Bottom Crown Modification , Periodic Testing , Certification And Painting Of 6X600 Mt And 2X1200 Mt Lpg Horton Spheres At Kanpur Bp ( Up ) . , Iocl Lpg Bp Kanpur-Uttar Pradesh

TDR : 21513476

Tender Notice
BOQ

Expired

Iocl Lpg Bp Kanpur , Uttar Pradesh

Tender Brief : Bottom Crown Modification , Periodic Testing , Certification And Painting Of 6X600 Mt And 2X1200 Mt Lpg Horton Spheres At Kanpur Bp ( Up ) .

Document Fees
Refer document

EMD
₹ 151248.0 /-

Tender Value
₹ 1.51 Crore /-

Submission Date
16-09-2019

Competition Type
Indian

Bidding Type
Tender

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Name of Work: Bottom Crown Modification, Periodic Testing, Certification and Painting of 6X600 MT and 2X1200 MT LPG Horton Spheres at Kanpur Bottling Plant
1	1.1	Supply of Steel flat, square bar , nut bolts etc required for fabrication of internal ladder as per approved drawing by PESO. Rate is inclusive of P&F charges,freight charges,TPIA charges etc all complete		7500	KG
2	2	Deboxing /Boxing, dismantling/putting back all the gadgets on Horton Sphere & also all jobs related to blind flanging upto first isolation valve.
3	2.01	a)600 MT horton sphere		6	Nos.
4	2.02	b)1200 MT horton sphere		2	Nos.
5	3	DECOMMISSIONING AND INTERNALCLEANING: Decommissioning, vessel isolation, degassing, internal cleaning, removal of sludge and its disposal as per instruction of site in-charge, isolation of fittings and preparation of surface as required for conducting tests, boxing up of the vessel and re commissioning of the vessel. For scaffolding, charges will be paid as per schedule of rates separately.
6	3.01	a)600 MT horton sphere	6	6	Nos.
7	3.02	b)1200 MT horton sphere	2	2	Nos.
8	4	OVERALL VISUAL INSPECTION :To conduct thorough “Visual Inspection” of outer and inner surface of Horton Spheres to check any surface defect abnormality like dents,pitting, erosion, craking, scaling, deposits etc. as per ASME Esc. V and meeting all requirement of PESO, retaining Wall, Inspection Tunnel, Bottom Nozzle & its suspension/Support, accessible top nozzles etc.
9	4.01	a)600 MT horton sphere		6	Nos.
10	4.02	b)1200 MT horton sphere		2	Nos.
11	5	Scaffolding : Arranging and safe erection of tubular (Steel Pipe) scaffolding materials as per requirement for internal and external portion of spheres to enable internal and external cleaning and for carrying out all Statutory NDT tests of Spheres and safe removal of the same on completion of work including transporting and handling of material. The charges include scaffolding for painting and all allied works in connectio with the work on hand which ever require scaffolding in total. Noother payment will be made for scaffolding other than the rates specified for this item.
12	5.1	a)600 MT horton sphere		6	Nos.
13	5.2	b)1200 MT horton sphere		2	Nos.
14	6	100% MAGNETIC PARTICLE TEST : a. To conduct “100% Magnetic Particle test” dry and wet of all weld joints including cleat welds, nozzles, man-holes at top and bottom and external reinforcing pad-welds at the support leg height, as per ASTM E –709-89. NOTE: Dry Magnetic Particle Test to be conducted below the equator and wet magnetic particle test above the equator line.
15	6.01	a)600 MT horton sphere		6	Nos.
16	6.02	b)1200 MT horton sphere		2	Nos.
17	7	DYE-PENETRATION TEST :To conduct “Dye-Penetrate Test” of Nozzles and leg support pads and any other in-accessible areas, as per ASTM E – 165-80.
18	7.01	a)600 MT horton sphere		6	Nos.
19	7.02	b)1200 MT horton sphere		2	Nos.
20	8	Ultrasonic Thickness Test:To conduct “Ultrasonic Thickness Test” on petals/shell of Mounded Bullets as per SMPV rule, ASTM A – 577-88 or equivalent codes. Mapping of each petal plate to cover the whole plate-say ten to twelve readings to be taken between each consecutive weld seam (Horizontal & Vertical), Nozzle, Manhole, Piping around installation upto first isolation valve.
21	8.01	a)600 MT horton sphere		6	Nos.
22	8.02	b)1200 MT horton sphere		2	Nos.
23	9	To conduct Ultrasonic flaw detection of butt welded joints on 100% \"T\" Joints from inside & 100 % both dish dish ends circimferential & longitudinal joints etc. as per ASTM A-577/578
24	9.01	a)600 MT horton sphere		6	Nos.
25	9.02	b)1200 MT horton sphere		2	Nos.
26	10	RADIOGRAPHY TEST:To conduct “ Radiography Test” for weld joints at selected locations if defect/flaws observed during test no. 4, 5 & 6 subject to maximum 10% of total weld length of pressure vessel as per ASTM SE –94 & E-1032 or equivalent codes. AND 100% radiography of Newly welded joints.
27	10.01	a)600 MT horton sphere		6	Nos.
28	10.02	b)1200 MT horton sphere		2	Nos.
29	11	HARDNESS TEST :To conduct Random “Hardness Test” with portable hardness tester on six to seven selected points/spots to cover weld, HAZ & Parent plate in each area i.e. bottom to top crown, equatorial polar petal plate & any site cleat weld areas etc. as per ASTM 110-89 or equivalent codes.
30	11.01	a)600 MT horton sphere		6	Nos.
31	11.02	b)1200 MT horton sphere		2	Nos.
32	12	Deboxup/boxup, testing and repair of 02 nos. per Horton Spheres SRVs with the nitrogen gas including supply of spares ( if required). After testing and inspection certification shall be given under SMPV(u) Rules.
33	12.01	a)600 MT horton sphere		6	Nos.
34	12.02	b)1200 MT horton sphere		2	Nos.
35	13	HYDROTEST & STRETCH TEST :To conduct “HYDROTEST TEST” of vessel and also connected pipings in total as required and as directed at site, after successful completion of all N.D. test as per SMPV rules and relevant codes.
36	13.01	a)600 MT horton sphere		6	Nos.
37	13.02	b)1200 MT horton sphere		2	Nos.
38	14	Hooking up, Purging and commissioning
39	14.01	a)600 MT horton sphere		6	Nos.
40	14.02	b)1200 MT horton sphere		2	Nos.
41	15	Arranging and erection of colored GI sheet and tubular pipes for Fire Screen as per PESO approved drawing /Barricading around horton spheres for carrrying out hot works		15000	Sq.Mtr.
42	16	TPI stage wise inspection including preparation of documents, Procedure , Drawings for Bottom Crown modification,Drawing for internal ladder and modification in nozzles ( if required) , and all connected works as per tender, as per site requirements in total including , degassing, hydrotesting etc in total as required ,Preparation of all procedures and related documents, submission to PESO before commencing the works and after completion of works duly vetted by TPI agency, inspection of Horton Spheres, all NDT activities, Checking of weld joints, Witessing and Review of Radiography film , Witness of Hydrotest of all 8 nos Spheres, preparation of all documents as per SMPV rules, duly witnessed and certified by approved TPI agency,submission to CCOE and co ordniation with CCOE and obtaining approvals- All Complete as required including amendment in Storage license. This includes testing and inspection certificates/reports and documents for all tests and inspection covered in the scope of work. The contractor shall be required to submit five sets of above as SMPV rules no 19 and WB Factories rules as applicable. FOR 6 X 600 MTs & 2X1200 MTs.		1	LS
43	17	Designing of internal ladder with complete Bill of Material and erection procedure. The design and erection procedure should be approved by PESO before start of site activities. No bolting is allowed within the ladder. Bolts can be used to fix the ladder with the attachment of sphere shell. Ladder should be attached with the sphere at the top and bottom end only, intermediate support on the sphere body is not acceptable.\n		1	SU
44	18	Fabrication & Installation of internal ladder: Cutting, welding & fabrication of MS flat & Ms round bar as per PESOapproved drawing and erect MS ladder inside Horton sphere.		7500	KG
45	19	Replacement of Nuts, Bolts, washers and Gaskets : Supply and fixing of all gaskets, studs & nuts for all fittings provided in Spheres.		8	Nos.
46	20	Manual cleaning & Painting of all pipes, valves etc.2 Coats of zinc phosphate & 2 coat of synthetic enamel paint/ Al. finish paint.Total thickness : 100 µm.		1200	Sq.Mtr.
47	21	Cleaning and painting of extrenal surface of Spheres as per following specification 1. Surface Preparation: Clean to SSPC SP2 or as approved by location in-charge (Hand Cleaning, Wire Brushing/ other method) 2. Paint System: One coat of tie coat (two component high build, high solid surface tolerant epoxy maintenance coating 200 microns) + Finish coat -1 coat of 2 pack of Aliphatic Acrylic Polyurethane 55 Microns (F1) 3. Total DFT (Min): minimum 255 micron . 4. The warranty period for this painting will be 5 years.		7500	Sq.Mtr.
48	22	Design,supply,fabrication,fixing of 500mm NB CS forged dish end conforming to SA420 WPL-6. The design drawings are to be approved by PESO by the tenderer. The Thickness of the dish end shall be as per approved design. The item includes cutting existing nozzle as per approved procedure.		8	Nos.

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Bottom Crown Modification , Periodic Testing , Certification And Painting Of 6X600 Mt And 2X1200 Mt Lpg Horton Spheres At Kanpur Bp ( Up ) . , Iocl Lpg Bp Kanpur-Uttar Pradesh

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Name of Work: Bottom Crown Modification, Periodic Testing, Certification and Painting of 6X600 MT and 2X1200 MT LPG Horton Spheres at Kanpur Bottling Plant
	Sl.No.	Item Description	Item Code / Make	Quantity	Units
1	1.1	Supply of Steel flat, square bar , nut bolts etc required for fabrication of internal ladder as per approved drawing by PESO. Rate is inclusive of P&F charges,freight charges,TPIA charges etc all complete		7500	KG
2	2	Deboxing /Boxing, dismantling/putting back all the gadgets on Horton Sphere & also all jobs related to blind flanging upto first isolation valve.
3	2.01	a)600 MT horton sphere		6	Nos.
4	2.02	b)1200 MT horton sphere		2	Nos.
5	3	DECOMMISSIONING AND INTERNALCLEANING: Decommissioning, vessel isolation, degassing, internal cleaning, removal of sludge and its disposal as per instruction of site in-charge, isolation of fittings and preparation of surface as required for conducting tests, boxing up of the vessel and re commissioning of the vessel. For scaffolding, charges will be paid as per schedule of rates separately.
6	3.01	a)600 MT horton sphere	6	6	Nos.
7	3.02	b)1200 MT horton sphere	2	2	Nos.
8	4	OVERALL VISUAL INSPECTION :To conduct thorough “Visual Inspection” of outer and inner surface of Horton Spheres to check any surface defect abnormality like dents,pitting, erosion, craking, scaling, deposits etc. as per ASME Esc. V and meeting all requirement of PESO, retaining Wall, Inspection Tunnel, Bottom Nozzle & its suspension/Support, accessible top nozzles etc.
9	4.01	a)600 MT horton sphere		6	Nos.
10	4.02	b)1200 MT horton sphere		2	Nos.
11	5	Scaffolding : Arranging and safe erection of tubular (Steel Pipe) scaffolding materials as per requirement for internal and external portion of spheres to enable internal and external cleaning and for carrying out all Statutory NDT tests of Spheres and safe removal of the same on completion of work including transporting and handling of material. The charges include scaffolding for painting and all allied works in connectio with the work on hand which ever require scaffolding in total. Noother payment will be made for scaffolding other than the rates specified for this item.
12	5.1	a)600 MT horton sphere		6	Nos.
13	5.2	b)1200 MT horton sphere		2	Nos.
14	6	100% MAGNETIC PARTICLE TEST : a. To conduct “100% Magnetic Particle test” dry and wet of all weld joints including cleat welds, nozzles, man-holes at top and bottom and external reinforcing pad-welds at the support leg height, as per ASTM E –709-89. NOTE: Dry Magnetic Particle Test to be conducted below the equator and wet magnetic particle test above the equator line.
15	6.01	a)600 MT horton sphere		6	Nos.
16	6.02	b)1200 MT horton sphere		2	Nos.
17	7	DYE-PENETRATION TEST :To conduct “Dye-Penetrate Test” of Nozzles and leg support pads and any other in-accessible areas, as per ASTM E – 165-80.
18	7.01	a)600 MT horton sphere		6	Nos.
19	7.02	b)1200 MT horton sphere		2	Nos.
20	8	Ultrasonic Thickness Test:To conduct “Ultrasonic Thickness Test” on petals/shell of Mounded Bullets as per SMPV rule, ASTM A – 577-88 or equivalent codes. Mapping of each petal plate to cover the whole plate-say ten to twelve readings to be taken between each consecutive weld seam (Horizontal & Vertical), Nozzle, Manhole, Piping around installation upto first isolation valve.
21	8.01	a)600 MT horton sphere		6	Nos.
22	8.02	b)1200 MT horton sphere		2	Nos.
23	9	To conduct Ultrasonic flaw detection of butt welded joints on 100% \"T\" Joints from inside & 100 % both dish dish ends circimferential & longitudinal joints etc. as per ASTM A-577/578
24	9.01	a)600 MT horton sphere		6	Nos.
25	9.02	b)1200 MT horton sphere		2	Nos.
26	10	RADIOGRAPHY TEST:To conduct “ Radiography Test” for weld joints at selected locations if defect/flaws observed during test no. 4, 5 & 6 subject to maximum 10% of total weld length of pressure vessel as per ASTM SE –94 & E-1032 or equivalent codes. AND 100% radiography of Newly welded joints.
27	10.01	a)600 MT horton sphere		6	Nos.
28	10.02	b)1200 MT horton sphere		2	Nos.
29	11	HARDNESS TEST :To conduct Random “Hardness Test” with portable hardness tester on six to seven selected points/spots to cover weld, HAZ & Parent plate in each area i.e. bottom to top crown, equatorial polar petal plate & any site cleat weld areas etc. as per ASTM 110-89 or equivalent codes.
30	11.01	a)600 MT horton sphere		6	Nos.
31	11.02	b)1200 MT horton sphere		2	Nos.
32	12	Deboxup/boxup, testing and repair of 02 nos. per Horton Spheres SRVs with the nitrogen gas including supply of spares ( if required). After testing and inspection certification shall be given under SMPV(u) Rules.
33	12.01	a)600 MT horton sphere		6	Nos.
34	12.02	b)1200 MT horton sphere		2	Nos.
35	13	HYDROTEST & STRETCH TEST :To conduct “HYDROTEST TEST” of vessel and also connected pipings in total as required and as directed at site, after successful completion of all N.D. test as per SMPV rules and relevant codes.
36	13.01	a)600 MT horton sphere		6	Nos.
37	13.02	b)1200 MT horton sphere		2	Nos.
38	14	Hooking up, Purging and commissioning
39	14.01	a)600 MT horton sphere		6	Nos.
40	14.02	b)1200 MT horton sphere		2	Nos.
41	15	Arranging and erection of colored GI sheet and tubular pipes for Fire Screen as per PESO approved drawing /Barricading around horton spheres for carrrying out hot works		15000	Sq.Mtr.
42	16	TPI stage wise inspection including preparation of documents, Procedure , Drawings for Bottom Crown modification,Drawing for internal ladder and modification in nozzles ( if required) , and all connected works as per tender, as per site requirements in total including , degassing, hydrotesting etc in total as required ,Preparation of all procedures and related documents, submission to PESO before commencing the works and after completion of works duly vetted by TPI agency, inspection of Horton Spheres, all NDT activities, Checking of weld joints, Witessing and Review of Radiography film , Witness of Hydrotest of all 8 nos Spheres, preparation of all documents as per SMPV rules, duly witnessed and certified by approved TPI agency,submission to CCOE and co ordniation with CCOE and obtaining approvals- All Complete as required including amendment in Storage license. This includes testing and inspection certificates/reports and documents for all tests and inspection covered in the scope of work. The contractor shall be required to submit five sets of above as SMPV rules no 19 and WB Factories rules as applicable. FOR 6 X 600 MTs & 2X1200 MTs.		1	LS
43	17	Designing of internal ladder with complete Bill of Material and erection procedure. The design and erection procedure should be approved by PESO before start of site activities. No bolting is allowed within the ladder. Bolts can be used to fix the ladder with the attachment of sphere shell. Ladder should be attached with the sphere at the top and bottom end only, intermediate support on the sphere body is not acceptable.\n		1	SU
44	18	Fabrication & Installation of internal ladder: Cutting, welding & fabrication of MS flat & Ms round bar as per PESOapproved drawing and erect MS ladder inside Horton sphere.		7500	KG
45	19	Replacement of Nuts, Bolts, washers and Gaskets : Supply and fixing of all gaskets, studs & nuts for all fittings provided in Spheres.		8	Nos.
46	20	Manual cleaning & Painting of all pipes, valves etc.2 Coats of zinc phosphate & 2 coat of synthetic enamel paint/ Al. finish paint.Total thickness : 100 µm.		1200	Sq.Mtr.
47	21	Cleaning and painting of extrenal surface of Spheres as per following specification 1. Surface Preparation: Clean to SSPC SP2 or as approved by location in-charge (Hand Cleaning, Wire Brushing/ other method) 2. Paint System: One coat of tie coat (two component high build, high solid surface tolerant epoxy maintenance coating 200 microns) + Finish coat -1 coat of 2 pack of Aliphatic Acrylic Polyurethane 55 Microns (F1) 3. Total DFT (Min): minimum 255 micron . 4. The warranty period for this painting will be 5 years.		7500	Sq.Mtr.
48	22	Design,supply,fabrication,fixing of 500mm NB CS forged dish end conforming to SA420 WPL-6. The design drawings are to be approved by PESO by the tenderer. The Thickness of the dish end shall be as per approved design. The item includes cutting existing nozzle as per approved procedure.		8	Nos.

Bottom Crown Modification , Periodic Testing , Certification And Painting Of 6X600 Mt And 2X1200 Mt Lpg Horton Spheres At Kanpur Bp ( Up ) . , Iocl Lpg Bp Kanpur-Uttar Pradesh

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