| 1 | 1 | Degassing and cleaning of Storage vessel with IOCL supplied water after making necessary connections for in and out flow with suitable pipelines/hoses arrangement as directed on site. The water used fordegassing should be disposed off safely in the drainage and the sludge if any found shall be carefully removed and disposed/kept in safe place as directed at site. The sludge shall be handled wet and buried as per the direction of the engineer in-charge for avoiding ignition of pyro-phoric iron compounds, if any. If required a sample of sludge shallbe submitted to the plant. | Item - 1 | 2 | SU |
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| 2 | 2 | Disconnecting the inlet, outlet of the Horton Sphere LPG liquid & vapour lines, SRV, Manhole, drain line, globe valves, ROV, HLA, Servo gauges and other fittings and disconnections of electrical cables wherever required to enable easy approach to all the areas inside the entire Horton Sphere. Any damage during de-box up / box up, the same shall be made good by the contractor at his own cost. | Item - 2 | 2 | SU |
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| 3 | 3 | Providing MS tubular ladder / scaffolding inside of the Horton Sphere suitably for cleaning of inner surface and for suitably carrying out all Statutory NDT testing like UFD, UTG, MPI, Hardness, DPT etc. as required under SMPV(U) Rules. Contractor has to arrange all equipmentsand consumables required for carrying out the job. Suitable arrangementby way of providing blower / exhaust fan and breathing apparatus, safetybelts for working personnel is to be made by the contractor as required. | Item - 3 | 2 | SU |
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| 4 | 4 | Providing flameproof lighting arrangement inside the Storage vessel for carrying out necessary inspection, cleaning and NDT Tests. Contractor tosupply the flameproof light fittings, junction boxes, required cablesetc., as directed at site. | Item - 4 | 2 | SU |
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| 5 | 5 | Thorough Cleaning of inner surface of Horton Sphere wherever required with water jets and clearing the sludge/rust material followed by thorough cleaning to remove the scale and dust by suitable means (wirebrush, buffing machine etc.) to expose the metal surface and thorough buffing of weld joints. The contractor has to provide all equipments and consumables for carrying out the cleaning jobs. Localised grinding ofthe welds to be done if required as directed by third party Inspecting Agency / IOC Site Engineer. | Item - 5 | 2 | SU |
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| 6 | 6 | Visual Examination: 100% Visual externalSurfaces for observation of any surface defects, weld defects, corrosion, pittings or otherwise physical / material defects etc. | Item - 6 | 2 | SU |
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| 7 | 7 | Ultrasonic thickness measurement on all Crown & Petal Plates, LPG pipelines and nozzles as per ASTM-A-578, ASTM-E-797 or other applicable codes and meeting all requirements of PESO. Ultrasonic Thickness Gauging (UTG). As per ASTM-E-797 around and on each nozzle-neck at four quadrants. Including LPG Pipelines upto 1st flange. | Item - 7 | 2 | SU |
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| 8 | 8 | UFD (Ultrasonic flaw detection) to check any internal defects of Hortonsphere weld joints on \na) 100 % \"T\" joints from inside \nb) Middlecircumferencial seam, bottom,& Crown weld, Internal 100%, \nc) Nozzle weld # neck to shell, Internal: 100% as per ASTM E # 577, Sec V Art. 4,5,23, Sec VIII Div 1 & 2 not less than 25 % covering and as applicable codes and meeting all requirements of PESO. | Item - 8 | 2 | SU |
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| 9 | 9 | WFMPI ( Wet fluorescent Magnetic particle Inspection) of weld joints of Horton spheres, including nozzle joints to check any surface /subsurface defects or linear type of indications over the welds covering HAZ on 100 % circumferential and longitudinal weld joints from inside and on outside portion exposed encompassing the nozzle welds etc and on weld joints of all nozzles, manholes, RF pads to shell wherever applicable (externally exposed weld) as per ASTM-E-709 and meeting all requirements of PESO.\n | Item - 9 | 2 | SU |
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| 10 | 10 | Hardness testing to check hardness value of welds, parent metals and HAZ on selected spots on welds, HAZ and parent metal in each accessible areaas per ASTM E - 110 and meeting all requirements of PESO | Item - 10 | 2 | SU |
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| 11 | 11 | Dye-Penetrant Test to check any surface defects over welds. Covering HAZ( heat affected zone) of all nozzles, manholes etc. for defects like porosity, cracks etc as per ASTM E-165-80 and meeting all requirements of PESO. | Item - 11 | 2 | SU |
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| 12 | 12 | Radiography test for weld joints as supporting test in case of defects observed if any in WFMPI as per ASTM-E-94 or applicable codes (12 Inch exposure). | Item - 12 | 2 | SU |
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| 13 | 13 | Dismantling the blind flanges, pipe joints of LPG Horton Sphere as required and thorough cleaning of the joints, fixing new supplied gaskets, studs and nuts (Supplied by contractor) and fixing back all the connected line valves including excess flow check valves, safety valves after testing and other instruments like servo gauge, HLA etc. fitted to the vessel and complete all such jobs in all respects to make the LPG Horton Sphere ready for commissioning after completion of inspection andtesting of LPG storage vessels duly certified by CCE approved parties. All tools, tackles and consumables required for the job is to be provided by the contractor. After commissioning of the LPG storage vessels, the work site is to be cleared of all debris to enable free and easy movement of operating personnel as per the instruction at site. Carry out leak testing of all flanges before commissioning. Finally correctness of level gauges has to be established. All gaskets and bolts will be supplied by M/s IOCL. | Item - 13 | 2 | SU |
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| 14 | 14 | Carrying out hydro testing/ Stretch test of LPG Horton Sphere at a specified test pressure as per design code up to first isolation valveas per ASME Sec VIII, Div I and relevant code after successful completion of all NDT as per SMPV Rules, using the IOCL supplied water and draining the water after completion of Hydro testing. Work also includes checking of settlement using dumpy level or theodolite during slow and gradual water filling operation in LPG Storage vessels. | Item - 14 | 2 | SU |
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| 15 | 15 | Surveillance by T.P.I.A, submission of inspection Dossier (4 numbers),Certification Under Rule 19 by recognized Third Party Inspection Agency (T.P.I.A.) submission of Inspection Dossier sketches / drawings withStatutory Certification under rule 19 of SMPV( U) Rules, 1981 | Item - 15 | 2 | SU |
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| 16 | 16 | Calibration of the Horton Sphere 2 x 600 MT and submission of calibration of certificate. | Item - 16 | 2 | SU |
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| 17 | 17 | PAINTING: \n1. Surface Preparation: Clean to SSPC SP2 or as approved by location in-charge (Hand Cleaning, Wire Brushing/ other method) \n2. Paint System: One coat of tie coat (two component high build, high solidsurface tolerant epoxy maintenance coating 200 microns) + Finish coat-1 coat of 2 pack of Aliphatic Acrylic Polyurethane 55 Microns (F1)\n3.Total DFT (Min): minimum 255 micron.\n4. The warranty period for this painting will be 5 years. \n5. Total outer surface area of Horton Sphere including catwalk, Structure, Staircase, pipeline near Horton Sphere area upto 1st isolation valve, Sprinkler line and Air network around sphere upto deluge valve. \n6. Rate should be including outside tubular scaffolding for painting with all safety arrangements for contract worker.Approved make for Paints: Asian/Berger/Shalimar or as approved by EIC | Item - 17 | 1600 | SQM |
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| 18 | 18 | Supply and fixing of all metal spiral gaskets (300Class) and stud (as perASTM A193 Grade-B7) Nuts(as per ASTM A 194 Grade-2H) upto 1st valve. | Item - 18 | 2 | SU |
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| 19 | 19 | Carrying out complete Residual Life Assessment of the Horton Sphere & to be vetted by a Govt. institution like IITs, NITs, Regional Engineering Institutes, etc. | Item - 19 | 2 | SU |
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