Tender For Bop Works On Modu Sagar Bhushan-Bop Works / Servicing Are To Be Carried Out On Turnkey Basis , The Installation And Commissioning Of Lmrp And Related Jobs As Detailed Below Including Materials To Be Supplied By Contractor As Specified Below. Refer Annexure Ss03 For Copy Of Po No. 4050013935 And 4010100101. This Job Will Be Done Under The Supervision Of Ongc And M / S. Nov Service Engineer ( Arranged By Ongc ) Subsea Bop Stack Consisting Lower Stack And Lmrp Assembly ( Refer Annexure Ss02 For Drawing ) Make- Shaffer ( Nov ) , Population - 01, Location - Moon Pool Area Following Jobs To Be Carried Out Under Ongc Supervision. Remove Choke And Kill Co-Flex Hoses, Flex Joint Along With Riser Adapter , Upper Annular, Riser Connector, Both Pods, All Lmrp Mounted Bottles From Old Lmrp Frame And Female Stabs. Dismantle All Elements ( Junction Box And Its Fittings, Spms, Hkr, Spm Base Plate, Blinds, Tubings, Kb Plate, Fittings ) Of Both Yellow And Blue Pod. Assemble All New Elements Of Lmrp ( Riser Connector, Upper Annular, Flex Joint With Kick Outs, Female Stabs, Choke And Kill Coflexes, Yellow And Blue Pod, Stack Mounted Bottles 26 Nos. With Racks ) In Lmrp Frame With Claps And Fasteners-Ongc Supply. Connect All Stack Mounted Bottles Hydraulically, Connect All Shuttle Valves, Fittings And Make All The Hydraulic Connctions Of Lmrp With Requred Nos. Of Hoses 2, 1-1 / 2, 1 And 1 / 2 Wp 3000Psi And Function Test. This Job Will Be Done Under The Supervision Of Ongc And M / S. Nov Service Engineer ( Arranged By Ongc ) . A ) Arrangements Prior To Dismantling The Stack I ) Fill The Lower Bop Stack Cavity With Water. Make Up A Drill Pipe Single ( Ongc Supply ) With The Test Stump Locked With Stack Connector. Ii ) Function Test All Of The Bop Functions Except Shear Ram. Iii ) Remove Test Pipe. Function Test Shear Ram. 10 Iv ) Unlock Stack Connector . Remove The Stump. 11 V ) Remove All Bop Function Hoses. Roll, Secure And Safely Store Them To Prevent Any Damage. 12 Vi ) Remove All Bop Shuttle Valves . 13 Vii ) Remove Intervention Panels. 14 Viii ) Remove Any Loose Connected Items. 15 Dismantling Of Bop Stack 16 The Lower Stack Needs To Be Dismantled Into Individual Bop Components To Facilitate Their Servicing. Bop Guide Posts Also Need To Be Fabricated As Specification. The Dismantling Jobs Requires. Scaffolding Around The Stack, Hot Work ( Gas Heating, Gas Cutting And Welding ) , Special Tools And Lifting Crane And Lifting Gears. 17 Required Special Tools To Be Arranged By Contractor. 18 I ) Torque Wrench For Ciw # 27 Bolts. Minimum Torque 12000 Ft- Lb. 2.5 Drive. Drive Sockets ( Ongc Supply ) 19 Ii ) Impact Wrench For Ciw#27 Bolts. 1 ½ Socket Drive. Drive Sockets ( Ongc Supply ) 20 Iii ) Impact Wrench For Ciw#5 , Bop Lock Ring Studs And For Fasteners Of Bop Guide Frame. 1 Drive. Torque 650 Ft Ib. Drive Sockets ( Ongc Supply ) 21 Iv ) Chain Pulleys Of 1 Ton, 2 Ton And 5- Ton Capacity In Sufficient Numbers ( Minimum 2 Quantities Of Each Capacity ) . ( Contractor Scope ) 22 V ) Heavy Duty Spanners Of Various Sizes ( Ongc Supply ) 23 Vi ) Hydraulic Jacks Of 5, 10, 20, Ton With Pump - 2 Nos Of Each Capacity. ( Contractor Scope ) 24 Vii ) Heavy Duty Waterproof Materials For Covering Like Canvas, Tarpaulin In Sufficient Quantity. ( Contractor Scope ) 25 Viii ) General Purpose Machine Tools. ( Contractor Scope ) 26 B ) Choke & Kill Co - Flex Hoses, Flex Joint And Upper Annular 27 I ) Remove Both Co- Flex Hoses From Lmrp. 28 Ii ) Open Ciw#27 Clamp Between Upper Annular And Riser Connector. Pick Up Flex Joint With Upper Annular Bop Lay Down. 29 Iii ) Disconnect Flex Joint From Upper Annular By Opening All Studs Between Them. 30 C ) Fail Safe Valves And Choke And Kill Line Spools 31 I ) Remove All 8 Nos Of Fail - Safe Valves, And C & K Spools. 32 Ii ) Grease Exposed Internal Surface And Cover With Heavy Duty Water Proof Cloth / Canvas Like Tarpaulin. 33 D ) Lower Annular Bop And Bop Mandrel 34 I ) Properly Secure Bop With Help Of Wire Ropes, Lifting Belts, Turn Buckles / Bottle Screws, Shackles, Eye Pads. 35 Ii ) Remove Bop Lock Ring On Top Of Lower Bop Stack By Opening All 20 Nos Hh / C 1.25- 7Unc5 ¾ Lg And 8 Nos Of Hhc 1.25-7Unc 6 ½ Lg Screws. 36 Iii ) Open Ciw#27 Clamp B / W Lower Annular And Upper Dual Ram Bop By Opening 4 Nos Of 2 2 ¾-8 Nos Screws. 37 Iv ) Pick Up Lower Annular With Bop Mandrel And Lay Down. 38 V ) Removed Mandrel Form La By Opening All Studs Between Them. 39 Vi ) Grease Exposed Internal Surface And Cover With Heavy Duty Water Proof Cloth / Canvas Like Tarpaulin. 40 E ) Bop Guide Frame 41 I ) Properly Secure Upper Dual Ram With Help Of Wire Ropes, Lifting Belts, And Turn Buckles / Bottle Screws, Shackles, Eye Pads. 42 Ii ) Remove Leg Bolts Screw Hhc 1 1 / 8 -8Un 6 Lg, 48 Nos Of All Four Bop Posts Between Bop Post And Lower Weldment. Gas Cut Pipe / Angle Support Welded Earlier Adjacent To Guide Post 1 To Lift Bop Guided Frame. 43 Iii ) Remove Bolts Between Main Guide Posts And Bop Upper Spider, Screw Shc 1 8Unc 3 Hg 64 Nos, Screw Hhc 1 -8Unc 4 ½ Lg 16 Nos. Lay Down Upper Spider, All Four Main Posts And Telescopic Pasts. 44 F ) Upper Dual Ram, Lower Dual Ram, Stack Connector And Lower Weldment 45 I ) Properly Secure Bop With Help Of Wire Ropes, Lifting Belts, Turn Buckles / Bottle Screws, Shackles, Eye Pads. 46 Ii ) Remove Upper Dual Ram Then Lower Dual Ram And Thereafter Stack Connector By Disconnecting The Ciw#27 Clamps Between Them. 47 Iii ) Pick Up The Lower Weldment From Bop Carriage. Lay Down The All Components At Suitable Place For Further Servicing. 48 Iv ) Grease Exposed Internal Surface And Cover With Heavy Duty Water Proof Cloth / Canvas Like Tarpaulin. 49 G ) Servicing Of Bop Stack Components The Following Required Special Tools And Consumables Are In Contractor Scope . 50 I ) Torque Wrench For Bop Door Bolts. Minimum Torque= 4500 Ft-Ib, 2.5 Drive. Sockets. ( Sockets Ongc Supply ) 51 Ii ) Impact Wrench For Bop Door Bolts. 1 1 / 2’’ Drive. ( Sockets Ongc Supply ) . 52 Iii ) Impact Wrench. 1’’ Drive. Maximum Torque = 650 Ft-Lb. ( Sockets Ongc Supply ) . 53 Iv ) Heavy Duty Spanner For Bop Door Bolts, Annular Bop Bolts, Various Bolts Of Guide Frame As Per Nut Size, Socket 2 9 / 16” For Ram Holder Bolts, Socket 3 1 / 8” For Bop Door Bolts, Socket 4 ¼’’ For Ciw#27 Bolts ( Ongc Supply ) . 54 V ) Jack Screw 1”- 8Unx10lg -6 Nos, Eye Bolts 1” -8Unc- 2 Nos, Eye Bolts 5 / 8”11Un -2 Nos ( For Spherical Bop ) . 55 Vi ) Lifting Gears Chain Pulleys, Shackles, Wire Ropes, Lifting Belts 56 Vii ) Fabricated Steel Structures For Hydraulic Jacking Arrangements ( As Per Requirement ) . 57 Viii ) Hydraulic Jacks Of 100-Ton Capacity And Its Pump – 2 Nos. 58 Ix ) High Pressure Hydraulic Pump Of Minimum Rwp Of 10, 000 Psi For Various Bop Pressure Testing With Calibrated Chart Recorder ( 0 To 10, 000Psi ) With Compatible Graph Paper. 59 X ) Electric / Pneumatic Buffers With Buffing Wheels Of Various Types And Sizes For Surface Rust Removal. 60 Xi ) Threaded Lifting Eyes As Per Requirement During Servicing. 61 Xii ) Low Pressure Air ( 90 To 120 Psi ) Supply. High Pressure Water Supply For Surface Cleaning. 62 Xiii ) Consumables ( As Per Requirement During Servicing ) - Water Resistant Protective Grease, Never Seize Grease For Bolts, Cotton Rags, Sand Papers, Wd40, Diesel , Stack Magic Bop Fluid ( Stack Magic Fluid Ongc Supply ) , Epoxy Adhesives, Polypropylene / Nylon Ropes 10 Mm. 63 Xiv ) General Machine Tools. 64 H ) Lower Dual Ram 65 I ) Open All Four-Ram Doors And Remove All Four Ram Blocks. 66 Ii ) Remove Ram Holders. Discard Old And Damaged Ram Rubbers. 67 Iii ) Clean Thoroughly And Buff All Dismantled Rusted Components Including Ram Cavity. 68 Iv ) Fit New Ram Rubbers ( Ongc Supply ) And Assemble The Ram Blocks With Lower Dual. 69 V ) Apply Water And Weather Resistant Protective Grease Thoroughly Inside The Ram Cavity Surface And Ram Blocks. 70 Vi ) Close The Ram Doors After Replacing Door Seals ( Ongc Supply ) And Tightened All Bolts To The 4500 Ftlb Torque. 71 Vii ) Function Test At 1500 Psi ( With Drill Pipe ) . Plot The Graph At Chart Recorder. 72 Viii ) Cover All The Ciw Hubs. 73 Ix ) External Surfaces Preparation And Painting As Per Marine Environment. 74 I ) Upper Dual Ram 75 I ) Open All Four Ram Door And Remove All Four Ram Blocks. 76 Ii ) Remove Ram Holders. Discard Old And Damaged Ram Rubbers. 77 Iii ) Buff And Thoroughly Clean All Dismantled Components Including Ram Cavity. 78 Iv ) Fit New Ram Rubbers ( Ongc Supply ) And Assemble The Ram Blocks With Upper Dual. 79 V ) Apply Water And Weather Resistant Protective Grease Thoroughly Inside The Ram Cavity Surface And Ram Blocks. 80 Vi ) Close The Ram Doors After Replacing Door Seals ( Ongc Supply ) And Tightened All Bolts To The Specified Torque ( 4500 Ft-Lb ) . 81 Vii ) Function Test Vbr At 1500Psi ( With Drill Pipe ) And Sr At 3000 Psi ( Without Drill Pipe ) . Plot The Graph At Chart Recorder. 82 Viii ) Cover All The Ciw Hubs. 83 Ix ) External Surfaces Preparation And Painting As Per Marine Environment. 84 J ) Annular Bop – 2 Nos 85 I ) It Is Preferable To Place Annular Bop Under Overhead Crane Assistance Of Minimum Load Capacity 18 Ton As The Job Requires Proper Alignment And Frequent Use Of Lifting Operation. 86 Ii ) Dismantle Annular Bop To Its Individual Components. Make Arrangement For Hydraulic Jacking. 87 Iii ) Clean And Buff Thoroughly Of All Rusted Components. 88 Iv ) Replace All Seals And Wear Rings ( Ongc Supply ) . 89 V ) Reassemble The All Components With New Annular Element ( Ongc Supply ) With A Fine Coating Of Grease On Exposed Surfaces. 90 Vi ) Function Test At 1500 Psi And Plot The Graph On Chart Recorder. 91 Vii ) Surface Preparation Of External Surfaces And Painting As Per Marine Enviroment. 92 K ) Fail Safe Valves – 8 Nos And Choke And Kill Line Spools 93 I ) Dismantle All 8 Nos Of Fail-Safe Valves. 94 Ii ) Clean And Buff Thoroughly All Components. 95 Iii ) Clean The Components. Grease And Assemble The Valves With New Seals. 96 Iv ) Fill Valves With Chemola Grease ( Ongc Supply ) Or Equivalent. 97 V ) Carry Out Function Test Of All Valves At 1500 Psi And Plot The Graph At Chart Recorder. 98 Vi ) Carry Out Pressure Test Of All Fail Safe Valves With The Help Of Blind Hub And Testing Hub At 200 Psi And 7, 500 Psi. Plot The Graph. 99 Vii ) Carry Out Visual Inspection And Ndt Of Choke And Kill Line Spools As Per Nov Report After Cyclone. If Damaged Fabricate / Procure As Per Specification ( Contractor Scope ) . 100 Viii ) Cover All Ciw#5 Hubs. 101 Ix ) External Surfaces Preparation And Painting As Per Marine Environment. 102 L ) Bop Guide Frame 103 Bop Guide Frame Is Severely Damaged During Cyclone. The Major Jobs Involve Fabrication Of Guide Posts, Telescopic Posts, Replacement Of Fasteners As Per Provided Drawing And Specification. 104 I ) Specification Of Steel Materials To Be Supplied By Contractor. Quantity / Length Of Material As Per Physical Sample Onboard. ( Below Given Approxmate Sizes ) 105 • Pipe 12’’* 5M Sch Xxs Astm A106-B -4 Nos 106 • Plate 5 / 8’’ * 1M * 1M Astm A516-70 -4 Nos 107 • Plate 1’’ * 1M * 1M Astm A516-70 -4 Nos 108 • Plate 2’’ * 1M * 1M Astm A516-70 -4 Nos 109 • Plate 1 / 2’’* 1M * 1M Astm A516-70 -4 Nos 110 • Beam 18 X 50 Astm A572-50 -2 Nos 111 • Beam 18 X 50 Astm A572-50 -2 Nos 112 • Square Bar ¾’’ * 1 Astm A529-50 - 100 Nos · 113 . Round Bar 1’’ C1018-- 100 Nos 114 • Pipe 8’’ * 3 M Sch 80 Astm A106-B--4 Nos 115 • Round Bar 5 / 8’’ --10 M 116 Ii ) Following Required Fasteners To Be Supplied By Contractor. 117 • Screw Hhc 1-1 / 8’’ - 8Un X 6’’ Lg Cad Plt - 48 Nos. 118 • Nut Hex 1-1 / 8’’ -8Un A194gr4 / 7 Cad Plt - 96 Nos. 119 • Washer Flat 1-1 / 8’’Cad Plt – 96 Nos. 120 • Washer Lk Helical Spring 1-1 / 8’’ – 96 Nos 121 • Screw Shc 1’’ - 8Unc X 3’’ Lg Cad Plt A320grl7 - 64 Nos. 122 • Screw Hhc 1’’ - 8Unc X 4 1 / 2’’ Lg Cad Plta320grl7 - 16 Nos. 123 • Nut Hex 1’’ -8Unc-2B A194gr4 / 7 Cad Plt +Nn - 80 Nos. 124 • Washer Flat 1’’Cad Plt – 160 Nos. 125 • Washer Lk Helical Spring 1’’ Cad Plt – 80 Nos 126 • Screw Hhc 3 / 4’’ - 10Unc X 3’’ Lg A320grl7 Cad Plt - 48 Nos. 127 • Nut Hex 3 / 4’’ -10Unc Cad Plt - 48 Nos 128 • Washer Flat 3 / 4’’Cad Plt – 96 Nos. 129 • Washer Lk Helical Spring 3 / 4’’ – 96 Nos 130 Iii ) Complete Renewal Of Bop Main Guide Post -4Nos As Per Sample / Given Specification / Drawing. 131 Iv ) Renewal Of 4 Nos Telescopic Posts As Per Sample / Given Specification / Drawing. 132 V ) Assemble Four Renewed Guide Posts And Telescopic Posts With Upper Weldment. 133 Vi ) Ndt Of All Ciw#5 &Ciw#27 Clamps And Studs. Replace If Found Damaged. Replace All The Fasteners Of Ciw#5. 134 V ) Painting Of All Items As Per Marine Environment. 135 M ) Stack Connector 136 I ) Dismantle Stack Connector To Its Individual Components. 137 Ii ) Check The Conditions Of Liners Pistons, Springs Etc. 138 Iii ) Replace Rubber Seals And Damaged Parts ( Ongc Supply ) . Assemble The Stack Connector. 139 Iv ) Grease The Stack Connector With Aico Ep 73 ( Ongc Supply ) Grease From Both Grease Outlets. 140 V ) Place The H4 Test Stump Under Stack Connector, Make Up And Lift The Stump With The Help Of A Drill Pipe Pump Joint. 141 Vi ) Carry Out Function Test At 1500 Psi Of All Lock And Unlock Functions And Plot The Graph At Chart Recorder. 142 Vii ) Apply Grease Thoroughly At Inside Exposed Surfaces And Cover The Ciw Hubs Of Stack Connector 143 Viii ) Surface Preparation And Painting As Per Specification And Marine Environment 144 N ) Assembly Of Lower Bop Lower Stack 145 I. Assemble Up To Lower Dual Ram As Per Standard Procedure With Fest Stump Below Stack Connector. 146 Ii. Pressure Test Kpr And Upr At 200 Psi And 7500 Psi. Plot The Graph. 147 Iii. Assemble Upper Dual Ram On Top Lower Dual Ram. 148 Iv. Pressure Test Vr And Sr At 200 Psi And 7500 Psi. Plot The Graph. 149 V. Assemble Bop Guide Frame And Lower Annular. 150 Vi. Pressure Test La At 200 Psi And 5000 Psi. Plot The Graph. 151 Vii. Make Up Bop Lock Ring. Tighten All Studs. 152 Viii. Assemble All Fail Safe Valves With C & K Line Spools. 153 Ix. Test Fail Safe Valves And Choke And Kill Line Spools At 200 Psi And 7500 Psi. Plot On Graph Paper. 154 X. Fill The Wellbore Cavity With Bop Stack Magic Fluid ( Ongc Supply ) With Stump Locked At Stack Connector. 155 Ss2101009 Remove Y-Block From Flex Joint, Transport To Work Shop, Build -Up, Machining And Thread Making As Per Threads Of Test Plug In Riser Adapter Choke And Kill Y-Blocks 2 Nos. Pressure Test And Fit Them Back. Refer The Drawing For Detail- Qty-4 Nos 156 Ss2101010 Fabricate One Nos. Rack For Lower Annular Surge Bottle With Ms Plate 10Mm 157 Fabricate Pod Stand 2 Nos. With 2 Sch-80 Ms Galvenised Pipe As Per Sample. 158 Painting And Marking On Lmrp And Bop Stack After Jet Washing. White Epoxy Marine White Paint And Black Paint For Marking. 159 Materials: Required Materials To Be Procured, Supplied And Fitment In Contractor Scope. As Specified Below. 160 Fitting 2 Nptx 2 Jic Ss 316 , Qty 4 Nos Ss2101011 161 Hose 2 Wp3000 Psi Wire Braided With Jic Swivel Female Ss 316Crimp Fitings At Ends 5Feet, Qty 1 No 162 Hose 2 Wp3000 Psi Wire Braided With Jic Swivel Female Crimp Fitings Ss 316 At Ends 8Feet, Qty 1 No 163 Anode, Mod, 25X4-1 / 2X2-1 / 2 P / N 20081179 , Qty 40 Nos 164 1 Wire Braided Hose Wp 3000 Psi 200M Length , Qty 1 No 165 1 Jic Female Swivel Crimp Fittings Ss 316 For 1 Wire Braided Hose Wp 3000 Psi , Qty 150 Nos 166 1 / 2 Wire Braided Hose Wp 3000 Psi 300M Length , Qty 1 No 167 1 / 2 Jic Female Swivel Crimp Fittings Ss 316 For 1 / 2 Wire Braided Hose Wp 3000 Psi , Qty 150 Nos 168 1-1 / 2 Wire Braided Hose Wp 3000 Psi With 1-1 / 2 Jic Female Swivel Crimp Fitting Ss 316 On Ends Sizes Of Hose: 11 Feet , Qty 5 Nos 169 1-1 / 2 Wire Braided Hose Wp 3000 Psi With 1-1 / 2 Jic Female Swivel Crimp Fitting Ss 316 On Ends Sizes Of Hose: 12 Feet , Qty 2 Nos 170 1-1 / 2 Wire Braided Hose Wp 3000 Psi With 1-1 / 2 Jic Female Swivel Crimp Fitting On Ends Ss 316 Sizes Of Hose: 13 Feet, Qty 1 No 171 Size 2 Sch-80 Ms Galvenised Pipe - 40 M 172 Ms Plate 10Mm - 1 Sq. Mtr 173 Dm2101425 Fabricate The Corner Stopper / Wedges For Bop Carriage And Lmrp Carriage - 4 Nos. Each For Lmrp And Bop Carriage As Per The Sample To Be Supplied By Contractor. Material Of The Stopper As Per The Manual Ah36 Grade. Fasteners Also To Be Provided As Per Sample.
