Professional Documents
Culture Documents
PROJECT DESCRIPTION
For balance job of Diesel Quality Upgra dation Project (DQUP) at Nu maligarh
Re finery requires t h e execution of following jobs.
Part: A - Dismantling and erection of Exchanger (04-EE-001) and fabrication & erection of
associated piping.
Part: B - Installation of Control Valve and fabrication & erection of associated piping
Part: C - installation of Air Fin fan Cooler (04-EA -001 A/B/C/D)
Contractor to note that work has to be performed during shut down and also in running plant
e xc luding prefabrication which has to be done during pre -shutdown period. The sche me of
work execut ion shall be approved by Owner/Eng ineer In -charge prior to ta king up these
activities in the p lant. Contractor has to ta ke ut mos t care & safety p recaut ions while working
in the p lant. Hot work permits / safety permits for wo rking in the p lant shall have to taken
fro m the Owner by the Contractor. Contractor shall carry out work only after obtain ing
clearance fro m the Owner.
1.0
Transportation of requ ired piping materials (as described in CL.1.2), p ipe support
materials (as described in CL.1.4) and a ll other neces sary p iping mate rials fro m
EILs /Owne rs storage po int o r Cont ractor's storage po int (in case of Contracto r's scope
of supply) to work site/shop includ ing raising store requ isitions for issue of materials in
the prescribed format & ma intaining an account of the materials received fro m
EILs/Owne rs stores & reconciliation of all EIL/ Owner supplied free issue materials.
1.2
Piping materials inc lude the fo llowing but is not limited to the sa me :
a.
b.
c.
d.
e.
f.
g.
h.
i.
1.3
Shop & field fabricat ion and erection of pip ing in accordance with docu ments listed
under CL. 2.0 i.e ., 'BASIS OF W ORK' inc lud ing erect ion of all pip ing materia ls
enu merated above.
1.4
Fabrication and erection o f pipe supports like shoes, saddles, guides, du mmy pipes, stops
anchors, c lips, crad les, hangers, turn buckles, special support, supporting fixtu res,
brac kets, cantilevers, stru ts, tee-posts, includ ing erect ion of spring supports, expansion
bellows, steam and condens ate man ifo lds support and sway brac es etc.
1.5
Fabrication Works
a.
Fabrication o f pip ing specials like specia l rad ius bends, reduce rs, miters, etc.
b.
Fabrication o f pla in and threaded n ipp les fro m p ipes, thread ing of p ipe ends as
required du ring erection.
c.
d.
Fabrication o f odd angle e lbows like 60, 30 or any other ang le fro m 90/45
elbo ws as and when required.
e.
Fabrication of flanges, reducing flanges, b lind flanges, spectacle blinds etc. as and
when requ ired .
f.
g.
Grind ing of edges of pipes, fittings, flanges, etc. to match mat ing edges of
uneven/differe nt thickness where ver required as per specifications including
beveling of pla in end p ipes & swages.
h.
i.
Tapping and drilling of holes in flanges, blind flanges, p ip ing connections for jack
screw, if required.
j.
Fabrication of special ite ms like weather protection shield, hood etc., if required.
k.
l.
1.6
Erection of control va lve shall be done after flushing/che mical c lean ing, etc. o f the line.
For erection of pip ing, te mpo ra ry spool piec es shall be installed in p lace of control va lves
along with temporary gas kets (contractor supplied). No separate pay ment sha ll be made
on this account.
1.8
Preparation of iso metrics and bill of materials fo r process and utility lines up to 1.5 size
and lines re lated to instrument and pu mp flushing/cooling, sprinkler pip ing over
pumps/vess els etc., purg ing, pump c a s ing vents & d rains, pump base p late dra ins, control
valve drain/vent to fla re, stea m tracing fro m supply station/header to condensate
recovery , supporting details of all Non -IBR lines up to and includ ing 1.5 (in case o f IBR
lines 1.5 & below only ind icative supporting shall be p rovided & detailing of such
supports is in contractors scope) and lines specified as field routed including subsequent
approval fro m Eng ineer In-charge as and when requ ired is in contractor scope o f wo rk. In
some cases control valve, pu mps, e xchange rs, instru ments like level gauge etc. are being
replaced where existing s mall bore piping to drains/vents, samp le connect ions, auxiliary
piping to pu mps may be ava ilable but th is may need to be modified/aug mented in vie w o f
the new d imens ions. Such mod ifications/re routing is to be done at site by contractor in
consultation with Eng ineer In-charge meeting P&ID require ments fo r wh ich no
is o metrics shall be availab le.
1.9
1.
Pre fabrication work shall be done to the maximu m possible extent and all
prefab ricated spools shall be properly tagged fo r easy identification during shut
down..
2. Marking of hook up po int shall be done o f exis t ing piping and e xisting lines getting
dis mantle shall be painted fo r identificat ion.
3. All the G A Ds/isometrics shall be verified at site be fore ta king up p refab rication
including nozzle flange size/ratin g. Any discrepancies shall be h ighlighted.
4. Scaffo ld ing/te mpo rary supporting work shall be completed for dismantling/ hook up works before
shut down.
1.10
Dismantling Works
Contracto r shall carry out dis mantling works (cutting, re moval) in HCU & HGU o f the
existing piping (bare/ insula ted/trac ed includ ing supports) and transport the sa me to
Owners/EI Ls des ignated storage po int and stacking the material (p iping/va lves/structure
steel). All the work shall be carried out as per instruction o f Eng ineer In-charge.
1. The d is mant led materia l may be reused as and when requ ired. In case o f reuse
materia l shall be transported from dis mantle s torage po int to work site/fab. yard and
no separate pay ment shall be made on this account..
2. Piping shall be dis mantle a long with supports and no separate payment shall be made
on this account.
3. Isolat ion o f existing line shall be done before d is mantling and p roper permit shall be
taken for disma ntling work. All s afety precautions shall be ta ken befo re carrying out
the job.
4. So me of the e xisting lines/structure may have to be dis mantled and
rerouted/re installed to avoid fouling with new lines.
5. Any da mage to existing facilities like piping, painting, insulation etc. shall be rectified
as per specification and no extra pa y ment shall be made.
6. All dis mantled valves, control valves shall be prope rly stac ked separately at
s torage area.
7. All traced lines shall be dis mantled along with trac ers and no sepa rate pay ment shall
be made for t race r lines.
1.12
In case e xisting lines requires pres sure testing due to hook up , the existing line shall be
tested up to the point of c losest isolation (e.g. flange, valve).
1.13
Rad iography, dye penetration test, magnetic partic le test, wet fluorescent magnetic
partic le test etc. as p e r specificat ion 6946-6-44-0016.
1.14
1.15
Performing PM I using alloy ana lyser as per Standard Specification for Positive Material
Identification at Construction Sites, 6-82-0002.
1.16
Flushing and testing of all piping systems shall be c arried out as per Standard
Specif icat ion for Inspection, Flushing and Testing o f Pip ing Systems, 6-44-0013.
Accessories required fo r blind ing the line with suitable plate a re to be arranged by
contractor. The scope of testing shall be inclusive of opening the flange jo int, prov iding
neces sary blind, de b linding the sys tem a fter test and re bo xing up includ ing to rque
tightening / bolt tension ing as per specification. Any defe cts noticed during hydro testing
shall be made good by the contractor.
2.0
1.17
Prov iding insert plates in concrete structures / paved floo rs and repair of platfo rm
gratings around pipe openings.
1.18
Making material reconciliat ion state ment and return o f EIL supplied left ove r materials to
EIL's storage.
1.19
Eng ineering, fabrication and erect ion of stea m supply/condensate recovery manifolds and
tracer pipes in a ccordance with drawing and s tandard specific ation for s tea m t racing 644-0007. Stea m trac ing shall be carried out for lines specified in P&ID/ Line Lis t/
Piping Drawings. Ste a m tracing o f e xist ing line, if any shall also in contracto r scope.
1.20
Hydraulic bolt tensioning & torquing shall be performed on flange joints as p e r the
require ments specified in Job specification for application of torq ue and hydraulic bolt
tension for flange jo int 6946-6-76-0002.
1.21
Wherever p iping class breaks of high pressure/ low pressure are involved, the highpressure circuit shall be tested upto piping c lass spec. break and the lo w pressure circuit
shall be done upto the nea rest flange of high pressure pip ing.
1.21
In case of high pressure piping certain equip ments will require to be included as a part of
piping hydro tes t circuit. Contra ctors scope shall inc lude making necess ary arrange ments
their of and equip ment dry ing after hydro testing. The rates for piping shall be inclusive
of said equipment testing and no separate pay ment shall be made on this account.
1.22
1.23
Prov iding low friction pads as specified in iso metrics/special support sketches.
1.24
Contracto r shall take all necessary pe rmits required to carry out the job in the plant and
ensure all s afety measures during the job .
1.25
Prov id ing manpower assis tance during p re-co mmission ing/co mmis sioning without any
additional cost.
1.26
1.27
Preparation of As-Built GA Ds & Iso metrics on Appro ved for Construction GADs &
Isometrics and get it checked & approved by Engineer In -charge . Preparation &
submission of these drawings is in contractors s cope and for wh ich no separate pay ment
shall be made & work is to be co mpleted within quoted rate o f p ip ing.
Approved for construction' drawings and sketches issued by EIL to the contractorPlans and / or Iso metrics / system iso metrics.
b.
Draw ings and sketches issued by Pac kage Vendor - Plans and / o r Iso metrics /
system iso metrics.
c.
Dra wings, sketches and docu ments prepa red by Contractor duly approved by
Engineer-in-charge (such as lines 1.5 & be low, lines requ ired to be field routed
etc.)
d.
e.
f.
Line List.
Job Specific ation o f Non-Destruct ive Exa mination Require ment of Pip ing
(6946-6-44-0016).
Any other EIL or other specification attached with Pip ing Material
Specif icat ion or elsewhere and specia l conditio ns of contract.
Job specification for app lication of torque and hydraulic bo lt tension for
flange joint 6946-6-76-0002.
ASM E B 31.3
ASM E Se c.VIII
IBR Regulations
IS:823
A S M E Sec. V
All the codes referred above shall be o f the lates t ed ition, at the time o f a ward o f cont ract.
Note : Specif ication/Standa rds 6-44-0005, 6-44-0016, 6-77-0005, 6-76-0002 mentioned in any
standard specification/standard, SOR o r e lsewhere to be read with prefix 6946.
3.0
i.
j.
k.
3.2
All cutting, fitting, weld ing, b razin g, c lean ing, g rin d ing, th reading tools & tackles
and consumab les.
b.
All industrial gases such as oxygen, acetylene , inert gases, all types of electrodes,
filler wire, flux wire, brushes, etc. Approva l for Ma ker and Brand o f e lect rodes,
filler wire shall be taken by Cont ractor before p rocure ment.
c.
Shims , wedges, and packing plates (mach ined wherever requ ired ).
d.
All materials such as hydraulic pu mps, metallic b linds, gauges, temporary gaskets,
bleed/drip rings, etc. and arrange ment required for hydrostatic testing.
e.
Arrange ment fo r compressed air, blin ds, g auges, te mporary gaskets etc. and
arrangement required for pneu matic pre ssure testing.
f.
g.
All materials and a rrangement required for all types of non-destruct ive tests such
as radiog raphy (Cobalt 60 Source) , DP/ M P, UT etc.
h.
i.
All materials, consumables, tools & tackles required for hydro testing o f exis t ing
lines upto the closest flange in case of hook up (if reqd.).
j.
Arrange ment and supply o f e xpe rienced manpo wer, che mica ls, consumables,
pumps, tanks, te mporary p ip ing, DM water, bo ilers, coupons and other testing
materials & equ ip ments required for che mica l cleanin g , pic kling and passivation of
lines.
k.
All materials, consu mab les, tools & tac kles required for the d is mantling work.
l.
All sealing and protect ing materia ls requ ired fo r protect ing mat erials/equip ments
supplied by EIL/Contractor.
n.
Oil, grease, graph ite, neoprene rubber, moly kote, sealing tapes, clean ing agents
including acids for cleaning of inte rna ls/packing/through/tray etc.
o.
Chain pulley b loc k and all other material hand ling equip ments as per requir e ments.
p.
Supply o f all items required for erect ion co mpris ing of:
q.
All safety equip ments required to conduct the job and avo id acc ident and keep
good house keeping and environ ment. fire blanke ts and water hoses for fire and
safety protection as required.
r.
Supply o f co ld ga lvan izing or zinc coating mate ria l with approva l o f Engineer Incharge.
s.
Grouting mate rial, if required shall be as p e r EIL Specif icat ion, dra wings and
instructions of the Eng ineer-in-cha rge.
t.
All tools and tackles required for assistance in p re -co mmis sion ing/co mmission ing.
u.
v.
4.0
All other materials though not specified above but required for co mpletion of the
work as per specification, drawings and instructions of the Eng ineer-in-charge.
PAINTING WORKS
The s cope of work broad ly consists of painting of piping, structural steel wo rk for corrosiv e
environ ment as detailed in schedule of rates as per drawings, job specification for shop and
field paint ing (spec. no. 6946-0642-PT-E08) & instructions of Eng ineer In-charge.
Painting of impu lse p ip ing (erection by others) and field pa inting of p iping (erection/pre fab.
by others) e .g. PSA pac kage shall a lso included in scope of wo rk o f Mechan ical Contracto r.
The scope of work shall consist of surface p repa ration as requir ed, se lection and app lication of
required paints on surfaces o f piping, steel structures etc. including but not limited to:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
5.0
All structural steel work in clud ing walk ways, pipe supports, ladders etc.
All un insulated p iping and fittings includ ing flanges and valves (inc luding prov id ing
identification ma rks).
Painting o f surfaces to be insulated as per require ments.
Repair & touch up of primer applied (by others) surfaces as deemed neces sary before
application of finish pa ints.
Repair o f da mage done on e xist ing painting of pip ing/equip ment during hoo k up
work.
Any other surface as d irected by Engine er In -charge .
Identification, colo ur b ands on all painted surface of pip ing.
Identification , lettering/numbe ring on a ll pain ted surface of pip ing.
Hazardous content ma rking/identification signs on pa inted surface of p iping.
Cleaning up the working areas regularly during the cours e of work for purpose of
good house keeping as well as clean ing up the site on completion of the wo rk as
directed by the Engineer In-cha rge.
Prov id ing scaffo ld ing for all he ights, all other incidental/ auxillary/ ancillary/
accessories, labour, material, tools & tackles, consumab les, supervision ,etc or any
enabling work not specifically mentioned in the specifications but necessary for the
execut ion and co mp letion of wo rk as envisaged in the tender docu ment.
5.2
6.0
INSULATION WORKS
The scope of work shall include hot insulation of p iping etc. as detailed in schedule o f rates as
per draw ings, standard specificat ion for hot insulation o f vessels, pip ing & equ ipment (6-440002) & instructions of Engineer In-charge.
Insulation of pip ing includ ing impu ls e pip ing (erection by others) and pip ing in pac kages e.g.
PSA shall a lso included in s cope of work o f Mechan ical Cont ractor.
The work in brief shall include the following but not limited to this only :
1.
2.
3.
4.
5.
6.
7.
8.
9.
7.0
Supply of all insulation and ancillary materia l like spacer-ring, stays, mill board,
lacing and b in d ing wires, screws, bands, studs, flats, support ring c lips, sealant and
mas tic, ce ment, glass cloth, a lu minum sheets/ GI sheets, necessary drilling m/c etc.
wherever specified and required. All insulation material shall be new and of approved
quality with co mplete test certificates and in acco rdance with the spec ifications.
Applicat ion o f insulation with weather proofing on p ip ing includ ing valves, flanges
etc. as per specification and instructions of Enginee r In-cha rge.
Contracto r shall supply material required for repair of exis ting insulatio n.
Prov id ing besides all materials and consumab les labour and supervis ion required for
carry ing out the insulation work, a ll safety devices, eq u ip ments, apparatuses,
instru ments etc. necessary and incidental requ ire ments to perform the work in
workmanship and efficient manner within the stipulated t ime period.
Co lour coding identification of piping etc. afte r insulation as per relevant specification
and ins truction of Enginee r In -charge .
Prope r storage and protection of insulation materia l and consu mables brought to site
by the contractor at all stages of work.
Prov id ing insulation p lugs and windo ws at all locations as per dra wings,
specificat ions and instruction of Eng ineer In -charge.
Cleaning up the wo rking areas regularly during the cou rs e of work for purpos e of
good house keep ing as well as clean ing up the site on completion of the work as
directed by the Engineer In-cha rge.
Prov id ing scaffo ld ing for all heights, all other incidental/ auxillary/ ancillary/
accessories, labour, material, too ls & tackles, consumab les, supervis ion etc. or any
enabling work not specifically mentioned in the specifications but necessary for the
execut ion and co mp letion of wo rk as envisaged in the tender docu ment.
7.2
8.0
S.No.
1
2
3
4
5
6
7
8
9.0
S.No.
1
2
3
4
5
6
7
8
9
10.0
S.No.
1
2
SPEC / ST D. No.
6946-6-44-0005
Rev.
2
6946-6-44-0016
6946-6-44-0078
6946-6-76-0002
6946-6-77-0005
6946-0642-PT-E08
6676-0642-CC-006-L08
0
0
0
6676-0642-CC-011-L08
SPEC / ST D. No.
Rev.
6-44-0002
6-44-0007
6-44-0012
6-44-0013
6-77-0001
6-82-0002
6-82-0003
6-82-1100
6-82-1500
SPEC / ST D. No.
7-44-0350
7-44-0351
7-44-0353
Rev.
2
2
2