Professional Documents
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SCOPE OF WORK
Sub: Repair of Regeneration Columns C-1202 and C-1302 of GSU-12 and GSU-13 Plants at
ONGC Uran Plant, Uran
The GSU units of plant removes the shore content like H2S & CO2 from hydrocarbon gas before
extracting the LPG,C2C3,LAN and sweet lean gas.
During the turnaround inspection of the columns C-1202 and C-1302, it is found that there is
thickness loss at various location on columns from inside as well as outside also. The thickness
loss has to be repaired for the service of the remaining life of the columns.
The repairing of columns has to be done by lap band repair at some of the location, at other
locations by weld build up. At some location SS cladding (inside the column C-1302) is
damaged, hence an internal repair including the replacement at some portion and patch weld/
weld build up repair at some location of clad/column is to be carried out.
Details of columns(C-1202 & C-1302)
SL no.
Details
1
Design pressure (Ks/cm2g)
2
Operating
pressure
(Ks/cm2g)
3
Design temperature ( C)
4
Service
5
ID
6
Capacity
7
Thickness of shell (mm)
8
9
10
11
12
Specification values
5.7
0.5/0.7
97.3(top)/125.7(bottom)
Sulfinol-X solvent+H2S+CO2+hydrocarbon gas traces
2550mm(top)/3500mm(bottom)
129.2m3
12(9+3) top 3 mm clad up to 5 m from top,15mm in
middle,19 mm at bottom
columns 25.7+1.15
Max height of
(meter)
MOC of shell/clad
Insulation thickness(mm)
Joint efficiency
Code
SA516Gr.60/ SA516Gr.60+A240-321
105
1.0/0.85
ASME Sec.VII DIV.I 1986
LOCATION
A/1ST
top
B/1ST
top
B/1ST
top
D/5th
top
E/5th
top
F/5th
top
G/5th
top
H/5th
top
I/5th
top
2
3
4
5
6
7
8
9
Nom
inal
thick
ness(
mm)
Observ
ed min.
thickne
ss(mm)
shell from 12
6.4
1.0x0.3
shell from 12
4.5
shell from 12
7.0
2.0x1.2
5
1.0x1.0
shell from 15
9.4
1.5x1.0
shell from 15
7.7
1.0x1.0
shell from 15
8.6
1.0x1.0
shell from 15
8.9
0.2x0.2
shell from 19
13.4
shell from 19
12.0
Area
to
repaired
S.No
be
Internal
3mm
SS
cladding area
to
be
replaced (m
X m)
1.5 X1.0
2.5x1.5
1.5x1.0
Nil
Nil
1.0x0.5
0.2x0.2
Nil
1.5
Nil
Nil
Nil
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5. After shut down blinding/DE blinding of columns shall be performed by contractor as per
instruction of EIC.
6. The repair is to be done at identified locations inside as well as outside of columns which
are at various height. The contractor may visit the site so as to get first hand details about
the job to be carried out.
7. The supply of all the material required (including logistics, loading/unloading etc.) to
execute the job as per SOW is in the scope of contractor.
8. The welder/welders deputed for the job shall be a qualified welder and requisite associated
manpower shall be made available at the site so as to complete the job within stipulated
time.
9. The procedure given for carrying out the repair shall be followed and as per the guidelines
of ASME Sec IX and ASME Sec II Part C.
10. The type of repair like lap banding, fillet weld of patch, weld overlay and clad (inside the
column) replacement have been provided above in the table but same is indicative only. If
needed repair work in more area shall be performed in addition to above. And the
contractor has to adopt the appropriate procedure to do all said repairing work accordingly.
11. Suitable NDT to be done after every root and final weld run. After completion of the
repair, radiography shall be done by the contractor as per the instructions of Engineer-incharge.
12. On completion of repair, two coats of high temperature & corrosion resistance
paint shall be applied over the repaired surface as well as on whole surface of columns after
properly cleaning and corrosion removing as per the standard procedure with minimum DFT
after each coat 20 microns.
13. The scrap generated during the execution of the repair job will become the property of
the contractor and shall be taken out of ONGC premises. Accordingly the bidder has to
quote the price for the safe disposal and comply all statutory requirement.
14. All the jobs to be carried out shall be executed as per the instructions of Engineer-incharge and within the given time period.
15. The columns shall be flushed and washed the whole column from inside properly by
contractor followed by oxygen test before taking repair job either from inside or from
outside of columns.
16. If needed the contractor has to remove nearly 7 trays, do the repair/replacement work
inside the column and then refit same trays properly.
17. Bidder has to do hydro test of column at test pressure for leak test at 1.5 times of design
pressure.
18. The contractor has to paint the railing, grating, ladder platform of the column with
suitable paint as per procedure.
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19. Contractor has to arrange PPE (Personal Protective Equipments) like safety shoes, safety
belts, helmets etc. for all his personals to be engaged during execution of job at site.
20. The contractor has to get gate pass for men and equipment himself. ONGC shall assist
him. Providing all required documents and police verification shall be responsibility of
contractor.
21. On accident if any for employees of contractor, ONGC shall not any responsibility for
same and ONGC shall transport the victim up to ONGC plant occupational health center.
Transportation of patient from ONGC premises to required hospital and treatment shall be
responsibility of contractor.
22. Following procedures of repairing of damaged at different portion of columns can be
adapted by bidder. Replacing the section or component containing the defect for clad
pad portion.
1. Damaged or eroded shell plates (reduced thickness) area may be repaired by
removing a section and replacing the plate as per required thickness and
material specification.
2. Full penetration groove weld to be provided.
3. The welds are radio graphically tested with applicable construction code.
Ultrasonic examination by an industry qualified UT shear wave examiner. May
be substituted by radiography if NOE procedure is approved.
4. All patch plates corners that do not extend to existing longitudinal or
horizontal weld shall be rounded having a 1 in. (2Smm) minimum radius. Weld
proximity to existing weld shall be reviewed by the engineer.
Fillet weld patches:
Following procedure should be used for fillet weld patches or weld build up:
Fillet weld patches may be used to make temporary repairs to damaged,
corroded or eroded areas of pressure vessel components. Temporary repairs
using fillet welded patches shall be approved by an inspector and engineer.
The use of fillet welded patches may be subject to the acceptance of the
governing jurisdiction.
Fillet welded patches require special design consideration specially related to
weld joint efficiency, filler welded patches may be applied to internal or
external surface of shell, heads and header provided that in the judgment of
the engineer, either of the following is true:- The fillet welded patches provide design safety
equivalent
to
reinforced
openings designed according to the applicable construction code.
a. The fillet welded patched are designed to absorb the membrane strains of
the parts so that in accordance with the rules of the applicable
construction code, the following result:
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Payment terms:
No advance payment shall be made. 100%Payment shall be made on successfully
completion of each column repair job as per Scope of Work and terms and conditions of the
contract.
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Bidder has to submit the bill/invoice in triplicate with all required documents in the name of
DGM (F&A), ONGC, Uran and should get tracking number from our HR/ER Section. The bill
after tracking no. shall be forwarded to concerned Engineer in charge by HR/ER for
certification, verification, and final release. Payment shall be released within 21 days from
the date of submission of bill to concerned Engineer-In-Charge.
Completion Schedule: Contractor has to complete the job of repair of each column within
20 days from the date of handing over the respective columns.
Mobilization: Maximum 15 days shall be allowed for mobilization of men, equipment and
machinery etc. from date of LOA.
Contract period: Contract period for the jobs will be 18 Months from placement of LOI.
Inspection: Inspection shall be carried out by ONGC representative/ TPI(arranged by ONGC)
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