided with an Inspection kit comprising of 500
grams ball pin hammer, torch, scrapper, pit gauge and tool bag.
17) The NDT requirements and extent of inspection shall be as per work list/as per site
inspection engineers requirements.
A) REPORTS & DOCUMENTATION:
1) All the Ultrasonic thickness, visual inspection and other NDT reports shall be
submitted prior to Hydrostatic testing / box up of equipments.
2) All the inspection documents/reports/sketches shall be submitted to BPCL in both

soft and hard copies. The soft copy shall be in PDF/AutoCAD document form.
3) Contractor shall submit one soft copy in word file and one hard copy of the
Turnaround report. Hard copies each to be submitted in A4 size after notebook
binding. The report shall indicate the following for each equipment / piping:
a. Observations: Details of visual inspection and observations and brief details of

NDT carried out and results of NDT.
b. Recommendations: The recommendations given.
c. The work carried out: The details of the repair and testing work and any other
work carried out including stage wise inspection details.
4) Contractor shall arrange one soft copy and one hard copy of Form 13 signed by the
competent person prescribed under Rule 65 of Maharashtra Factory rules 1963, as
per factories act, for equipment and piping inspected during the turnaround and
submit the same to BPCL.
5) The contractor shall take ultrasonic thickness measurements and write the same in
the Sketches at TMLs (Thickness Measurement Locations) shown in the sketch.
The contractor shall also fill the values of thicknesses at TMLs in the excel file
attached to the sketch. Contractor shall compile all TML values of all similar assets
in a single excel file and submit to BPCL for mass upload in Meridium system.
6) All attendance sheets of Inspection manpower and entry challans for NDT
equipment to be submitted.
7) Inspector shall maintain the records of the valves inspected, valves

recommended for repairs and valves renewals.
8) Inspectors shall prepare RV reconciliation statement towards the end of the turnaround.
They shall scrutinize all the RV testing records, lists etc. They shall physically visit each
equipment and pipeline where RVs are installed as per master list and check the tag
nos. of RVs to ensure correct RVs are installed and RVs have been tested. The
reconciliation list to indicate missing RVs or RVs not tested and any other discrepancies
etc
B) LIASON WITH GBI AUTHORITIES
1) Contractor shall carry out liaisoning and coordination work with GBI Authorities
for the various GBI related activities like material identification, approval of
drawings if any, repair of waste heat Boilers / steam piping, cleaning of
boilers/steam piping, Inspection of boilers / steam piping, dry inspection of
Boilers, hydrostatic inspection of boilers / steam piping, obtaining of certificate of
use for boilers/piping, IBR welders etc. as per the case applicable.
2) All coordination work involving bringing the inspector to site and taking him back
shall be in contractors scope. Only conveyance to and fro for GBI inspector and
inspection fees for Boilers shall be in BPCLs scope.
3) The details of work/repair required on Boilers/steam piping shall be as per the
work list and recommendations released during turnaround based on the
observations by the GBI/BPCL Inspection.
NHGU:
ANNEXURE-1 for NHGU
SCOPE OF NDT
1. Visual Inspection:
Visual inspection shall be carried out as per applicable codes and standards for
inspection of various equipments. Internal and external visual inspection shall be
carried out on equipment and shall cover all pressure and non-pressure parts.
External inspection of the following shall be carried out:

a) Foundation: Settlement, condition of anchor bolts.
b) Fire Proofing: Spalling, cracking, corrosion of reinforcement under cracked
locations.
c) Skirt: Corrosion, weld cracks at joint between skirt and column/vessel, distortion,
if fire proofing is properly bonded to skirt.
d) Saddle Supports: General condition, corrosion of shell at crevice between
saddles and steel, adequacy of expansion provision of floating support.
e) Ladders, stairs, platforms and structures: Paint condition, general corrosion,
weld cracks, condition of chequered plates, toe plates, fasteners.
f) Insulation: Condition of the insulation material if rotten, damages to Insulation
and insulation protection, corrosion of underlying material.
g) Protective coating/lining: Condition of painting, any cracks on external FRP
lining, corrosion of metal at cracks on lining.
h) Earthing Connections: Damage to cable and its electrical connections
continuity.
i) Nozzles: Check for weld cracks, leakages through telltale holes.
j) External surface of pressure parts: External corrosion due to rain water seepage
inside insulation, atmospheric corrosion, undue vibration/swaying, hot spots on
internally lined pressure vessels, mechanical damage, and weld
cracks/leakages.
k) Refractory lining, hangers and spigots inspection for heater.
2) Ultrasonic Thickness measurement:
The pressure parts of all the equipment shall be ultrasonically gauged for thickness
and the thickness readings shall be recorded on inspection sketches showing
corresponding Thickness Measurement Locations (TMLs). The number of
thickness monitoring locations shall be adequate enough to assess any metal loss.
In case of any significant metal loss is observed, the effected area shall be closely
scanned. The following shall be considered as a guide line for each type of
equipment for deriving the TMLs.
2.1 Columns:
a) Shell plate: In 4 compass directions at each tray level.
b) Dished ends: In 4 compass directions in crown and knuckle area.
c) All connected nozzles neck thickness in four compass directions.
d) Skirt: In 4 compass directions.
e) Internals: Trays (10% of trays, 4 locations on each tray) and distributors (100%,
one set of readings {4 compass directions} at every one meter length).
2.2 Vessels and reactors:

a) Shell plate: In 4 compass directions for all shell courses.
b) Dished ends: In 4 compass directions at crown and knuckle area.
d) Skirt (for vertical vessels): In 4 compass directions.
e) Internals: All Baffles (4 locations on each baffle) and distributors (100%, one set
of readings {4 compass directions} at every one meter length).
2.3 Heaters:
Radiation Section:
a) Straight tubes: In 4 compass directions at 3 levels (1st level shall be approx. 1
mtr. from floor level).
b) Return bends: All bends, min. 3 readings on the outer radius of each bend.
Convection Section (Hydrocarbon Coils, BFW Coils, Steam Generating Coils and
Super Heater Coils):
a) Tubes (straight sections): In 4 compass directions adjacent to each bend.
b) Return bends: All bends, min. 3 readings on the outer radius of each bend.
c) Bottom shock tubes: In 3 compass directions at 3 locations.
Stack:
One set of readings on each shell course along the staircase.
Air Duct (Horizontal sections):

One set of 3 to 4 readings on top plate at every 6 meters length.
2.4 Exchangers:
a) Shell & shell cover: In 4 compass directions for all shell courses (At min. 3
locations).
b) Dished ends: In 4 compass directions at crown and knuckle area.
d) Tube OD measurement on peripheral tubes, Thickness by measuring ID & OD.
2.5 Air fin coolers:

a) Inlet and outlet Header boxes (all 4 plates at 3 locations).
b) All connected nozzles neck thickness in four compass directions.
2.6 Piping:
a) All elbows, tees and reducers.
b) Pipe: one set of readings in 4 compass directions at every 10 mtrs length. In
case of small pipe sections i.e. less than 10 mtrs. length, one set of readings in
every section of straight pipe.
Note: In case of cladded equipment, ultrasonic thickness technique shall be

deployed to explore the cladding damages like lamination, blistering etc.
3) Specialized reformer tube inspection services
a) Reformer heater catalyst tube inspection shall be carried out on all tubes by an
agency specialized in this job. Following inspection activities shall be carried
out:
1. Complete inspection and assessment of all the tubes using Laser Optic Tube
Inspection technique (LOTIS). After inspection, all the tubes shall be
categorized considering various defects in the tubes.
2. Dye Penetrant test of all Reformer tube welds, pig tail welds to tubes and
headers.
3. Visual inspection.
4. Bowing measurement.
b) All necessary man power, equipment and consumables for the specialized
inspection of Reformer tubes is in the scope of party.
c) The report shall be submitted in soft copy (CD) and one hard copy.
d) Specialized Reformer tube inspection agency shall have experienced

personnel and the agency should have carried out LOTIS of at least 3
Reformer heaters in last 3 years having at least 60 nos. tubes each. Necessary
documents supporting above experience shall be submitted along with the
Technical bid.
4) Magnetic Particle Examination:
a) Carryout Magnetic partial test (MPT) of columns, vessels, reactors skirt

attachment weld and exchangers in ferromagnetic material shell welds and
nozzle welds as specified in work list.
b) Carry out buffing (6 inches on both sides of weld) for all MPT locations.
c) Magnetic Particle Examination shall be carried out as per ASME Section V
Article 7.
5) Liquid Penetration Examination:
a) Carryout Liquid penetration test (LPT) of stainless steel welds of piping, heaters
and weld overlays as per scope of work.
b) Liquid Penetration Examination shall be carried out as per ASME Section V
Article 6.
6) Eddy current testing:
a) Eddy current testing (ECT) shall be carried out as per ASME Section V Article 8.
The contractor to submit NDT party details and procedure to BPCL for approval.
Battery operated equipment is to be deployed. ECT shall be deployed for
checking of non magnetic tubes like non ferrous tubes and stainless steels.
b) Refer work list for exchangers / AFCs for ECT.
c) Based on inspection findings, ECT % per bundle may be increased or reduced.
7) REMOTE FIELD ELECTROMAGNETIC TECHNIQUE (RFET):
a) Remote Field Electromagnetic Technique (RFET) shall be carried out in

standard manner. The contractor to submit NDT party details and procedure to
BPCL for approval. Battery operated equipment is to be deployed. RFET shall
be deployed for checking of magnetic tubes like ferrous tubes and duplex
stainless steels.
b) Refer work list for exchangers / AFCs for RFET.
c) Based on inspection findings, RFET % per bundle may be increased or reduced.
8) SWUT (SHEAR WAVE ULTRASONIC TESTING)
Cracks identified by NDTs like DP and MPI in equipment will require to be sized
using SWUT (shear wave ultrasonic testing). Provide one no. SWUT battery
operated machine and operators for sizing of cracks found by DP/MPI.
9) RADIOGRAPHY:
All radiography work shall be in the scope of contractor. No storage for source and
processing space shall be provided by BPCL
Radiographic Examination for fabrication of piping (for replacement / modification

work) and repairs to equipment shall be carried out as per ASME Section V Article
2. The extent of radiography for butt joints shall be as follows:
9.1 Piping:
a) LPG, C3C4 and Gas pipe lines 100 %.

b) All other Hydrocarbon piping 10 %.
c) Stress relieved joints 100 % before and after SR.
d) IBR Pipe lines 20 %.
e) Utility pipe lines (LP steam, air & Nitrogen) 10 %.
f) Water pipe lines including raw water and sea water Nil.
g) All field joints 100 %.
9.2 Equipment:
a) All butt joints of pressure vessels and nozzle flange butt joints 100 %.
b) Stress relieved joints 100 % before and after SR.
10) NDT manpower/machinery Resources required during turnaround shall be as per

table indicated below. The resources given herewith are the minimum required and
shall be augmented based on the load of work during turnaround. The decision of
BPCL inspection shall be final in this regard.
TYPE OF NDT RESOURCES

LPT 2 TEAMS (2 persons per team)
MPT (battery operated machine) 1 TEAM ( 2 persons per team) with 3 machines
i.e. each team will have a machine
ECT (battery operated machine) 2 Machines with respective teams
RFET(battery operated machine) 2 Machines with respective teams
SWUT (Shear Wave Ultrasonic 1 team and equipment for scanning
Testing :- Battery operated machine)
Specialized inspection/ NDE services 1 team with all equipment and consumables for
for Reformer tubes. external /internal inspection of all tubes and
RLA.
Radiography 2 nos. Sources (Min. strength 5 Curies) with
respective team of 3 persons for each source.
Ultrasonic thickness measurements 9 teams with machines (2 persons per team)
In-situ metallography machine and 1 team and equipment (battery operated).
technicians for obtaining
metallography for heater tubes and
other high temperature
Equipment.
For the equipment where NDT needs to be done refer work list. Above resources
shall be used to carry out NDT as required in the NHGU complex during
turnaround.
11) QUALIFICATION OF NDT TECHNITIANS:
e) All NDT activities shall be carried out by persons with suitable experience and
having minimum ASNT Level-2 qualification.
f) SWUT (Shear Wave Ultrasonic Testing shall be carried out by the Inspection
agency having experienced personnel with valid ASNT level-2 qualification
under supervision of Level -3 NDT specialist. The reports shall be reviewed and
certified by Level -3 NDT specialist.
ANNEXURE-2 for NHGU
INSPECTORS QUALIFICATION / EXPERIENCE
1) The contractor shall mobilize the following numbers of inspectors.

a) Inspection coordinator (API 510 certified) 1 no. (Day shift)
b) Inspection coordinator (API 510 conversant) 1 no. (Night shift)
c) Certified API-510 Inspectors 3 nos.
d) Certified API-570 Inspectors 2 no.
e) Certified API-936 Inspectors 1 no.
f) API 510 or 570 conversant 7 nos.
2) The minimum qualifications / experience for Diploma / Degree holders in Mechanical

/ Metallurgical engineering shall be as shown below. The experience shall be in on-
stream / shutdown inspection of equipment in process industry.
Years of Experience
Description Nos. Engineers Diploma
API Inspectors (API-510 /

API-570 / API-936) 7 4 6
Inspectors conversant with

API / Civil jobs 11 4 6
Inspection Coordinators 2 10 12
3) Successful LSTK contractor should submit CVs of proposed Inspectors and

coordinators meeting above requirements. BPCL Inspection Dept. will short list
suitable candidates and will call for Technical Interview.
All shortlisted Inspectors and coordinators will be finally selected thru a technical
interview conducted by BPCL Inspection Department.
4) The contractor shall mobilize 2 nos. API 570 piping inspectors 7 days prior to plant
shutdown. All remaining inspectors and coordinators shall be mobilized 2 days prior
to shutdown.
5) Experience shall be in inspection of In-Service Process Equipment viz. Vessels,

Columns, Heaters, Exchangers, and Piping etc. in Refinery / Petrochemical industry.
Candidate must have good ability to understand equipment/piping isometrics and GA
drawings
6) API conversant inspector shall be familiar with various API Codes like API-510, API-
RP-572, API-RP-573, API-570, API-574, API-576, API-571, API-577, API-936 (for
refractory) and applicable Codes.
7) Inspectors should be conversant with ASME Sec II, V, VIII, IX, ANSI, API, AWS, and
Indian Standards.
8) Inspector should be able to make the total observations of equipment status /

condition and recommend necessary repairs as per applicable codes.
9) Inspector should be well conversant with WPS, PQR, and Welder Qualification as
per ASME Sec. IX.
10) Inspector should be able to carry out stage wise inspection of fabrication of piping,
vessels etc. viz. fit ups / edge preparation, Preheat / post heat/ inter pass temp. /
Stress relieving cycles monitoring, consumables checking, final welding, and co-
ordination with Radiographic agency during radiography, interpretation of
radiographs, witnessing hydro test, documentation, mechanical clearance etc. during
fabrication of new & old piping.
11) Inspector should be able to document all activities during fabrication and stage wise
inspection of repairs and new piping modification, in a standard manner.
12) The age of inspection coordinator shall not be more than 50 years.
13) The age of inspector shall not be more than 45 years.
14) Inspectors and coordinator should be comfortable working at height.
15) All inspectors and coordinators should be medically fit for working in confined space.
Their medical fitness shall be certified by MBBS Doctor.
16) Inspector should communicate fluently in at least one of the following languages: Hindi,
Marathi, and English.
17) Inspector must be able to make observations about equipment status/condition and provide
feedback to BPCL inspection in written format. He must be good at writing skills
18) Civil inspector shall have experience as mentioned in table above (Point no 2) for on stream
inspection of refractory work, civil structures, mechanical structures, cement lining of pipes
etc.
LOBS:
ANNEXURE-1 for LOBS
SCOPE OF NDT
2. Visual Inspection:
Visual inspection shall be carried out as per applicable codes and standards for
inspection of various equipments. Internal and external visual inspection shall be
carried out on equipment and shall cover all pressure and non-pressure parts.
External inspection of the following shall be carried out:

l) Foundation: Settlement, condition of anchor bolts.
m) Fire Proofing: Spalling, cracking, corrosion of reinforcement under cracked
locations.
n) Skirt: Corrosion, weld cracks at joint between skirt and column/vessel, distortion,
if fire proofing is properly bonded to skirt.
o) Saddle Supports: General condition, corrosion of shell at crevice between
saddles and steel, adequacy of expansion provision of floating support.
p) Ladders, stairs, platforms and structures: Paint condition, general corrosion,
weld cracks, condition of chequered plates, toe plates, fasteners.
q) Insulation: Condition of the insulation material if rotten, damages to Insulation
and insulation protection, corrosion of underlying material.
r) Protective coating/lining: Condition of painting, any cracks on external FRP
lining, corrosion of metal at cracks on lining.
s) Earthing Connections: Damage to cable and its electrical connections
continuity.
t) Nozzles: Check for weld cracks, leakages through telltale holes.
u) External surface of pressure parts: External corrosion due to rain water seepage
inside insulation, atmospheric corrosion, undue vibration/swaying, hot spots on
internally lined pressure vessels, mechanical damage, and weld
cracks/leakages.
v) Refractory lining, hangers and spigots inspection for heater.
2) Ultrasonic Thickness measurement:
The pressure parts of all the equipment shall be ultrasonically gauged for thickness
and the thickness readings shall be recorded on inspection sketches showing
corresponding Thickness Measurement Locations (TMLs). The number of
thickness monitoring locations shall be adequate enough to assess any metal loss.
In case of any significant metal loss is observed, the effected area shall be closely
scanned. The following shall be considered as a guide line for each type of
equipment for deriving the TMLs.
2.1 Columns:
f) Shell plate: In 4 compass directions at each tray level.
g) Dished ends: In 4 compass directions in crown and knuckle area.
h) All connected nozzles neck thickness in four compass directions.
i) Skirt: In 4 compass directions.
j) Internals: Trays (10% of trays, 4 locations on each tray) and distributors (100%,
one set of readings {4 compass directions} at every one meter length).
2.2 Vessels and reactors:

f) Shell plate: In 4 compass directions for all shell courses.
g) Dished ends: In 4 compass directions at crown and knuckle area.
h) All connected nozzles neck thickness in four compass directions.
i) Skirt (for vertical vessels): In 4 compass directions.
j) Internals: All Baffles (4 locations on each baffle) and distributors (100%, one set
of readings {4 compass directions} at every one meter length).
2.3 Heaters:
Radiation Section:
c) Straight tubes: In 4 compass directions at 3 levels (1st level shall be approx. 1
mtr. from floor level).
d) Return bends: All bends, min. 3 readings on the outer radius of each bend.
Convection Section (Hydrocarbon Coils, BFW Coils, Steam Generating Coils and
Super Heater Coils):
d) Tubes (straight sections): In 4 compass directions adjacent to each bend.
e) Return bends: All bends, min. 3 readings on the outer radius of each bend.
f) Bottom shock tubes: In 3 compass directions at 3 locations.
Stack:
One set of readings on each shell course along the staircase.
Air Duct (Horizontal sections):

One set of 3 to 4 readings on top plate at every 6 meters length.
2.4 Exchangers:
e) Shell & shell cover: In 4 compass directions for all shell courses (At min. 3
locations).
f) Dished ends: In 4 compass directions at crown and knuckle area.
g) All connected nozzles neck thickness in four compass directions.
h) Tube OD measurement on peripheral tubes, Thickness by measuring ID & OD.
2.5 Air fin coolers:

c) Inlet and outlet Header boxes (all 4 plates at 3 locations).
d) All connected nozzles neck thickness in four compass directions.
2.6 Piping:
c) All elbows, tees and reducers.
d) Pipe: one set of readings in 4 compass directions at every 10 mtrs length. In
case of small pipe sections i.e. less than 10 mtrs. length, one set of readings in
every section of straight pipe.
Note: In case of cladded equipment, ultrasonic thickness technique shall be

deployed to explore the cladding damages like lamination, blistering etc.
3) OD and Bowing/sagging measurements of heater tubes:
1. Manual OD measurements of all radiant tubes shall be carried out at every 2

mtrs height.
2. Sagging /bowing measurements using plumb to be carried out for all radiant
tubes.
4) Magnetic Particle Examination:
d) Carryout Magnetic partial test (MPT) of columns, vessels, reactors skirt

attachment weld and exchangers in ferromagnetic material shell welds and
nozzle welds as specified in work list.
e) Carry out buffing (6 inches on both sides of weld) for all MPT locations.
f) Magnetic Particle Examination shall be carried out as per ASME Section V
Article 7.
5) Liquid Penetration Examination:
c) Carryout Liquid penetration test (LPT) of stainless steel welds of piping, heaters
and weld overlays as per scope of work.
d) Reactor attachment welds of all the nozzles, thermocouple, bottom vortex
breaker, tray and catalyst support cone from inside.
e) For ring type gasket joints, all the gasket and ring grooves of all the three
reactors.
f) Bed thermocouple weld joints of all reactors from inside and outside the reactor
shell.
g) Liquid Penetration Examination shall be carried out as per ASME Section V
Article 6.
6) Eddy current testing:
a) Eddy current testing (ECT) shall be carried out as per ASME Section V Article 8.
The contractor to submit NDT party details and procedure to BPCL for approval.
Battery operated equipment is to be deployed. ECT shall be deployed for
checking of non magnetic tubes like non ferrous tubes and stainless steels.
b) Refer work list for exchangers / AFCs for ECT.
c) Based on inspection findings, ECT % per bundle may be increased or reduced.
7) REMOTE FIELD ELECTROMAGNETIC TECHNIQUE (RFET):
b) Remote Field Electromagnetic Technique (RFET) shall be carried out in

standard manner. The contractor to submit NDT party details and procedure to
BPCL for approval. Battery operated equipment is to be deployed. RFET shall
be deployed for checking of magnetic tubes like ferrous tubes and duplex
stainless steels.
b) Refer work list for exchangers / AFCs for RFET.
c) Based on inspection findings, RFET % per bundle may be increased or reduced.
8) SWUT (SHEAR WAVE ULTRASONIC TESTING)
Cracks identified by NDTs like DP and MPI in equipment will require to be sized
using SWUT (shear wave ultrasonic testing). Provide one no. SWUT battery
operated machine and operators for sizing of cracks found by DP/MPI.
9) TOFD / PAUT / AUBT / VELOCITY RATIO COMPARISON FOR 2 nos. HP

REACTORS
a) Carry out Time of Flight Diffraction (TOFD) scanning of 3 nos. circumferential

welds and 2 nos. longitudinal welds of each Reactor. Carry out buffing of 500 to
550 mm on both sides of welds for TOFD.
c) Carry out Phased Array Ultrasonic Testing (PAUT) of all nozzle welds and skirt
attachment welds of reactors. Carry out buffing of 500 to 550 mm from welds for
PAUT.
d) For TOFD and PAUT of low alloy steel Reactors, base metal with SS347 weld
overlay, a carbon steel calibration block of 500 mm x 500 mm x 120 mm thick
shall be provided by BPCL. Required machining, drilling and generating
notches/holes shall be carried out by contractor in consultation with NDT
specialist. The calibration block shall be handed over to BPCL after completion
of job and it will be a BPCL property.
e) In case of any indication found, the same shall be sized and characterized as
follows by PAUT and/or SWUT.
Observation Action
Isolated cavities Monitor
Oriented cavities Formalize NDE program
Cavity linkage (micro-cracks) FFS, with limited service time to repair
Macro-cracks Plan to repair immediately
f) Based on above NDTs, in case FFS is applicable, contractor shall carry out level
3 Fitness for Service (FFS) as per API RP 579 through the specialist in FFS
within 5 days from the date of observation of the flaw. The FFS agency shall be
approved by BPCL. The FFS report shall give the pressure/temperature
withstanding capacity and in service monitoring requirements, repairs and
replacements.
g) Velocity ratio comparison, Advanced Ultrasonic Backscatter Technique (AUBT)
and Insitu-metallography shall be carried at 2 nos. circumferential weld joints
and 2 nos. selected locations on shell of each Reactor by NDT specialist.
10) RADIOGRAPHY:
All radiography work shall be in the scope of contractor. No storage for source and
processing space shall be provided by BPCL.
Radiographic Examination for fabrication of piping (for replacement / modification

work) and repairs to equipment shall be carried out as per ASME Section V Article
2. The extent of radiography for butt joints shall be as follows:
10.1 Piping:
h) LPG, C3C4 and Gas pipe lines 100 %.

i) All other Hydrocarbon piping 10 %.
j) Stress relieved joints 100 % before and after SR.
k) IBR Pipe lines 20 %.
l) Utility pipe lines (LP steam, air & Nitrogen) 10 %.
m) Water pipe lines including raw water and sea water
Nil.
n) All field joints 100 %.
10.2 Equipment:
c) All butt joints of pressure vessels and nozzle flange butt joints 100 %.
d) Stress relieved joints 100 % before and after SR.
11) NDT manpower/machinery Resources required during turnaround shall be as per

table indicated below. The resources given herewith are the minimum required and
shall be augmented based on the load of work during turnaround. The decision of
BPCL inspection shall be final in this regard.

LPT 2 TEAMS (2 persons per team)
MPT (battery operated machine) 2 TEAMS ( 2 persons per team) with 3 machines
i.e. each team will have a machine
ECT (battery operated machine) 2 Machines with respective teams
RFET(battery operated machine) 2 Machines with respective teams
SWUT (Shear Wave Ultrasonic 1 team and equipment for scanning
Testing :- Battery operated machine)
TOFD and PAUT (Battery operated 1 Machine each with respective teams each for
machines) TOFD and PAUT
AUBT/Velocity Ratio Comparison 1 Machines with respective teams
(Battery operated machines)
Radiography a) 2 sources (Min. strength 5 Curies) with
respective team of 3 persons for each
source.
b) 1 source for close proximity radiography for
piping jobs upto 100dia.
Ultrasonic thickness measurements 10 teams with machines (2 persons per team)
In-situ metallography machine and 1 team and equipment (battery operated).
technicians for obtaining
metallography for heater tubes and
other high temperature
Equipment.
LRUT of pipe lines (battery operated 1 Machines with respective teams for Hydrogen
Machine). quench lines from HCU battery limit to both
Reactors.
For the equipment where NDT needs to be done refer work list. Above resources
shall be used to carry out NDT as required in the LOBS complex during
turnaround.
12) QUALIFICATION OF NDT TECHNITIANS:
a) All NDT activities shall be carried out by persons with suitable experience and
having minimum ASNT Level-2 qualification.
b) SWUT (Shear Wave Ultrasonic Testing shall be carried out by the Inspection
agency having experienced personnel with valid ASNT level-2 qualification
under supervision of Level -3 NDT specialist. The reports shall be reviewed and
certified by Level -3 NDT specialist.
c) TOFD, PAUT, AUBT and Velocity Ratio Comparison shall be carried out by the
Inspection agency having experienced personnel with valid ASNT level-2
qualification under supervision of Level -3 NDT specialist. The reports shall be
reviewed and certified by Level -3 NDT specialist. Both NDT technician and
NDT specialist should have experience in carrying out these jobs for
thicknesses more than 100 mm. Prior to deploying the Inspection agency for
this job, all supporting documents shall be submitted to BPCL Inspection Dept.
for verification and approval. The procedure and data shall be evaluated by
ASNT/EN level-3 NDT specialist with more than 10 years of experience in the
relevant field.
ANNEXURE-2 for LOBS
INSPECTORS QUALIFICATION / EXPERIENCE
1) The contractor shall mobilize the following numbers of inspectors.

g) Inspection coordinator (API 510 certified) 1 no. (Day shift)
h) Inspection coordinator (API 510 conversant) 1 no. (Night shift)
i) Certified API-510 Inspectors 4 nos.
j) Certified API-570 Inspectors 2 no.
k) API 510 or 570 conversant 7 nos.
l) Civil / Structural / Painting inspector 1 no.
2) The minimum qualifications / experience for Diploma / Degree holders in Mechanical

/ Metallurgical engineering shall be as shown below. The experience shall be in on-
stream / shutdown inspection of equipment in process industry.
Years of Experience
Description Nos. Engineers Diploma
API Inspectors (API-510 /

API-570 / API-936) 7 4 6
Inspectors conversant with

API / Civil jobs 11 4 6
Inspection Coordinators 2 10 12
3) Successful LSTK contractor should submit CVs of proposed Inspectors and

coordinators meeting above requirements. BPCL Inspection Dept. will short list
suitable candidates and will call for Technical Interview.
All shortlisted Inspectors and coordinators will be finally selected thru a technical
interview conducted by BPCL Inspection Department.
4) The contractor shall mobilize 2 nos. API 570 piping inspectors, 7 days prior to plant
shutdown. All remaining inspectors and coordinators shall be mobilized 2 days prior
to shutdown.
5) Experience shall be in inspection of In-Service Process Equipment viz. Vessels,

Columns, Heaters, Exchangers, and Piping etc. in Refinery / Petrochemical industry.
Candidate must have good ability to understand equipment/piping isometrics and GA
drawings
6) API conversant inspector shall be familiar with various API Codes like API-510, API-
RP-572, API-RP-573, API-570, API-574, API-576, API-571, API-577, API-936 (for
refractory) and applicable Codes.
7) Inspectors should be conversant with ASME Sec II, V, VIII, IX, ANSI, API, AWS, and
Indian Standards.
8) Inspector should be able to make the total observations of equipment status /

condition and recommend necessary repairs as per applicable codes.
9) Inspector should be well conversant with WPS, PQR, and Welder Qualification as
per ASME Sec. IX.
10) Inspector should be able to carry out stage wise inspection of fabrication of piping,
vessels etc. viz. fit ups / edge preparation, Preheat / post heat/ inter pass temp. /
Stress relieving cycles monitoring, consumables checking, final welding, and co-
ordination with Radiographic agency during radiography, interpretation of
radiographs, witnessing hydro test, documentation, mechanical clearance etc. during
fabrication of new & old piping.
11) Inspector should be able to document all activities during fabrication and stage wise
inspection of repairs and new piping modification, in a standard manner.
12) The age of inspection coordinator shall not be more than 50 years.
13) The age of inspector shall not be more than 45 years.
14) Inspectors and coordinator should be comfortable working at height.
15) All inspectors and coordinators should be medically fit for working in confined space.
Their medical fitness shall be certified by MBBS Doctor.
16) Inspector should communicate fluently in at least one of the following languages: Hindi,
Marathi, and English.
17) Inspector must be able to make observations about equipment status/condition and provide
feedback to BPCL inspection in written format. He must be good at writing skills.
18) Civil inspector shall have experience as mentioned in table above (Point no 2) for on
stream inspection of refractory work, civil structures, mechanical structures, cement
lining of pipes etc.
ATTACHMENT 11 SECTION R

UNIT ( NHGU / LOBS) : ADMIN SERVICES
A) SUPPLY OF PORTA CABINS DURING TURNAROUND 2017

Supply the AC porta cabins for a period of 2 months (60 days). The porta cabins shall
be provided with window air conditioner, all necessary electrical fittings, telephone point
, furniture as detailed under technical specification.
All windows / doors shall be provided with monsoon protection made out of MS sheet
and all the window glasses shall be provided with sun films. Also, sliding curtains to be
provided from inside for all the windows in all the cabins.
The scope also includes all transportation / placement services / unloading / loading at
BPCL refinery site.
Similarly contractor will be required to collect and transport the porta cabin from BPCL
site back to their works on instructions of engineer in-charge.
For loading / unloading at BPCL premises, the required crane shall be provided by
Contractor. Contractor shall arrange sufficient nos. of Slings, D shackles & manpower
for making rigging arrangement and loading / unloading of the porta cabins including
placement at designated place.
For any problem related to the electrical fitting / equipment, contractor shall arrange to
rectify the defective equipment within 12 hrs and same shall be made good without any
cost to BPCL.
Technical specifications of Porta Cabin:
Size of porta cabin
20' x 10' x 8'6" (all dimension in feet) with suitable lifting arrangements. Total quantity 2
nos.
Exterior
Colored corrugated mild steel panels, white / blue paint.

Interior
Insulation, MDF laminated sheets
Windows
3 nos. aluminum sliding glass windows with sun films and curtain rods & curtains for 20
x 10 feet cabin
Door / Locking facilities
Suitable locking facility both inside and outside with number locks. The doors shall be
provided along the width of the cabins.
Electrical Facilities
1 no. main supply board for lighting with ELCB shall be mounted outside in a M.S.
board. The board shall have an isolator 63 Amp and connector suitable for terminating 4
core 16 sq.mm copper cables for incoming supply. Electric distribution shall be 1 phase
distribution and 1 phase ELCB + MCB with 25 A , 30 mA sensitivity.
The porta cabin shall be supplied with complete internal wiring facilities. The porta cabin
shall be in ready to use condition with all electrical accessories as listed below once the
incoming supply is provided by BPCL.
4 nos. 5 x 15 Amps plug point and 4 nos. spike guards with all wiring from the main
incoming board. Please ensure availability of spike guards in all the cabins.
Suitable capacity power points are to be provided in the office cabins for window air
conditioners.
Two additional spare power points to be provided near the doors as spare to take care
of any additional requirements.
Air conditioners / Fans
1 no. 1.5 to 2 ton window air conditioner for 20 x 10 feet porta cabins
2 nos. Rotary grill ceiling fans with complete wiring for 20 x 10 feet porta cabin
Other Accessories
Standard tube lights with complete wiring.
2 nos. earthing point at different locations on the container body.

Internal telephone wiring at one location along with telephone jack pin socket inclusive
of wiring till main junction box. Telephone junction box shall be provided with krone
connector. Junction box for incoming cables shall be provided outside the cabins.
All the 20 x 10 feet cabin shall be provided with two nos. computer table , one no. book
shelf with glass doors & locks, 10 nos.Plastic molded chairs (In Red / Green / White
color) & 3 nos. tables (Wooden with sun mica top) of size 4 feet. x 2 feet
All the cabins shall be provided with one 'WHITE BOARD' of 5'x3' size (Each
cabin) along with two marker pens and magnetic duster.
Ground clearance for all the cabins shall maintained by build on four legs of 9 inch high
from the ground level.
Special requirement
All cabins shall be provided with wash basin & mirror with drain and incoming line
connection mounted / coming outside the cabin.
B) TEMPORARY TEA POINTS & SUPPLY OF CHAIRS, TABLES AND FANS (AIR
CIRCULATORS) DURING RMP COMPLEX TURNAROUND 2017 for PERIOD OF
2 MONTHS
Make temporary tea points for BPCL staff of size 50 x 15 x 10 2 nos using
scaffolding pipes and the same shall be covered with good quality precoated sheets of
blue colour from sides and top. There should be proper entry and top 2 shall be open
from sides for ventilation. The exact location for tea point shall be shown by Area
Incharge during Turnaround.
Supply following items at tea points of RMP Turnaround for a period of 2 months (60
days) -
Plastic molded chairs (In Red / Green / White color) - Total quantity 200 nos.
Tables (Wooden with sun mica top) of size 4 feet. x 2 feet - Total quantity 50 nos.
600 mm Fans (Pedestal type 230 V with oscillation) - Total quantity 6 nos.
To and Fro transportation of the chairs/ tables / fans from BPCL Mumbai refinery to
contractors place is in Contractors scope.
Contractor shall supply chairs, tables and fans of good quality and as per details given
in Scope of Work. Broken / damaged /inferior quality chairs / tables / fans will be
rejected and will not be paid for.
Any problem in running of fans (air circulators) shall be attended by contractor on urgent
basis on the same day.
Chairs / tables / fans shall be delivered at the plant locations inside BPCL Mumbai
refinery as per instructions of Engineer-in-Charge. Loading / unloading of chairs / tables
/ fans at site and contractors place shall be arranged by contractor.
Contractor will be required to supply and collect chairs / tables / fans in two or more trips
on different days. Exact dates of delivery will be intimated later.
Contractor shall arrange to collect back the chairs/ tables / fans within one day on
instruction of Engineer-in-Charge. Collection of chairs /tables / fans will be required in
phases on different days.
ATTACHMENT 11 SECTION S

UNIT ( NHGU / LOBS) : INSULATION JOBS
A) INSULATION WORK IN LUMPSUM SCOPE
1. For package no. 3, with respect to insulation work on all the equipment and piping,
lumpsum scope shall include following quantities.
a. Insulation removal and application : 8700 m2
b. Removal and application of asbestos rope : 1000 Inch Meter
c. Making inspection windows for equipment / piping: 4500 nos.
Any upward / downward variation in the insulation quantities estimated above
shall be dealt through applicable SOR.
Kindly note
1. The job involves transportation of free issue materials from warehouse, cutting /
rolling of aluminum sheet in required size/ shape/ form suiting the piping / equipment,
insulation of surfaces with LRB mattress / rock wool of various thicknesses and
provide aluminum cladding with overlapping at all heights . GI screws shall be
screwed at regular intervals of 100 / 150 / 200 mm based on site conditions.
Application of salli-coat or equivalent mastic materials and cladding if any required
for the job is also included. Scrap shall be disposed as directed by BPCL site in-
charge. The job shall be done strictly as per BPCL specifications. Payment will be
effected for finished surface area of insulation. Scaffolding if required shall be
provided by the contractor with his material for execution of the job and the same to
be removed upon completion of the job as directed by the Engineer in charge. Rate
Shall Be Applicable for Insulation up to 100 mm thickness and is inclusive of removal
of old insulation / cladding / cleaning / painting of the lines with two coats of zinc dust
graphite paint.
2. After removal of insulation (cladding and mineral wool), carry out thorough cleaning
for UT gauging and offering to Inspection.
3. If no insulation windows exist on the shell, then contractor shall cut the insulation
window as per insulation standard procedure. The removable window shall be of the
same basic material and thickness as the rest of the insulation and of sufficient
rigidity to withstand handling.
Page 1 of 2
4. Before fixing insulation, carry out painting as per AES 5430 Rev 1.
5. After completion of the job, carry out insulation and cladding as per BPCL insulation
procedure given in Attachment 12.
6. Insulation wool and cladding sheet shall be free supply from M/s BPCL. However,all
ancillary material for insulation work like Self tapping screws of slotted pan
head/round head. (Size 7 & 10 - 1/2 & 3/4 long), Bituminized anticorrosive paint,
Bituminous felt (Tar felt), Asian paint make Apcolite knifing paste filler grey,
Tarpaulin, Mastic sealing compound, fiber solution, A1 strapping band (25 mm x 24
SWG), 1.5 x 25 MM carbon steel strip support ring, 3 mm thick Asbestos mill board
and 25 mm x 3 mm thick asbestos band / tape, Mesh woven glass fiber for moisture
barrier, Asbestos flop shall be in Contractor scope.
7. The measurement shall be as per IS 14164:2008 and application shall be as per
BPCL Standard AE-DEP-M-12 Rev 3.
8. Application of asbestos rope includes supply and application of weather proofing
Compund and quick setting plaster.
Page 2 of 2

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ATTACHMENT 11 SECTION A

WORK PACKAGE FOR PACKAGE NO. 3

NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE

2 Waxy 100N side

DWLT Lube side

WORK PACKAGE FOR PACKAGE NO. 3

NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE

1 EQUIPMENT NO 133-F-301 Service Reformer Heater

b) Duct between APH 301 and APH 302.

c) APH 302 bypass duct.

1) FD fan suction dampers: 2 nos.

Spade List for 133-F-301

Sr No. Location Size Rating

1 EQUIPMENT NO 132-F-204 Service FPU Feed Heater

Spade List for 132-F-204

2 EQUIPMENT NO 132-F-205 Service DW Reactor Feed

Spade List for 132-F-205

3 EQUIPMENT NO 132-F-206 Service DW Vacuum Column

1. Erect metal scaffolding.

2. Open all the connected duct flange bolts.

6. For dismantling and assembly of baffles following procedure shall be followed,

8. Remove the scaffolding on completion of the job.

NEW HYDROGEN GENERATION UNIT & LUBE OIL BASE

TAG NO 133-E-306 TYPE BHU(H)

TAG NO 133-E-309 A/B TYPE NHN

TAG NO 133-E-311 A/B TYPE BEM(V)

TAG NO 133-E-312 A/B TYPE BEU

TAG NO 133-E-313 TYPE NEN

TAG NO 133-E-314 A/B/C TYPE BEM(H)

TAG NO 133-E-316 TYPE NEN

TAG NO 133-E-317 TYPE NJ21N(H)

TAG NO 133-E-331 TYPE

TAG NO 133-E-332 TYPE

TAG NO 133-E-333 A/B TYPE AES

TAG NO 133-E-335 TYPE AES

802 GSKT,SW,255X309X4.5,PN:802,W/OP 1 85.41.10.135.5

TAG NO 133-E-336 TYPE AES

TAG NO 133-E-337 TYPE AES

TAG NO 133-E-343 TYPE

TAG NO 133-EA-301 TYPE AFC

TAG NO 132-E-253 A/B/C/D TYPE AES(H)

TAG NO 132-E-259 TYPE AEM(H)

TAG NO 132-E-261 TYPE AEM(H)

AG NO 132-E-271 A TYPE AXS H

TAG NO 132-E-271 B TYPE AES H

TAG NO 132-E-275 A TYPE AES H

TAG NO 132-E-275 B TYPE AES H

TAG NO 132-E-275 C TYPE AES H

TAG NO 132-EA-224 TYPE AFC

TAG NO 132-EA-226 TYPE AFC

1. Spading on shell and tube side including utilities connection.

TAG NO 133-E-307 A/B TYPE BHU

TAG NO 133-E-315 TYPE BJ21U

TAG NO 133-E-318 TYPE BJ21U

TAG NO 133-E-344 TYPE

TAG NO 132-E-257 A/B TYPE AES(H)

TAG NO 132-E-263 TYPE AEM H

TAG NO 132-EA-221 A/B/C/D TYPE AFC

TAG NO 132-EA-221 ST A/B/C/D TYPE AFC

TAG NO 132-EA-222 TYPE AFC

TAG NO 132-EA-222 ST TYPE AFC

TAG NO 132-EA-223 ST TYPE AFC

TAG NO 132-EA-225 TYPE AFC

TAG NO 132-EA-227 TYPE AFC