DHDS T&I ’09: MAIN CONTRACT
Annexure 1: Part II
UNIT RATE SCOPE OF JOBS
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
INDEX
1. PART – II : UNIT RATE JOBS .............................................................................. 4
1.1.
INTRODUCTION............................................................................................. 4
1.2.
BLINDING AND DE-BLINDING ................................................................... 4
1.3.
PIPING REPLACEMENT............................................................................... 5
1.4.
DYE PENETRATE TEST AND WFMPT ...................................................... 8
1.5.
RADIOGRAPHY .............................................................................................. 9
1.6.
STRESS RELIEVING OF WELD JOINTS ................................................... 9
1.7.
ULTRA SONIC FLAW DETECTION TEST .............................................. 10
1.8.
DROPPING AND REINSTALLATION OF VALVES ............................... 10
1.9.
CS /SS OVERLAY PATCH WORK.............................................................. 10
1.10. CS /SS INLAY PATCH WORK ..................................................................... 11
1.11. WELD BUILD UP JOBS ................................................................................ 11
1.12. WELD RUNS................................................................................................... 12
1.13. SCAFFOLDING ............................................................................................. 12
1.14. CEMENT LINING OF VESSELS ................................................................. 13
1.15. REFRACTORY REPLACEMENT BY CASTING ..................................... 13
1.16. GUNNITING OF REFRACTORY WITH ANCHOR REPLACEMENT . 13
1.17. FABRICATION AND WELDING OF ANCHORS ..................................... 14
1.18. BRICK LINING .............................................................................................. 14
1.19. CERAMIC FIBRE BLANKET LINING ...................................................... 15
1.20. CERAMIC FIBRE MODULES REPLACEMENT ..................................... 16
1.21. REPLACEMENT OF THERMO COUPLES .............................................. 16
1.22. HYDROTEST OF HEATER TUBE PASSES .............................................. 17
1.23. REPLACEMENT OF REFORMER TUBES. .............................................. 17
1.24. REPLACEMENT OF REFORMER PIGTAILS ......................................... 18
1.25. FABRICATION & INSTALLATION OF BURNER COMPONENTS ..... 18
1.26. REPLACEMENT OF BURNER BLOCK (SET) ......................................... 19
1.27. REPAIR/ REPLACEMENT OF SS PERFORATED SHEETS .................. 19
1.28. ORIFICE PLATE ........................................................................................... 20
1.29. REPLACEMENT OF CEMENT LINED PIPES ......................................... 20
1.30. FABRICATION OF MITERS/REDUCERS ................................................ 21
1.31. CEMENT LINING OF PIPES, FITTINGS, MITRES, BENDS AND
SPECIALS ................................................................................................................... 21
1.32. CS CASING PLATE REPLACEMENT ....................................................... 23
1.33. STRUCTURAL WORKS ............................................................................... 23
1.34. RELIEF VALVES........................................................................................... 25
1.35. LEVEL GAUGES ........................................................................................... 25
1.36. CIVIL WORKS ............................................................................................... 26
1.37. CHANNEL SECTION PARTITION PLATE REPAIRS ............................ 29
1.38. REPLACEMENT/ REPAIRS OF LINER PLATES .................................... 30
1.39. LINING FOR EXCHANGER COMPONENTS .......................................... 31
1.40. RETUBING OF EXCHANGERS/ COOLERS ............................................ 34
Annexure 1 – Part II / Page 2 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
1.41. MACHINING OF GASKET FACES OF CHANNEL SECTIONS
OUTSIDE REFINERY ............................................................................................... 34
1.42. REPEAT SHELL TEST AND TUBE TEST ON EXCHANGERS ............. 35
1.43. HYDROTESTING OF PIPING ..................................................................... 35
1.44. GASKET REPLACEMENT .......................................................................... 35
1.45. SUCTION STRAINERS CLEANING .......................................................... 35
1.46. DROPPING & RE-INSTALLATION OF CONTROL VALVES.............. 36
1.47. TRAY/DOWN COMER/SEAL PAN REPLACEMENT IN COLUMNS .. 36
1.48. VALVE RECONDITIONING ....................................................................... 37
1.49. IN-SITU MACHINING .................................................................................. 39
1.50. POSITIVE MATERIAL IDENTIFICATION.............................................. 39
1.51. JOBS ON EXCHANGER NOT PART OF LUMPSUM SCOPE ................ 39
1.52. JOBS ON MANPOWER SUPPLY BASIS.................................................... 40
Annexure 1 – Part II / Page 3 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1. PART – II : UNIT RATE JOBS
1.1. INTRODUCTION
1.1.1. These unit rates are for carrying out jobs not covered under
the lumpsum scope of work. The scope under this head
includes mobilization and supply of all items including
skilled manpower on round-the-clock basis with
supervision, all required equipment, tools and tackles,
consumables, transportation of all required materials from
HPCL’s warehouse or other designated areas
within/adjacent to the Refinery premises as well as
agency’s material etc required for carrying out the job in
totality unless otherwise specifically mentioned as under
HPCL’s scope. Rates for the jobs are given in PR lines.
1.1.2. For all items where rate payable is on the basis of inch dia,
this shall be on the basis of nominal dia of the pipe. In case
of any ambiguity, agency shall obtain all clarifications
prior to quoting.
After placement of order, the
interpretation thereof and decision of HPCL shall be final
and binding on the agency.
1.2. BLINDING AND DE-BLINDING
1.2.1. Isolate various systems as advised by job engineer by
fabricating and installing necessary blinds. All required
blinds should be fabricated by the agency. Initially blinds
are to be installed in spread condition for steaming and
after steaming those are to be made-up fully. Remove
blinds as per job engineer’s advice and make up the flanges
with new gaskets. Approval of Operations and inspection
groups shall also be obtained before making up the flanges
with new gaskets.
1.2.2. Rate payable is per inch dia of blinding & de-blinding done.
Annexure 1 – Part II / Page 4 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
1.3. PIPING REPLACEMENT
1.3.1. Job scope includes cutting to size, dismantling, edge
preparation, bending, welding, threading and laying above
ground/below ground/overhead on racks, painting etc at all
elevations. Replacement/repairs/ modification of pipelines
in the unit and all rundown lines in offsite locations for
different pressure and temperature ratings of all sizes &
schedules, flanges, orifice assemblies etc and all types of
fittings like elbows, reducers, tees, stubs, valves, corrosion
pads, RF pads, threaded parts etc as per the specifications,
drawings and instructions of Engineer-in-charge including
providing
shoe
supports
to
piping,
hydro
testing/inspection of the replaced portion, scaffolding,
blinding, de-blinding and making arrangements for
flushing the lines as required are covered under this
scope and no additional payment shall be made for
these items. Payment for hydrotesting of un replaced
portion will be paid extra.
1.3.2. Cutting and removal of the old pipes and other associated
jobs is part of the job. Agency shall carryout replacement
of IBR piping using IBR approved welder with CS 6010/7018 electrodes for butt joint and E 7018 for fillet
joint. For provision of piping as per schemes, agency shall
be provided drawings by HPCL. All connected civil works
of excavation, backfilling, dewatering, etc and pypkote
wrap coating shall be additionally payable under applicable
unit rate items.
1.3.3. Agency shall carryout all allocated works using either
electrical operated or diesel operated machines. HPCL
shall provide electrical power for carrying out works within
the unit battery limit but for works outside the unit battery
limit where electrical power source cannot be provided by
HPCL, agency shall mobilize adequate diesel operated
welding generators with source for lighting and grinding
machines. Additional rates are payable for carrying out
Annexure 1 – Part II / Page 5 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
works using diesel operated machines which include all
costs towards operator, consumables such as diesel, engine
oils, etc., as per applicable unit rate items given in PR lines.
1.3.4. Agency shall use E-6010 electrodes for root weld, E-7018
for filler/final weld runs for butt-welding for CS pipes. E502/ER-502 electrodes shall be used for P5, E-505/ER-505
for P9, E-308/309/309 Mo /316/316L for SS piping.
1.3.5. For CS fillet joint E 7018 electrodes shall be used as per job
Engineer. For NACE piping agency shall use ER 70-S2
electrodes for root run and E 7018 for filler runs.
1.3.6. Suitable electrodes to be used for SS and AS welding in
other areas as per job Engineer. Root welds for all SS,
Alloy steel and Carbon steel NACE piping weld joint shall
be done using TIG welding. Agency shall mobilize TIG
welding set along with Argon gas and other consumables
for all SS & Alloy steel welding jobs.
1.3.7. Carryout wrap coating of 4mm thickness for underground
lines by sandblasting, application one layer of inorganic
zinc silicate primer, @ 65 DFT, subsequently apply 2
layers, each of 2 mm thick, "Pypkote" wrapping material,
as per manufacturer's guidelines. The agency shall carryout
spark testing of both the layers stage-wise and offer for
inspection, carryout repairs, if any, and obtain clearance.
Charges for sandblasting, painting, supply/apply of wrap
coating, spark testing including mobilization of spark
testing equipment, etc are included under this unit rate item
for wrap coating.
1.3.8. Charges towards DP Test, Radiography and stress relieving
will be paid separately on unit rate 1.4, 1.5, 1.6 & 1.7. In
case of any weld failure, the agency shall redo the entire
job at no extra cost.
Annexure 1 – Part II / Page 6 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
1.3.9. Rate for provision of Reinforcement pads includes Air
testing of the RF pad after making all necessary
arrangements for the same and obtaining clearance from
Inspection. The rate for RF pads shall be payable for the
NB size of the branch piping. All replaced items shall be
sand blasted and painted as per attached specification for
painting of piping and steel structural items and are payable
as per respective unit rate item.
1.3.10. Agency to carryout sandblasting & one coat of primer paint
( under the inspection of HPCL Corrossion Cell group ) for
all replacements of piping including fittings prior to
installation. All piping and connected materials shall be
sand blasted to SA 2 1/2 of Swedish standard SIS 055900-1967. HPCL Corrosion cell group shall inspect the
Sandblasting job and only on obtaining clearance from
Corrosion cell group, primer coat shall be applied. Offer to
HPCL for DFT checking after drying of Primer. Painting
specification to be followed as per annexure. The payment
for the same shall be made separately on Unit rate basis.
Further coats of paintings shall be applied by separate
agency deputed by HPCL corrosion cell.
1.3.11. For replacement of nozzles on equipment such as columns,
vessels, etc, agency shall gouge out the existing nozzles
with care or puncture the shell in case of provision of new
nozzle as marked by HPCL job engineer. Fabricate nozzle
pipe, offer fit up of the fabricated nozzle pipe to the
equipment obtain inspection clearance, carryout root
welding using E 7018 electrodes and offer DP test,
carryout back gouging and offer DP test, obtain inspection
clearance and carryout final welding.
1.3.12. Offer final welds for visual inspection and carryout box
hydrotest by welding of box inside the equipment. After
hydrotest remove the box and flush grind the burrs and
obtain inspection clearance. The rate payable under this
item covers the entire scope of this work. This item is
Annexure 1 – Part II / Page 7 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
applicable only for the nozzle to the shell joint and for the
rest of the nozzle connected piping weld joints are payable
under piping works. Radiography/SR/RF pad for nozzle
shall be payable separately.
1.3.13. IBR PIPING
1.3.13.1. Fabrication, erection, welding, testing and painting of
IBR piping for various schemes in the unit is covered in
this. Scope of work includes all necessary coordination
for obtaining IBR approvals from CIB/DCIB for the
drawings and the job to be carried out as in piping as
applicable. Agency shall carryout replacement of IBR
piping using IBR approved welder with CS - 6010/7018
electrodes for butt joint and E 7018 for fillet joint. For
provision of piping as per schemes, agency shall be
provided drawings by HPCL.
1.3.13.2. Agency shall have a valid boiler repair certificate from
Director of Boilers, Andhra Pradesh.
1.3.13.3. Provide all necessary coordination with the Inspector
of Boilers to execute all jobs as detailed below to
complete the schemes. Obtain IBR approvals from
CIB/DCIB for the drawings and the job.
1.3.14. Rate payable is per inch dia
1.4. DYE PENETRATE TEST AND WFMPT
1.4.1. Carry out DP test and Wet Fluorescent Magnetic Particle
Test of welds as advised by Inspection department. Scope
includes all necessary equipments, materials, skilled
personnel, etc required to execute the work at all elevations
as per instructions of job Engineer. Only “MAGNA
FLUX” or P-MET” DP material is acceptable. Cleaning of
the area to be tested, by buffing, is part of the scope of
work.
1.4.2. Rate payable is per running foot length of DP test/
WFMPT done.
Annexure 1 – Part II / Page 8 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
1.5. RADIOGRAPHY
1.5.1. Perform Radiographic
inspection
on
all
types
piping/equipment, which includes providing / hiring of all
necessary equipment and facilities to perform the work
safely as per instructions of Engineer. Radiographs shall be
submitted to Engineer-in-charge.
1.5.2. Repeat radiography due to defective technique, defective
films or radiography on repaired joints due to contractor’s
fault or due to poor performance of contractor’s welders
are not payable.
1.5.3. Rate payable is per running foot of film exposed.
1.6. STRESS RELIEVING OF WELD JOINTS
1.6.1. Carry out stress relieving of different weld joints as required
by HPCL. Agency shall provide all necessary equipments,
accessories and qualified personnel required to carry out
the job. Temperature recorders shall be calibrated at HPCL
Instrumentation workshop and record for the same shall be
obtained.
1.6.2. Agency shall start stress relieving jobs within 12hrs of being
informed of the job. Approval from HPCL Inspection shall
be obtained on stress relieving charts at site before starting
the job and after job completion. Agency shall carryout all
allocated works using either electrical operated or diesel
operated machines.
1.6.3. HPCL shall provide electrical power for carrying out works
within the unit battery limit, for works outside the unit
battery limit where electrical power source cannot be
provided by HPCL, agency shall mobilize adequate diesel
operated power source. Additional rates are payable for
carrying out works using diesel operated machines which
include all costs towards operator, consumables such as
diesel, engine oils, etc as per applicable unit rate items
given in PR lines.
1.6.4. Rate payable is for SR Done per Running foot length of
weld joint
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Annexure 1 – Part II
Part – II - UNIT RATES
1.7. ULTRA SONIC FLAW DETECTION TEST
1.7.1. Carry out Ultra Sonic Flaw Detection Test on equipments as
per Inspection. The scope includes mobilization of
equipment within 12hrs of informing, ASNT level 2
qualified technicians, with certificates, to carry out the job
round the clock, submission of written report on the
findings of the test to our Inspection Dept.
1.7.2. Rate payable is per 8hrs of UFDT job carried out at site
(minimum)
1.8. DROPPING AND REINSTALLATION OF VALVES
1.8.1. Scope includes opening the flanges and dropping of any type
of valves at any elevation, transporting the same to valve
section for servicing, transportation of valves back to the
job site, reinstallation with new gaskets etc. In case existing
valve requires replacement, new valve shall be drawn from
the Warehouse and transported to site apart from the above
activities. Any minor job like freeing up, gland pulling etc
shall be carried by the agency.
1.8.2. Rate payable is per inch diameter of valve
1.9. CS /SS OVERLAY PATCH WORK
1.9.1. Agency to carry out Inlay patch plate fabrication, welding
and testing of 5 to 8 mm thick CS/SS plate on Heater,
reformer, casing plate roof plate, floor plate at all
elevations as per Inspection. Scope of the job for Inlay
patch involves drawing materials from stores, marking,
cutting to size, fabrication to shape by rolling, bending etc
cutting the existing plate from the equipment, edge
preparation, fit up, root weld, DP test, back grinding and
DP test, full welding. Radiography will be paid extra...
1.9.2. Rate payable is Per Square foot of SS/CS overlay patch
for various thicknesses
Annexure 1 – Part II / Page 10 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
1.10. CS /SS INLAY PATCH WORK
1.10.1. Agency to carry out Inlay patch plate fabrication, welding
and testing of 8mm/12mm thick CS/SS plate on any
equipment or any pipe line at all elevations as per
Inspection. Scope of the job for Inlay patch involves
drawing materials from stores, marking, cutting to size,
fabrication to shape by rolling, bending etc cutting the
existing plate from the equipment, edge preparation, fit up,
root weld, DP test, back grinding and DP test, full welding.
Radiography will be paid extra.
1.10.2. Incase of inlay patch work for heater, reformer casing
plates ref item 1.26 for casing plates
1.10.3. Rate payable is per Square foot of inlay patch work
done
1.11. WELD BUILD UP JOBS
1.11.1. Scope of job involves grinding the surface and weld build
up using CS/SS electrodes for 3mm thick deposition after
finish grinding. DP test the weld deposited area after finish
grinding and obtain clearance from inspection. Flange face
rectification also to be carried out, if required.
1.11.2. The agency shall be paid only for 3mm thick weld
deposition. If however it has to be more than 3mm job
engineers approval is necessary before starting the job.
1.11.3. Rate payable is:
1.11.3.1. Per square inch for Carbon Steel with E-7018 /
ER70S2 electrodes.
1.11.3.2. Per square inch for Carbon Steel with E-7018-A1
electrodes.
1.11.3.3. Per square inch for Stainless Steel with E308/309/310-15 Electrodes
Annexure 1 – Part II / Page 11 of 40
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Part – II - UNIT RATES
1.11.3.4. Per square inch for Stainless Steel with E309Mo/385/ 316/316L Electrodes.
1.11.3.5. Per square inch with Monel (E-NiCu-7)/90-10
Copper Nickel (E-Cu Ni) Electrodes.
1.12. WELD RUNS
1.12.1. Scope of the job involves grinding the surface and
providing weld runs using CS/SS electrodes/ Equivalent
Tig wire for 3mm thick deposition after finish grinding. DP
test the weld deposited area after finish grinding and obtain
clearance from inspection. Flange face ratification also to
be carried out, if required. Upto 5mm thick (finished) width
will be considered as single run, thereafter proportionate
multiple.
1.12.2. Rate payable is:
1.12.2.1. Per running foot for CS with E-7018 electrodes.
1.12.2.2. Per running foot of SS with E-308/309/310
electrodes.
1.12.2.3. Per running foot of SS with E-309Mo electrodes.
1.12.2.4. Per running foot of Monel with Monel electrode.
1.13. SCAFFOLDING
1.13.1. Agency shall provide system scaffolding wherever required
at all elevations. Scaffolding shall be erected with 1.5” dia
steel tubular pipe with suitable safe clamping arrangement.
Distance between adjacent vertical members shall not be
more than six feet and distance between adjacent horizontal
members shall not be more than three feet. At one or two
locations of the scaffolding erected, the distance between
horizontal members shall not be more than 1 ½ feet, so that
climbing is safe. Provide sufficient number of iron gratings
and tie with wire at each floor level of scaffolding. Detailed
scaffolding specifications and requirements are given in
annexures on scaffolding and safety which has to be strictly
Annexure 1 – Part II / Page 12 of 40
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Part – II - UNIT RATES
adhered to. Rate to be inclusive of safety net, fire retardant
cloth wherever required.
1.13.2. Rate payable is per block of scaffolding (3M x 3M x
3M).
1.14. CEMENT LINING OF VESSELS
1.14.1. Carry out lining of vessels as per Job Engineer. Weld nuts
and tie with 2x2x12G mesh as advised. Cement to sand
ratio shall be 1:1. Apply FOSROC compound on the
cement-lined surface.
1.14.2. Rate payable is per sft of cement lining replaced .
1.15. REFRACTORY REPLACEMENT BY CASTING
1.15.1. This covers all jobs required for execution of
repair/replacement of internal refractory lining of Furnaces,
ducts, APH or any other area in the unit. The agency shall
furnish all the resources like skilled personnel, tools &
tackles, equipment and materials including all the
consumables etc except those specified under HPCL scope
of supply and carry out all jobs as per the given scope to
complete all jobs in their entirety.
1.15.2. The scope of job shall be as per the Annexure 4 –
Attachment 4.1 : Standard procedure for jobs on
heaters. Agency to use the approved agencies as per
standard attachment for carrying out the refractory jobs.
1.15.3. Rate payable is per Square meter area .
1.16. GUNNITING OF
REPLACEMENT
REFRACTORY
WITH
ANCHOR
1.16.1. The scope of job shall be as per the Annexure 4 –
Attachment 4.1 : Standard attachment for heaters.
Annexure 1 – Part II / Page 13 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
Agency to use the approved agencies as per standard
attachment for carrying out the refractory jobs.
1.16.2. Rate payable is per Square meter area
1.17. FABRICATION AND WELDING OF ANCHORS
1.17.1. Fabricate required number of new anchors for replacing
existing anchors using 3mm dia to 12mm dia SS 304/316
rods supplied by HPCL. Fabrication of anchors shall be
done by cold forming and no heating is permitted.
1.17.1.1. Rate payable is per anchor fabricated.
1.17.2. Grind out the existing damaged anchors and weld new
anchors as per drawing and specification. Chip out slag and
obtain inspection clearance. Install plastic caps supplied
HPCL on individual anchor legs.
1.17.2.1. Rate payable is per anchor welded.
1.17.3. After fabrication of anchors by cold/hot work, agency shall
carry out solution annealing prior to welding.
1.17.3.1. Rate payable is per batch of anchors solution
annealed.
1.18. BRICK LINING
1.18.1. The scope of job involves drawing insulating
bricks/refractory firebricks from warehouse or any other
designated location inside the refinery premises as advised
by the Engineer-in-charge, transportation of these materials
to the work spot. The agency shall ensure that refractory
material issued from HPCL warehouse is stored in a dry
place at the agency’s work shed.
Annexure 1 – Part II / Page 14 of 40
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1.18.2. The scope covers removal of insulating bricks /refractory
firebricks from inside Furnaces at all elevations.
Scaffolding required for carrying out the subject job is
included in the agency’s scope of work. While removal of
brick lining the agency shall recover all bricks that are in
good shape for reuse. Clean the surface of the casing plate
thoroughly, free from all scales, deposits etc by sand
blasting/power tool cleaning as advised by HPCL and offer
for inspection. Replacement of anchors if required shall be
carried out by the agency. On obtaining clearance from
HPCL Inspection, re-lay new insulating bricks/ Refractory
firebricks as per the drawing with or without mortar.
Cutting of bricks to shape if required is a part of agency’s
scope. The entire job is subject to stage wise inspection to
avoid any job delays.
1.18.3. Rate payable is per Cubic mtr area of job done for:
1.18.3.1. Brick lining without Mortar
1.18.3.2. Brick lining with Mortar
1.19. CERAMIC FIBRE BLANKET LINING
1.19.1. The scope of job involves drawing cerawool blankets,
hardware, Stainless wire etc from warehouse or any other
designated location inside the refinery premises as advised
by the Engineer-in-charge and transportation of the same to
the work spot. Mobilisation of hand lamps, step down
transformers (24V DC), Switch boards, lighting cables etc
required for carrying out these jobs inside various
equipment.
1.19.2. The agency shall remove all loose/damaged cerawool from
various locations & at all elevations in Furnaces etc as
advised by the Engineer-in-charge. Scaffolding required for
carrying out the job is included in the agency’s scope. On
obtaining inspection clearance fix back new cerawool
blankets in place using speed fix washers or any other
hardware as per the job requirement. Welding of anchors is
covered under the scope of the agency. Pack loose
Annexure 1 – Part II / Page 15 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
cerawool wherever required as per the advice of HPCL
Inspection.
1.20. CERAMIC FIBRE MODULES REPLACEMENT
1.20.1. This item covers the replacement of Ceramic Fibre
Modules in the reformer radiant section walls and roof. The
scope of job involves drawing ceramic module. Anchor
studs etc from warehouse or any other designated location
inside the refinery premises as advised by the Engineer-incharge and transportation of the same to the work spot.
Mobilisation of hand lamps, step down transformers (24V
DC), Switch boards, lighting cables etc required for
carrying out these jobs inside various equipment.
1.20.2. The agency shall remove all loose/damaged ceramic
modules from various locations & at all elevations in
Furnaces etc as advised by the Engineer-in-charge.
Scaffolding required for carrying out the job is included in
the agency’s scope. On obtaining inspection clearance fix
back new ceramic modules under the guidance of
representative deputed by HPCL. In case of any studs
replacement the welding shall be paid under manpower
rates.
1.20.3. Rate payable will be per square meter area of module
replacement.
1.21. REPLACEMENT OF THERMO COUPLES
1.21.1. Carry out replacement or welding of new Skin Thermo
couples of Heater Tubes in kind as advised after the
inspection. Scope includes scaffolding, grinding and
removal of existing thermocouple carefully, cleaning the
pad by grinding and buffing, welding of new thermo
couple as per Job Engineer. The job shall be carried out
win close coordination with HPCL’s Instrumentation
department. Carry out DP test of the weld and obtain
clearance from Inspection department. Care shall be taken
not to damage the tubes and refractory while carrying out
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the job. Inconel electrode & filler wire for TIG welding is
in vendor’s scope.
1.21.2. Rate payable is per Thermocouple replaced.
1.22. HYDROTEST OF HEATER TUBE PASSES
1.22.1. Scope includes all necessary jobs required to carry out
Hydro testing of Heater Tube coils at specified pressure.
This is only for additional hydrotesting of passes after
repair (If damage was observed during the previous
hydrotest and the joint had not been attended by the agency
before that hydrotest)
1.22.2. Rate payable is for hydro testing of
1.22.2.1. One pass of Hydrocarbon coil of any heater
1.22.2.2. One pass of steam coil
1.23. REPLACEMENT OF REFORMER TUBES.
1.23.1. This item covers the replacement of reformer catalyst tubes
as per inspection advice.
1.23.2. Scope involves cutting and removal of damaged tubes,
transportation of new tube assemblies from warehouse to
site, installation of the tube assembly and alignment and
welding to the pigtails.
1.23.3. This rate is applicable only if the tubes have been replaced
with new ones. For any repairs done to the weld joint the
payment shall be made under inch dia of welding done.
1.23.4. Scope of work also includes edge preparation, stage wise
DP test, radiography, pre& post weld heat treatment and
radiography after PWHT.
1.23.5. Remove the roof & related obstructing structures at the
tube location for crane accessibility. Ensure to provide firm
support to the dismantle structural supports by fixing
temporary supports.
1.23.6. Repair the existing weld joints as per Inspection including
grinding out the defect, D.P. testing, weld repairs,
radiography, stress relieving, radiography after S.R. etc
1.23.7. Rate payable is:
Annexure 1 – Part II / Page 17 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.23.7.1. Per tube replaced ( inclusive of cutting and welding,
NDT and heat treatment)
1.23.7.2. Per inch dia of the welding repairs carried out for joint
previously not attended by the agency.
1.24. REPLACEMENT OF REFORMER PIGTAILS
1.24.1. Scope involves cutting and replacement of reformer inlet
pigtails located above the roof section and outlet pigtails
located below the floor of the reformer.
1.24.2. The job to be done as per HPCL inspection advice
1.24.3. The job involves cutting and removal of damaged pigtails,
transportation of new pigtails from HPCL warehouse to
site , installation in position and carrying out welding.
1.24.4. Scope of work also includes edge preparation, stage wise
DP test, radiography, pre& post weld heat treatment and
radiography after PWHT.
1.24.5. Rate payable will be :
1.24.5.1. Per inlet pigtail replaced inclusive of welding, NDT
and heat treatment.
1.24.5.2. Per outlet pigtail replaced inclusive of welding &
NDT
1.25. FABRICATION
COMPONENTS
&
INSTALLATION
OF
BURNER
1.25.1. Fabricate and replace in kind various components like
primary and secondary barrels, burner bottom plate, Regen
tile casing plate, etc for burners and retainer plates around
Man ways. Scope of the job involves dismantling the
damaged component of the burner, drawing materials from
stores, marking, cutting to size, rolling, bending, mock
assembly, fit up, fabrication and reassembly of various
components. Cut and remove existing damaged
components. Fabricate, weld and install new components
using 3mm thickness stainless steel plate of SS 304 / 316 /
410 metallurgy, to exactly match the original dimensions.
Annexure 1 – Part II / Page 18 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
Job shall be carried out with stage wise inspection
clearance.
1.25.2. Rate payable is per sq.ft of plate replaced of the
component.
1.26. REPLACEMENT OF BURNER BLOCK (SET)
1.26.1. The scope of job involves drawing burner tiles from
warehouse or any other designated location inside the
refinery premises as advised by the job engineer,
transportation to the work spot and installation. In case part
or all of the burner block segments have to be re-used,
remove the same carefully and keep in a secure place. The
agency shall ensure that enough care is taken while
handling & transportation of these materials to the work
spot to avoid any damage.
1.26.2. The job scope covers removal of existing damaged burner
blocks without damaging the segments in good condition.
Clean the area thoroughly free from all loose refractory
materials and offer for Inspection. After carrying out
repairs to floor plate if any, obtain clearance from
inspection, fix new burner blocks in position. Carry out
alignment of the assembly and offer to TSD/Inspection
sections and obtain approval. One set comprises of many
tiles in segments forming a complete block per burner.
1.26.3. Rate payable is per burner set
1.27. REPAIR/
SHEETS
REPLACEMENT
OF
SS
PERFORATED
1.27.1. Repair/replace the oxidized and buckled perforated
Stainless steel sheets of Plenum boxes of all burners (each
burner has one panel of perforated sheet on all four sides) .
Grind and remove all the existing damaged perforated
sheets lining the acoustic insulation of the Plenum boxes.
Annexure 1 – Part II / Page 19 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
Straighten the removed panels of SS perforated sheet and
offer for inspection. Discard all panels that cannot be
reused. Recover the reusable panels after carrying out
necessary repairs. Replace the damaged panels using new
2mm thick SS316 perforated sheets. Straighten the base
plates of the Plenum boxes made of CS plates primary and
secondary guides. Line the plenum boxes with 25mm thick
Ceramic wool and install the perforated sheet panels. Weld
the perforated sheet panels in place. Obtain stage wise
clearance from HPCL’s inspection.
1.27.2. Rate payable is per sq.ft of perforated plate replaced.
1.28. ORIFICE PLATE
1.28.1. The scope includes dropping of orifice plates as per job
engineer and hand over it to Operations. Agency shall
match mark the plate before opening the bolts. Install the
plates under Maint- Instrumentation guidance with proper
gaskets and ensure proper direction.
1.28.2. Rate payable is 1.5 times the rate for gasket replacement
1.29. REPLACEMENT OF CEMENT LINED PIPES
1.29.1. Scope includes cutting and removal of existing
underground and above ground cement lined piping works
including piping and fittings, trimming of pipe edges after
cutting to size, fabrication of collars, complete welding of
fabricated collars on to the pipe joint after fit up, including
welding of all connected fittings such as flanges, tees,
mitres, reducers, RF pads, etc. Fabrication of collar shall be
as per EIL class J5A and Corolac resin shall be applied on
the inside of the collar and outside surface of the pipe
before welding. While welding the collars, care to be
taken, such that resin (Corolac) is not heated beyond
100deg.c. All associated civil works shall be carried out by
the agency under part III unit rate items for civil works.
Annexure 1 – Part II / Page 20 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
Civil works and pypkote wrap coating shall be additionally
payable under respective unit rate items. HPCL shall
provide electrical power for carrying out works within the
unit battery limit, for works outside the unit battery limit
where electrical power source cannot be provided by
HPCL, agency shall mobilize adequate diesel operated
power source. Additional rates are payable for carrying out
works using diesel operated machines which include all
costs towards operator, consumables such as diesel, engine
oils, etc. as per applicable unit rate items given in PR lines.
Cement lined pipes shall be supplied by HPCL.
1.29.2. Rate payable is per inch dia meter (inch dia per meter
length) pipe replaced.
1.30. FABRICATION OF MITERS/REDUCERS
1.30.1. Scope includes fabrication of miters/reducers as per EIL
specification 7-44-33 / 7-44-485/ 487 . HPCL's scope of
supply is limited to piping material only. HPCL shall
provide electrical power for carrying out works within the
unit battery limit, for works outside the unit battery limit
where electrical power source cannot be provided by
HPCL, agency shall mobilize adequate diesel operated
power source. Additional rates are payable for carrying out
works using diesel operated machines which include all
costs towards operator, consumables such as diesel, engine
oils, etc as per applicable unit rate items given in PR lines
1.30.2. Rate payable is
1.30.2.1. Per inch dia of miter joint
1.30.2.2. Per inch dia of bigger end of reducer fabricated
1.31. CEMENT LINING OF PIPES, FITTINGS, MITRES,
BENDS AND SPECIALS
1.31.1. Agency shall collect the bare specials from any designated
location within the refinery and transport to the works for
Annexure 1 – Part II / Page 21 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
cement lining within or outside the refinery. Clean the
surface internally free of rust, dust, scales, etc prior to
cement lining by sandblasting or manual means and
carryout cement mortar lining as below.
1.31.2. The cement lining shall be suitable for transporting sea
water, brackish water upto 65degC at 10 kgs/cm2.
1.31.3. The cement mortar material of sand shall confirm to IS
383, cement to IS 1489 and fresh, clean water free from
any foreign materials like oil, acid, alkali, salt or organic
matter.
1.31.4. The density of mortar shall be sufficient not to leave voids
so as to achieve water tightness and also adhere firmly to
the pipe surface. Cement sand ratio shall be 1:1.5 upto 6
mm thick and 1:1 above 6 mm thick. Water cement ratio
shall be between 0.3-0.4.
1.31.5. Finished mortar lining shall be free from any honey
combing, cracks and irregularities.
1.31.6. Pipes, Fittings, mitres, bends, specials, etc shall be properly
lined with cement concrete lining by manual applications /
toweling etc.
1.31.7. For pipe dia meters 8" and above, cement lining of miters,
fittings and specials shall be done after welding of MS nuts
at a pitch as per HPCL recommendations and tying of 16
gauge wire mesh to the nuts all along the area to be lined.
This is for reinforcement and for proper adhesion of
cement lining on to the metal substrate.
1.31.8. Cement lining thickness shall be as given below.
1.31.8.1. Size 2" to 10" NB thickness shall be 6mm
tolerance of + 3 /- 1.5mm.
1.31.8.2. Size 12" to 22: NB thickness shall be 8mm
tolerance of + 3 / - 1.5mm.
1.31.8.3. Size 24" to 36" NB thickness shall be 10mm
tolerance of + 3 / - 1.5mm.
1.31.8.4. Size above 36" NB thickness shall be 13mm
tolerance of +3 / -1.5mm.
with
with
with
with
Annexure 1 – Part II / Page 22 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.31.9. Curing: Water / LP steam curing of cement mortar lining
shall be commenced after lining gets set. Curing shall be
done for a period not less than 14 days. Mortar shall be
allowed to dehydrate.
1.31.10. Finishing: The mortar lining shall be straight smooth,
dense, hard and free from honey combing, cracks,
irregularities etc. Mortar lining shall be inspected and
approved by HPCL. If any defects are found, the same
shall be rectified, removed or replaced by the contractor at
no extra cost.
1.31.11. Rate payable is per
1.31.11.1. Inch
dia
mtr
of
cement
lining
pipes/fittings/mitres/specials by water curing
1.31.11.2. Inch
dia
mtr
of
cement
lining
pipes/fittings/mitres/specials by steam curing.
of
of
1.32. CS CASING PLATE REPLACEMENT
1.32.1. Agency to carry out Inlay patch plate fabrication, welding
and testing of 5 to 8 mm thick CS plate on Heater,
reformer, casing plate roof plate, floor plate at all
elevations as per Inspection. Scope of the job for Inlay
patch involves drawing materials from stores, marking,
cutting to size, fabrication to shape by cutting the existing
plate from the equipment, edge preparation, fit up, root
weld and DP test, full welding. Radiography will be paid
extra.
1.32.2. Rate payable is per Sq Foot of replacement done
1.33. STRUCTURAL WORKS
1.33.1. Agency shall carry out structural steel plates repair /
replacement works like providing Monorails, additional
ladders, replacing old ladders, staircases, gratings, railings,
platforms, chequered plates, etc as directed by the
Annexure 1 – Part II / Page 23 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
engineer-in-charge during the T&I. This includes removal
of the old structural if required, fabrication, erection,
welding of the above mentioned structural using channels,
angles, I beams, flats, chequered plates, rounds, handrailing
pipe & GI / Electro forged gratings etc at all elevations
Agency shall carryout all allocated works using either
electrical operated or diesel operated machines. HPCL
shall provide electrical power for carrying out works within
the unit battery limit, for works outside the unit battery
limit where electrical power source cannot be provided by
HPCL, agency shall mobilize adequate diesel operated
welding generators with source for lighting and grinding
machines.
1.33.2. Agency shall also be required to carryout structural works
at various locations as per scope given above including the
supply of material. Agency shall procure and supply
material of quality IS 2062 / IS 226, make SAIL, TISCO,
IISCO, RINL, from reputed vendors, including
transportation to site, handling, etc. Re rolled grade of
material shall not be accepted. This material shall be
procured on written advice by HPCL only. Agency shall
arrange for the material within a maximum of 4 days from
the date of HPCL advice. The material will required to be
weighed in the refinery weighbridge and payment shall be
made against submission of the weighment slip duly
certified by job engineer. Agency shall submit the MTC of
the structural material duly endorsed by the supplier.
1.33.3. Agency to carryout sandblasting & one coat of primer paint
( under the inspection of HPCL Corrossion Cell group ) for
all replacements of structurals prior to installation. All
structurals shall be sand blasted to SA 2 ? of Swedish
standard SIS 05-5900-1967. HPCL Corrosion cell group
shall inspect the Sandblasting job and only on obtaining
clearance from Corrosion cell group, primer coat shall be
applied. Offer to HPCL for DFT checking after drying of
Primer. Painting specification to be followed as per
annexure. The payment for the same shall be made
separately on Unit rate basis. Further coats of paintings
Annexure 1 – Part II / Page 24 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
shall be applied by separate agency deputed by HPCL
corrosion cell
1.33.4. Additional rates are payable for carrying out works using
diesel operated machines which include all costs towards
operator, consumables such as diesel, engine oils, etc., as
per applicable unit rate items given in PR lines. Staging
required for the job is to be arranged by the agency.
1.33.5. Rate payable is per
1.33.5.1. Metric Ton of finished structure installed & welded,
with HPCL material supply.
1.33.5.2. Metric Ton of finished structure installed & welded,
with agency material supply.
1.34. RELIEF VALVES
1.34.1. Dropping and reinstallation of relief valves other than 96
nos valves mentioned in the Lumpsum scope, is covered
under this.
1.34.2. The jobs shall be carried out as given in the attachment for
Relief Valves.
1.34.3. Rate payable is per inch diameter of the relief valve
removed & re-installed. Relief valve outlet flange size is
considered for measurement of Inch dia
1.35. LEVEL GAUGES
1.35.1. Carry out Removal, transportation and re-fixing of gauge
glasses other than the 59 nos mentioned in the Lumpsum
scope on various equipments in the unit as per scope of
work given in the attachment for Level Gauges.
1.35.2. The rate payable is:
1.35.2.1. For each level gauge (size < or equal to 2 segments)
1.35.2.2. For each level gauge (size >2 and < or equal to 4
segments)
Annexure 1 – Part II / Page 25 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.35.2.3. For each level gauge (size >4 and < or equal to 6
segments)
1.36. CIVIL WORKS
1.36.1. Carryout the following civil works in the unit in order to
attend to related mechanical works such as underground
piping replacement, etc:
1.36.2. Excavation: Earth work in excavation below ground levels
for all kinds of works in foundations including trenches,
pavements, footings etc., in all types of soils including all
labour, material, dressing of sides, leveling, grading and
ramming of bottoms, pumping and bailing out rain or subsoil water, disposal or stacking of surplus excavated
material within a lead of 50M etc., complete for the line
trenches.
1.36.2.1. Rate payable is per cu.mtr
1.36.3. Backfilling: Back filling after execution of the work to
proper grade and level with selected materials from
available excavated soil from soil heaps within a lead of
50M, including re-excavating the deposited soil excavated
earlier, breaking clods, laying at all depths and heights in
layers of thickness not exceeding 15 cms, watering and
ramming to compaction, dressing etc. complete in
foundation, plinth, trenches etc.
1.36.3.1. Rate payable is per cu.mtr
1.36.4. Transportation: Transporting the surplus earth and debris
from construction area beyond the initial lead of 50M
including re-excavating the deposited soil excavated
earlier, transportation, loading, unloading, laying at all
depths and heights, stacking, levelling and dressing both
the areas (viz., from where the earth is transported and
where it is deposited) to the required levels and slopes
Annexure 1 – Part II / Page 26 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
complete with all lifts as directed up to a lead of 2.0
KM.from the line trenches.
1.36.4.1. Rate payable is per cu.mtr
1.36.5. RCC dismantling: Dismantling of RCC work for all
heights /depths including disposal of unserviceable
material within a lead of 50m and handing over
reinforcement / steel to the scrap yard as directed by the
Engineer-in-charge including all labor, tools for demolition
etc., complete.
1.36.5.1. Rate payable is per cu.mtr
1.36.6. Sand filling : Supplying and filling sand of approved
quality under floors, in foundation and plinth etc.,
including the cost of sand, transportation for all leads,
loading, unloading spreading in layers of 15 cm thickness
at all depths, watering, ramming, compacting to required
depth, leveling etc., complete.
1.36.6.1. Rate payable is per cu.mtr
1.36.7. RCC works: Supplying and laying Reinforced Cement
Concrete (RCC) 1:11/2:3 (1: cement :11/2 sand : 3 HBG
metal of 20 mm nominal size) including, mixing, placing,
compacting, including neat cement finishing, curing etc.,
complete as per IS:456:1978, in foundations & pits / sumps
for all depths, footings, plinth beams, pavements etc.,
complete including hacking of old concrete surface if any
(excluding shuttering and reinforcement).
1.36.7.1. Rate payable is per cu.mtr
1.36.8. HBG metal filling: The scope includes cost of HBG metal,
royalities, transportations to site for all leads and lifts
including loading, unloading spreading in layers all
complete as per job engineer.
1.36.8.1. Rate payable is per cu.mtr
Annexure 1 – Part II / Page 27 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
1.36.9. Reinforcement steel: Supplying and fixing in position
high yield deformed bars reinforcement conforming to
IS:1786 for RCC works including cost of steel,
transportation, straightening, cutting, bending to the
required shapes as per details, binding with 16 SWG black
soft annealed binding wire, placing with proper cover
blocks, supports, chairs, spacers etc., for all heights and
depths as per the directions of the engineer-in-charge.
1.36.9.1. Rate payable is per MT
1.36.10. Centering and shuttering: Supplying and providing
centering and shuttering with approved plywood / steel
sheets including strutting, propping to the required levels
and sizes and removal of form work etc., complete for
footings, columns, beams, lintels, chajjas, slabs, trenches
etc., all levels.
1.36.10.1. Rate payable is per sq.mtr
1.36.11. Grouting: Providing grouting/repairs to the existing
deteriorated/ improper slope / cracked grouts of base plates
/ anchor bolts on pedestals / columns including the
removal of cracked / deteriorated grouts, cleaning the
surface by removing oil, grease etc and grouting using
non-shrink high strength grout of CONBEXTRA GP1 of
FOSROC mixed with coarse aggregate (HBG metal of
10mm down size) 50% by weight or equivalent approved
by the Engineer-in-charge including shuttering, finishing,
all equipment, skilled manpower, consumable etc.
complete.
1.36.11.1. Rate payable is per cu.mtr.
1.36.12. Shoring: Providing and installing approved type of
"SHORING AND STRUTTING" for all depths to retain
earth including dismantling and removal of the same etc.,
Annexure 1 – Part II / Page 28 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
from site after completion of work etc., all complete as
directed by Open Timbering method.
1.36.12.1. Rate payable is per sq.mtr.
1.36.13. Dewatering: Agency shall supply diesel operated
dewatering pumps of capacity 5 HP/10 HP including all
consumables such as diesel, operator, sufficient length of
hoses with foot valve, to facilitate uninterrupted welding
works. The pumps should be fitted flame arrestors.
1.36.13.1. Rate payable for per hour
1.36.14. Fireproofing
1.36.14.1. Agency shall carry out fireproofing of assigned areas
including chipping out of old fireproofing, applying
single coat primer, laying of wire mesh, applying of
vermiculate cementitious compound, curing compound
and application of fire retardant paint.
1.36.14.2. Rate payable per cu m of fireproofing done.
1.37. CHANNEL SECTION PARTITION PLATE REPAIRS
1.37.1. Scope of the job involves drawing material (10/12 mm
thick CS) from stores, marking, cutting to size, cutting the
existing plate to be replaced, edge preparation, fit-up, root
weld, full welding, DP test. Partition plate replacement
may be sectional or full and agency shall be prepared for
the same. Includes removal of existing lining and cleaning,
offering for Inspection. This scope includes sectional
replacement of shell plate (inlay patch). Rolling of
replacement plate to match shell contour is part of the
replacement job.
1.37.2. Stiffeners shall be welded to avoid distortion. and grinding
after completion.
1.37.3. Welding per foot is inclusive of top and bottom welding (
Double "V" welding).
Annexure 1 – Part II / Page 29 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.37.4. Carry out weld repair on the existing partition plate weld
joints with specified electrodes as instructed by the job
engineer. This shall cover the additional build up on the
existing joints after necessary cleaning, buffing, grinding,
DP testing with all consumable and equipment in agency's
scope.
1.37.5. Weld build up : In case of weld build up of pits, 8 nos of
weld bulid up of pits will be considered as one Rft for
compensation. Flush grinding is part of the scope.
1.37.6. Payment for weld repairs are quantified in terms of Rft of
weld completed in its entirety and not the no. of weld runs
to achieve the quality.
1.37.7. Rate payable:
1.37.7.1. Per running foot of finished weld joint for plate
replacement.
1.37.7.2. Per running foot of finished weld joint for weld
repairs.
1.38. REPLACEMENT/ REPAIRS OF LINER PLATES
1.38.1. Scope of the job includes grinding out the defective liner
plate, thorough cleaning the base plate by buffing, drawing
3mm thick new liner plate from ware house, fabrication of
new liner plate to size including rolling, fit-up, welding,
DP test and air test. Liner replacement can be sectional or
total, agency shall be prepared to carry out the same.
1.38.2. Electrodes lining
Er Cu Ni Al
for
Nickel Al Bronze
1.38.3. E Ni Cu 7 for monel lining
1.38.4. All replacement and repairs against this scope shall be
carried out by TIG welding only.
1.38.5. As for testing of iron absorption in monel welding,
Potassium ferro cyanide test shall be carried out by the
agency. In case of absorption more than allowable, agency
Annexure 1 – Part II / Page 30 of 40
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shall redo the welding at that location after required surface
preparation at no extra cost.
1.38.6. Rate payable is per running foot of finished weld joint
1.39. LINING FOR EXCHANGER COMPONENTS
1.39.1. Carry out FRE or FRP lining (3mm thick) of exchanger
components and tube sheets as per standard specification
and advise of Job Engineer. Area for measuring lining on
tube sheets includes the tube holes
1.39.2. Supply and application of cold compound for protection of
Tube sheets and glass flake epoxy coating on the
components for the specified coolers and Condensers.
Necessary sand blasting / power tool cleaning / sand
blasting for surface preparation of the area to be coated and
application as per the specifications given below. For the
purpose of calculation the area where compound is not
applied, the same shall not be considered for payment, such
as tube holes, etc.
1.39.3. Brushable ceramic coating Specification:
1.39.3.1. The cold compound application shall be done on the
tube sheet locations after the Shell test of the respective
cooler has been completed.
1.39.3.2. Agency to follow surface preparation , base coat
preparation and top coat application as per
manufacturers standard procedure.
1.39.3.3. For surface preparation, agency to carry out sand
blasting.
1.39.3.4. During sand blasting for surface preparation, all
necessary care shall be taken to ensure that work in the
surrounding areas is not affected and sand/grit does not
fly on to other equipments. The whole area shall be
covered using Tarpaulin. Each Tube shall be plugged to
avoid sand getting deposited inside the Tubes. After
sand/grit blasting is completed, the entire area and the
exchanger shall be thoroughly cleaned of all sand and
Annexure 1 – Part II / Page 31 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
other debris. In case of power tool cleaning care should
be taken not damage the tube ends projecting from
tubesheets. Compound to be supplied by the agency.
The following are the approved makes for supply and
application of cold compounds along witht eh surface
preparation required.
1.39.3.4.1. ITW Devcon:
Surface preparation : Blast cleaning
Base coat : Titanium putty ~ 1.2mm thk.
Top coat ( 2 coats) : Brushable cerami lining ~
0.8mm thk.
1.39.3.4.2. Belzona
Surface preparation: Blast cleaning
Base coat: Belzona-1511 ~ 2mm thk
Top coat: Belzona 5891 ~ 0.25mm thk.
1.39.3.4.3. Sentinel
Surface preparation:Blast cleaning
Base coat: Epxylon Titanium reinforced putty- 9104
~ 1.2mm thk.
Top coat: Wear Tuff brushon-9201 ~ 1mm thk.
1.39.3.4.4. Demech
Surface preparation: Blast cleaning
Base coat: Koroguard primer- 0.25mm thk
Top coat: Koroguard -GF - 2.0 mm thk.
1.39.3.5. Rate payable is per sq foot of FRE/FRP lining done.
1.39.3.6. For cold compound application rate payable is per Sq.
meter of application done.
1.39.4. Glass flake epoxy coating specification:
1.39.4.1. Surface Preparation: Abrasive Blast Clean to Sa2.5
using non-sparking sieved copper slag of uniform size
conforming to SSPC-SP-10
1.39.4.2. Coating System: One coat of two component glass
flake filled high build self priming epoxy coating of @
100 microns / per coat, followed by 2 coats of two
component solvent free high build glass flake filled
Annexure 1 – Part II / Page 32 of 40
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Annexure 1 – Part II
Part – II - UNIT RATES
epoxy coating @ 200 microns DFT per coat = 2X 200
microns DFT = 400 microns. Total DFT =500 microns
minimum
1.39.4.3. Recommended manufacturers and paints
Sl.
no.
Manufacturer's
Name
Surface
tolerant Solvent free / high build
polyamine cured self polyamine cured glass
priming epoxy coating flake filled epoxy coating
1.
M/s. Akzo
Coatings
2.
M/s. Sigma Coatings
Sigma Cover primer
Sigma cover TCP / CSF Glass flake
3.
M/s. Jotun Paints
Jota mastic 87 primer
Marathon
4.
M/s. Berger Paints Portectomastic
Ltd.
Epilux super build Glass
Flake epoxy
5.
M/s.
Brothers
Plasmet ZE
6.
M/s. Chemtreat India Chempruf
Ltd. (Atlas Minerals primer
& Chemicals Corp.
USA)
7.
M/s. Winn & Coales Archo - Rigidon System
(Denso)
Ltd.,
England
Nobel Interplus 256
Interzone 505
Kirloskar Plasmet ZF
Epoxy Chempruf 121 primer
1.39.4.4. Guarantee: The agency shall provide guarantee for
trouble free and good performance of the coating for a
period of 3 (three) years. Any damage to the coating
and/or components due to failure of the product shall be
repaired by the agency free of cost.
1.39.4.5. Rate payable is per sq mtr of coating done.
1.39.5. Note: For the purpose of calculating the area under all items of
14, only the area where compound is applied shall be
considered. The area where compound is not applied shall not
be considered for payment, such as tube holes, etc. Further, for
calculating area of the coating, total thickness of the finished
coating shall be considered and not the area of the individual
coats.
Annexure 1 – Part II / Page 33 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.40. RETUBING OF EXCHANGERS/ COOLERS
1.40.1. RETUBING: Inspection Engineer will mark the tubes that
require replacement. Pull out the marked tubes using Jenny
puller. Cut three sections (both ends and middle) of two
tubes into pieces of one-foot length. Split the tubes axially
into two halves and hand over to Inspection Engineer.
Clean the Tube sheet Holes and the serrations inside them.
Offer for Inspection. Agency shall record and submit the
internal diameters of tube sheet holes using a calibrated
dial gage. The tube shall be identified in the record basis
row and tube number. Insert new tubes of required
specification into the Tube Holes. Roll and expand the tube
ends into the tube sheet grooves as per Job Engineer. Scope
includes supply of all necessary equipments and
accessories to execute the job. New tube will be supplied
by HPCL. In case of requirement for 100% re-tubing of
any bundle, cutting and removal the old tubes, removing
the tube stubs from the tube sheets and baffles, cleaning
and offering the tube sheets and cage for Inspection and retubing etc are part of the job scope.
1.40.2. For welded tubes rates for fillet weld & NDT shall be paid
extra.
1.40.3. Rate payable is per tube replaced by re-tubing.
1.41. MACHINING OF GASKET FACES OF CHANNEL
SECTIONS OUTSIDE REFINERY
1.41.1. Agency shall transport components such as channel
sections/ shell covers of diameter greater than 1 meter,
whose gasket faces are to be machined to a reputed
machine shop, arrange to machine gasket faces and bring
back them. Agency is responsible for safety of the
components. Amount shall be deducted from bills of
agency, in case of any damages to the component.
1.41.2. Rate payable is per gasket face machined for various
dia.
Annexure 1 – Part II / Page 34 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.42. REPEAT SHELL
EXCHANGERS
TEST
AND
TUBE
TEST
ON
1.42.1. Repeat Shell test and Tube test on exchangers in case Tube
leak is found during Tube test or during Shell cover test on
any exchanger at the specified test pressure. The procedure
for the tests is given under I.A.1 of lump sum job scope.
1.42.2. Rate payable is per Shell/Tube/Shell Cover repeat test
carried out
1.42.2.1. For exchangers of Shell diameter less than 900mm
1.42.3. For exchangers of Shell diameter more than 900mm
1.43. HYDROTESTING OF PIPING
1.43.1. Carryout hydrotesting of loops (other than loops given in
lumpsum, if any) and other piping sections as advised by
the job engineer. The agency carryout jobs as per the
attachment for Hydrotesting .
1.43.2. Separate rates shall be payable for blinding/deblinding,
scaffolding, valve dropping under the respective unit rate
items for hydrotesting jobs.
1.43.3. Rate payable is per inch dia. meter (inch dia x meter
length).
1.44. GASKET REPLACEMENT
1.44.1. This unit rate is for replacement of all gaskets that does not
form a part of the Lumpsum scope like jobs as per HPCLOperations etc.
1.44.2. Replace gaskets of various flanges as per instruction of job
Engineer. Open the existing flange joint by removing the
bolts, wedge gap between the flanges, clean the flange
gasket face free of all foreign particles, offer new gasket to
Inspection and obtain approval, insert new gasket between
the flanges and make up the flange after obtaining approval
from Inspection and Operation Engineers.
1.44.3. Rate payable is per inch dia of piping
1.45. SUCTION STRAINERS CLEANING
Annexure 1 – Part II / Page 35 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.45.1. The job involves removal of strainer, cleaning thoroughly,
carry out minor repairs, if any and after clearance from job
engineer fix back the strainer along with gasket
replacement.
1.45.2. Rate payable is per inch dia (Pipe NB Dia)
1.46. DROPPING
VALVES
& RE-INSTALLATION OF CONTROL
1.46.1. : Drop control valves on Hydro test loops before
pressurizing the system. Coordinate with HPCL’s
Instrumentation department for disconnection of cables,
Copper tubing etc. All the control valves shall be dropped
and transported to Instrumentation section & back to site
under the Maint-Instrumentation supervision. Reinstall the
control valves after Hydro test. Care shall be taken not to
damage any components during dropping, transportation
and re-fixing of control valves. This entire job to be done
under HPCL instrumentation including certification of
challans.
1.46.2. Rate payable per Inch Dia of Control Valve
1.47. TRAY/DOWN COMER/SEAL PAN REPLACEMENT IN
COLUMNS
1.47.1. Scope of work covers jobs to be executed for refixing/replacement of any dislodged/damaged segment of
tray/ down comer/seal pan.
1.47.2. Number the tray segments and down comers for
identification as per drawing. Remove all fallen, displaced,
distorted tray segments. Open all the clamps of the tray
segments, weir angles etc to be repaired/ replaced. Remove
the segments and bring them to ground level, if required,
for repairs.
1.47.3. Service all tray clamps wherever the tray segments, down
comers are removed and replace the damaged ones.
Annexure 1 – Part II / Page 36 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
Recover all the tray valves that can be reused. Fix new tray
valves that are missing.
1.47.4. Straighten tray segments, down comer plates, angles etc. if
they can be reused as per Inspection. In case the distorted
segments cannot be repaired, draw new segments from
warehouse and bring to site.
1.47.5. Assemble the down comer plates, seal pans, tray segments
etc. in position along with the overflow weir angle and
clamps as per drawing. Minor modifications that may have
to be carried out to make the new tray segments to suit the
field conditions shall be carried out by the agency at no
additional cost. Agency shall mobilize required drilling
machines for modification of mismatched bolt holes while
assembling new and old tray segments, to suit to field
conditions
1.47.6. Ensure proper overlap and alignment is maintained as per
drawing on segment- to-segment joint while fixing.
Agency shall co-ordinate with Operations and Inspection
departments for obtaining necessary stage wise approvals.
1.47.7. Tray segments adjacent to damaged/ fallen trays which
have to be removed and re-fixed to facilitate removal and
reinstallation of the damaged trays will also be considered
for payment under this category. No additional payments
shall be made for removing, repairing and re-fixing weir
angles and support angles of trays.
1.47.8. Rate payable is per square meter of tray removed, repaired/
replaced and reinstalled.
1.48. VALVE RECONDITIONING
1.48.1. The scope of the job involves servicing of the valves of
different sizes and ratings in the DHDS unit insitu or at a
servicing yard by the agency.
1.48.2. The agency shall mobilise adequate manpower along with
all tools & tackles, equipment like lapping machine, test
bench along with supervision to execute the jobs.
Annexure 1 – Part II / Page 37 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.48.3. In case of non availability of spares alternate spares like
hand wheels, etc shall be recovered from other valves
available at site and replaced.
1.48.4. The job is subject to stage wise inspection by HPCL.
Agency shall maintain a book for all the valves
reconditioned with a record of the valve size, rating, type
of repair attended duly endorsed by HPCL representative.
All repaired valves shall be tagged by agency with a metal
strip with date and company name.
1.48.5. Valve servicing without opening bonnet.
1.48.5.1. Dismantling of the gland follower, removal of entire
old existing packing. Thorough cleaning/polishing of
the spindle and inspection. Replacement of total gland
packing by cutting rings from packing material. Reassembly of gland. Free-up the valve as required.
1.48.6. Valve servicing opening the bonnet
1.48.6.1. Opening of the valve bonnet, dismantling of gland
follower, removal of entire old existing packing.
Thorough cleaning of all internals like spindle, yoke
bush, sleeve, etc, servicing of all bolts and inspection.
All repairs like lapping and blue matching, weld build
up at grooved/pitted locations, grinding and servicing of
bonnet gasket surface, gate, seat.
1.48.6.2. Replacement of total gland packing. Re-assembly of
valve, after replacing the bonnet gasket. Free-up the
valve as required. Agency shall mobilize the required
gaskets for the bonnets.
1.48.6.3. Agency on dismantling the valve shall immediately
indicate to HPCL the dimensions of the bonnet gasket
and make arrangements to procure the same within 72
hrs. the same has to be procured from approved gasket
manufacturers only. It may be noted that these are non
standard gaskets and their dimension and MOC shall be
obtained and sketch made only after opening the
bonnets. To ensure close co-ordination and availability
Annexure 1 – Part II / Page 38 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
of gaskets in time, the agency shall station a person at
the gasket manufacturer’s factory.
1.48.7. Rate payable is
1.48.7.1. Per each valve of various sizes (all ratings)
serviced without bonnet opening.
1.48.7.2. Per each valve of various sizes (all ratings) serviced
with bonnet opening and bonnet gasket replacement.
1.48.8. Other miscellaneous jobs on valves which are not covered
under the above scope such as valves freeing up, cleaning
of valve spindle / bushes free of sand and foreign matter &
greasing, replacement of damaged hand wheels in the
location, replacement of damaged gland follower eye bolts,
etc as advised by the job engineer etc shall be
compensated on manpower basis.
1.49. IN-SITU MACHINING
1.49.1. This covers the machining of the flange faces Insitu using
flange facers. Rate is inclusive of mobilization of necessary
flange facers and manpower.
1.49.2. Rate payable is per inch dia of flange machined.
1.50. POSITIVE MATERIAL IDENTIFICATION
1.50.1. Scope involves usage of portable alloy analyser for
checking metallurgy of pipes, plates tubes etc. The PMI
portable alloy analyzer instrument shall measure alloy
compositions of common elements like Silicon,
Manganese, Chromium, Nickel, Molybdenum, Iron,
Tungsten, Vanadium, Niobium, Tantalum, Titanium,
Copper, Aluminum, Zinc, Tin, Antimony, Sulfur,
Phosphorus, and Cobalt among others.
1.50.2. Rate payable is per shift of PMI carried out.
1.51. JOBS ON EXCHANGER NOT PART OF LUMPSUM
SCOPE
Annexure 1 – Part II / Page 39 of 40
DHDS T&I’09: Main Contract
Annexure 1 – Part II
Part – II - UNIT RATES
1.51.1. Scope of job involves jobs on the exchangers which are not
part of Lumpsum scope.
1.51.2. Carry out all the jobs on the exchanger as per Annexure 4
– Attachment 4.2: Standard procedure for jobs on
exchangers.
1.51.3. Box up after inspection clearance and make up flanges.
1.51.4. Rate payable is lumpsum per exchanger for different
range of diameter.
1.52. JOBS ON MANPOWER SUPPLY BASIS
1.52.1. This covers manpower to be utilized for executing any
additional work, which is not covered under any of the unit
rate items mentioned above. Agency shall mobilize
manpower with all tools, equipment, consumables,
electrical services, supervision etc. and execute the job.
1.52.2. Rate payable is per head per 8hrs Hrs shift. Rate payable
for 12hrs shift shall be double of the rate payable for 8hrs
shift
Annexure 1 – Part II / Page 40 of 40