Bids Are Invited For Custom Bid For Services -Hydro Testing of CNG Cascade --1) Assam: Detail of CNG cascades installed at CNG stations of AGCL is enclosed as AnnexureI. Scope of Work for cascade hydro testing work is as below: 1) Hydro stretch testing, cleaning, painting and certification of CNG cascades (static 40 /60 cylinders in each cascade of 75 WL each cylinder capacity). All the work executed shall be strictly in accordance with latest editions of IS 5844, IS7285, OISD 179 and Gas cylinder rules 2004 & its amendment 2016. 2) Dismantling/re fitment and loading/un loading of CNG cascades at both AGCL sites and at contractor’s workshop is in the scope of contractor. Arrangement of crane/hydra, transportation vehicle all are in the scope of service provider. Proper commissioning of tested cascade at AGCL site is sole responsibility of service provider along with all tools & tackles, labour etc. 3) Dismantling, refitment of CNG cylinders from/to cascades including testing of SS tubing of the cascade after re fitment is in the scope of contractor. 4) Replacement of all 40 nos /60 nos. of burst discs is mandatory in all cascades and in the scope of contractor under hydro testing. Contractor is required to include the rate of burst discs in hydro testing work. No additional payment will be given against replacement of burst discs. 5) Replacement of supporting rubber packing of all 40 nos./60 nos of cylinders is mandatory in all cascades and in the scope of contractor under hydro testing. No additional payment will be given in this regard. 6) Payment against replacement of chargeable spares found damaged/needs replacement during hydro testing will be on actual basis as per approved price list of spares and certified by AGCL engineer in charge. Quoting the rates of chargeable spares in attached chargeable spare list is compulsory. 7) Transportation charges: Transportation charges from AGCL CNG stations to contractor’s workshop and contractors’ workshop to AGCL CNG stations are in the scope of contractor for all sites in the state of Assam. 8) Transit Insurance charges: Transit insurance charges from AGCL CNG stations to contractors workshop and contractors’ workshop to AGCL CNG stations are in the scope of contractor. 9) After hydro testing, tag plate shall be installed on cascade having following details: a) Cascade Sl. No. b) Cylinder Nos. (from/to) c) Hydro testing date d) Next due date e) Year of supply 10) Stickers written with “CNG” (white base/Green words) shall be pasted on each cylinder after painting. 11) Punching of hydro testing date on cylinder neck is not allowed. Metal plate (challa) mentioning the hydro test date and next due date shall be fixed on each cylinder valve. Shape and colour coding of circular plate to be fixed on cylinder valve shall be as per Gas Cylinder Rule 2004 & its amendment in 2016. Safety precautions during loading/un loading & transportation/Hydro testing of CNG cascades As some of the CNG cascades are kept above the roof (height), safety precautions are required for safe loading/unloading and transportation of CNG cascades for hydro testing from CNG stations to hydro test facility and hydro test facility to CNG stations. To ensure the safety during loading/un loading and transportation and hydro testing, following are required from vendor before start of hydro testing work/During hydro test work: 1) Crane/hydra fitness certificate. 2) Driving license of crane/hydra driver and valid registration documents of crane/hydra. 3) Vehicle used for transportation shall be closed type along with valid registration documents. 4) Driving license of vehicle driver. 5) Test/calibration certificates of equipment’s/instruments used for hydro testing. 6) Hydro test procedure as per codes and standards prescribed by PESO, Govt. Of India. 7) Dismantling of cylinders and SS/brass tubing and fittings and its testing and re fitment shall be carried out by trained and competent technicians. If any problem will occur during installation of cascade at site after hydro testing, it shall be rectified by vendor free of cost. 8) All the Manpower working in the Job should in proper PPE’s . DETAILED SCOPE OF WORK 1. Safe Degasifying & dismantling of tubing and other accessories of Cascade at AGCL’s specified location/ sites is in Bidder’s scope. 2. Loading of cascade by Hydra/ Crane shall be carried out by bidder from / at specified locations/sites of AGCL. 3. Loading of Cascade by Hydra/Crane in Bidder provided Transport vehicle. 4. The entire responsibility of cascade such as safe transportation of cascade on road, transit insurance, third party insurance etc. shall be in the scope of the Bidder till the same is reinstalled in the AGCL’s site successfully after hydrotesting. 5. Unloading of CNG Cascade by Hydra/Crane at Bidder’s Premisesshall be in Bidder’sscope. 6. Dismantling all Fittings, Tubes & Cylinders. 7. Opening Valves, De-gassing the Cylinders and Nitrogen Purging to vent out the complete gas. 8. Hot water cleaning of the cylinders from inside and weighting the Cylinders. 9. Hydrotesting of Cylinders as per standard by Water Jacket Method. 10. Internal Blasting and Vacuum Cleaning of Cylinders. 11. External Blasting of Cylinders and Frame Structure. 12. Cascade painting as per relevant Standards. 13. Check the good working Condition of Valve and Pneumatic testing of each valve, inspection of Threading, Burst disc, tunings and fittings. 14. Inspection of canopy and repair if required. 15. Dismantling & Re-Installation of cylinder valve with proper torque. 16. Repairing of Cylinder clamps and replacement of nuts with new one. 17. Any other repairing, if required, is/are to be done by Bidder with a prior approval of the owner. Supply of required spares is/are in the scope of Bidder. However, payment of spare/s will be made based on SOR rate. 18. Re-manifolding of cascade by using existing tubing & fitting as per cascade piping schematic diagram. 19. Pneumatic Testing of Tubing after assembling at Working Pressure. 20. Replacement of existing Burst Disc with Vanaz make Burst Disc. All necessary modifications required for the same shall be in Bidder’s scope. 21. All necessary spares required for the modification will be in Bidder’s scope. However, payment of spare/s will be made based on SOR rate. 22. All necessary maintenance of the cascade after hydrotesting will be in Bidder’s scope. Supply of required spare/s are in the scope of Bidder. However, payment of spare/s will be made based on SOR rate. 23. The scope/specification covers the minimum specified requirement for the various activities to be carried out by the bidder toward the Cascades (Complete Structure with Assembled Cylinders, Tubes & Fittings) / CNG cylinders Re-Testing and related works. 24. Workshops recognized by Petroleum and Explosives organization as “CNG cylinder testing stations” can only test cascades. Bidder shall have valid authorization from Petroleum of Explosives and Safety Organization (PESO) for CNG cylinder retesting. The authorization should be valid during the tenure of Hydrotesting. Bidder along with the bid shall submit valid authorization letter from PESO. Bidder along with the bid shall also submit details of testing equipment available with them. AGCL may inspect testing facility of bidder for ascertaining its capability. Bidder shall inform AGCL within 24 hrs, if PESO issues any objection on the certification for hydrotesting. AGCL reserves the right to check the certificate at any time during the contract period. 25. Bidder shall, with due care diligence, execute the work in compliance with all laws, bylaws, ordinances, regulations etc. and provide all services and labour inclusive of supervision therof. 26. All the materials, equipment, appliances or other things of whatsoever nature required in or about the execution of the work, whether of temporary or permanent nature shall be provided by the bidder. 27. Bidder shall provide cylinder testing certificate along with PESO certification of workshop and Test Reports (performed on the cascades) along with bill/cascade. 28. Bidder shall agree to indemnify ACGL directly or indirectly any loss or injury caused to ACGL employee/agent/customer/public due to careless, negligent, inexperienced act or default of the Bidder, his/her agents, representatives or employees. AGCL/EIC shall be the sole judge as regards the quantum of loss or damage and it shall be entitled to deduct from the amounts payable hereof to the Bidder, the cost of repairs or the amount of loss or damages. Further bidder shall be responsible for indemnity of AGCL’s Cascade/cylinders. If the works are not done as per EIC’s satisfaction then bidder shall do the necessary rework at his own cost. The cascade after testing has to be transported to concerned site , unloaded, reconnected, leak checked and taken in service by the Bidder. However, if any leakage or any other fault/issue arises during startup shall, Bidder shall rectify the same without any additional cost. 29. In case of any hazard like fire, leakage etc. due to gross negligence of the Bidder at AGCL’s premises, AGCL reserves the right to impose penalty up to the actual damage cost and/or termination of work order depending upon the gravity of the situation. 30. Bidder shall keep the photographs of the cascades as a proof of the condition of the cascade after dismantling. 31. Bidder shall carry out transportation of cylinder and cascade from AGCL’s location to their work premises. 32. The Bidder shall submit to AGCL the statutory approval certificates of PRDs & Valves. The bidder has to provide the certificates regarding suitability of the valves & PRDs for CNG application from the OEM for these items. 33. Bidder shall carry out cascade hydro-stretch testing as per the gas cylinder rule 2016 and subsequent amendment. Hydro-stretch testing job has to be completed as per IS 8451 ( Water Jacket Method ) with future amendment. 34. Bidder shall carry out ultrasonic testing of cylinders as per IS 8451: 2009 amendment no 1 st May 2013. 35. Bidder must have all the required instruments, i.e. high-pressure pump, drying unit, ultrasonic thickness measuring instruments, baroscopic camera, oxygen analyzer, rolling machine for internal and external cleaning, sand blasting machine & other required instruments to carry out the jobs. Bidder shall submit list of such tools. 36. The indicative steps/procedure is as given below along with Process Flow Chart. a) Degasifying CNG Cascade at AGCL site/ specified locations. b) Safe dismantling of tubing’s of CNG Cascade at AGCL site/ specified locations. c) Loading of CNG Cascade at Transport Vehicle via Hydra/ Crane. d) Transportation of CNG Cascade safely to the Bidder’s Premises. e) Unloading of CNG Cascade by Hydra/Crane at Bidder’s Premises. f) Depressurizing Cascade safely to make it hydrocarbon free. g) Safe dismantling (disconnection of all pipe fittings) of the Cascade after depressurizing. h) Dismantling all Fittings, Tubes & Cylinders. i) Opening Valves, De-gassing the Cylinders and Nitrogen Purging to vent out the complete gas. j) Hot water cleaning of the cylinders from inside and weighting the Cylinders. k) Bidder shall carry out cascade hydro-stretch testing as per the gas cylinder rule 2016 and subsequent amendment. Hydro-stretch testing job has to be completed as per IS 8451 ( Water Jacket Method ) with future amendment. l) The Normal operating pressure of CNG Cylinders is 260 Kgf/cm2 and testing shall be carried out at 435 Kgf/cm2 or as mentioned in the cylinder m) Bidder shall carry out Internal Blasting and Vacuum Cleaning of Cylinders. n) The interior of each cylinder shall be thoroughly dried by a suitable method at a temperature not exceeding 300⁰C immediately after hydraulic pressure testing, so that there is no trace of water. The interior of the cylinder shall be inspected to ensure that it is dry and free from other contaminants. o) Bidder shall carry out External Blasting of Cylinders and Frame Structure. p) Cascade painting as per relevant Standards. q) Check the good working Condition of Valve and Pneumatic testing of each valve, inspection of Threading, Burst disc, tunings and fittings. r) Inspection of canopy and repair if required. s) Dismantling & Re-Installation of cylinder valve with proper torque. t) Repairing of Cylinder clamps and replacement of nuts with new one. u) Any other repairing, if required, is/are to be done by Bidder with a prior approval of the owner. Supply of required spares is/are in the scope of Bidder. However payment of spare/s will be made based on LIST OF SPARES ON CHARGEABLE BASIS rate. v) Re-manifolding of cascade by using existing tubing & fitting as per cascade piping schematic diagram. w) Pneumatic Testing of Tubing after assembling at Working Pressure. x) After connection of the tubing, Pneumatic Leak Testing of the cascade is to be carried out at full pressure for 4 Hrs by Bidder’s Personnel in presence of AGCL’s representative. y) All necessary maintenance of the cascade after hydrotesting will be in Bidder’s scope. Supply of required spare/s are in the scope of bidder. However, payment of spare/s will be made based on SOR rate. z) Loading of cascade by Hydra/Crane in Bidder provided transport vehicle. aa) Transportation (to & fro) of cascade will be in Bidder’s scope. bb) Loading of Hydrotested CNG Cascade by Hydra/ Crane at original AGCL site/ specified locations. cc) Reconnection of CNG Cascade & Leak check and taken in service by Bidder. -- Total Quantity :
