Attachment to PR

CS_KCS_AS_SS PIPING jobs for FR Onsite areas - Revised Job Scope & Notes to Vendors

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Please arrange to provide necessary Skilled Manpower services, expert Full-time Supervision, Transportation, Materials, Tools & Tackles, Equipment, etc. for CS/KCS/AS/SS PIPING JOBS (Hydrocarbon/Utility lines)FOR ENTIRE FR-ONSITEas per the Terms & Conditions specified below.

PO validity period:-

As given in tender OR revised PO validity Period OR 100% utilisation of the PO financial limit whichever occurs earlier.

PO End date: - As given in tender OR Revised PO End date.

PO validity Extension & Fin. Limit Enhancement Criteria:-PO validity Extension & Fin. Limit Enhancement,either or both shall be granted depending on the Vendor's performance with Vendor's consent but at HPCL's discretion only.

SCOPE OF JOB:-

ITEM GROUP A: SPADING OR DESPADING

A.1.SPADING OR DE-SPADING

Carry out required Spading or De-Spading of Flanges of various Sizes and Ratings, as per HPCL advice, with necessary servicing of Joint Bolts. Note that Spading/De-Spading required for Hydro testing of newly fabricated lines at the Fabrication Yard will NOT be paid separately. However, Spading/De-Spading required at Site for Isolation, Hydro testing, Steaming, Flushing of old associated lines will be paid separately.

A.2.CUTTING OF SLIP BLINDS

In case of non-availability of Slip Blinds at HPCL’s Store, Vendor may be advised to carry out fabrication of necessary Slip Blinds. Payment for the same will be made separately on Pipeline Nominal Bore Inch Dia basis. Plate required for fabrication of Slip Blinds will be provided by HPCL as Free-Issue Material. All such Slip Blinds shall be credited to Tool Room, LR after completion of the desired jobs.

ITEM GROUP B: FABRICATION & INSTALLATION OF SLEEVES FOR UNDERGROUND PIPING

  1. Provide Sleeves for underground Pipelines at the Road crossings after Excavation. In such cases, payment will be made on Inch Meter basis of the Sleeve provided. Vendor’s scope includes cutting of the Pipe (for Sleeve) to its required Length, including transportation of the same from Scrap Yard or any other issuing location, as advised by the concerned HPCL Supervisor to the Fabrication/Job Site.
  2. In case of Sleeves being made from multiple Pipes, intermediate Welding of Pipes shall be carried out and payment in such cases will be made on the basis of Rates for ITEM GROUP D(Temporary Line fabrication and erection).
  3. Pipe Sleeve details are provided in the attached Drawing no. 7-44-404, Rev.0. Plates required for fabrication of Sealing Plate, Guide Plate and Segmental Plate would be issued by HPCL as FIM. All Welding required for Sealing Plate, Guide Plate & Segmental Plate welding will be paid separately as per the relevant PO Line ITEM GROUP Rate, basis per Running Feet of 6mm Thick Fillet Welding. Any Thickness other than 6mm Fillet Weld will be paid on pro-rata basis. Calculation of the amount payable will be arrived at by Quantity Adjustment.
  4. Carry out Excavation, Sand filling and Backfilling, as required for installation of the same and separate payment will be made as per the relevant PO Line ITEM GROUP Rates.

ITEM GROUP C: FABRICATION OF BENDS FOR ½", ¾”, 1", 1 ½” & 2” DIA LINE SIZES

  1. Provide necessary services to carry out Cold Bending of the above sized Pipes, where required, using Cold Bending Machine.
  2. Supply of Cold Bending Machine will be in Vendor’s Scope as a part of the Job.

ITEM GROUP D: FABRICATION & INSTALLATION OF TEMPORARY PIPING

  1. Carry out fabrication and erection of temporary piping as per requirement. Collect required materials from Scrap Yard or any other issuing location, as per advice of the concerned HPCL Supervisor.

ITEM GROUP E: FABRICATION/ERECTION OF STRUCTURAL SUPPORTS FOR PIPING

  1. Fabricate, weld and erect Structural supports for Piping, wherever required, as per advice of the concerned HPCL Supervisor.
  2. Structural Materials will be provided by HPCL, as FIM.
  3. Payment will be made basis Metric Ton of the installed Weight of Structural.

ITEM GROUP F: CS FILLET WELDING

  1. Please quote Rate for 6mm Thick Fillet Welding. For any other Thickness of Fillet Welding, Payment will be made on pro-rata basis. Calculation of the amount payable will be arrived at by Quantity Adjustment.

ITEM GROUP G: SCAFFOLDING JOBS

Please refer relevant section/s of the “Attachment SC”

ITEM GROUP H: REMOVAL & INSTALLATION OF FLANGED VALVES

  1. Removal & installation of Flanged Valves coming in between the line being replaced will be paid as per this ITEM GROUP. Certain Valves may have to be serviced. In such case, transportation of the same to & from Workshop or any other location, as advised by HPCL, will be in Vendor’s scope.
  2. Vendor may also have to replace Valves at locations other than coming within the replacement Section, as per advice of the concerned HPCL Supervisor.
  3. Welded Valves will not be paid under this ITEM GROUP and they will be included in the Weld Joint Rates.
  4. In case of only installation or only removal of any Flanged Valve, 50% payment will be made. This shall be arrived at by Quantity Adjustment against the respective PO Line ITEM GROUP.

ITEM GROUP I: REMOVAL OF CS/KCS/AS/SS PIPELINES AND REINSTALLATION OF THE SAME AFTER REPAIRS AND / OR MODIFICATION

  1. Scope of this ITEM GROUP includes removal of the line that is to be repaired/modified by de-Bolting and/or Cold/Hot cut, as per advice of the concerned HPCL Supervisor.
  2. Vendor to cut the line in such a way that re-fixing of line is done with the minimum number of Weld Joints. Reinstall the line by Bolting and/or Welding, as per the Site requirement or as advised by the concerned HPCL Supervisor.
  3. Vendor will be paid for removal and reinstallation of line on Inch Meter basis. This Rate will be inclusive of Bolting/de-Bolting and no separate payment will be made for the same.
  4. Weld Joints, Corrosion Pad, Reinforcement Pad, Corrosion Pad with Shoe Support, Spading/de-Spading, etc. carried out for modification jobs will be paid extra as per the applicable PO Rates.

ITEM GROUP J/K/L/M:-

REPLACEMENT OF CARBON STEEL (CS) / KILLED CARBON STEEL (KCS) / ALLOY STEEL (AS) / STAINLESS STELL (SS) of all grades PIPING, FITTINGS, CORROSION PAD, REINFORCEMENT PAD, SHOE SUPPORT(from ½" to 36" NB Pipeline sizes)

1.CS /KCS/AS/SS PIPING

a)Piping will be de-pressurized by HPCL and handed over to the Vendor for necessary Spading/de-Spading. Spading/de-Spading will be paid separately as per ITEM GROUP A. Flushing and Gas freeing of the Circuit shall be carried out by HPCL. However, Vendor to provide necessary assistance for the same. Fabrication of temporary lines, if any, for de-pressurizing the Circuit, is included in Vendor’s scope of job. Vendor shall fabricate the temporary CS line, generally from Scrap Pipe (to be collected from the available materials in the Scrap Yard, as advised by HPCL Supervisor). Payment for such temporary Piping will be made separately on Inch Dia basis as per ITEM GROUP D. After completion of jobs, such temporary connections shall be removed and shifted back to the Scrap Yard.

b)The existing Piping to be cut or disconnected and removed. Vendor may have to carry out Cold cutting, depending upon the Site condition. New Piping shall thereafter be installed after proper fabrication. This includes fabrication/replacement of ½ to 2 Threaded / Welded Piping, provision of Bleeders/Vents on Pipelines, along with Gussets, as per requirement and as advised by HPCL Supervisor (Back welding of threaded joints of Pipe & Valves, if required, is included in the scope of job). However, in case of Old lines, as advised by concerned Supervisor-in-charge of HPCL, Vendor to provide Gussets as required and the same shall be paid separately as per ITEM GROUP F. For thickness lower or higher, payment shall be made on pro-rata basis and calculation of the amount payable will be arrived at by Quantity adjustment. In case the existing Piping is not to be removed and only new Piping is to be fabricated & installed, then 90% of the applicable Line ITEM GROUP Rates will be paid (This will be applicable to all fabrication ITEM GROUP Rates only. This will however exclude ITEM GROUP s like Spading/de-Spading, Excavation & backfilling, Stress Relieving, Radiography, Cutting of Slip Blinds & Dewatering Pump Operation). Calculation of the amount payable will be arrived at by Quantity Adjustment.

c)As a part of the job, Vendor shall carry out disconnection/reconnection of any Tie-in Piping or Electrical/Instrumentation Fittings (like Thermocouples, etc.) and provide suitable temporary Supports.As a part of the job and as advised by the concerned HPCL Supervisor, Vendor shall provide Plugs and Caps on Vents and Drains. Plugs and Caps shall be supplied by HPCL as FIM.

d)Erection/dismantling of Scaffolding, wherever required for the job, will be within Vendor's scope of job. This will be paid separately as per relevant Line ITEM GROUP Rates in PO.

e)Vendor shall depute only approved & Coded Welders for all Welding jobs. Jobs will be awarded to Vendor only after the Welders are duly approved by HPCL's Material Inspection Section.

f)The entire job will be subjected to stage-wise Inspection and Approval by HPCL MI Department. All Weld Joints must be of X-Ray quality. Weld Joints will be subjected to Radiography checks, as per HPCL Inspection requirements. Payment for the same will be made as per ITEM GROUP N. However, if any Weld Joint fails in Radiography, Vendor shall repair the same at no extra Cost to HPCL and shall bear the re-Radiography/Hydro testing charges.

g)Stress Relieve the Weld Joints, Corrosion Pads, etc. as advised by HPCL Inspection. All activities required for carrying out Stress Relieving will be in Vendor’s Scope of job. Required Power supply for Stress Relieving will be provided by HPCL. All requirements for Heat Treatment shall be as per ASME B31.3. Also, Vendor to take HPCL MI advice for details of Stress Relieving Cycle, requirement, Procedure, etc and furnish all Results, as required by MI. Vendor shall use appropriate number of Thermo Couples and position them at the required Pitch, as per the specification of applicable ANSI/ASME Standard. Vendor shall insulate Weld Joints to the required Thickness, as specified in ANSI/ASME Standard. The entire job will be subjected to Inspection and Approval of HPCL MI Section. Vendor to obtain certification of SR Charts from HPCL MI in-Charge during the process as well as after completion of the job. Stress Relieving will be paid separately as per ITEM GROUP O. If any Weld Joint fails in Radiography after Stress Relieving, the entire repair, re-Radiography, Stress Relieving, Hydro testing, etc. shall be carried out by the Vendor at no extra Cost to HPCL.

h)Only HPCL approved Welding Electrodes shall be used for the entire jobs under this Contract, as per the list provided in ANNEXURE WE.

i)In case of CS, for Welding of Thickness <12mm, AWS E6010 shall be used for Root Welding and AWS E6013 Electrodes shall be used for subsequent Passes. For Welding of Thickness >=12mm, AWS E6010 shall be used for Root Welding and AWS E7018 Electrodes shall be used for subsequent Passes. For Fillet Weld & Socket Weld Joints, AWS E6013 Electrodes shall be used.

j)Fabricate Steam Tracing lines, as per the Field requirements/as advised by HPCL. Fix Steam Tracing lines with the help of Holding Lugs (provision of Holding Lugs will be in Vendor’s scope, including Materials, Electrodes, etc. as required for the same and no separate payment shall be made). Also, bend the Steam Tracing lines as per Site condition/as advised by HPCL. Payment for Bending the Steam Tracing lines will be made as per ITEM GROUP C.

k)For nipple/pipe of vent/drain bleeder connections, vendor to offer Fit up of all socket welded Joints & offer these welds for inspection / DPT examination for checking Integrity after completion of welding.Vendor to carry out DP check of socket welds for ensuring quality. Scope includes all necessary equipments, materials, skilled personnel, etc required to carry out DP Test as per advice of HPCL Supervisor. Only “MAGNA FLUX” or P-MET” DP material is acceptable. Cleaning of the area to be tested, by buffing etc. as required, is part of the scope of work. No separate payment shall be made for carrying out such above jobs including DP Testing.

2. CS/KCS/AS/SS CORROSION PADS

a)Weld Corrosion Pads, as required, beneath the Piping sections, which will be resting on the Sleepers. Size and orientation of the Corrosion Pads should be as follows -12" Long Corrosion Pads, covering 1/3rd of the Pipe, circumferentially at the Bottom.

b)Payment will be made on Nominal Bore Pipeline Inch Dia basis.

3. CS/KCS/AS/SS SHOE SUPPORTS

a)Provide Shoe Supports for Pipelines, where required, as per the attached HPCL Drawing no. N-648, Sheet 1 of 2.

b)Welding of Corrosion Pad on the Pipeline is a part of Shoe Support job.

4.CS/KCS/AS/SS REINFORCEMENT PADS

a)Vendor may have to carry out Branching of Pipelines, as required, in case Tees are not available. Payment of the Joint will be made on the basis of NB Diameter of the Branch Pipeline.

b)Provide Reinforcement Pads as per Refinery Standard (2D, where ‘D’ is the NB Diameter of Branch Pipeline), wherever direct Tapping is taken from the Pipeline.

c)Payment for Reinforcement Pad Welding will be made on the basis of NB Diameter of Tapping.

5. CS/KCS/AS/SS FABRICATION OF ECCENTRIC / CONCENTRIC REDUCERS

a)Cut Strips/Sections from Pipes and fabricate CS/KCS/AS/SS Reducers, as per instruction of the concerned HPCL Supervisor.

b)Fabrication shall be carried out as per the Standard procedure. Vendor shall carry out optimum Cutting and Welding for fabrication of the Reducers.

c)The extent of Circumferential and Longitudinal Radiography shall be as directed by HPCL Ml in-Charge. Please refer to Clause # 1.6 of ITEM GROUP J/K/L/M for the scope of Radiography. Payment towards Radiography will be made separately as per applicable PO Rate.

d)In case of fabrication of Reducers, Vendor to quote per Running Feet of 10mm Thick Butt Welding. Any other Thickness of Butt Welding will be paid on pro-rata basis. Calculation of the amount payable will be arrived at by Quantity Adjustment.

ITEM GROUP N:
RADIOGRAPHY
  1. Vendor shall carry out Radiography for Piping jobs, as advised by HPCL MI Section. Broad indicative requirement is given below:
  • 100% Radiography: For Piping in 900# Class, Toxic/Lethal service & wherever required by Pipeline class requirement or Piping Drawings
  • 100% Radiography: For Pipelines in LPG, Propane and Hydrogen service
  • 20% Radiography: For Pipelines in Crude and Naphtha service
  • For other Hydrocarbon lines: 10% of Weld Joints, Welder wise
  • For Utilities and Class-D Fluid service (as per ANSI B31.3): 2% of Weld Joints.
  • Acceptance criteria & Penalty Clause will be applicable as per ANSI B31.3 Spot Radiography for other than 100% Radiography.
  1. Vendor shall use own portable Gamma Ray Source, as approved by BARC, along with necessary Equipment and Accessories.
  2. Industrial Radiography Films, manufactured by AGFA, FUJI, HP or KODAK, corresponding to Film Type 1 or 2, as per ASTM E94 and E142, shall be used. Normally all Radiographs shall meet the required sensitivity of 2% of Wall Thickness, unless specifically approved/agreed otherwise.
  3. Strictly adhere to all applicable Safety regulations of BARC & HPCL. Take necessary Work Permits for carrying out Radiography in HPCL premises with Radiation Badges and cordon off the work place up to safe distance, with proper Caution Notices and Radiation Field Indicators.
  4. All exposed Radiography Films will be HPCL property and Vendor shall hand over the same to HPCL MI Section accordingly.
  5. Payment will be made on Running Feet basis, as per relevant PO Line ITEM GROUP.

ITEM GROUP O:

STRESS RELIEVING OF JOINTS

Stress Relieve the Weld Joints, Corrosion Pads, etc. as advised by HPCL Inspection. All activities required for carrying out Stress Relieving will be in Vendor’s Scope of job. Required Power supply for Stress Relieving will be provided by HPCL. All requirements for Heat Treatment shall be as per ASME B31.3. Also, Vendor to take HPCL MI advice for details of Stress Relieving Cycle, requirement, Procedure, etc and furnish all Results, as required by MI. Vendor shall use appropriate number of Thermo Couples and position them at the required Pitch, as per the specification of applicable ANSI/ASME Standard. Vendor shall insulate Weld Joints to the required Thickness, as specified in ANSI/ASME Standard. The entire job will be subjected to Inspection and Approval of HPCL MI Section. Vendor to obtain certification of SR Charts from HPCL MI in-Charge during the process, as well as after completion of the job. If any Weld Joint fails in Radiography after Stress Relieving, the entire repair, re-Radiography, Stress Relieving, Hydro testing, etc. shall be carried out by the Vendor at no extra Cost to HPCL.

ITEM GROUP P:

CORROSION PROTECTION OF UNDERGROUND PIPELINES

ITEM GROUP P1: CORROSION PROTECTION OF PIPELINES WITH PRIMER/COLD APPLIED COATEK PVC BACKED TAPE SYSTEM

As advised by the concerned Supervisor-in-charge of HPCL, carry out Coating & Wrapping of Pipeline with Cold applied Coatek ‘PVC’ backed Tape System, as per the detailed scope given below:

SPECIFICATION AND PROCEDURE FOR COATING & WRAPPING OF PIPELINES

1.COLD APPLIED COATEK PVC BACKED TAPE

This is a Cold applied PVC backed self-adhesive Rubberised Compound Tape, with a Release-coated Paper.

1.1.TAPE CHARACTERISTICS

Elongation:260% (Minimum)

Tensile Strength:13N/mm (Minimum)

Holiday Test:Single layer, 15 KV

Dielectric Strength:20,000 V/mm

Adhesion to Steel:2 N/mm

Total Tape Thickness:1.8mm

Compound Thickness:0.9mm

PVC Thickness:0.75mm (Minimum)

2.PRIMER

The Primer shall be a Rubberised Solution and fast drying, consisting of Synthetic Plasticizers and is Solvent based. The Primer is meant to provide strong bond between metal surface and the subsequent Tape System.

Drying Time for the Primer would be less than 15 Minutes. Clean, dry, prepared surface shall be primed with One Coat of Primer (of DFT 35 ) and allowed to dry.

2.1.PRIMER CHARACTERISTICS

Flash Point:23 OC (Minimum)

As per ASTM D3941-90 / IS-101 1964

Drying Time:5 to 15 Minutes

As per ASTM D1640-83/89 / IS-10221