ATTACHMENT- 1

SCOPE OF WORK- GENERAL REQUIREMENTS

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1.1 SUMMARY OF WORK

Undertake planned Turnaround maintenance work of the Train III COMPLEX

consisting of {Crude Distillation Unit - 3 and Vacuum Distillation unit
(CDU-3/ VDU), Hydrocracker ( HCU), New Hydrogen Generation Unit (
NHGU) & Lube Oil Base Stock Unit ( LOBS) and Train III Sulphur
Recovery Unit (SRU) complex along with Sour Water Stripper (SWS) &
Amine Treating Unit ( ATU) at Bharat Petroleum Corporation Ltd., Mumbai
Refinery.
The work scope consists of spading / despading, removal / replacement of
insulation, opening , cleaning, testing, lining, inspection, repairs , and all jobs as
per scope of work , boxing up and other miscellaneous works as summarized in
the submitted Bill of Quantities , and as directed by the Engineer in Charge .
The Shutdown Mechanical work programme shall be commenced tentatively in
Feb 2017 .Completion of all shutdown works required for the plant start-up,
commissioning is envisaged as set forth in Appendix H. However, the planned
shutdown commencement date may vary from the actual required date due to
operational requirements, but not to a significant extent.

1.2 COORDINATION BY CONTRACTOR WITH OTHER CONTRACTORS

1.2.1 The CONTRACTOR shall be entirely responsible for the coordination, proper
execution and COMPLETION of the WORK. CONTRACTOR will be required to
coordinate with other contractors who are directly employed by OWNER. The
CONTRACTOR shall coordinate the work of each discipline with that of all other
disciplines and shall ensure that all disciplines co-operate to assure the required
and steady progress of all work under the CONTRACT. The CONTRACTOR shall
plan his activities in such a way that there will be no interference between the
other contractors. OWNER will not be responsible for any additional cost or time
sustained by the CONTRACTOR by failure to coordinate with other contractors.
1.2.2 All Sub Contractors appointed by the CONTRACTOR shall be approved by
OWNER.
1.2.3 The CONTRACTOR shall as required by the Engineer In Charge participate in
regular co-ordination meetings with other contractors. The CONTRACTOR shall
if required, provide additional information to other contractors in this regard to
ensure proper co-coordinated sequencing of the Shutdown Project.

1.3 REGULATORY REQUIREMENTS

1.3.1 All plant, machinery, equipment, tools, consumable and workshop shall be in
accordance with clause no.22 of SCC.
1.3.2 Scaffolding work shall be erected in accordance with BPCL Safety Regulations.
1.3.3 All scaffold pipe and fittings shall conform to IS 1161 & IS1362 and timber scaffold
boards shall not be permitted.

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 1.4 IDENTIFICATION SYSTEM
Security and Identification of items removed for Overhaul Inspection.
The CONTRACTOR is to ensure complete Protection, Sealing and Tagging of all
items removed for overhaul or inspection. Particular attention is to be paid to
relief valves, control valves, open ended pipe work, heat exchangers parts and
heater burners. The CONTRACTOR shall supply wear proof tags which shall be
suitably marked with the Tag No. and date removed. These tags shall be
attached by wire to items of equipment and associated flanges before removal.

1.5 REFERENCE
Standard specifications, Codes and Practice and Regulations.
All relevant Standards, Codes of Practice and regulations shall be strictly adhered
to. The following abbreviations which are used for Standard Specifications:

API SPEC - American Petroleum Institute Specification.

ASTM - American Society for Testing and Materials.
ANSI - American National Standards Institute.
BS - British Standard.
BIS - British Standard Institute.
NACE - National Association of Corrosion Engineers,
TEMA - Tubular Exchangers Manufacturing Association
EIL - Engineers India Ltd. Standard Specifications
IS - Indian standards

1.6 SPECIAL SHUTDOWN MAINTENANCE WORK PROCEDURE

1.6.1 All fire, safety and security procedures shall be fully implemented in accordance
with BPCL Fire & Safety regulations.

1.6.3 Protection of Austenitic Stainless Steel against Stress Corrosion Cracking by use
of Neutralization Solution Procedure. See Appendix A, Attachment 12.

1.6.5 Lifting tool Inspection Procedure:

All items of handing & lifting equipment including cranes, tools, (hand and
others), air movers, ducting, lifting tackles, wire ropes, chain block ,
shackles, eye bolts, etc., required for the satisfactory execution of WORK shall
be certified by a current inspection and test reports. OWNER reserves the right
to, at its discretion, request and view the original of the inspection/test report.
OWNER also reserves the right to, at its discretion, reject any items of equipment
it considers unfit for the intended service/duty,

Details of lifting equipment shall be specifically set out with the date of last
inspection and test by a recognized inspection agency approved by statutory
authorities marked against each item. All proposed equipment shall be included
in the CONTRACT.

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 The CONTRACTOR shall provide the original test certificates for all cranes and
lifting equipment to OWNER for approval before any WORK start.

Copies of the original test certification for all lifting equipment brought on site by
the CONTRACTOR or his nominated SUB-CONTRACTOR shall be maintained in
the CONTRACTOR'S site office throughout the duration of this CONTRACT.

1.6.6 Spade Installation and removal

It is expected that extensive use of pneumatic or hydraulic impact wrenches will

be required to meet complete isolation and fixing. The CONTRACTOR must take
this into account when tooling up with special tools, air compressors and
Breathing Apparatus sets.

The CONTRACTOR must provide the service for the installation of spading and
de-spading, the spades (blinds) & temporary gaskets, hose connections for
decommissioning including plant battery limit spades, wedge opening for gas /
Hydro Carbon freeing equipments / piping , replacement of the leaky gaskets and
commissioning spading / de-spading . (See lists in Appendix A, Attachment 11
section N & spade list given against each equipment ), The CONTRACTOR also
has to provide the service for the installation of spading and de-spading, the
spades(blinds) and temporary gaskets, for equipment entry , for hydro testing ,
decontamination / chemical cleaning , pneumatic / hydro testing of piping and
equipments . Process and Instrumentation Diagrams (P&ID 'S) will be supplied
after CONTRACT award. Owner shall supply all the spades of required size.

1.6.7 Working Hours

CONTRACTOR will be required to work on two shifts each of 12 working hours,

day shift from 7.45 hours to 19.45 hours and night shift from 19.45 hours to 07.45
hours daily on the round clock basis.

1.6.8 Bolting Procedures

It is brought to the CONTRACTOR'S attention that mainly three classes of

bolting are present on this site and it is fairly common to have two different
classes on one piece of equipment. The CONTRACTOR is to pay particular
attention to the replacement of nuts and bolts and at all times shall ensure that
the correct specification of bolting be used. Cases of doubt must be referred to
the Engineer in Charge for resolution. To avoid possible mixing of different
classes of bolting, the CONTRACTOR shall provide bags which should be
physically attached to or identified with the relevant flange. It shall be the
CONTRACTORS responsibility to clean and service all bolts/ nuts prior to re-use.
Hand dressing of thread forms with files is not permitted. In case of doubt,
reference shall be made to the Engineer in Charge. If required CONTRACTOR
shall arrange for Positive Material Identification (PMI) of the bolts used and rectify
the same if any discrepancy is observed during the PMI testing. All bolting shall
be carried out as per procedure given in Appendix A Attachment 12. For
Hydrocracker & NHGU complex, the Torquing / tensioning values shall be as per
the EIL standard. Torquing values for individual equipment shall be given during
execution.

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1.6.9 Welding Procedure

All the welders provided under this CONTRACTOR shall be qualified in

accordance with the requirements of ASME Boiler and Pressure Vessel Code -
Section IX, Welding qualification in the position of 6G i.e., all welding positions.

All welding works must be performed by suitably qualified welders working to

welding procedures approved by the BPCL inspection section.

The welding procedures, qualification records and welder qualification must be

submitted for review and acceptance at least six weeks prior to the shutdown
start date. This includes welding procedures for seal welding of heat exchanger
tubes.

All welders tests shall be witnessed by the BPCL inspection section or a BPCL
inspection section approved inspecting authority prior to commencement of the
Contract. Two passport type photographs of each qualified welder shall be
provided to OWNER for identification purposes.

All welders tests shall be carried out in accordance with approved welding
procedures which have been agreed upon by BPCL inspection section and the
CONTRACTOR fifteen(15) day prior to commencement of CONTRACT work or
commencement of pre fabrication works, whichever is earlier.

All welders shall be qualified and capable of welding materials in carbon steel,
stainless steel, chrome moly steel and super duplex stainless steel to the
appropriate qualified welding procedures. Welders who fail to pass the relevant
welding test will be disqualified from working on the plant during the CONTRACT.

1.7 PLANNING, SCHEDULING AND MONITORING & CONTROL SYSTEM

Please refer Annexure A for detailed procedure for planning, scheduling,

monitoring & control system

1.8 QUALITY CONTROL / INSPECTION

CONTRACTOR'S shall execute all the jobs as per BPCL Quality control /
inspection requirement.

1.9 SHUTDOWN MAINTENANCE WORK FACILITIES AND TEMPORARY WORKS

CONTROL.

1.9.1 Mobilization

The CONTRACTOR shall complete the mobilization of all his required resources
(Manpower and equipments) five (5) days advance from the date of shutdown of
the unit.

The CONTRACTOR must mobilize adequate qualified management staff to

administer the shutdown maintenance works as well as carry out project control
work on site and the overall responsibilities of the preparatory / shutdown work
progress.

Within 15 days of award of the contract, CONTRACTOR shall mobilize adequate

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manpower and resources to undertake preshutdown jobs like insulation removal,
scaffolding, pre fabrication, pre shutdown exchangers and vessels, etc and
complete them in timely manner as per Instruction from BPCL Incharge.

The CONTRACTOR must list all his management and technical staff in the
CONTRACT document together with their CV's for review and prior approval by
OWNER. Manpower required for the shut down work and CONTRACTOR key
personnel such as site managers, engineers, supervisors and foremen shall be
interviewed by OWNER. All expenses for travel and accommodation will be borne
by the CONTRACTOR.

Following management / technical staff who shall be on the direct employment of

the contractor shall be mobilized as minimum and they shall conform to the
minimum requirements as mentioned below. The age of any staff shall not be
more than 60 years and they shall be physically fit to supervise turnaround
activities. Resumes of these staff shall be submitted to BPCL approval within 15
days of award of contract.

Sr Designation Minimum Requirement

No.
1 Shutdown Project Graduate in Mechanical Engineering with 12 to 15 years
Leader (Site in- of experience of working in refinery turnaround /
charge) refinery projects / refinery Maintenance.
2 Planning coordinator Graduate / Diploma in Mechanical Engineering with
minimum 8 years of experience of Turnaround Planning,
shall be conversant with planning software such as
Primavera, MS Project and MS Office
3 Piping coordinator Graduate / Diploma in Mechanical Engineering with
minimum 8 years of experience of piping works in
refinery/ petrochemical/ fertilizers.
4 Equipment Graduate / Diploma in Mechanical Engineering with
coordinators ( 3) minimum 8 years of experience on exchangers/ Heaters
1- Columns/ Vessels / columns/ pressure vessels in refinery/ petrochemical/
1- Heaters fertilizers.
1- Exchangers
5 Civil coordinator Graduate / Diploma in Civil Engineering with minimum
8 years of experience on refractory works, civil
foundations, painting, structural works etc in process
plants.
6 Materials coordinator Graduate / Diploma in Mechanical Engineering with
minimum 8 years of experience, shall be conversant with
material specifications for pipes/ pipe fittings/ valves etc.
7 Safety Coordinator Diploma in Industrial Safety with minimum 8 years of
experience in Safety in construction / turnaround in
reputed organizations.
8 Housekeeping Minimum 5 years of experience regarding sub-contractor
Coordinator management, management of cranes, trucks etc and
housekeeping activities.
Note: For candidates having long work experience in Refinery Shutdowns,
the educational qualification criteria may be relaxed at the discretion of
BPCL for some of the above positions.

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 In addition to the above, the CONTRACTOR shall supply Quality Control
In-charge and sufficient numbers of dedicated Quality Control Supervisors
to carry out Quality Control Activities to ensure that all shutdown
maintenance works are carried out in accordance with good standard of
Engineering practice and using correct materials specified for the work as
well as to ensure the completion of work within the shutdown scheduled
period. The requirements regarding QA/QC staff are covered in details in
Attachment 11 Section Q Inspection Services.

I. SHUTDOWN PROJECT LEADER (CONTRACTOR)

The CONTRACTOR is responsible to deploy the shutdown project leader

who will have overall responsibility of the shutdown work under this
CONTRACT.

II. SHUTDOWN PLANNING/SCHEDULING CORINATOR (CONTRACTOR)

Shall be responsible for CONTRACTOR'S resources, planning and monitor

and controlling the overhaul plant shutdown schedule. The CONTRACTOR
shall submit details of the manpower and other resources to be deployed
on daily basis against a breakdown of the shutdown work scope activities
in a format specified by Engineer in Charge.

The CONTRACTOR'S Planning and Scheduling Engineer shall liaise on a

daily basis with the OWNER REPRESENTATIVE in providing the
information and report on items of the WORK that have been completed
every day for the total duration of the Shutdown period.

The 'CONTRACTOR shall provide adequate number of competent

planning /execution supervisors to assist in preparation of a
comprehensive work plan for execution of shutdown works, breakdown
the shutdown work scope into activities, define the required resources for
each activity, schedule, define quality requirements, preparation of
planning daily progress reports, histogram maintaining shutdown
documentation records, preparation and updating of progress graphs and
'S' curves graph for Engineer In Charge review and update the network
shutdown work program clearly.

The PLANNINGS SUPERVISOR must have Engineering Diploma as

minimum qualification with 10 Years maintenance experience in
Oil/Gas/Refinery or Petrochemical Industry with 3 years experience in the
field of Shutdown Maintenance Planning. He should have Good
knowledge in Computerized Maintenance Management Systems
(SAP/MAXIMO/TEROMAN/etc.) and Primavera experience is mandatory.
Good command in English, both speaking and written.

III. PIPING COORDINATOR (CONTRACTOR)

Shall be responsible for supervision and timely execution of all piping

jobs, piping modifications jobs, hydro testing of process lines, valves
testing and reconditioning, piping rejection jobs etc as per Inspection
Recommendation. Shall be able to lead a team of piping engineers /

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 supervisors and comply with Quality Assurance requirements of BPCL.
Piping coordinators shall be assisted by adequate number of piping
engineers/ supervisors. The minimum numbers of the engineers /
supervisor staff shall be based on a ratio of one Engineer to every 3
supervisors and a ratio of one Supervisor to every ten workers/laborers
available on site.

IV. EQUIPMENT COORDINATOR (CONTRACTOR)

Shall be responsible for supervision and timely execution of all jobs on

Heaters, Columns, Vessels, Exchangers etc (both pre planned as per
scope and informed during shutdown based on Inspection
Recommendation). There shall be minimum two Equipment coordinators
and each shall be assisted by adequate number of engineers /
supervisors. The minimum numbers of the engineers / supervisor staff
shall be based on a ratio of one Engineer to every 3 supervisors and a
ratio of one Supervisor to every ten workers/laborers available on site.

In addition to the above, The CONTRACTOR shall provide adequate

number of experienced and competent rigging supervisors including
helpers and all required certified lifting equipment with copies of test
certificates which shall be available on site for OWNER Refinery's review.

V. CIVIL COORDINATOR (CONTRACTOR)

Shall be responsible for supervision and timely execution of all civil jobs
like refractory works in Heaters, Structural works, civil foundations,
RCC/PCC, painting, etc. He shall assisted by adequate number of
engineers / supervisors. The minimum numbers of the engineers /
supervisor staff shall be based on a ratio of one Engineer to every 3
supervisors and a ratio of one Supervisor to every ten workers/laborers
available on site.

VI. MATERIALS COORDINATOR (CONTRACTOR)

Shall be responsible for understanding Bill of Materials, raising reservation

for BPCL supplied materials, arranging contractor supplied materials and
ensure that no work is held up for want of materials. He shall be well
conversant with piping materials, fittings, flanges, gaskets and their
specifications etc.

VII. SAFETY COORDINATOR (CONTRACTOR)

Shall be responsible for Safety in all work performed at site, for ensuring
use of PPE, following BPCL safety standards and achieving incident free
turnaround. He shall be assisted by adequate number of safety
supervisors in each shift. The ratio of Safety supervisor to workmen shall
be 1 : 50. Contractor shall deploy these safety supervisors in addition to
sub-contractor safety supervisors, if any.

VIII. HOUSEKEEPING COORDINATOR (CONTRACTOR)

Shall be responsible for housekeeping at site, marinating the site clean of

scrap and debris and organizing the materials movement. Shall ensure

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 that all debris are taken out of BPCL within 24 hours of generation and
that all valuable scrap is shifted to BPCL designated location in inside
refinery within 24 hours of generation.

VII. SHUTDOWN INSTRUMENT MAINTENANCE ENGINEERS /

SUPERVISORS (CONTRACTOR)

CONTRACTOR shall provide adequate qualified competent Instrument

Maintenance Engineers/Supervisors to supervise and control the
instrument maintenance works during the execution of works. The
minimum numbers of the engineers / supervisor staff shall be based on
a ratio of one Engineer to every 3 supervisors and a ratio of one
Supervisor to every ten workers/laborers available on site.

1.9.2 Schedule of Skilled labour.

The CONTRACTOR must mobilize adequate skilled labour in order to accomplish

the given shutdown Scope of Work within the planned shutdown scheduled time.

1.9.3 Schedule of Plant. Machinery & Equipment

The CONTRACTOR must mobilize adequate plant, equipment, machinery and

toots to carry out the WORK in an efficient manner and within the limited given
shutdown work schedule. The CONTRACTOR must list all his construction
plant/equipment along with its details.

The CONTRACTOR will be requested to submit a log sheet through his Planning
Engineer, containing all his machinery, plant and equipment on site each shift ,
starting from mobilization date until the last day of his de-mobilization, for
Engineer In Charge review and against the shutdown original plant proposals.

1.9.4 Manpower Supply Specification

CONTRACTOR will be responsible in supplying all equipment, tools or testing

instruments that may be required by the CONTRACTOR'S personnel.. The
manpower specification, qualifications and experience requirements are as
follows:-

1.9.4.1 ELECTRICAL TECHNICIANS

The Electrical Technician must have Electrical Diploma as minimum qualification,

work experience of not less than 10 years in Refineries/Petrochemical Plants and
fluent in English language both written and speaking. They must be able to
maintain O.C.B, A.C.B, HV/MV switchgear, motors, UPS & chargers and other
electrical equipment. They must have knowledge of how to use electrical
instruments such as megger, avometer, high current injection test instruments
and others.

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1.9.4.2 ELECTRICAL HELPERS

Electrical Helpers must understand English language (failure to understand

English may result in rejecting the helpers on site) and have a basic concept of
electrical equipment cleaning (i.e. not to damage motor winding by wire brush).
They should be able to keep house cleaning and their age should not be more
than 45 years.

1.9.4.3 INSTRUMENTATION TECHNICIANS.

Instrument technicians that shall be adequately qualified with a minimum of

seven years experience in Refineries / Petrochemical Plants and also working
under OWNER supervision.
1.9.4.4 INSTRUMENTATION HELPERS

Helpers - Instrument shall be unskilled labor capable of assisting the above

technicians and also working under OWNER supervision.

1.9.4.5 TECHNICAL DRAUGHTSMEN.

Completion of Secondary (12 years) education with NCTVT certificate having

five Years experience in Oil / Gas / Refinery or Petrochemical Industry with 3
years experience in the field of Technical Draughtsman. Good command in
English both speaking and written.

1.9.4.6 FABRICATOR/PIPE FABRICATOR.

Fabricator/Pipe Fabricators shall be adequately qualified with a minimum of 5

years experience in Refineries / Petrochemical Plants, capable of fabricating
pipeline sections and assemblies, able to read and understand isometric
drawings and prepare piping sketches. They should be experienced to work with
for carbon steel, stainless steel, crome moly steel and Super duplex stainless
steel. They must be equipped with all tools required for fabrication work such as
squares, levels, spanners, hammers, measuring tapes 3m, 5m & 50m, pipe
wrap, hacksaw frame 12", grinding goggles, safety belts for working high levels,
electric grinders for 7" dia. & 7/8" ID grinding wheel with plug for 240V power
supply. Good command in English /Hindi speaking a must and be able to
supervise contractor manpower.

1.9.4.7 QUALIFIED CODED WELDER (CERTIFIED)

Welders shall be adequately qualified with a minimum of 5 years experience in

Refineries / Petrochemical Plants. They must be qualified to weld various
materials and pipe diameters inclusive carbon steel, stainless steel and chrome
moly steel using TIG welding technic for 6G position weld and should possess
valid test certificates. They must be equipped with all tools required such as
welding helmet, welding hand gloves, grinding goggles, safety belts for working
high levels, electric grinders for 4" dia. & 7/8" ID grinding wheel with plug for 240V
power supply. Good command in English /Hindi speaking a must.

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1.9.4.8 PIPE FITTER

Pipe fitters shall be adequately qualified with a minimum of 5 years experience in

Refineries / Petrochemical Plants, capable of boxing up flanges, valves,
manholes, equipment internals, hydrostatic and pneumatic pressure test
execution, etc. They must have their own tool box complete with ordinary flat and
ring spanners, pipe wrench, hammers, hacksaw 12" frame, grinding goggles,
safety belts for working at high levels, and all other tools required for pipe fitting
jobs. Good command in English /Hindi speaking a must.

1.9.4.9 ASSISTANT/HELPER PIPE FITTER/FABRICATOR/WELDER.

Assistant Pipe fitters/fabricators/welders shall have a minimum of 5 years

experience in Refineries / Petrochemical Plants in assisting pipe
fitters/fabricators/welders in their works. They must be equipped with grinding
goggles and safety belts. Good command in English /Hindi speaking is a must.

1 9.4.10 MECHANICAI FITTER - ROTARY

Mechanical Fitters-Rotary shall be adequately qualified with a minimum of 5

years experience in Refineries / Petrochemical Plants, capable of repairing all
types of Refinery pumps and compressors, alignment thereoff and test runs if
required. They must have their own tool box complete with ordinary flat and ring
spanners, hammers, grinding goggles, safety belts for working at high levels,
and all other tools required for rotary equipment removal, overhaul and
installation jobs. Good command in English /Hindi speaking is a must.

1.9.4.11 VALVE TECHNICIAN

Valve Technicians shall be adequately qualified with a minimum of 5 years

experience in Refineries / Petrochemical Plants, capable of boxing up flanges,
gland packing of valves, manholes, equipment internals, hydrostatic and
pneumatic pressure and leak test execution, etc. They must have their own tool
box complete with ordinary flat and ring spanners, hammers, grinding goggles,
safety belts for working at high levels, and all other tools required for valve
removal, overhaul and installation jobs. Good command in English /Hindi
speaking is a must.

1.9.4.12 CRANE OPERATOR

Should have completed 12 years Secondary education with 5 years Refinery /

Petrochemical experience. Must be able to operate mobile cranes, overhead
cranes and forklifts with valid certification. Good command in English /Hindi
speaking is a must.

1.9.4.13 RIGGER

Should have completed 12 years Secondary education with 5 years Refinery /

Petrochemical experience. Must be conversant with all types of lifting equipment
i.e. types of slings, block and tackles, chain blocks and rigging sign language..
Must be able to communicate with crane operator via signs and have good
command in speaking English & Hindi..

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1.9.4.14 INSPECTION HELPER

Inspection Helpers will assist the engineers and technicians in cleaning for
thickness gauging, UFDT, MPI etc. They have to carry heavy equipment
holdings, carrying ladders etc. for technicians for inspection, carrying out other
physical jobs required during inspection. The jobs will be done both inside and
outside the equipment at various elevations. The job demands heavy physical
work. They must be able to understand and communicate in English /Hindi and
must be physically very fit. Should be able to work both inside and outside the
equipment at various elevations. Age - Between 25 and 35 years

Safety Equipment: The CONTRACTOR shall provide the hired manpower along
with their personnel safety equipment such as - safety shoes, safety helmet,
gloves, boiler suits, safety goggles and Safety Belt.

1.9.4.15 REFRACTORY MASON

Refractory Masons shall be adequately qualified with a minimum of 5 years

experience of refractory application / repairs in Petrochemical Refinery Plants. He
must be conversant with different types of refractories used in Refineries, mixing
methods and application tools. He must be able to read and follow drawings and
technical instructions. Good command in English/Hindi speaking is a must.

1.9.4.16 REFRACTORY MASON HELPER

Refractory Mason Helper must have at least 3 years of experience in Refractory

application / repairs in Refinery / Petrochemical plants. He must be conversant
with working methods for different refractory types. Good command in English &
Hindi speaking is a must.

1.9.4.17 TURNER

Completion of 12 years Secondary education. Must be adequately qualified with

valid certificates to perform duties on lathes, milling, shaping and portable flange
facing machines, grinders and drills. Minimum of 5 years refinery experience
and be capable to identify and work with various types of materials. Must be
equipped with safety equipment and tools required for precision
measurement, i.e. micrometers, verniers, etc. Must be able to read
manufacturing drawings and be familiar with the different types of tolerances
and fits. Good command in speaking and written English& Hindi.

1.9.4.18 FOREMEN (Construction Workshop)

Completion of 12 years Secondary education and have 10 years experience in a

Refinery works. Be able to supervise fabrication and welding technicians and
contractor personnel. Supervise shutdown and normal day to day activities in the
workshop. Coordinate availability of materials and consumables. Should be
computer literate with good command of English & Hindi speaking and written.

1.9.4.19 UNSKILLED LABOUR

Must have worked in a technical environment previously and must be able to

speak and understand Hindi.

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1.10 TEMPORARY UTILITIES

1.10.1 Temporary Potable Water Supply

OWNER shall provide potable water free of cost at one point near the shutdown
site for the cleaning and hydro- testing of the Refinery shutdown works as well as
for drinking purposes. However, it is the CONTRACTOR'S responsibility to draw
the water supply from the source point and make distribution arrangements as
per work requirements & transport it to wherever required.

Suitable facilities must be provided to direct waste water to plant drainages to

prevent flooding of the work areas. The plant drainages will have to be cleared
on a daily basis to ensure smooth flow.

1.10.2 Temporary Electricity

OWNER shall provide free electrical power supply at four corners of the plant
within 75 meter radius as construction power. The CONTRACTOR shall be
responsible for making distribution arrangements including supply of power
cables as per work requirements & BPCL electrical section instructions for
welding, stress relieving and other purposes such as exhaust fans,
AC/ventilation units etc.

1.10.3 Temporary Lighting

The provision of all temporary lighting along with flameproof light fittings and hand
lamps for maintaining the essential services within the shutdown site and all
equipments (Furnaces, columns, vessels, heat exchangers....etc.) as well as
CONTRACTOR'S site facilities shall be provided by the OWNER . However it
shall be contractors responsibility to shift the lighting equipments to the
respective location and maintain the lighting fittings provided in good condition
and return the same to owner in good condition. Contractor shall make all
arrangements for illumination wherever required.

1.10.4 Temporary Cooling and Ventilation

The provision of all temporary cooling and ventilation equipment and appliances
for maintaining the essential services within the shutdown area and equipment
and the temporary site facilities shall be the sole responsibility of the
CONTRACTOR. This includes provision of continuous air educators / Exhaust
fans and air hoses inside the equipment (if required) to make it free of
hydrocarbon smell. CONTRACTOR shall provide AC ventilation units for working
inside the equipment as per detailed in individual equipment scope in volume III
of this tender document.

1.10.5 Temporary Telephone

OWNER may provide local MTNL telephone facilities at the CONTRACTOR'S

site office and as well as at CONTRACTOR site offices based on availability of
spare MTNL lines. The CONTRACTOR shall arrange for laying the telephone
cables.

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1.10.6 Communication facilities by contractor

Contractor shall provide adequate on site communication facility such as

VHF sets. Contractor shall obtain necessary prior approval from owner for
use of these communication equipments.

1.10.7 Temporary Sanitary Facilities

Temporary sanitary facility shall be provided by owner.

1.10.8 Temporary Site Infrastructure

The CONTRACTOR is responsible to supply install and erect a temporary

materials store with enough space to handle the volume of the shutdown work
scope.

The CONTRACTOR is responsible to supply, install and erect decent size porta
cabins for site offices, temporary mess, rest areas for use of his direct staff and/or
sub-Contractors staff.

1.10.8 Temporary Mobile Air Compressor

The CONTRACTOR to be equipped with their own Mobile Air Compressor units
with adequate distribution piping for air supply. The CONTRACTOR shall assess
the total requirements for compressed air for the complete work list. In addition,
the assessment must include for use of air line breathing apparatus (B.A.) sets,
powering of air tools, needs of any temporary workshop, breakdowns/
maintenance, for the gas freeing of vessels and ventilation of vessels.

1.11 CONSTRUCTION AIDS

1.11.1 Hoists and Cranes

The CONTRACTOR shall arrange for adequate numbers of certified heavy duty
cranes with various capacities and exchanger bundle pullers to carry out the
proposed Refinery shutdown Maintenance works within the given shutdown work
programme.

1.11.2Tools and Tackles

The CONTRACTOR should be well equipped with all the required tools and
tackles including lifting tools such as chain blocks and slings to carry out the
shutdown activities. A tool room with a caretaker to take care of the requirements
around the clock is to be provided. Special tools such as Torgue Wrenches, bolt
tensioning tools/sockets and machines and pneumatic tools are to be kept in the
tool room in adequate numbers. The provision of the trolleys on the lifting beam
provided at site shall be carried out by contractor. BPCL shall supply the trolleys
of required size from the rigging yard.

1.11.3 Scaffolding and Platforms

The CONTRACTOR shall provide all scaffolding required including, but not
limited to, scaffold boards, rails, shackles, putlogs, fixing pieces, tubes, etc., all to

Page 14 of 36
the complete satisfaction of the OWNER site engineers and erected in
compliance with the BPCL Refinery Safety Regulations.

All scaffolding erected by the CONTRACTOR for the purpose of maintenance

shall remain in position for Owners utilization till further notice of removal from
the Engineer in charge. All scaffold tubes and fittings shall conform to IS1161 &
IS 1362. No timber scaffold boards shall be permitted.

Scaffolds are to be erected in accordance with BPCL Refinery Safety regulations.

Any scaffolding which does not conform to the above requirements shall be
immediately withdrawn from service, dismantled and re-erected such that the
requirements are complied with. If the CONTRACTOR intends to use sub-
contract scaffolding, details must be provided in the CONTRACT TENDER.

All the scaffolding work and scaffolder shall comply with following
requirement.

a) Contractor shall appoint competent person who is authorized to

inspect and certify scaffolding as per OSHA std 29 CFR 1926,
subpart L.
b) Operating platform shall be fully covered with metal planks and
adequately secured. If it is not require/possible to cover entire
platform with metal boards/planks then in such case provide
minimum three number of boards/planks in working area and
remaining area shall be made inaccessible with hand rails, mid rails
and toe boards to restrict the entry in that area.
c) Toe boards shall be provided at all the side of operating platform of
scaffolding.
d) Hand rail and mid rail shall be provided at all the working platform
level of the scaffolding.
e) Ladder shall be provided to approach working platform. Length of
the ladder shall not be more than 6 m.
f) Ensure adequate stability of scaffold by use of adequate No. of cross
bracings and other types of supports
g) Unsafe to use board shall be provided during erection of
scaffolding.
h) Only trained & certified scaffolders shall be allowed to work on
scaffolding with Unsafe to use board.
i) After erection of scaffolding the authorized person contractor
mentioned in Sr. No. 1 above, shall inspect & certify the scaffolding
and after his full satisfaction that it is safe for use he shall put
personally Green Tag duly signed by him. The green tag shall
have validity. The contractor shall also provide Safe to use
board after approval of scaffolding by the competent person for
visibility from distance.
j) Once scaffold is certified as safe to use, then nobody shall be
allowed to alter/modify the scaffold for any purpose. If at all it is
altered / modified then their certificates as safe to use stand
cancelled.
k) Joint coupler or sleeve coupler shall only be used for extending the
scaffold pipes.
l) Scaffolding shall be provided with base plates.

Page 15 of 36
 m) The material used for scaffolding shall be standard scaffold material
as specified in Fire & Safety Regulation and shall be free from any
defects
n) The contractor shall follow the guidelines mentioned in Fire & Safety
Regulation for the construction of scaffolding.

1.12 First Aid

The 'First Aid' facilities will be arranged by the CONTRACTOR at site .However
OWNER shall provide immediate medical aid at Owners medical centre free of
cost based on requirement before taking the patient outside for further
specialized medical assistance. However, the CONTRACTOR shall specify and
list all his employees who have completed professional training in 'First Aid', H2S,
and B.A self contained and air line.

1.13 SECURITY

The CONTRACTOR shall provide adequate security measures to ensure full

protection of the workforce, materials and other necessary equipment of the
shutdown maintenance works and the property of the Refinery.

The work shall be carried out in the OWNERS refinery premises and the
CONTRACTOR'S personnel shall comply in all respects with such security
instructions as may be issued to them from time to time by OWNER. Gate Entry
passes shall be issued by the OWNER based on the information provided by the
CONTRACTOR, however it shall be the contractors responsibility to ensure the
good character of employed staff of its own as well as subcontractor. Application
for the gate entry to the OWNER must be made in the prescribed manner and in
sufficient time to allow mobilization on schedule and to meet the work
commencement date.
OWNER can advise on current requirements which could include permissions
required as per statutory / GOVT. authorities for all employees.

1.14 ACCESS ROAD AND PARKING AREA

The CONTRACTOR will be directed by Engineer in charge for the utilization of

the access roads and parking area.

1.15 TEMPORARY CONTROLS

1.15.1 Plant Cleanliness

The CONTRACTOR will be completely responsible for the daily cleaning all
equipment and units after every shift as well as keeping the units and all
equipment clean.

The CONTRACTOR shall provide a sufficient number of waste skips and

sufficient numbers of general workers meant exclusively for housekeeping
purpose. The CONTRACTOR shall make arrangement for the collection and
safe disposal to a Government approved municipal dump, of all waste materials
used during the shutdown works. The CONTRACTOR shall ensure all waste

Page 16 of 36
 skips are strategically positioned, emptied on a daily basis and re-sited as
required, throughout the shutdown works duration to maintain the plant and work
areas in a clean, safe and hygienic condition. All the insulation material shall be
disposed outside refinery premises through MPCB / CPCB approved Insulation
Waste Management Authorities without giving rise to any obligation from the local
/ statutory bodies. Necessary disposal slips / documents shall be submitted to
BPCL.

1.15.2 SURFACE WATER CONTROL

The CONTRACTOR must provide suitable facilities to direct waste water to plant
drainages to prevent flooding of the work area. The plant drainages will have to
be cleared on a daily basis to ensure smooth flow,

1.16 TRAFFIC REGULATIONS AND ON SITE TRANSPORTATION

The CONTRACTOR must comply with BPCL traffic& safety Regulations during
the whole of the shutdown works period. The CONTRACTOR must provide onsite
transportation for his own personnel, shutdown manpower personnel and sub-
contractor personnel. However OWNER shall provide the transport facility to
contractor employees from main gate to Worksite and back at the
beginning of the shift and at the end of the shift respectively.

1.17 MATERIALS AND EQUIPMENT

All materials and spare parts materials (Excluding CONTRACTOR supplied

spares as specified in the Scope of Work and Bill of Quantity) will be provided to
the CONTRACTOR free of cost. However, the CONTRACTOR must supply and
provide all services (including the installation of spading & de- spading, temporary
gasket for hydro testing), with no limitations as well as the following consumable
materials.

Welding electrodes, grinding wheels, grinding shields, welding screens, paints,

lubricants, "general and lint free" fuel cleaning rags, lifting equipment, safety
protective clothing, tags, pipe wrap, pipe covers etc.

All CONTRACTOR supplied spares and materials (as specified in the Scope of
Work and Bill of Quantity) must include "MATERIAL SAFETY DATA SHEETS".

The CONTRACTOR is responsible to raise all necessary materials requisition

vouchers and obtain the appropriate approval of engineer in charge for collection,
transport, delivery and safe custody of all OWNERS issued materials.
The CONTRACTOR may note that Owners Main Stores will be opened all seven
days a week for all shutdown working hours.
The CONTRACTOR is responsible to maintain a proper register indicating
location of application and Material Issue Vouchers for all OWNERS free issue
materials as well as the materials utilized in shutdown works for checking by
OWNER Maintenance Engineers on daily basis.
All surpluses OWNER issued materials must be returned to Owners Stores in
their original condition. The CONTRACTOR must maintain and safe-guard all
OWNWER issued materials in an appropriate temporary location as well as in a
proper and correct manner.

Page 17 of 36
 The CONTRACTOR must notify Engineer in charge to obtain free-issue materials
with at least four hours notice, prior to the required time of application.

1.18 FACILITY START-UP / COMMISSIONING

The CONTRACTOR shall be responsible for any start-up delays due to any
defects, damages or failures to be rectified for the completion of commissioning
works on schedule. The CONTRACTOR must ensure to obtain the appropriate
Engineer in charge approval on every sequence of activities/ work in order to
avoid any time/ cost wastage or duplication of efforts. Contractor shall provide
their all resources during shutdown and start up of the plant till stabilization.

1.19 CONTRACT CLOSE-OUT

1.19.1 FINAL REFINERY CLEANING

The CONTRACTOR must obtain in writing the approval from the Maintenance /
operations Manager on the final cleaning of the works and making the plant site
clean and tidy after the shutdown works have been completed, prior to the
issue of the "CERTIFICATE OF COMPLETION".

1.19.2 SHUTDOWN MAINTENANCE RECORD DOCUMENTS

The CONTRACTOR must maintain log sheets and registers, which contain the
attendance of the CONTRACTOR's resources on a daily basis, commencing from
the first day of mobilization period up to the final day of the demobilization period.

All these attendance sheets must be verified by Engineer in charge every single
shift .On completion of the shutdown works, a set of duplicate copies must be
handed over to Engineer in charge.

The CONTRACTOR must provide OWNER with a detailed Shutdown Project

Close-out report prior to the issue of the "CERTIFICATE OF COMPLETION. The
Close-out Report must include the following information:-
1. CONTRACTOR Shutdown Policy
2. CONTRACTOR PERSONNEL statistics, e.g. Number of personnel per
discipline and supervisor, engineer, management level utilized including
actual and overtime hours worked.
3. CONTRACTOR safety statistics, e.g. number of incidents and accidents
including seriousness.
4. Final scheduled planned and actual Execution Plan statistics.
5. Scope of Work statistics, e.g. number of each type of equipment worked on
including all types of valves.
6. Major unplanned work done.
7. Problems experienced during Mobilization, Execution and De-mobilization.
8. Recommendations.

1.19.3 SPARE PARTS AND MAINTENANCE MATERIALS

The CONTRACTOR shall return all the surplus free issue materials to OWNER s

Page 18 of 36
 Stores and the CONTRACTOR's storekeeper must ensure that all the relevant
materials issued requisitions covering all the surplus spare parts and
maintenance materials are verified and endorsed by Engineer in charge prior to
the CONTRACT close-out.

1.19.4 DISPOSAL OF SCRAP / DEBRIS

Metal scrap shall be deposited after segregation / cutting to required size

to Owners disposal yard in warehouse.

Debris such as surplus earth after backfilling, RCC / PCC material,

wooden scrap, cleaning consumables, empty paint drums to disposed out
side the OWNERS premises without giving any complaints from Local /
statutory bodies / Government authorities.

All the insulation / refractory material shall be disposed outside refinery

premises through MPCB / CPCB approved Insulation Waste Management
Authorities without giving rise to any obligation from the local / statutory
bodies / Government authorities. Necessary disposal slips / documents
shall be submitted to BPCL.

1.19.5 GUARANTEE

The CONTRACTOR will be the solely responsible for all work carried out by his
staff before and after the shutdown commissioning works. CONTRACTOR shall
guarantee the WORK for a period of 12 months in accordance with clause no.28
and 29 of SCC.

1.19.6 PUNCH LIST ITEMS

The CONTRACTOR must attend any punch list covering the outstanding works
and any defects/ damages after the commissioning works have been completed
prior to the issue of the "CERTIFICATE OF COMPLETION".

1.20.1 EQUIPMENT AND PIPING GASKETS

The CONTRACTOR shall identify the equipment and piping gasket including
material specification based on the PMS / drawings while installation of the
gaskets..

1.20.2 OWNERS WAREHOUSE INVENTORY CHECK

The CONTRACTOR shall carry out physical checking of all the free issue
material in Owners warehouse during planning stage before commencing the pre
/ main shutdown jobs.

Page 19 of 36
 ANNEXURE -A

PROJECT PLANNING, SCHEDULING, MONITORING

&

CONTROL SYSTEM

FOR

TURNAROUND JOBS FEB-MAR 2017

Page 20 of 36
 CONTENTS

CLAUSE DESCRIPTION

1.0 INTRODUCTION

2.0 DOCUMENTS ALONG WITH BID

3.0 AFTER AWARD OF WORK

4.0 TURNAROUND SCHEDULES

5.0 UPDATION OF TURNAROUND SCHEDULES

6.0 REVIEW MEETINGS

7.0 PROGRESS REPOERTING

8.0 PLANNING PACKAGE

9.0 CONTROL ROOM DISPLAY

10.0 SOFTWARE PACKAGES

Page 21 of 36
1.0 INTRODUCTION

To ensure timely completion, the Contractor shall establish and maintain

an effective Planning, Scheduling, Monitoring and Control system,
including mobilization of required number of professionally qualified and
experienced Planning Engineers for evolution of adequate preventive
actions for likely slippages, and formulation of suitable catch-up schedule
for delays, if any, that have occurred.

Schedules, reports and documents shall be prepared and submitted by the

contractor for review of OWNER at various stages and details of meetings
shall be held are described here.

The CONTRACTOR shall be responsible for submitting adequate planning

data (Primavera P6.2 format or latest version) with regard to the
development and maintenance/update of the CONTRACTOR'S detail
Work Scope Execution Programme for the approval of the Engineer in
Charge. (Refer to Appendix H, Annexure 1)

The CONTRACTOR shall use Primavera P6.2 or latest version for

Shutdown Planning and Scheduling Software.

2.0 DOCUMENTS ALONG WITH BID

The bidder shall submit following documents along with the bid:

a. Proposed Overall turnaround Schedule in network form showing details

of all units.
b. Write up on turnaround Planning, Scheduling, Monitoring and Control
system (proposed )
c. Organizational set up for Planning, Scheduling, Monitoring & Control at
Contractors Site Office.
d. Turn Around execution methodology.
e. Function wise Resource Deployment Schedule (manpower &
construction equipment) inclusive of subcontractor jobs schedule
f. Statement confirming compliance to the Planning, Scheduling,
Monitoring and Control System requirements regarding contents of the
documents to be submitted to OWNER.

3.0 AFTER AWARD OF WORK

3.1 FRONT END SCHEDULE

The Contractor shall prepare and submit a detailed front-end schedule for
preparatory work / mobilization as well as for main shutdown activities.
Pending finalization of functional schedules, this schedule shall be the
basis of monitoring of front-end activities. The schedule shall cover all
activities to be carried out during entire period of the contract. The
schedule shall be reviewed in the kick-off meeting.

Page 22 of 36
3.2 KICK OFF MEETING

A Kick off Meeting shall be organized within two weeks of award of

contract. The meeting shall be attended by OWNERs representatives.
During the meeting the following with respect to Planning, Scheduling, and
monitoring and Control system shall be discussed and finalized.

1. Planning deliverables required for turnaround Monitoring and

Control.
2. Work Breakdown Structure for turnaround Schedules, organization
and level of detailing for Overall turnaround Schedules and
Functional Schedules.
3. Procedure for turnaround Planning, Scheduling, Monitoring &
Control system including all reporting formats.
4. List of equipment wise milestones to be included in the network
5. Any other document as required.

3.3 PROGRESS MEASUREMENT METHODOLOGY

Contractor shall submit during Kick off Meeting, the detailed methodology
of progress measurement of Ordering, Sub-contracting, Construction and
Commissioning for review by OWNER. Contractor shall also furnish the
methodology of progress measurement for sub-contracted packages such
as furnace decoking, dry ice blasting, and AFC foam cleaning etc. and
integration of the same with the overall progress.

Progress figures at Unit / Function/Discipline level shall be summarized

from deliverable level and indicated in the functional schedules.

Contractor shall develop the Turn around schedule for arriving at resource
leveling up to level 4 identifying the resources in terms of manpower as
well as tools/tackles & construction equipment/machinery required to
complete the job. During the execution of the job contractors planning
engineer shall issue the job order for each activity indicating resource
requirement and compare the same with actual used one before closing
the job order .For completion of each job/ activity , the completed job order
shall form the basis.

4 TURNAROUND SCHEDULES

Following schedules shall be prepared and submitted by contractor to

OWNER for approval.

4.1 OVERALL TURNAROUND SCHEDULE

Contractor shall submit a network based overall turnaround schedule on

time scale in AO size, shutdown activities including all activities in the
package and all functions of the work along with a Work Breakdown
Structure indicating unit wise workload The schedule shall highlight

Page 23 of 36
 interface activities in the scope of OWNER and clearly reflect strategies
and philosophy of execution. Major milestones for each unit shall be
depicted at the beginning of the network. The turnaround schedule shall
be developed for contractual duration. The schedule shall be reviewed by
OWNER and the comments if any shall be incorporated and the schedule
shall be issued for if any shall be incorporated and the schedule shall be
issued for implementation with one week from the receipt of comments.
The Turnaround Master Schedule depicts in general the key activities and
milestones and the duration allotted. This schedule must include all pre-
shutdown activities such as recruitment, interviews and mobilization of
manpower and equipment. The CONTRACTOR shall be required to plan,
perform and coordinate the WORK with that of other direct contractors to
meet the time requirements of the Shutdown.

4.2 OTHER SCHEDULES

The control philosophy for shutdown activities involves monitoring at the

unit/discipline/subcontract from the initial stages of shutdown and
supplementing it with monitoring at the system/ loop level as construction
advances towards mechanical completion/ pre-commissioning/
commissioning stages. To meet this objective, the following
schedules/deliverables shall be prepared by Contractor.

4.2.1 SUB CONTRACTOR SCHEDULE

Contractor shall ensure preparation of detailed schedules for all works in

the scope of each subcontract awarded by him, for monitoring of
construction progress. These schedules shall have quantity/work load
details of all work items and S curve for each of the sub contracts. The
Contractor shall ensure updating of the same on weekly basis. OWNER
reserve the right to check these schedules at any time.

4.2.2 CATCH-UP SCHEDULE

Contractor shall generate and submit catch-up schedule for completion of

all balance activities including the unidentified activities at the preparation
of overall schedule without change in contractual completion date with
detailed resource reinforcement as and when asked by OWNER. The
catch-up schedules shall be submitted for OWNER review. Accordingly the
S curves for catch-up schedules shall be made and shown along with the
original schedules and actual S curves.

During updation of overall project schedule and construction schedule, the

catch-up schedule shall be shown in bar charts along with the original
schedule.

Page 24 of 36
5. UPDATING OF TURNAROUND SCHEDULES

The various schedules as described herein shall be updated for

submission to OWNER. Updation of the schedule is to determine the
Turnaround trend, with the objective of taking preventive/ corrective action.
While updating, the following shall be considered:

- Actual date of start and completion for the activities.

- Contractual completion dates for vendors and sub-
contractors/turnkey agencies, any change of duration due to
offloading of vendors/sub-contractors agencies to be reflected.
- Duration of activities not yet started shall remain the same as per
the original schedule.
- Anticipated dates of activities in progress.
- Addition/deletion of any activity if required or any change on job
logic.
- Any change in drawing/material availability or change in activity
duration.
- Any change in resource planning.
- Change in philosophy/strategy in execution of balance works
keeping in mind the actual status of the project.

6.0 REVIEW MEETINGS

Contractor shall present turnaround status, turnaround highlights and

action plan as applicable at various review meetings as described below..

6.1 Management level Review Meeting

Level of participation : Senior management of OWNER and

Contractor.
Agenda frequency and venue : To be decided by OWNER.

6.1.1 Daily review meeting for Site Activities

Level of participation: OWNER & LSTK Contractor along with Subcontractor

Agenda: 1) Work front availability

2) Weekly programme v/s Achievement
3) Resource mobilization
4) Reasons for shortfall
5) Catch-up Schedule
6) Progress statistics
7) Programme for next week.
8) Status of resources deployed v/s planned.

7.0 PROGRESS REPORTING

The LSTK Contractor shall submit the following reports on regular basis for
OWNER information/ review.

Page 25 of 36
7.1 Daily Progress Report

LSTK Contractor shall submit (daily before noon), for status of previous
working day a daily report including the following

Programme v/s Progress for the day

Programme for next day

Critical areas

Action taken / to be taken for slippages

Front available

Constraints, if any

Resources deployed against planned with reasons for shortfall in
resources deployment

Important achievements for the day

Materials receipt for the day

Man power / Machinery deployment report Required v/s Deployed

8.0 PLANNING PACKAGE

Details of time submission, frequency of submission and tentative number

of copies for all documents to be submitted by the LSTK contractor shall
be decided mutually.

Once the majority of the schedules are finalized, the LSTK contractor shall
compile the same and submit in the form of a Planning Package. The
Planning Package shall consist of the following:

- Introduction
- Overall schedule bar chart (Summarised)
- WBS
- Progress measurement methodology
- Overall schedule
- Functional schedules
- Sub-contractor schedule
- Progress S curves
- Manpower and Machinery deployment schedule

LSTK Contractor shall submit reports, updated schedule, programmes etc.

as described till the completion of all work in the scope of the contract. No
chapter/annexure of any report shall be deleted without prior written
approval of OWNER.

9.0 CONTROL ROOM DISPLAY

LSTK Contractor shall display charts featuring salient static information of

the project, schedules, status of progress, resource deployment
Hindrances if any , block flow diagram, plot plan, work break down
structure etc. in contractors control point office .The status shall be
updated at least on weekly basis.

Page 26 of 36
10.0 SOFTWARE PACKAGES

For schedule preparation and updation, the LSTK contractor shall use
Primavera Project Planner P6.2 , Project Scheduler and submit the backup
of the schedules on pen drive along with the hard copy whenever
submission of the schedules are called for. The electronic files for all other
deliverables shall be compatible with Microsoft Office.

Page 27 of 36
 ANNEXURE 1 - CONTRACTOR PERSONNEL

A) CONTRACTOR REPRESENTATIVE

None of CONTRACTOR PERSONNEL listed here shall be removed or relocated

from the positions indicated or replaced without the prior written approval of
OWNER. Personnel removed shall be immediately replaced with new personnel
who, in the sole opinion of OWNER are of, at least, an equivalent standard as the
personnel removed.

CONTRACTOR REPRESENTATIVE shall be

Name : NNNNNNNNNNNNNNN.
Position : NNNNNNNNNNNNNNN.

CONTRACTOR REPRESENTATIVE nominated deputy (ies) shall be a ________

Engineer who will be in permanent pay roll of CONTRACTOR, for at least last
three years, with a minimum of ten (10) years relevant experience.

Name : NNNNNNNNNNNNNNN.
Position : NNNNNNNNNNNNNNN.
Address : NNNNNNNNNNNNNNN.
Telex No : NNNNNNNNNNNNNNN.
Telephone : NNNNNNNNNNNNNNN.

The above nominated deputy (ies) cannot be changed during execution of the
CONTRACT.

The above nominated deputy(ies) is/are authorised to act on behalf of

CONTRACTOR REPRESENTATIVE on the following matters under the
CONTRACT:-

(a) NNNNNNNNNNNNNNN.
(b) NNNNNNNNNNNNNNN.
(c) NNNNNNNNNNNNNNN.

B) CONTRACTOR KEY PERSONNEL

Contractor shall submit resumes for BPCL approval of all the key personnel
mentioned in clause no. 1.9.1 Mobilization of this Attachment 1.BPCL reserves
the right to approve / reject key personnel based on their resumes. Interviews will
also be conducted, if required.

Page 28 of 36
 ANNEXURE2 - FACILITIES. PLANT AND EQUIPMENT

CONTRACTOR states below the details of its resources and facilities intended to
be utilised for this CONTRACT. CONTRACTOR design office, design facilities,
expediting and procurement agencies, fabrication yard (location and facilities)
etc. are listed.

CONTRACTOR states below the details of the main items of constructional plant
and equipment, which it proposes to use for this CONTRACT. Details of all
equipments etc. are specified. This list is the minimum that CONTRACTOR will
be required to provide on WORKSITE. CONTRACTOR states whether the tool
or equipment is already in CONTRACTOR ownership or will be purchased or
hired. Details of any special tools should be highlighted.

Description Capacity and Manufacture and No. of Units

present year of
Whereabouts manufacture

The provision of this information shall not relieve CONTRACTOR from providing
such information as OWNER may require in accordance with the CONTRACT
more information of the special equipment and tools CONTRACTOR proposes
to supply or use, neither shall it in any way relieve CONTRACTOR of any of its
obligations to carry out, and, complete the WORK in accordance with the
CONTRACT.

Page 29 of 36
 ANNEXURE3 - SUBCONTRACTORS

Sub-contracting of the entire scope of work or majority of the scope of work is not
permitted. Contractor can sublet only parts of the work on prior approval from
BPCL and the sub-contractors credentials shall be submitted to BPCL for
approval. Contractor is responsible for supervision of all sub-contracted works.
Any sub-contracting does absolve contractor of any of its contractual obligations.

CONTRACTOR shall furnish in following format, the names and addresses of all
SUBCONTRACTORS from whom it proposes to obtain services.

CONTRACTOR is not permitted to change any SUBCONTRACTOR named in

this list without first obtaining OWNER written approval

Full technical submissions are required for all services rendered under the
CONTRACT as required by the General Conditions of Contract & special
conditions of contract and the Specifications.

SUB-
CONTRACTOR /
EQUIPMENT ACTIVITY REMAKRS
PRINCIPLE
CONTRACTOR

Page 30 of 36
 ANNEXURE4 - SUPPLIERS

CONTRACTOR states below the names and addresses of all suppliers from
where it proposes to procure goods.

CONTRACTOR is not permitted to change any supplier named in this list without
first obtaining OWNER written authority.

Full technical submissions are required for all goods procured under the
CONTRACT as required by the General Conditions of Contract and the
Specifications.

Supplier Goods to be supplied

Page 31 of 36
ANNEXURE 5 - CONTRACTOR COMPANY ORGANISATION CHART

CONTRACTOR inserts a copy of its organization chart which clearly shows the
Company structure with respect to Subsidiaries and Joint Venture Partners, if
applicable. The organogram indicates positions of Company Directors,
Managers, Partners, etc.

Page 32 of 36
ANNEXURE 6 - CONTRACTOR PROJECT ORGANISATION CHART

CONTRACTOR provides the proposed organization chart for this CONTRACT

(including key SUBCONTRACTOR personnel, where applicable, and the person
responsible for QA/QC, safety, execution etc.). The C.V's of all the personnel
identified under this Annexure shall be submitted.

Page 33 of 36
 ANNEXURE 7 - QA/QC PROCEDURES

CONTRACTOR Quality Assurance and Control System dedicated for this

CONTRACT shall confirm to OWNER Quality System Requirements.

CONTRACTOR shall develop Shutdown Quality Plan" following the guidelines

set out in above document to implement the activities relevant to the Scope of
Work; The Quality plan should be accompanied by a complete package of
supporting documentation.

CONTRACT EXECUTION PLAN

Under this Appendix CONTRACTOR shall include the following annexure

highlighting the method of execution and programme for the WORK.

Annexure 1 : EXECUTION PROGRAMME, Manpower Histogram and Progress

S- Curve.

Annexure 2 : CONTRACTOR Method Statement

ANNEXURE - 2 - CONTRACTOR METHOD STATEMENT

CONTRACTOR shall provide a detailed method statement and procedures

detailing the proposed method of executing the WORK, in accordance with
CONTRACT EXECUTION PLAN.

Page 34 of 36
 UNDERTAKING TO BE SIGNED BY THE BIDDER REGARDING
MOBILIZATION AND HOUSEKEEPING

In case of award of contract, we (the bidder) undertake to comply with following

conditions for mobilization and housekeeping activities, over and above all the
other contract terms and conditions mentioned in the tender.

1. Sub-contracting of the entire scope of work or majority of the scope of work is not
permitted. Contractor can sublet only parts of the work on prior approval from
BPCL and the sub-contractors credentials shall be submitted to BPCL for
approval. Contractor is responsible for supervision of all sub-contracted works.
Any sub-contracting does absolve contractor of any of its contractual obligations.

2. The contractor shall employ staff from his own organization for key positions such
as the Shutdown Project Leader (site in-charge), Planning coordinator, Piping
coordinator, Equipment coordinator, Quality Assurance coordinator, civil
coordinator, safety coordinator and housekeeping coordinator. Contractor shall
submit resumes of these staff to BPCL for approval. The key personnel shall
conform to educational qualification and experience requirements as mentioned
in the clause 1.9.1 Mobilization. The organization chart shall be submitted for
BPCL approval within 15 days of award of contract.

3. Contractor shall maintain Attendance Register for his staff for key positions as
mentioned in the above para. The contract staff shall mark their attendance by
putting a signature against the date at the beginning of each shift. This
Attendance Register shall be maintained in BPCL site office. BPCL Engineer in-
charge / his representative shall verify the attendance on random basis.

4. Inadequate mobilization and shortage of supervisory staff with respect to the

agreed organization chart shall be treated as violation of contract and there will
be penalty deducible from contractor invoices as under.

Sr No. Violation Penalty

1 Non availability of Shutdown Project Leader (Site Rs. 15,000/-
in-charge) at site per day.
2 Non availability of any one of the Coordinators Rs. 10,000/-
(as defined in clause 1.9.1. of Attachment 1) at per day per
site person.
3 Inadequate number of safety engineers Rs. 10,000/-
per safety
engineer per
shift.
4 Failure to maintain Contractor coordinators Rs. 15,000/-
attendance and Contractor safety supervisors per day
attendance register for both shifts in BPCL site
office.
5 Delay in removal of scrap or debris more than 48 Rs. 15,000/-
hours of scrap generation, due to reasons per day.
attributable to the contractor.

Page 35 of 36
 6 Non availability of updated report from Contractor Rs. 15,000/-per
Planning on daily basis at specified time or day.
submitting incorrect reporting.

The above penalties are in addition to the penalties for violation of HSE norm
attached separately in the tender document and also in addition to the Liquidated
Damages clause for delays in achieving contractual completion.

6. Contractor to provide exclusive manpower and coordinator for housekeeping

activities. Delays in housekeeping activities shall result into penalties as above.
Contractor shall maintain their site office and temporary storage place neat and
clean. Only box type porta cabins or sheds covered from all side with high quality
pre-coated sheets (blue in colour) are permitted. Temporary sheds with GI sheet /
tarpaulin covering etc are banned.

7. In case of repeated deviations by the contractor to the clauses regarding

mobilization and/ or inadequate number of safety engineers and/or repeated
violations of work permit safety conditions, BPCL will initiate penal actions
against the contractor, which may include Holiday Listing of the contractor.

All the above clauses are understood and agreed.

____________________________
Bidders Signature and seal

Page 36 of 36
 APPENDIX A: ATTACHMENT 2

SCOPE OF WORK: COLUMNS

1. GENERAL

a. Contractor shall carry out all the jobs on Column as detailed below
including specific job detailed under Attachment 11: Section A.

2. SPADING / DE-SPADING

a. Contractor shall carry out all the preparatory work which includes
graphiting (servicing by opening one by one) of the bolts, connection of
temporary hose for water washing, steaming, venting and draining the
equipment.
b. Carry out spading / de-spading as per the blind list.
c. Carry out wedge opening on the spades for gas freeing the equipment
using flange spreader.
d. Before entry all the wedge opened spade shall be normalized by
removing the wedge and tightening the flange.
e. After completion of the work carry out de-spading / spading to restore the
condition of equipment for normal operations.
f. Contractor shall provide necessary assistance to owners contractor for
chemical cleaning / decontamination for connection of hoses, spading /
de-spading etc.

3. MANWAY OPENING AND BOX UP

a. Open all the column manways and dish end covers including skirt
opening.
b. Keep all the fasteners of manway in separate bins with identification tag
on it, service all the fasteners by cleaning with wire brush and applying
molykote / antisieze compound.
c. All Man way davits shall be made free by using rust remover or heating
using gas torch.
d. After completion of the job on column, box up all manways in presence of
operation and maintenance representative.

4. ENTRY IN COLUMN

a. The contractor shall enter the equipment only after obtaining specific
permit for entry. Standby personnel shall be kept always near the
equipment manway (outside) during men at work inside the equipment. A
specific equipment based confines space entry logsheet/register needs to
be maintained by contractor for every person entering into confined space
as per safety norms of BPCL.
b. Provide air ventilation system such as exhaust fan / eductor / air hose and
dismantle connected lines for ventilation to carry out jobs in columns. The
supply of exhaust fan / educator is in contractor scope.

Page 1 of 6
 c. Contractor shall provide air conditioners as per work package scope.
d. Provide adequate lighting inside the column using 24 volt flame proof
hand lamps and transformer.

5. DISMANTLING & RE-FIXING OF INTERNALS:

a. The contractor shall dismantle & remove the equipment internals

wherever required as detailed under equipment specific work scope in
Attachment 11: Section A. The equipment internals shall include trays,
tray components, demister pads, structured packing, random packing,
Distributors, steam coils, grids, and structural items used for supporting
the internals.

b. The contractor shall mark legibly using permanent marker and non
tearable tags on tray sections, tray manways, distributor piping and all
other removable internals before dismantling for better identification
during re-fixing.

c. Wherever distributors are removed out of the column, it shall be cleaned

including all nozzles and branches, assembled out side the column and
shall be checked for blockage if any. All the nozzles shall be tested at
competent testing laboratory for spray pattern testing. For distributor
which are not possible for removal out side the equipment , all the
nozzles shall be removed , cleaned and carry out spray pattern testing of
all the nozzles at competent testing laboratory.

d. The contractor shall open the tray manways of all the trays for columns
having trays.

e. All the demisters wherever applicable shall be removed and replaced with
new one. Removed demisters shall be cleaned with hot water to make
them suitable for disposal. The demisters shall be installed with the
assistance of suppliers if required. Services of the supplier shall be
arranged by Owner.

f. Remove the structured packing, random packing in part or full and

carryout necessary replacements in presence of original packing supplier.
Services of packing supplier shall be arranged by Owner.

g. The contractor shall re-fix, either repaired internals or with replacement

materials after obtaining necessary clearance from operations/,
Inspection and technology.

6. Preservation of Tray hardware:

a. The contractor shall keep the tray hard wares viz fasteners, clamps,
washers, etc., wherever removed in a safe custody and the same need to
be reused after servicing.

Page 2 of 6
 b. Servicing of fasteners includes cleaning by kerosene, wire brushing and
application of antiseize compound like Molysulf etc.

7. SCAFFOLDING

a. The contractor shall provide necessary scaffolding or Ladder inside the

equipment at the required locations to access trays /, internals /, internal
surface of the shell, top and bottom dish end, or any other location as per
EIC (Engineer In charge) instructions. The Contractor shall also provide
scaffolding externally surrounding the equipment as required for
inspection of nozzles, column piping and removal of instruments etc.

b. Erect scaffolding inside the skirt for inspection of the bottom elbows / dish
end of the columns.

c. The contractor shall dismantle & remove the scaffolding or ladder after
completion of all the maintenance work.

8. CLEANING

a. The contractor shall clean the internal surface of the equipment and
internals including down comers, seal pans, distributors, its nozzles ,
support grids, etc., thoroughly free from scales, rust, coke, deposits using
mechanized cleaning system wherever possible and cold work cleaning
methods viz scrapers, wire brush in areas inaccessible by mechanized
tools.

b. The contractor shall clean the internal surface of the equipment in such a
way as to prevent debris falling on any of the troughs / seal pans / down
comers / tray decks.

c. The contractor shall carry out shot blasting / power brushing of the weld
seams 6 on either side of the weld joints to carry out Wet fluorescent
magnetic particle inspection (WFMPI) wherever required and spot buff the
parent metal surface of the equipment for ultra sonic thickness gauging.

d. The contractor shall clean the internal stainless steel lining & weld seams
using Stainless steel wire brush only.

e. The contractor shall clean the tray valves / bubble caps / fasteners /
clamps, etc., and replace with new one wherever found missing as per
scope of works.

f. Cleaning of the column for removal of dust and rust shall be carried out
using heavy duty industrial vacuum cleaner.

g. The contractor shall carry out the cleaning of fire water sprinkler nozzle of
respective columns. The scope includes removal of the nozzle, cleaning
and fitting back the same or new nozzle.

Page 3 of 6
9. UNLOADING & LOADING OF RANDOM PACKING / RASCHING RINGS

a. The contractor shall erect necessary temporary shelter using scaffolding

pipes & tin sheets , brick work near the equipment for safe storage of the
packing, raschig rings etc and dispose it on immediate basis at owner
designated place after necessary cleaning and making them hydrocarbon
free.

b. The Contractor shall unload all the random packing and rasching ring by
providing necessary chute / hopper arrangement. Crane, pneumatic /
electric winch required for loading / unloading of the packing shall be
arranged by the contractor.

c. All the random packing to be reused or otherwise shall be cleaned

properly using high pressure water jet to make it free of all the deposits,
muck and foreign material.

10. UNLOADING & LOADING OF STRUCTURED PACKING

a. Remove structured packing from the equipment as detailed in scope of

work in presence of original packing supplier.

b. Stack the packing near designated place, clean the same to make it
hydrocarbon free using hot / cold water and dispose.

c. All the removed structured packing shall be either replaced with new one
or old packing shall be reused as per instruction from site in charge.
Packing loading shall be carried out in presence of original packing
supplier. The services of packing supplier shall be provided by BPCL.

d. Dispose the damaged packing on immediate basis at owner designated

place after necessary cleaning and making them hydrocarbon free.

11. SEAL PAN TESTING OF DRAW OFF TRAYS:

a. The contractor shall carry out seal pan test for the draw off trays /
chimney and seal pans wherever required as per Attachment 11:
Section A and shall be offered to BPCL technologist.

12. DISTRIBUTORS :

a. All the distributors shall be removed, cleaned and offered for inspection to
Technology & Inspection department.
b. For Pipe type distributors, the flow test of the assembly shall be offered
outside the column.
c. For distributors with nozzles, remove all the nozzles, clean and sent to
recognized spray testing laboratory to check the Flow pattern / Angle,
capacity etc.

Page 4 of 6
13. EQUIPMENT NOZZLES:

a. The contractor shall de-plug the entire nozzles to clear from all deposits,
flush & clean all the nozzles using water and offer the same to operations
for witness.
b. Remove the corrosion coupon/probe from the column overhead lines and
offer to inspection. Fit back the same after inspection.
c. Clean and flush all the instrumentation main tapping nozzles with valves
on equipment.
d. Contractor shall remove the insulation on the nozzle / equipment as per
work scope and shall be restored back after completion of the inspection.

14. EQUIPMENT FIRST ISOLATION VALVES:

a. The contractor shall service all the first isolation valves except those
which are planned for removal, dismantling and testing.

b. Valve servicing includes opening of the valve, cleaning stem, greasing the
stem, flushing the valve through nozzle using water hose , making valve
free for opening / closing and gland repacking / pull up.

15. EQUIPMENT GAUGE GLASS :

a. The contractor shall remove all the gauge glasses along with
manifold/stand pipe from the column and carry out repair / servicing as
per procedure detailed under Attachment 12.
b. The contractor shall carry out the hydrotest of the stand pipes at column
hydrotest pressure.

16. EQUIPMENT BOX-UP:

a. The contractor shall box up all the dismantled internals / tray man-ways /
shell man-ways / top covers, etc with proper gaskets / packing after
obtaining necessary clearances from Operations & Tech. Services
department.

17. MULTIPLE WORK FRONT:

a. The contractor shall plan the resources properly & execute in such a way
that work at multiple location for the column can proceed without affecting
the other work at other location.
b. Contractor shall also be required to take multiple columns simultaneously
so as to complete the work as per the time schedule.

Page 5 of 6
18. INTERNAL REPAIRS:

a. The contractor shall carry out minor repairs to equipment internals and
the equipment parent surface as required. All these repairs /
replacements shall be done using cold work or hot work including but not
limited to straightening & bend removal of tray segments, removal of
cracks by grinding & welding, repairing of equipment internal lining & tray
support ring (TSR) as required. The entire repair by cold work is part of
lump sump scope.

b. In case of major repairs to trays, the contractor shall shift the trays to
construction shop and provide manpower assistance for carrying out
repairs to the trays. This is part of LS scope.

c. Tray valves and fittings shall be replaced wherever found missing as per
the EIC instructions.

d. Payment for repairs using hot work like removal of cracks by

grinding and welding, internal lining replacement, TSR welding will
be made as per applicable SOR based on the actual measurements.

19. JOB COMPLETION & STARTUP COVERAGE:

a. The contractor shall carryout boxing up of all flanges, manways, nozzles,

etc., with proper gaskets after obtaining necessary clearances from
Operations & Tech. Services department. For RTJ flanges, the flanges
shall be tightened by torquing/tensioning only.
b. Contractor shall carry out insulation in standard manner on all the
locations from where the insulation is removed.
c. The contractor shall do hot bolting during startup & commissioning of the
equipment and shall provide start up coverage till commissioning.

20. INSULATION REMOVAL:

a. Remove insulation for spading, de-spading, opening of column.

b. Remove Insulation around all the manways and nozzles up to first flange
or 250 mm from the column shell to assess CUI / UT gauging.
c. Make insulation pockets at all the platform level on all the four compass
direction for UT gauging.
d. If no insulation windows exist on the shell, then contractor shall cut the
insulation window as per insulation standard procedure. The removable
window shall be of the same basic material and thickness as the rest of
the insulation and of sufficient rigidity to withstand handling.
e. All the surfaces where insulation is removed has to be thoroughly cleaned
before offering to Inspection
f. After completion of the job, carry out painting as per AES 5430 Rev 1 and
then carry out insulation and cladding as per BPCL insulation procedure
given in Attachment 12.
Note: All the surfaces where insulation is removed ahs to be thoroughly
cleaned before offering to Inspection.

Page 6 of 6
 APPENDIX A: ATTACHMENT 3

SCOPE OF WORK: HEATERS

1. GENERAL

a) Contractor shall carry out all the jobs on heater as detailed below including
specific job detailed under Attachment 11 section B.

2. BLINDING & DE-BLINDING

a) The contractor shall carry out all preparatory works & blinding / spading for
Decoking and Passivation , removal / rotation of swing the elbows to facilitate
decoking , for isolation, entry of the equipment as per blind list and as
required at site.
b) The contractor shall swing the elbows back to the original position after
completion of decoking and de-blind on completion of all activities in the
heater.
c) Contractor shall provide necessary assistance to owners contractor for
chemical cleaning/ decontamination for connection of hoses, spading / de-
spading, temporary piping.

3. PANELS/COVERS/DOORS/MANWAYS/PEEP HOLE COVERS: -

a) The contractor shall dismantle all removable panels, covers, doors, man ways,
etc, as required and place them at the respective grade level or to ground level
as per site conditions.
b) Carry out necessary repair / rectification including welding of refractory anchors
and re-install on completion of work.
c) The contractor shall ease out the furnace explosion doors / peep hole doors,
keep them in open condition during execution of work inside the furnace and re-
fix back on completion of all activities.
d) Replace all the damaged bolts of the man way covers/ panels
e) The contractor shall weld refractory anchors wherever required.
f) The contractor shall carry out patch repair or fabricate panels, covers, door, man
ways, etc., wherever required.
g) Cutting of necessary gasket, packing ropes / tapes etc for panel installation shall
be carried out by contractor.

Page 1 of 9
4. SERVICING OF BURNERS:

a) The contractor shall remove all the burners with proper identification marks.
b) The contractor shall service the burners by dismantling of all items including
burner guns with match marks, cleaning, proving all the nozzles, and servicing of
Air registers, cleaning of sight glass.
c) Carry out removal / repair / replacement of cup throats / burner tiles / muffle
blocks as recommended.
d) The contractor shall blow out & prove the burner piping, hoses, etc., using steam
or air and obtain clearances from Inspection & Operations.
e) The contractor shall take necessary precautions to protect the burner muffle
blocks by covering with wooden covers whenever work is executed inside the
heater.

f) The contractor shall re-fix the serviced burners or with new ones, obtain
clearance from operations and box up on completion of all activities.
g) Burner gun assembly shall be carried out in presence of BPCL Energy and
Environment section engineer.
h) After Installation, burner shall be offered to Energy and Environment section
engineer for inspection i.e. for measurement of tip distance from reference point,
nozzle angles, pilot positioning etc.
i) Cutting of necessary gasket, packing ropes / tapes etc for burners installation
shall be carried out by contractor.
j) If burner assembly is not dropped, carry out covering of the burner from inside
the heater with solid metal plate to avoid damage to burner assembly.

5. SCAFFOLDING

a) The contractor shall erect scaffolding inside the heater in radiation section up to a
full height.
b) Planks shall be laid & tied properly with the scaffolding pipes at every 2 metres
height interval with two plank widths along the radius of heater tubes and the
arrangement shall be made in such a way that cleaning & inspection of all the
radiant tubes & bottom row of convection section tubes are comfortable.
c) The contractor shall also provide aluminum ladders at two locations for the full
height of the scaffolding for easy climbing.

d) The contractor shall also provide scaffolding inside the stack up to the stack
damper level.
e) The contractor shall also provide scaffolding externally for removal of convection
panels, inspection of cross over piping between radiation and convection section ,
heater shell man way opening, soot blower removal , air pre heater man way

Page 2 of 9
 opening, FD and ID duct man way opening , inspection and overhauling all
dampers / guillotines and stack painting .
f) Contractor shall also erect internal scaffolding in air pre heater duct, FD duct, ID
duct for inspection and repair.
g) After completion of the repair / inspection work, remove scaffolding.

6. EXTERNAL PASSIVATION OF TUBES:

a) Prepare the Passivation solution as per standard procedure given in Attachment

12 for pickling and Passivation.
b) The Passivation of the hand reach tubes shall be carried out immediately on
entry inside the heater and on completion of the internal scaffolding for balance
tubes.
c) Carry out spraying of the solution on the external surface of the tubes and ensure
that the entire tube surface is applied with the Passivation solution.
d) In case spraying is not possible, then carry out the mopping of the tubes with the
solution.

7. TUBE CLEANING:

a) The contractor shall clean the radiant tubes including return bends thoroughly
either using wire brush, scrappers or Copper slag blasting, as specified in
specific scope or by any other method to remove the deposits / scales.
Stainless steel tubes shall be cleaned using SS wire brush. Proper protection
to the refractory lining shall be provided before starting the copper blasting of
the tubes. Proper tarpaulin cover shall be placed behind the tubes to protect
the damage to the refractory lining. Any accidental damage to the refractory
shall be made good by the contractor on completion of the copper slag
blasting
b) The contractor shall also carry out spot cleaning at locations using emery
sheets, wire brush or power brush etc, for ultrasonic thickness measurement
and provide assistance to inspection for UT gauging.
c) The contractor shall power brush the weld seams & Heat Affected Zone of
weld ( 6 on either side of the weld) to carry out Dye penetrant testing (DPT)
and spot buff the parent metal tube surface for thickness gauging.
d) The contractor shall clean the convection tubes by water washing.
e) Necessary quantity of water proof tarpaulins / water collector shall be fixed
below convection coil bank during water washing of the coil. While water
washing of the convection tubes take proper care to avoid any damage to the
refractory / roof arch insulation blankets. The wash water collector drain shall
be taken out of the heater with proper chute arrangement.

Page 3 of 9
8. TUBE HANGERS AND SPIGOTS

a) Clean and offer the bottom Spigot supports to Inspection for free movements in
the guide sleeves provided in the bottom plate and offer DP test of all Spigot pipe
weld joints.
b) Clean and carry out inspection of roof hangers pin located inside the radiation
section just below the furnace roof.

9. CASING / FLOOR / PLENUM CHAMBER / APH / ID/FD DUCT CASING PLATE

REPLACEMENT / REPAIRS:

a) The contractor shall carry out replacement of furnace casing / Floor / Plenum/
ID/FD Duct casing plate as recommended by cutting, removal of the existing
casing plate along with stiffeners / supports, fabricate & erect the casing plate
matching to the existing profile along with required stiffeners in position, weld
to the adjoining casing or structural member and grind flush all the welds.
b) Contractor shall carry out cutting / re-welding of the duct plate at various
locations for internal inspection of the ducting.
c) The contractor shall provide over lap patch plate on the perforated casing
plate locations as recommended by fabricating a new casing plate to the
required size, erect in position, weld over the existing casing and grind flush
all the fillet welds.
d) The contractor shall weld refractory anchors wherever required.

10. THERMOCOUPLE REPLACEMENT

The contractor shall replace the skin thermocouple points as per following procedure.

a) Cut and remove the existing thermocouple. Welding pads for the existing
thermocouples should be retained in position.
b) Clean tube area 3*3 by grinding. Locate the clamp firmly in place. Centre of v
pad must touch the tube. Weld the clamp in place. Welding of new
thermocouples should be carried out adjacent to the existing thermocouples.
c) Carry out pre heating and post weld heat treatment.
d) Use GTAW process and electrode as per inspection recommendation.
e) After final welding carryout slow cooling by wrapping insulation.
f) Carry out pickling / passivation of the weld joint as required.
g) Offer weld joint for DP testing after completion of the welding

Page 4 of 9
11. HYDRO TEST:

a) The contractor shall carry out hydro testing of heater radiant, convection &
super heater steam coils to the specified test pressure.
b) The contractor shall fabricate necessary manifolds, laying temporary piping,
providing hose connections from the source of water supply to the heater coil
/ temporary storage tank, etc., for preparing hydro test.
c) Contractor shall arrange booster pump and temporary / piping up to heater
coil for filling water in all the coils simultaneously.
d) The contractor shall fill up the water in the heater coils, vent entrapped air,
pressurize to the required hydro test pressure with necessary test pumps,
and offer the coils for inspection.
e) Pressure gauge shall be provided on individual coil vent and drain.
f) The contractor shall drain the filled water on completion of hydro test and
displace the entrapped water using compressed air / nitrogen.
g) Steam super heater / Boiler feed water coil hydro test wherever applicable
shall be offered to Boiler inspector along with the steam generator circuit in
addition to BPCL inspection.
Note: To ensure the sufficient service water pressure during filling the
hydro testing circuit, contractor shall provide booster pump with temporary
water hold up tank.

12. PACKING OF EXPANSION GAPS:

a) The contractor shall pack the expansion gaps on the brick wall, expansion
joints, and on the header box between plain tubes & tube sheet holes using
ceramic fiber blankets.

13. SERVICING OF PNEUMATIC CYLINDERS

a) Remove pneumatic cylinders.

b) Dismantle and clean the actuators.

c) Replace consumables such as `O rings, Piston seals, Oil seals and Cylinder
end cover gaskets / O rings. Supply of all consumables is in your scope.

d) Carryout repairs such as servicing of Piston clamp, Cylinder mounting clamp,

rod clamp swivel joint, Piston rod machining, chrome plating, Cylinder barrel
honing and chrome plating.

e) Assemble the actuators, test and carryout painting.

Page 5 of 9
14. DAMPER SERVICING:

a) The contractor shall carry out easing and servicing of all the dampers
including stack damper, guide vanes etc on stack, ID / FD ducting, Air Pre
Heater ducts. ,
b) Servicing includes, making the damper free for operation, lubrication of the
mechanism, replacement of the wire ropes, and checking the operability of
the dampers.
c) The contractor shall carry out winch servicing/ replacement along with pulleys
& wire ropes.
d) The scope shall also include servicing of the peep hole door hinges, servicing
of wire ropes and replacement of rope if required.
e) For multi louver damper following procedure shall be followed.
i. Delink the multi louver damper from its operating mechanism.
ii. Remove the common connection link of all the multi louvers.
iii. Carry out easing of the individual louver and opening / greasing of
all individual plumer block bearings.
iv. On completion of the easing, offer individual louver operation to
BPCL.
v. Connect the common link and operating mechanism and offer the
damper for operation.
vi. For checking the proper functioning of the damper, nearby duct
man ways shall be opened and damper operation shall be
checked from the same.
vii. Make proper lighting / Scaffolding arrangement inside the duct for
checking of the damper operation.
viii. On completion of the checking, box up the duct manways &
remove all Scaffolding.
ix. Carry out replacement of the missing / damaged duct manways
bolts

15. REPLACEMENT OF EXPANSION JOINT FABRIC :

a) Open all the bolts for non metallic expansion joint fabric cloth.
b) Remove the old damaged fabric.
c) Carry out hole drilling to the new fabric in presence and with assistance of
OEM. Services of OEM shall be arranged by Owner.
d) Install the fabric on the expansion joint.
e) Carry out bolt tightening.

Page 6 of 9
16. REFRACTORY:

a) Carry out Refractory jobs as required in the work details and as per
Inspection.
b) Refractory jobs shall include replacement / repairs to radiant wall / floor /
convection panel / stack internal / convection ducting, air pre heater ducts, ID
ducts by brick lining / castable / ceramic fiber as applicable.
c) Cast able refractory renewal shall be done by gunniting / Hand application as
required and patch repair by trowel application as per recommended
application procedures.
d) Refractory repairs include welding of anchor hooks and supports and all such
related mechanical work.
e) Carry out removal and re-fixing and repair to the Muffle blocks and burner
throat as required.

17. GENERAL CLEANING:

a) The contractor shall remove the fallen refractory, insulation materials, debris
& other materials inside the heaters & ducts on completion of all activities and
maintain the area in & around the furnace with better house keeping.

18. TRANSFER LINE

Transfer line means line coming out from the individual pass of heater and going
to the main column either as individual or as single line after joining to common
header.

a) Erect scaffolding / boson chair arrangement for inspection of the line.

b) Remove insulation at all the bends of all the transfer lines.
c) Make insulation pocket / window at every 10 meter interval in four compass
directions on straight line.
d) Clean and make spot on the line for UT gauging / scanning.
e) Open the end blind flanges on the transfer line including that for the nozzles
and offer line for inspection.
f) Offer line for UT gauging.
g) After completion of the inspection, insulate the line as per BPCL insulation
procedure and remove scaffolding / bosom chair arrangement.

Page 7 of 9
19. AIR PRE HEATERS
a) Open APH duct man ways.
b) Erect internal scaffolding.
c) Carry out flue gas side water washing of all the Glass and Cast air pre heater
using high pressure water jet. Before cleaning, provide proper water
collection arrangement including chute below the bottom most module and
route the drain water out of the APH duct. No water shall be allowed to spray
on the refractory lining of the APH duct.
d) Carry out internal scrape cleaning and painting of the duct as required.

20. STACK INSPECTION AND PAINTING

a) Open stack man way.
b) Make boson chair arrangement for internal inspection of the stack. Boson
chair shall be supplied by BPCL, however contractor shall arrange necessary
steel wire rope winch.
c) Carry out fabrication of the structural beam for mounting on the stack top for
guiding and supporting the boson chair and its wire rope.
d) Boson chair arrangement shall be offered for load test to BPCL safety
inspector before its actual use.
e) Operation of the boson chair during inspection and repair of the refractory is
included in your scope.
f) Carry out repair to internal refractory lining as per scope of work. Refractory
repair shall include removal of old refractory and anchors, welding of new
anchors and refractory lining.
g) Carry out external scrape cleaning and painting of the stack with 2 coats of
zinc dust graphite using rope access technology / equivalent method.
Painting of stack with conventional box scaffolding shall not be allowed.
h) After completion of inspection, remove the boson chair arrangement and box
up stack man way.

21. BURNER VALVES FOR OIL AND FUEL GAS

a) Scope includes removal of all the Ball / Plug / Gate / flapper type valves of the
burner.
b) Clean the valve internally.
c) Repack the gland / grease the plug valve.
d) Carry out hydro testing, body and seat, of the valve as per flange rating.
e) Replace / repair the passing valve

Page 8 of 9
22. FUEL GAS LINE(PILOT &MAIN)
a) Carry out card blasting of fuel gas line after hydrotest.

23. DUCTS
Ducts includes all the following ducting,

Hot air duct

FD suction and discharge duct

Flue gas ducting

Individual burner combustion duct & wind box .

a) Open all the duct man ways including FD discharge to individual burners.
b) Erect scaffolding internally.
c) Carry out internal cleaning of all the ducts and FD ducts up to burners
including cleaning of individual burner mesh. Removal and installation of the
baffles inside the duct shall be carried out.
d) Scrape clean the duct plate internally and paint as per BPCL painting
specification AES 5430.
e) Carry out cleaning of Individual burner combustion duct & wind box to remove
the oils accumulation if any.
f) After completion of the painting, remove scaffolding, box up man ways.

24. JOB COMPLETION:

a) The contractor shall carryout boxing up of all the man ways, flanges with
proper gaskets after obtaining necessary clearances .Carry out tack welding
of all bolts of all ducts manway/burner assemblies wherever required.
Replace all the broken bolts of all ducts manway/burner assemblies as
required.
b) Carry out insulation in standard on all the locations from where the insulation
is removed
c) Remove all the spades provided for hydro testing of the heater coil
d) Remove the entry / isolation spaded on completion of the job.

Page 9 of 9
 APPENDIX A: ATTACHMENT 4

SCOPE OF WORK: HEAT EXCHANGERS & AFC

1. GENERAL

a) Contractor shall carry out all the jobs on heat exchangers as detailed below including
specific job detailed under Attachment 11 Section C.

2. PREPARATORY JOBS / BLINDING / DE-BLINDING:

a) The contractor shall carry out all preparatory works & blinding for isolation and
testing. The blind shall be installed on the inlet and out let side of the shell and tube
side nozzles and all process connection to the heat exchangers.
b) The Contractor shall erect necessary scaffolding, wherever required to facilitate
removal of covers and shall dismantle / remove on completion of all activities.
c) The contractor shall also provide necessary rigging facilities for lifting & lowering the
heat exchanger component to the respective structural platforms near the equipment.
d) The contractor shall service the test rings intended for the equipment including all
fasteners before starting the exchanger maintenance work, clean all ring on
completion of testing activities and secure it on the test ring stand firmly.
e) Contractor shall ensure that all dismantled parts of heat exchangers are segregated
& painted with proper identification marks including the fasteners in order to eliminate
mix up of parts. Contractor shall store all the fasteners in separate bins.
f) The contractor shall carry out de-blinding on completion of all maintenance activities,
box up the flanges with new gaskets and tightening of studs (replace the defective
studs / nuts) to ensure zero leak of joints including hot bolting.

3. REMOVAL OF COVERS & TUBE BUNDLES:

a) The contractor shall open the exchanger channel cover, channel box, shell cover,
floating head cover, etc de-bolting by pneumatic tools / torque wrench (cold / gas
cutting if required), and place the covers at the grade level.

b) In case of Fin fan coolers with plug design, the contractor shall remove the 2 nos.
plugs each on inlet and out let side of each pass of Air Fin cooler. Wherever re-
tubing is required all plug shall require opening.

Page 1 of 10
c) In case of Fin fan coolers with cover design, the contractor shall remove and drop all
the end covers of air fin coolers at both ends using chain pulley blocks/ crane
wherever applicable.

d) All exchangers with float head type & U tube design, the contractor shall pull out the
tube bundle from the shell using bundle pullers and crane / escort / hydra in safe
manner and take the tube bundle at ground level and load on the low bed trailer
( Trailer wheel diameter not more than 300 mm )

e) Contractor shall select the suitable capacity of bundle puller and crane / escort /
hydra based on bundle weight and exchanger elevation.

f) At some locations, to facilitate the bundle removal, the structure / piping obstructing
the process shall be removed and same shall be restored back after completion of
the job.

4. TRANSPORTATION OF TUBE BUNDLES:

a) After loading the tube bundle on the trailer, bind the bundle using load binder.

b) The contractor shall carry out to & fro transportation of tube bundles from the work
site to following locations for executing work as detailed below:

Tube bundle cleaning yard or the designated place for cleaning

Exchanger shop for tube bundle re-tubing.

Note: All the tube bundles requiring re-tubing at BPCL shop, shall be
cleaned internally / externally carry out inspection activities like ECT /
RFET and then shall be sent to shop.

5. CLEANING OF EXCHANGER TUBE BUNDLE, COMPONENTS & FIN FAN

COOLER TUBES:

a) The contractor shall carry out cleaning of exchanger tube bundle, its components &
fin cooler tubes as detailed below.

5.1 In-Position Cleaning

a) The contractor shall carry out in position to bare metal cleaning of the following
component of exchanger using hydro jetting / Power lance machine ( Electric driven
only ) having capacity to develop at least 20,000 psi hydraulic pressure at the nozzle.

Page 2 of 10
 o Internal tube cleaning of the fixed tube sheet design heat exchanger

o Internal cleaning of air fin cooler tubes.

o Channel cover, channel box, shell, float head cover including split ring,
shell cover.

5.2 Cleaning of Pulled out Tube Bundles:

The contractor shall clean the tube bundle (internally and externally) using hydro jetting
machine / Power lance (Electric driven only) having capacity to develop at least 20,000
psi hydraulic pressure at the nozzle.

5.2.1 Tube internal cleaning:

Hydro jetting / Power lance : The exchanger tube internal surfaces are to be cleaned
to bare metal using hydro jetting / Power lance machine (Electric driven only ) having
capacity to develop at least 20,000 psi hydraulic pressure at the nozzle. .

5.2.2 Tube external cleaning:

Hydro jetting / Power lance: The exchanger tube external surfaces are to bare metal
using hydro jetting machine (Electric driven) having capacity to develop at least 20,000
psi hydraulic pressure at the nozzle.

Note: For all the hydro jetting machines, machine mounted water tank supply line
shall be provided with the ball & float arrangement to avoid the wastage of the
water. No overflow of the water shall be allowed from the water tank.

The contractor shall carry out the cleaning of fire water sprinkler nozzle of
respective AFC/exchanger. The scope includes removal of the nozzle, cleaning
and fitting back the same or new nozzle.
6. REPLACEMENT OF HDPE / METALLIC INSERTS:-

a) All coolers in sea water service are having either HDPE or Metallic inserts at
their inlet and outlet. These inserts shall be removed completely before
cleaning the tube bundle and shall be replaced with new one as existing.
Flaring of the new metallic inserts shall be carried out by the contractor.

7. REPLACEMENT OF ANODES:-

a) The sacrificial CS / Zinc / Magnesium anodes welded / fastened to the

channel head, floating head & covers are to be removed & shall be replaced
with new one.

Page 3 of 10
 b) If anode holding studs are found damaged, then carry out replacement of the
same.

8. PAINTING OF THE HEAT EXCHANGER COMPONENT: -

a) For all heat exchanger with cooling water service on tube side other than
those identified for glass flake coating, following component shall be painted
with Coal tar epoxy paint as per BPCL painting specification AES 5430.

o Both tube sheet

o Channel box

o Channel cover

o Float head cover

9. SHOT-BLASTING/ POWER BRUSHING FOR WFMPI OF SHELL WELD JOINTS:-

a) Contractor shall carry out shot blasting / power brushing of the weld joint
covering 6 inch area on either side of the weld joint of shell and other
component of exchanger as detailed against each equipment (Attachment
11 Section C) and offer for WFMPI testing.

10. INSULATION REMOVAL:

a) Remove insulation for spading, de-spading, opening of heat exchanger.

b) Remove Insulation around all the nozzles up to first flange or 250 mm from
the shell to assess CUI / UT gauging.

c) Remove Insulation at insulation support rings for all exchanger shells to

assess CUI

d) Make insulation pockets for taking UT gauging at every 2 meters on shell (In
all four directions), dish ends / covers (4 directions) for UT gauging.

e) If no insulation windows exist on the shell, then contractor shall cut the
insulation window as per insulation standard procedure. The removable
window shall be of the same basic material and thickness as the rest of the
insulation and of sufficient rigidity to withstand handling.

Page 4 of 10
 f) After completion of the job, carry out insulation and cladding as per BPCL
insulation procedure given in Attachment 12. The same also includes
painting with 2 coats of Zinc dust Graphite(2 x 30 micron)

Notes:

1. Point (c) related to Insulation rings shall not be applicable if not

mentioned against specific equipment.

11. COLD & WELD REPAIRS:

Following jobs on the heat exchanger component shall be carried out as detailed against
each equipment task list or as recommended during course of inspection of equipment.

a) The contractor shall rectify the transverse baffle edges, tie rods, spacers,
impingement plates, longitudinal baffles, sacrificial anodes, etc., by grinding /
bend removal / weld repairs, etc.,

b) The contractor shall carry out weld repairs on shell, tube bundle &
components like channel box, channel cover, floating head cover, shell cover,
sacrificial anodes holding studs , in-situ machining.

c) The contractor shall carry out weld reinforcement to the eroded / corroded
portions on tube sheet, gasket seating surfaces of components & on tube
seal welds.

d) The contractor shall replace the channel head pass partition plate wherever
required.

12. IN-SITU RE-TUBING OF FIXED TUBE EXCHANGERS / AIR FIN COOLER

INCLUDING SEAL WELDING:-

The contractor shall carry out

In-situ re-tubing of all fixed tube heat exchanger and air fin coolers as
specified against individual exchanger / air fin coolers scope.

In-situ re-tubing for leaky tubes identified during hydro testing for fixed head,
AFC or Floating head type exchangers / coolers.

as per following procedure.

Page 5 of 10
 a) After removal of all the covers, channel box, opening of the plugs, make
necessary working platform arrangement by erecting scaffolding and planks
to facilitate the tube removal.

b) Remove seal welding of the tubes by grinding / suitable means if applicable.

c) Carry out cutting of the tubes at one end as required using pneumatic /
electrically operated internal tube cutter.

d) Using appropriate puller remove the tubes from tube sheet.

e) Remove the left out ends of the tubes on other end of the tube sheet.

f) Unload all the removed tubes on the ground floor and transport them back to
warehouse for disposal.

g) Shift all the new tubes to site / at equipment installed grade level.

h) Clean the tube holes in both the tube sheet.

i) Insert the tube and carry out expansion of the tube in both the ends.

j) Cary out seal welding as required for a tube bundle. The contractor shall
carry out the same after expansion / rolling. Seal welding procedure shall be
based on the tube / plug material.

k) Roll leak if any found during hydro testing shall be rectified by the contractor.

Note: Wherever the tube bundles are being sent to BPCL shop, the retubing shall
be carried out by BPCL.

13. RE-INSTALLATION OF TUBE BUNDLES & COMPONENTS:

a) The contractor shall re-install the tube bundles after cleaning / re-tubing &
obtaining clearance from BPCL Maintenance, Inspection and Operations
Departments by using bundle puller , crane , chain pulley block , trolley etc,

b) The contractor shall re-install the components of heat exchangers after

cleaning & obtaining clearance from BPCL Maintenance, Inspection and
Operations Departments in a stage wise manner to facilitate hydro testing.

c) The contractor shall renew all the gaskets pertaining to the exchanger
components and disturbed flanges while re-assembly.

Page 6 of 10
 d) The contractor shall clean & salvage all the RTJ Gaskets and re-use. Cary
out necessary lapping of the RTJ flange groove to obtain leak free joint.

14. HYDRO-TEST:

a) The contractor shall carry out hydrostatic testing of the exchanger to the
specified test pressures after re-installing the tube bundles & components as
detailed below.

Note: To ensure the sufficient service water pressure during filling the
hydro testing circuit, contractor shall provide booster pump with temporary
water hold up tank.
15.1 SHELL TEST:

Shell test is applicable for all types of exchangers as detailed below.

Float head type heat exchanger: The contractor shall conduct shell test by
installing channel box on the stationary end side & a test ring between the floating
head tube sheet and shell.

Fixed tube sheet heat exchanger: The contractor shall conduct shell test without
installing channel box.

U tube bundle design: The contractor shall conduct shell test without installing
channel box. Test to be conducted by either installing test ring or for tube sheet
having tapped holes without ring. On the stationary end side, fix the shell covers if
applicable.

Hydro test Procedure:

The contractor shall fill up water in shell & pressurize the shell side of exchanger
gradually. The contractor shall clean all the visible weld joints and the flanges
between fixed tube sheet and shell flange and offer for inspection at the specified
test pressure. The contractor shall remove the water accumulated inside the tubes
by high pressure air before offering the test for Inspection.

The contractor shall plug both the tube ends in case of a tube leak with tapered
plugs of material conforming to tube material in the presence of BPCL Inspection.

Incase of plugging the tube; cutting of the tube, puncturing, seal welding of plug
based on material of construction shall be carried out by the contractor.

Page 7 of 10
 Shell test shall be deemed completed till satisfactory results are observed without
any tube or roll leaks.

For Waste heat boilers, re-boilers & condensers under the purview of IBR
requirements, shell test shall be offered to the statutory authority in addition to BPCL
inspection as per scope of work.

15.2 TUBE TEST:-

Tube test is applicable for fin fan coolers and all types of exchangers as detailed below

Float head design heat exchanger: The contractor shall conduct tube test by
removing the test ring on floating head side installed for shell test and fixing floating
head cover in position. The contractor shall also fix channel head cover in position
with proper tightening.

Fixed head heat exchanger: The contractor shall conduct tube test by installing
channel box, channel cover and shell cover(Backside channel box and cover).

Kettle type re-boiler / U tube design bundles / floating head tube bundle with
fixed shell cover exchangers: - The contractor shall conduct a tube test outside the
shell by fixing channel box and test ring.

The contractor shall fill up water in tube side through the channel section &
pressurize the tube side of exchanger gradually to the specified tube test pressure.
The contractor shall air blow the floating head & channel cover flanges and look for
any leaks. The contractor shall tighten all the fasteners uniformly using torque
wrenches in order to eliminate all leaks and offer for inspection.

In case of pressure drop observed through the pressure gauges and there is no leak
through the floating head & channel cover flange gaskets, the contractor shall open
the shell side drain valve for water accumulation in shell.

In case of a failure of tube test, the contractor shall re-do the shell test to identify the
leaky tube.

Tube test shall be deemed completed till satisfactory results are observed without
any leaks through floating head & channel cover gaskets and water accumulation
through shell drain connection and no pressure drop on gauges.

Page 8 of 10
 For Waste heat boilers, re-boilers & condensers under the purview of IBR
requirements, tube test shall be offered to the statutory authority in addition to BPCL
inspection as per scope of work.

TUBE TEST FOR AFC

The contractor shall conduct tube test by installing both the header box cover / plugs.

The contractor shall fill up water in tube side through the header box & pressurize the
tube side of air fin cooler gradually to the specified tube test pressure. The contractor
shall air blow both the cover flange location and look for any leaks. The contractor
shall tighten all the fasteners uniformly using torque wrenches in order to eliminate
all leaks and offer for inspection.

The contractor shall erect scaffolding below the AFC to inspect for roll leaks.The
external surfaces of the tube shall be cleaned by air blowing.

Tube test shall be deemed completed till satisfactory results are observed without
any leaks through cover gaskets / plugs/roll leaks

15.3 COMBINE TEST:-

Combine shall be conducted as detailed below.

The contractor shall conduct combine test by fixing channel box and cover over the
shell test set up.

The contractor shall fill up water in shell and tube & pressurize the exchanger
gradually to respective pressure. The contractor shall air blow the flange gasket
area and offer for inspection at the specified test pressure. The contractor shall
tighten all the fasteners uniformly in order to eliminate leaks through the gasket.

Combine test shall be deemed completed till satisfactory results are observed
without any leaks.

16. JOB COMPLETION & DE-SPADING:

After completion of the testing, the contractor shall carryout de-spading and boxing
up of all flanges, nozzles, etc., with proper gaskets / packing after obtaining
necessary clearance. For RTJ flanges, the flanges shall be tightened by
torquing/tensioning only.

Page 9 of 10
 Carry out insulation in standard on all the locations from where the insulation is
removed.

***********************

Page 10 of 10
 APPENDIX A: ATTACHMENT 5

SCOPE OF WORK: VESSELS

1. GENERAL

a. Contractor shall carry out all the required jobs on Vessels as detailed
below including specific job detailed under ATTACHMENT 11 sections E.

2. SPADING / DE-SPADING

a. Contractor shall carry out all the preparatory work including connection of
temporary hose for washing, steaming, venting and draining the
equipment.
b. Carry out spading / de-spading as per the blind list.
c. Carry out wedge opening on the spades for gas freeing the equipment.
d. Before entry all the wedge opened spade shall be normalized.
e. After completion of the work carry out de-spading / spading to restore the
condition of equipment for normal operations.
f. Contractor shall provide necessary assistance to owners contractor for
chemical cleaning/ decontamination for connection of hoses, spading /
de-spading etc

3. MANWAY OPENING AND BOX UP

a. Open all the vessels manways including skirt opening.

b. Keep all the fasteners of manway in separate bag with identification tag
on it.
c. Man way davit shall be made free by using rust remover of heating using
gas torch.
d. After completion of the job on vessels, box up all manways in presence of
operation and maintenance representative.

4. ENTRY IN VESSELS

a. The contractor shall enter the equipment only after obtaining specific
permit / clearance for entry. Standby personnel shall be kept always near
the equipment manway (outside) during men at work inside the
equipment.
b. Provide air ventilation system such as exhaust fan / eductor / air hose and
dismantle connected lines for ventilation to carry out jobs in vessel.
Exhaust fan / educator shall be supplied by contractor.
c. Provide adequate lighting inside the vessels using 24 volt flame proof
hand lamps and transformer.

5. DISMANTLING & RE-FIXING OF INTERNALS:

a. The contractor shall dismantle & remove the equipment internals

wherever required as detailed under equipment specific work scope in

Page 1 of 6
 ATTACHMENT 11 sections E. The equipment internals shall include
catalyst, sand, filter element, demister pads, rasching ring , distributors,
steam coils, grids, and structural items used for supporting the internals.

b. The contractor shall mark legibly using permanent marker and non
tearable tags on all the internals, distributor piping and all other
removable internals before dismantling for better identification during re-
fixing.

c. All the demisters wherever applicable shall be removed and replaced with
new one. Removed demisters shall be cleaned with hot water to make
them suitable for disposal at owners designated place. All demisters shall
be installed with the assistance of suppliers.

d. The contractor shall re-fix either with repaired internals or with

replacement materials after obtaining necessary clearance from
Operations / Inspection.

e. In case of Dosing tanks, contractor shall remove the agitator assembly

wherever applicable and fit back the same after cleaning.

6. Preservation of internals and its hardware:

a. The contractor shall keep the hard wares (viz.,) fasteners, clamps,
washers, etc., wherever removed in a safe custody and the same need to
be reused after servicing.
b. Servicing of fasteners includes cleaning by kerosene, wire brushing and
application of antiseize compound like Molysulf etc.

7. SCAFFOLDING

a. The contractor shall provide necessary scaffolding or Ladder inside the

equipment at the required locations to access internals / internal surface
of the vessel. The Contractor shall also provide scaffolding externally
surrounding the equipment as required for inspection of nozzles, removal
of instruments etc.

b. Erect scaffolding inside the skirt for inspection of the bottom elbows / dish
end of the vessels.

c. The contractor shall dismantle & remove the scaffolding or ladder after
completion of all the maintenance work.

8. CLEANING

a. The contractor shall clean the internal surface of the equipment and
internals including distributors, its nozzles , support grids, etc., thoroughly
free from scales, rust, coke, deposits using mechanized cleaning system

Page 2 of 6
 wherever possible and cold work cleaning methods (viz) scrapers, wire
brush in inaccessible area.

b. The contractor shall clean the internal surface of the equipment in such a
way as to prevent debris falling on any of the nozzles.

c. The contractor shall carry out shot blasting / power brushing of the weld
seams 6 on either side of the weld joints to carry out Wet fluorescent
magnetic particle Inspection (WFMPI) wherever required and spot buff
the parent metal surface of the equipment for thickness gauging. After
WFMPI, carry out the painting of the shot blasted/power brushed surface
as per AES 5430 Rev 1, wherever applicable.

d. The contractor shall clean the internal stainless steel lining & weld seams
using SS wire brush and pickling.

e. The contractor shall clean and service fasteners / clamps, etc., and
replace with new one wherever found missing as per EIC Instructions.

9. UNLOADING & LOADING OF CATALYST , SAND & RASCHIG RINGS

a. The contractor shall erect necessary temporary shelter using scaffolding

pipes & with tin sheets near the equipment for safe storage of the catalyst
/ sand, rasching rings etc and dispose it on immediate basis after
necessary cleaning and making them hydrocarbon free.

b. All the catalyst / sand etc ring shall be replaced with new one.

10. EQUIPMENT NOZZLES:

a. The contractor shall flush & clean all the nozzles using water hoses, de-
plug the nozzle clear from all deposits and offer the same to operations
for witness.
b. Clean and flush all the instrumentation main tapping nozzles with valves
on equipment.

11. INSLUATION REMOVAL

a. Remove Insulation at insulation support rings for all insulated vessels to

assess CUI wherever mentioned against specific equipment.

b. Remove insulation around all the manways and nozzles up to first flange /
250 mm from the shell for UT gauging.

c. Make insulation pockets on the shell for taking UT gauging at every 2

meters on shell in all four directions, dish ends (4 directions) for UT
gauging.

Page 3 of 6
 d. If no insulation windows exist on the shell, then contractor shall cut the
insulation window as per insulation standard procedure. The removable
window shall be of the same basic material and thickness as the rest of
the insulation and of sufficient rigidity to withstand handling.

e. After completion of the job, carry out insulation and cladding as per BPCL
insulation procedure given in Attachment 12. The same also includes
painting with 2 coats of Zinc dust Graphite(2 x 30 micron)

Notes:

1. Point a related to Insulation rings shall not be applicable if not

mentioned against specific equipment.

12. EQUIPMENT FIRST ISOLATION VALVES:

a. The contractor shall service all the first isolation valves except those
which are planned for removal, dismantling and testing.

b. Valve servicing includes opening of the valve, cleaning steam, greasing

the stem, flushing the valve through nozzle using water hose and making
valve free for opening and closing.

13. MIXER / STIRRER ASSEMBLY FOR CHEMICAL TANKS /

VESSLES

a. The contractor shall remove the mixer / stirrer assembly and over the
same to site in-charge for overhauling of any. After replacement / repair,
assemble the mixer assembly.

14. EQUIPMENT GAUGE GLASS :

a. The contractor shall remove all the gauge glass from the vessels along
with manifold/stand pipe wherever applicable and carry out repair as per
procedure detailed under Attachment 12.
b. The contractor shall carry out the hydrotest of the stand pipes at vessel
hydrotest pressure

15. EQUIPMENT BOX-UP:

a. The contractor shall box up all the dismantled internals / tray man-ways /
shell man-ways / top covers, etc., with proper gaskets / packing after
obtaining necessary clearances from Operations & Tech. Services
department.

Page 4 of 6
16. EQUIPMENT EXTERNAL / INTERNAL PAINTING :

a. The contractor shall carry out internal / external painting of the vessels as
per specified painting class and BPCL panting specification AES 5430
given in Attachment 12.

17. HYDRO TESTING OF VESSEL

a. Carry out hydro testing / water fill up test of the vessels as per test
pressure.

b. During hydro testing all the spades installed for entry of the vessel shall
be relocated on downstream of isolation valve for including the entire first
isolation valve in hydro test circuit for body test.

c. Hydro testing of the vessel shall be carried out with all internals fitted
inside.

d. During hydro testing, initially all the flanged isolation valve shall be kept in
open condition to check the integrity of the valve body. On completion of
hydro test with all valves in open condition, close the entire valve, open
the downstream flange of the valve and check the valve for seat passing /
testing. Seat testing shall be witnessed by inspection / Process engineer
of Owner.

e. After completion of the hydro test, drain the water slowly after taking
necessary precaution.

f. In vessels having sand, charcoal, etc hydrotest shall be done prior to

filling of san , charcoal back inside the vessel and again manway shall be
opened for filling of sand, charcoal, etc.Final box up of manway shall be
after filling sand, charcoal ,etc inside the vessel.

Note: To ensure the sufficient service water pressure during filling

the hydro testing circuit, contractor shall provide booster pump with
temporary water hold up tank.

18. MULTIPLE WORK FRONT:

a. The contractor shall plan the resources properly & execute in such a way
that work at multiple location for the vessel can proceed without affecting
the other work at other location.

b. Contractor shall also be required to take multiple vessels simultaneously

so as to complete the work as per the time schedule.

Page 5 of 6
19. INTERNAL REPAIRS:

a. The contractor shall carry out minor repairs to equipment internals and
the equipment parent surface as required. All these repairs /
replacements shall be done using cold work like straightening & bend
removal of internals support / plates.

b. The contractor shall carry repair to the vessel internal / internals by hot
work like removal of cracks by grinding & welding, repairing of internal /
external surface pits by welding and grinding, removal and welding of
cracks on support ring (TSR), replacement of nozzles as required.

c. Payment for repairs using hot work shall be made as per applicable
SOR based on the actual measurements.

20. JOB COMPLETION & STARTUP COVERAGE:

a. The contractor shall carryout boxing up of all flanges, manways, nozzles,

etc., with proper gaskets after obtaining necessary clearances from
Operations & Tech. Services department. For RTJ flanges, the flanges
shall be tightened by torquing/tensioning only.
b. Carry out insulation in standard on all the locations from where the
insulation is removed.
c. The contractor shall do hot bolting during startup & commissioning of the
equipment and shall provide start up coverage till commissioning.

Page 6 of 6
 APPENDIX A: ATTACHMENT 6

SCOPE OF WORK: EJECTORS

Contractor shall carry out all the jobs on ejectors as detailed below. List of ejectors is
given in Attachment 11 section F.

a) Erect necessary external scaffolding.

b) Carry out spading on steam inlet and process fluid inlet and outlet.

c) Entire shell of the ejectors shall be offered for external UT gauging / scanning.

d) Make necessary rigging arrangement for removal of the steam nozzle assembly.

e) Open the ejector steam nozzle flange and remove the assembly out of the shell/
mixing chamber.

f) Care shall be taken to avoid any damage to the steam nozzle bolts. In case of
damage beyond control, all the broken studs for the steam nozzle flange shall be
removed by drilling and then carry out the tapping for reassembly of the nozzles.

g) Clean and offer the steam nozzle for inspection and dimensional check to
Inspection / Technology

h) Make necessary scaffolding / ropes ladder arrangement for inspection of the

throat diameter. Throat diameter check shall be carried out by BPCL technologist.

i) After completion of the inspection, remove the ladder / scaffolding from shell,
assemble the steam nozzle assembly.

j) Necessary repair / replacement based on inspection recommendation shall be

carried out by the contractor.

k) Carry out restoration of all the old damaged insulation cladding for ejector shells.

l) De-spade and box up all the flanges.

m) Remove scaffolding after completion of the job.

Page 1 of 1
 APPENDIX A: ATTACHMENT 7

SCOPE OF WORK: PROCESS / CW VALVES

Following procedure shall be followed for servicing of the process valves /

cooling water piping valves.

A) ISOLATION VALVES FOR COOLING WATER SERVICE (LIST OF VALVES IS

GIVEN IN ATTACHMENT 11 section J)

(Type of valve: Gate / Check and Globe)

1. Removal of valve

a) Erect necessary scaffolding.

b) Provide metal tag on the valve and pipe nozzle indicating the location of the
valve and original mounting direction like stem position Vertical or
horizontal on North/ South/East/West etc.

c) Open and remove both the flange bolts.

d) Make necessary rigging arrangement.

e) Lower the valve from pipe line to ground level.

2. Transportation of valve

a) After removal, load the valve on hand cart / low bed trailer.

b) If required, use load binder to avoid falling of valve from cart / trailer during
transportation.

c) Shift the valve to central hydro testing / repair area.

3. Dismantling of valves

a) Dismantle the valve completely.

b) Clean all the component of valve like, body, bonnet, gate, stem, seat,
seat rings free of foreign material using raw water high pressure jet after
removal of the FRE lining.

Page 1 of 6
4. Inspection of valve

a) Offer the entire component of valve to inspection.

b) Based on inspection finding / recommendation valve shall be assembled

or reconditioned as per procedure given in Attachment 12.

5. Assembly of valves

a) After inspection, carry out FRE lining on the wet part of the body, bonnet
and gate / check valve as per procedure given in Attachment 12. FRE
lining on gate for non ferrous trim valve is not applicable.

b) For globe valve, carry out glass flake coating on all wet part as per EIL
specification no. 4691-0642-01 given in Attachment 12.

c) Cut the bonnet gasket from compressed asbestos fiber sheet.

d) Assemble the valve.

e) Replace the gland packing.

f) Grease the stem.

g) After final assembly, operate the valve and check for its free ness /
operability.

6. Installation of the valve

a) Shift the valve to respective location.

b) Make necessary rigging arrangement.

c) Place the valve in position.

d) Check the valve mounting direction on the tag.

.
e) Fit back the valve in position accordingly and tighten the flange bolts. Use
new gasket while installation of valve.

f) Remove scaffolding.

B) ISOLATION VALVES FOR COOLING WATER SERVICE (LIST OF VALVES IS

GIVEN IN ATTACHMENT 11 section J)

(Type of valve: Butterfly valve)

1. Removal of valve

a) Erect necessary scaffolding.

Page 2 of 6
 b) Provide metal tag on the valve and pipe nozzle indicating the location of
the valve and original mounting direction like wheel position, Vertical or
horizontal on North/ South/East/West etc.

c) Open and remove both the flange bolts.

d) Make necessary rigging arrangement.

e) Lower the valve from pipe line to ground level.

2. Transportation of valve

a) After removal, load the valve on hand cart / low bed trailer.

b) If required, use load binder to avoid falling of valve from cart / trailer
during transportation.

c) Shift the valve to central cleaning area.

3. Dismantling of valves

a) Open the gear box cover for 10 inch and above valves.

b) Clean the internal component, grease/ oil them.

c) Clean all the component of valve like, body externally and internally, seat,
seat rings, and disc free of foreign material using raw water high pressure
jet.

d) Replace the rubber seal ring O ring of the valve with new one. Supply of
O ring is in contractors scope.

4. Inspection of valve

a) Offer the entire valve for visual inspection.

b) Incase valve is found damaged and not serviceable; same shall be

repaired / reconditioned as per procedure given in Attachment 12.

5. Installation of the valve

a) Shift the valve to respective location.

b) Make necessary rigging arrangement.

c) Place the valve in position.

d) Check the valve mounting direction on the tag.

Page 3 of 6
 e) Fit back the valve in position accordingly and tighten the flange bolts. Use
new gasket while installation of valve.

f) Remove scaffolding.

C) ISOLATION VALVES ON PROCESS (LIST OF VALVES IS GIVEN IN

ATTACHMENT 11 section G)

(Type of valve: Gate, Globe, Ball, Plug, Check, Butterfly)

1. Removal of valve

a) Erect necessary scaffolding.

b) Provide metal tag on the valve and pipe nozzle indicating the location of
the valve and original mounting direction like stem position Vertical or
horizontal on North/ South/East/West etc.

c) Open and remove both the flange bolts.

d) Make necessary rigging arrangement.

e) Lower the valve from pipe line to ground level.

2. Transportation of valve

a) After removal, load the valve on hand cart / low bed trailer.

b) If required, use load binder to avoid falling of valve from cart / trailer
during transportation.

c) Shift the valve to central hydro testing / repair area.

3. Cleaning of valves

a) Open the valve gate. Dismantling of valve is not required.

b) Clean the valve body internally / externally, seat free of foreign material
using raw water high pressure jet or steam / hot condensate for heavier
hydrocarbon service valves.

4. Inspection of valve

a) Offer the valve in clean condition to inspection for visual inspection.

5. Hydro testing of valves

a) After visual inspection and clearance from inspection authority, replace

the gland packing of valve.

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 b) Carry out body and seat hydro test as per applicable standard and offer to
inspection.

c) Blind flanges required for hydro testing to be provided by the contractor.

d) If valve is found leaking from the bonnet gasket, then opening of the
bonnet and replacement of the gasket shall be carried out.

e) Hydro test of valve shall deem to be completed, when it complies with the
requirement of referred testing code.

f) However if the valve is found passing excessively beyond permissible

limit of the code, then it shall be taken for repair/ reconditioning as per
procedure given in Attachment 12.

6. Installation of the valve

a) After hydro testing/ repair shift the valve to respective location.

b) Make necessary rigging arrangement.

c) Place the valve in position.

d) Check the valve mounting direction on the tag.

e) Fit back the valve in position accordingly and tighten the flange bolts. Use
new gasket while installation of valve.

f) Remove scaffolding.

GLAND PACKING MATERIAL FOR PROCESS VALVE REPACKING

Packing material :- NON ASBESTOS METALLIC EXPANDED PURE GRAPHITE ( >

99.5% ) PACKING REINFORCED WITH MULTIPLE INCONNEL WIRE AND FURTHER
JACKETED WITH INCONNEL WIRE MESH IN EACH YARN. ( MIN. 3 & MAX.5) or
Equivalent packing material satisfying all the following specifications.

1.) Packing shall be suitable for use in all types of Valves in handling fluid media
containing Hydrocarbon / Hydrogen Sulphide / Hydrogen / Steam / Thermic Fluid / Hot
Oil/ BFW/ Condensate /catalyst/ Fire water/ Raw cooling water/ sea cooling water/Air/
N2/Gases or any other kind of chemicals handled in refinery to withstand Temperature
range from 50C to + 650C, Working Pressure up to 250 Kg/cm2 and PH range 0-14.

2.) For gland packing with inconel wire mesh / reinforcement , vendor shall submit test
Certificate from any reputed Metallurgical Testing Laboratory that Inconnel wire material
confirms to the specifications as per "UNS Nickel material grade having Min. Nickel 76%
and Chromium Min 18%". The Test is to be witnessed and reviewed by 3rd Party
Inspection Agency.

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3.) Surface of the packing has to be smooth enough and no wire should be visible
on surface.

4.) Packing has to have Type Test Certificate as per API 589 (Fire Test for
Evaluation of Valve Stem Packing) and API 607 (Fire Test for Soft -Seated Quarter-Turn
Valves). A copy of the sample Test Certificate shall be enclosed along with the offer. The
Test should be conducted at Yarmouth Laboratory USA or any other Laboratory
approved by API.

5.) Packing must have Fugitive Emission Test Certificate to Tightness Class B as
per SHELL MESC SPE 77/312 and API 622 latest edition or equivalent certification from
any reputed 3rd Party Laboratory.

GLAND PACKING MATERIAL FOR SEA WATER VALVES REPACKING

Packing material: - Corrosion resistance Aldehyde braided square packing having break
in lubricant to work under ph range 2-14 suitable for handling sea water to withstand
temp upto 100 deg C and pressure upto 10 bar

The material meeting above specification for repacking of Process valves and cooling
water valves shall be sourced from vendor / manufacturer like BUMA, CHESETERTON,
SPITMAN, JAMES WALKER INMARCO, CHAMPION or any other reputed vendor. The
material shall have the related test certificates and shall be submitted to BPCL for review.

NOTE: Reconditioning of valves: Final decision for reconditioning of the valve shall be in
consultation with the owner. Owner reserve the right to issue new valve if available
instead of going for reconditioning. Payment for reconditioning of the valves shall be as
per applicable schedule of rates and reconditioning of the valve is not included in lump
sum scope.

Also note that in case of MOV (Motor operated valve), remove the actuator assembly
and make temporary wheel arrangement for testing of valve. Fix the actuator back at site
after valve fitment.

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 APPENDIX A: ATTACHMENT 8

SCOPE OF WORK: RELIEF VALVES / RUPTURE DISC

For removal, testing, repair and reinstallation of Relief Valve (RV) / Safety Valve (SV) / Rupture
Disc (RD) , following procedure shall be followed. List of RV is given in Attachment 11 section
H.

a. Erect the scaffolding wherever required.

b. Make necessary rigging arrangement such as chain blocks, crane, slings, and temporary
structure.

c. Provide Aluminum tags on RV / SV's / RD and punch the tag no on them. Also provide tag no.
on nozzles from where the valves / RD have been removed.

d. Open the inlet and outlets flanges bolts and remove the safety valve / relief valve & RD as per
the list enclosed. In case of rupture disc, before removal of the disc, remove all the connection
such as pressure gauge & all the attached tubing.

e. Lower the relief valve using suitable rigging arrangement like crane, chain block.

f. All the opening on the inlet and outlet nozzle of RV/SVs shall be blinded by fabricating plate
type blind flange using 6 to 8 mm thick CS plate.

g. Prepare job request to machine shop for servicing / testing of the individual valve as per RV/SV
tag no in SAP, punch the job request no on the aluminum tag and transport the valves to
machine shop.

h. After completion of the repair, servicing and testing of the valves at machine shop which shall
be carried out by OWNER, transport the valves back to the site.

i. In Case of rupture disc, after removal, clean the disc and offer for inspection. Based on the
condition of the disc, same or new one shall be assembled. After assembly of the disc, restore
all the connections such as pressure gauge and all he tubings.

j. Refit the valves on their respective position after removal of blind flanges and tighten the RV
inlet and out let flange.

k. Remove scaffolding / lifting arrangement after fitment of the valve.

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 APPENDIX A: ATTACHMENT 9

SCOPE OF WORK: ISBL PROCESS PIPING

GENERAL: List of process piping requiring Hydro testing is given in ATTACHMENT
11 section I. However scope also applies to all the balance process piping inside
the battery limit which shall be offered for inspection. Based on inspection &
subsequent recommendation for repair shall be given. Necessary repair shall be
carried out by contractor as per BPCL requirement. Payment towards repair shall
be made as per applicable SOR unless explicitly mentioned in the specific
scope.

1. Offer all the process pipelines inside the battery for visual inspection, Ultrasonic
thickness gauging, scanning, Hammer testing.
2. Provide scaffolding for all the piping inspection.
3. For CDU-3 / VDU/ NHGU / LOBS / SRU /HCU complex the process piping are
classified under three tables as below,
Table A: - Insulated lines whose operating temperature falls in CUI range i.e.
below 120 Deg C. These lines shall be offered for comprehensive inspection after
removal of the insulation as below.

For Vertical section: 1 meter Insulation band shall be opened after every 10
meters of straight length. Insulation shall also be opened at all the branches,
support locations, elbows, T sections, reducers, drains and vents.

For Horizontal section: 1 meter insulation band shall be opened at every support
location. Insulation shall also be opened at all the branches, elbows, T sections,
reducers, drains and vents.

Table B: High temperature insulated line. These lines shall be offered for
comprehensive inspection after removal of the insulation as below.

Open insulation pocket at every support location, all elbows, all T section and
one insulation pocket at every 10 meter of straight section of the line.

Note:- Insulation pocket shall be of 6 x 6 size. On the nozzles the pocket can
be smaller depending on nozzle size. Incase making pocket is not feasible on
nozzle then full insulation to be removed. On elbows of pipelines the pocket shall
be made on the outer radius. On Tees pocket shall be on outside of top stroke of
T. On horizontal straight sections of pipelines the pocket shall be provided on the
6 o clock position

Tables C: Bare lines

Lift the pipe line at beam support locations and offer for inspection
4. Removal of insulation on all insulated pipe wherever applicable shall be in your
scope.

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5. Close the inspection windows / bands/ pockets after inspection / repairs.
6. Insulation shall be carried out as per insulation procedure given in Attachment 12.
7. Welding of branch connection if required on the pipe lines shall be carried out as
per Company Standard Procedure for branch connection given in Attachment 12.
8. Steam traps shall be installed as per Company Standard Procedure no. 019.
9. All the newly fabricated line sections required for repairing / replacement shall be
shot blasted as per Sa 2.5 and to be painted with the type of paint as per BPCL
painting specification.
10. Carry out necessary spading and offer hydro test of the pipe lines ( List of such
line is provided in Attachment 11 Section I.) as per the following test pressure,

FLANGE EXTERNALLY INSULATED PRESSURE

RATING
150 # NO 18.0 Kg/cm2g
150 # YES 22.0 Kg/cm2g.
300 # NO 36.0 Kg/cm2g.
300 # YES 45.0 Kg/cm2g.
600 # NO 65.0 Kg/cm2g.
600 # YES 85.0 Kg/cm2g.

11. Carry out pneumatic testing of the lines with Air or Nitrogen (wherever required) at
7.5 Kg/cm2. All the necessary safety equipments shall be provided while carrying
out the pneumatic testing of the lines and contractor shall submit the method
statement for the same along with the bid.
12. If any line which is identified for hydro testing / Pneumatic testing is having leak or
clamping, then this line shall be hydro tested after completion of recommended
repair.
13. Fermanited flanges shall be offered to inspection after opening of flange. Carry
out weld built up of grooves and box up the flange with permanent gasket.
14. After completion of hydro tests / Pneumatic test, remove all spades.
15. Provide necessary temporary supports to the overhead lines during hydro test to
take water load.
16. Mark and Lock all the spring support at their cold condition of line before filling
water for hydro testing and release the same after completion of the hydro testing
and draining of the water.
17. Erect necessary scaffolding and service all the spring support which includes
cleaning, greasing / oiling.
18. Clean the lines in the trenches after removal of the concrete slabs and offer for
inspection in clean condition. After completion of the job, put back the concrete
slabs.

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19. All the trenches are to be cleared free of congealed products / muck / salt water
stagnation.
20. Remove all the damaged FRP coating on pipelines wherever applicable, clean
and offer lines for inspection. After Completion of inspection and repair, carry out
FRP lining as per procedure.
21. Make Bosons chair arrangement / provide scaffolding for taking pipe wall
thickness measurements on all the column over head and heater transfer lines.
22. After completion of the inspection / repair job remove the scaffolding.

Note: To ensure the sufficient service water pressure during filling the hydro
testing circuit, contractor shall provide booster pump with temporary water
hold up tank.

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