INSPECTION PACKAGE SCOPE FOR NHGU TURN AROUND

(JANUARY 2017)

A) GENERAL REQUIREMENTS:

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.

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B) SCOPE OF WORK:

The scope of work 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.

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.

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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. 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. 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.

C) 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.

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 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.

D) 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.

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 ANNEXURE-1

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.

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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.
c) All connected nozzles neck thickness in four compass directions.
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.
c) All connected nozzles neck thickness in four compass directions.
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.

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 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.

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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 %.

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 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
MPT (battery operated machine)
ECT (battery operated machine)
RFET(battery operated machine)
SWUT (Shear Wave Ultrasonic
Testing :- Battery operated machine)
Specialized inspection/ NDE services
for Reformer tubes.
Radiography
Ultrasonic thickness measurements
In-situ metallography machine and
technicians for obtaining
metallography for heater tubes and
other high temperature
Equipment.
2 TEAMS (2 persons per team)
1 TEAM ( 2 persons per team) with 3 machines
i.e. each team will have a machine
2 Machines with respective teams
2 Machines with respective teams
1 team and equipment for scanning
1 team with all equipment and consumables for
external /internal inspection of all tubes and
RLA.
2 nos. Sources (Min. strength 5 Curies) with
respective team of 3 persons for each source.
9 teams with machines (2 persons per team)
1 team and equipment (battery operated).

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.

12) 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.

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 ANNEXURE-2

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.

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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.

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