Bpcl Volume Ii 2017

ATTACHMENT- 1

SCOPE OF WORK- GENERAL REQUIREMENTS

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1.1

SUMMARY OF WORK Undertake planned Turnaround maintenance work of the Train III COMPLEX consisting of {Crude Distillation Unit - 3 and Vacuum Distillation unit

(CDU-3/ VDU), Hydrocracker ( HCU), New Hydrogen Generation Unit ( NHGU) & Lube Oil Base Stock Unit ( LOBS) and Train III Sulphur Recovery Unit (SRU) complex along with Sour Water Stripper (SWS) & Amine Treating Unit ( ATU) at Bharat Petroleum Corporation Ltd., Mumbai Refinery. The work scope consists of spading / despading, removal / replacement of insulation, opening , cleaning, testing, lining, inspection, repairs , and all jobs as per scope of work , boxing up and other miscellaneous works as summarized in the submitted Bill of Quantities , and as directed by the Engineer in Charge . The Shutdown Mechanical work programme shall be commenced tentatively in Feb 2017 .Completion of all shutdown works required for the plant start-up, commissioning is envisaged as set forth in Appendix H. However, the planned shutdown commencement date may vary from the actual required date due to operational requirements, but not to a significant extent. 1.2 COORDINATION BY CONTRACTOR WITH OTHER CONTRACTORS 1.2.1 The CONTRACTOR shall be entirely responsible for the coordination, proper execution and COMPLETION of the WORK. CONTRACTOR will be required to coordinate with other contractors who are directly employed by OWNER. The CONTRACTOR shall coordinate the work of each discipline with that of all other disciplines and shall ensure that all disciplines co-operate to assure the required and steady progress of all work under the CONTRACT. The CONTRACTOR shall plan his activities in such a way that there will be no interference between the other contractors. OWNER will not be responsible for any additional cost or time sustained by the CONTRACTOR by failure to coordinate with other contractors. 1.2.2 All Sub Contractors appointed by the CONTRACTOR shall be approved by OWNER. 1.2.3 The CONTRACTOR shall as required by the Engineer In Charge participate in regular co-ordination meetings with other contractors. The CONTRACTOR shall if required, provide additional information to other contractors in this regard to ensure proper co-coordinated sequencing of the Shutdown Project. 1.3

REGULATORY REQUIREMENTS

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

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1.4

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

1.5

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

-

American Petroleum Institute Specification.

ASTM

-

American Society for Testing and Materials.

ANSI

-

American National Standards Institute.

BS

-

British Standard.

BIS

-

British Standard Institute.

NACE

-

National Association of Corrosion Engineers,

TEMA

-

Tubular Exchangers Manufacturing Association

EIL

-

Engineers India Ltd. Standard Specifications

IS

-

Indian standards

1.6

SPECIAL SHUTDOWN MAINTENANCE WORK PROCEDURE

1.6.1

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

1.6.3

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

1.6.5

Lifting tool Inspection Procedure: All items of handing & lifting equipment including cranes, tools, (hand and others), air movers, ducting, lifting tackles, wire ropes, chain block , shackles, eye bolts, etc., required for the satisfactory execution of WORK shall be certified by a current inspection and test reports. OWNER reserves the right to, at its discretion, request and view the original of the inspection/test report. OWNER also reserves the right to, at its discretion, reject any items of equipment it considers unfit for the intended service/duty, Details of lifting equipment shall be specifically set out with the date of last inspection and test by a recognized inspection agency approved by statutory authorities marked against each item. All proposed equipment shall be included in the CONTRACT.

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The CONTRACTOR shall provide the original test certificates for all cranes and lifting equipment to OWNER for approval before any WORK start. Copies of the original test certification for all lifting equipment brought on site by the CONTRACTOR or his nominated SUB-CONTRACTOR shall be maintained in the CONTRACTOR'S site office throughout the duration of this CONTRACT. 1.6.6

Spade Installation and removal It is expected that extensive use of pneumatic or hydraulic impact wrenches will be required to meet complete isolation and fixing. The CONTRACTOR must take this into account when tooling up with special tools, air compressors and Breathing Apparatus sets. The CONTRACTOR must provide the service for the installation of spading and de-spading, the spades (blinds) & temporary gaskets, hose connections for decommissioning including plant battery limit spades, wedge opening for gas / Hydro Carbon freeing equipments / piping , replacement of the leaky gaskets and commissioning spading / de-spading . (See lists in Appendix A, Attachment 11 section N & spade list given against each equipment ), The CONTRACTOR also has to provide the service for the installation of spading and de-spading, the spades(blinds) and temporary gaskets, for equipment entry , for hydro testing , decontamination / chemical cleaning , pneumatic / hydro testing of piping and equipments . Process and Instrumentation Diagrams (P&ID 'S) will be supplied after CONTRACT award. Owner shall supply all the spades of required size.

1.6.7

Working Hours CONTRACTOR will be required to work on two shifts each of 12 working hours, day shift from 7.45 hours to 19.45 hours and night shift from 19.45 hours to 07.45 hours daily on the round clock basis.

1.6.8

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

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1.6.9

Welding Procedure All the welders provided under this CONTRACTOR shall be qualified in accordance with the requirements of ASME Boiler and Pressure Vessel Code Section IX, Welding qualification in the position of 6G i.e., all welding positions. All welding works must be performed by suitably qualified welders working to welding procedures approved by the BPCL inspection section. The welding procedures, qualification records and welder qualification must be submitted for review and acceptance at least six weeks prior to the shutdown start date. This includes welding procedures for seal welding of heat exchanger tubes. All welders tests shall be witnessed by the BPCL inspection section or a BPCL inspection section approved inspecting authority prior to commencement of the Contract. Two passport type photographs of each qualified welder shall be provided to OWNER for identification purposes. All welders tests shall be carried out in accordance with approved welding procedures which have been agreed upon by BPCL inspection section and the CONTRACTOR fifteen(15) day prior to commencement of CONTRACT work or commencement of pre fabrication works, whichever is earlier. All welders shall be qualified and capable of welding materials in carbon steel, stainless steel, chrome moly steel and super duplex stainless steel to the appropriate qualified welding procedures. Welders who fail to pass the relevant welding test will be disqualified from working on the plant during the CONTRACT.

1.7

PLANNING, SCHEDULING AND MONITORING & CONTROL SYSTEM Please refer Annexure –A for detailed procedure for planning, scheduling, monitoring & control system

1.8

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

1.9

SHUTDOWN MAINTENANCE WORK FACILITIES AND TEMPORARY WORKS CONTROL.

1.9.1

Mobilization The CONTRACTOR shall complete the mobilization of all his required resources (Manpower and equipments) five (5) days advance from the date of shutdown of the unit. The CONTRACTOR must mobilize adequate qualified management staff to administer the shutdown maintenance works as well as carry out project control work on site and the overall responsibilities of the preparatory / shutdown work progress. Within 15 days of award of the contract, CONTRACTOR shall mobilize adequate

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manpower and resources to undertake preshutdown jobs like insulation removal, scaffolding, pre fabrication, pre shutdown exchangers and vessels, etc and complete them in timely manner as per Instruction from BPCL Incharge. The CONTRACTOR must list all his management and technical staff in the CONTRACT document together with their CV's for review and prior approval by OWNER. Manpower required for the shut down work and CONTRACTOR key personnel such as site managers, engineers, supervisors and foremen shall be interviewed by OWNER. All expenses for travel and accommodation will be borne by the CONTRACTOR. Following management / technical staff who shall be on the direct employment of the contractor shall be mobilized as minimum and they shall conform to the minimum requirements as mentioned below. The age of any staff shall not be more than 60 years and they shall be physically fit to supervise turnaround activities. Resumes of these staff shall be submitted to BPCL approval within 15 days of award of contract. Sr Designation No. 1 Shutdown Project Leader (Site incharge) 2 Planning coordinator

3

Piping coordinator

4

Equipment coordinators ( 3) 1- Columns/ Vessels 1- Heaters 1- Exchangers Civil coordinator

5

6

7

8

Minimum Requirement Graduate in Mechanical Engineering with 12 to 15 years of experience of working in refinery turnaround / refinery projects / refinery Maintenance. Graduate / Diploma in Mechanical Engineering with minimum 8 years of experience of Turnaround Planning, shall be conversant with planning software such as Primavera, MS Project and MS Office Graduate / Diploma in Mechanical Engineering with minimum 8 years of experience of piping works in refinery/ petrochemical/ fertilizers. Graduate / Diploma in Mechanical Engineering with minimum 8 years of experience on exchangers/ Heaters / columns/ pressure vessels in refinery/ petrochemical/ fertilizers.

Graduate / Diploma in Civil Engineering with minimum 8 years of experience on refractory works, civil foundations, painting, structural works etc in process plants. Materials coordinator Graduate / Diploma in Mechanical Engineering with minimum 8 years of experience, shall be conversant with material specifications for pipes/ pipe fittings/ valves etc. Safety Coordinator Diploma in Industrial Safety with minimum 8 years of experience in Safety in construction / turnaround in reputed organizations. Housekeeping Minimum 5 years of experience regarding sub-contractor Coordinator management, management of cranes, trucks etc and housekeeping activities. Note: For candidates having long work experience in Refinery Shutdowns, the educational qualification criteria may be relaxed at the discretion of BPCL for some of the above positions.

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

I.

SHUTDOWN PROJECT LEADER (CONTRACTOR) The CONTRACTOR is responsible to deploy the shutdown project leader who will have overall responsibility of the shutdown work under this CONTRACT.

II.

SHUTDOWN PLANNING/SCHEDULING CORINATOR (CONTRACTOR) Shall be responsible for CONTRACTOR'S resources, planning and monitor and controlling the overhaul plant shutdown schedule. The CONTRACTOR shall submit details of the manpower and other resources to be deployed on daily basis against a breakdown of the shutdown work scope activities in a format specified by Engineer in Charge. The CONTRACTOR'S Planning and Scheduling Engineer shall liaise on a daily basis with the OWNER REPRESENTATIVE in providing the information and report on items of the WORK that have been completed every day for the total duration of the Shutdown period. The 'CONTRACTOR shall provide adequate number of competent planning /execution supervisors to assist in preparation of a comprehensive work plan for execution of shutdown works, breakdown the shutdown work scope into activities, define the required resources for each activity, schedule, define quality requirements, preparation of planning daily progress reports, histogram maintaining shutdown documentation records, preparation and updating of progress graphs and 'S' curves graph for Engineer In Charge review and update the network shutdown work program clearly. The PLANNINGS SUPERVISOR must have Engineering Diploma as minimum qualification with 10 Years maintenance experience in Oil/Gas/Refinery or Petrochemical Industry with 3 years experience in the field of Shutdown Maintenance Planning. He should have Good knowledge in Computerized Maintenance Management Systems (SAP/MAXIMO/TEROMAN/etc.) and Primavera experience is mandatory. Good command in English, both speaking and written.

III.

PIPING COORDINATOR (CONTRACTOR) Shall be responsible for supervision and timely execution of all piping jobs, piping modifications jobs, hydro testing of process lines, valves testing and reconditioning, piping rejection jobs etc as per Inspection Recommendation. Shall be able to lead a team of piping engineers /

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

EQUIPMENT COORDINATOR (CONTRACTOR) Shall be responsible for supervision and timely execution of all jobs on Heaters, Columns, Vessels, Exchangers etc (both pre planned as per scope and informed during shutdown based on Inspection Recommendation). There shall be minimum two Equipment coordinators and each shall be assisted by adequate number of engineers / supervisors. The minimum numbers of the engineers / supervisor staff shall be based on a ratio of one Engineer to every 3 supervisors and a ratio of one Supervisor to every ten workers/laborers available on site. In addition to the above, The CONTRACTOR shall provide adequate number of experienced and competent rigging supervisors including helpers and all required certified lifting equipment with copies of test certificates which shall be available on site for OWNER Refinery's review.

V.

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

VI.

MATERIALS COORDINATOR (CONTRACTOR) Shall be responsible for understanding Bill of Materials, raising reservation for BPCL supplied materials, arranging contractor supplied materials and ensure that no work is held up for want of materials. He shall be well conversant with piping materials, fittings, flanges, gaskets and their specifications etc.

VII.

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

VIII.

HOUSEKEEPING COORDINATOR (CONTRACTOR) Shall be responsible for housekeeping at site, marinating the site clean of scrap and debris and organizing the materials movement. Shall ensure

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

VII.

SHUTDOWN INSTRUMENT MAINTENANCE SUPERVISORS (CONTRACTOR)

ENGINEERS

/

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

1.9.2

Schedule of Skilled labour. The CONTRACTOR must mobilize adequate skilled labour in order to accomplish the given shutdown Scope of Work within the planned shutdown scheduled time.

1.9.3

Schedule of Plant. Machinery & Equipment The CONTRACTOR must mobilize adequate plant, equipment, machinery and toots to carry out the WORK in an efficient manner and within the limited given shutdown work schedule. The CONTRACTOR must list all his construction plant/equipment along with its details. The CONTRACTOR will be requested to submit a log sheet through his Planning Engineer, containing all his machinery, plant and equipment on site each shift , starting from mobilization date until the last day of his de-mobilization, for Engineer In Charge review and against the shutdown original plant proposals.

1.9.4

Manpower Supply Specification CONTRACTOR will be responsible in supplying all equipment, tools or testing instruments that may be required by the CONTRACTOR'S personnel.. The manpower specification, qualifications and experience requirements are as follows:-

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

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1.9.4.2 ELECTRICAL HELPERS Electrical Helpers must understand English language (failure to understand English may result in rejecting the helpers on site) and have a basic concept of electrical equipment cleaning (i.e. not to damage motor winding by wire brush). They should be able to keep house cleaning and their age should not be more than 45 years. 1.9.4.3 INSTRUMENTATION TECHNICIANS. Instrument technicians that shall be adequately qualified with a minimum of seven years experience in Refineries / Petrochemical Plants and also working under OWNER supervision. 1.9.4.4 INSTRUMENTATION HELPERS Helpers - Instrument shall be unskilled labor capable of assisting the above technicians and also working under OWNER supervision. 1.9.4.5 TECHNICAL DRAUGHTSMEN. Completion of Secondary (12 years) education with NCTVT certificate having five Years experience in Oil / Gas / Refinery or Petrochemical Industry with 3 years experience in the field of Technical Draughtsman. Good command in English both speaking and written. 1.9.4.6 FABRICATOR/PIPE FABRICATOR. Fabricator/Pipe Fabricators shall be adequately qualified with a minimum of 5 years experience in Refineries / Petrochemical Plants, capable of fabricating pipeline sections and assemblies, able to read and understand isometric drawings and prepare piping sketches. They should be experienced to work with for carbon steel, stainless steel, crome moly steel and Super duplex stainless steel. They must be equipped with all tools required for fabrication work such as squares, levels, spanners, hammers, measuring tapes 3m, 5m & 50m, pipe wrap, hacksaw frame 12", grinding goggles, safety belts for working high levels, electric grinders for 7" dia. & 7/8" ID grinding wheel with plug for 240V power supply. Good command in English /Hindi speaking a must and be able to supervise contractor manpower. 1.9.4.7 QUALIFIED CODED WELDER (CERTIFIED) Welders shall be adequately qualified with a minimum of 5 years experience in Refineries / Petrochemical Plants. They must be qualified to weld various materials and pipe diameters inclusive carbon steel, stainless steel and chrome moly steel using TIG welding technic for 6G position weld and should possess valid test certificates. They must be equipped with all tools required such as welding helmet, welding hand gloves, grinding goggles, safety belts for working high levels, electric grinders for 4" dia. & 7/8" ID grinding wheel with plug for 240V power supply. Good command in English /Hindi speaking a must.

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1.9.4.8 PIPE FITTER Pipe fitters shall be adequately qualified with a minimum of 5 years experience in Refineries / Petrochemical Plants, capable of boxing up flanges, valves, manholes, equipment internals, hydrostatic and pneumatic pressure test execution, etc. They must have their own tool box complete with ordinary flat and ring spanners, pipe wrench, hammers, hacksaw 12" frame, grinding goggles, safety belts for working at high levels, and all other tools required for pipe fitting jobs. Good command in English /Hindi speaking a must. 1.9.4.9 ASSISTANT/HELPER PIPE FITTER/FABRICATOR/WELDER. Assistant Pipe fitters/fabricators/welders shall have a minimum of 5 years experience in Refineries / Petrochemical Plants in assisting pipe fitters/fabricators/welders in their works. They must be equipped with grinding goggles and safety belts. Good command in English /Hindi speaking is a must. 1 9.4.10 MECHANICAI FITTER - ROTARY Mechanical Fitters-Rotary shall be adequately qualified with a minimum of 5 years experience in Refineries / Petrochemical Plants, capable of repairing all types of Refinery pumps and compressors, alignment thereoff and test runs if required. They must have their own tool box complete with ordinary flat and ring spanners, hammers, grinding goggles, safety belts for working at high levels, and all other tools required for rotary equipment removal, overhaul and installation jobs. Good command in English /Hindi speaking is a must. 1.9.4.11 VALVE TECHNICIAN Valve Technicians shall be adequately qualified with a minimum of 5 years experience in Refineries / Petrochemical Plants, capable of boxing up flanges, gland packing of valves, manholes, equipment internals, hydrostatic and pneumatic pressure and leak test execution, etc. They must have their own tool box complete with ordinary flat and ring spanners, hammers, grinding goggles, safety belts for working at high levels, and all other tools required for valve removal, overhaul and installation jobs. Good command in English /Hindi speaking is a must. 1.9.4.12 CRANE OPERATOR Should have completed 12 years Secondary education with 5 years Refinery / Petrochemical experience. Must be able to operate mobile cranes, overhead cranes and forklifts with valid certification. Good command in English /Hindi speaking is a must. 1.9.4.13 RIGGER Should have completed 12 years Secondary education with 5 years Refinery / Petrochemical experience. Must be conversant with all types of lifting equipment i.e. types of slings, block and tackles, chain blocks and rigging sign language.. Must be able to communicate with crane operator via signs and have good command in speaking English & Hindi..

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1.9.4.14 INSPECTION HELPER Inspection Helpers will assist the engineers and technicians in cleaning for thickness gauging, UFDT, MPI etc. They have to carry heavy equipment holdings, carrying ladders etc. for technicians for inspection, carrying out other physical jobs required during inspection. The jobs will be done both inside and outside the equipment at various elevations. The job demands heavy physical work. They must be able to understand and communicate in English /Hindi and must be physically very fit. Should be able to work both inside and outside the equipment at various elevations. Age - Between 25 and 35 years Safety Equipment: The CONTRACTOR shall provide the hired manpower along with their personnel safety equipment such as - safety shoes, safety helmet, gloves, boiler suits, safety goggles and Safety Belt. 1.9.4.15 REFRACTORY MASON Refractory Masons shall be adequately qualified with a minimum of 5 years experience of refractory application / repairs in Petrochemical Refinery Plants. He must be conversant with different types of refractories used in Refineries, mixing methods and application tools. He must be able to read and follow drawings and technical instructions. Good command in English/Hindi speaking is a must. 1.9.4.16 REFRACTORY MASON HELPER Refractory Mason Helper must have at least 3 years of experience in Refractory application / repairs in Refinery / Petrochemical plants. He must be conversant with working methods for different refractory types. Good command in English & Hindi speaking is a must. 1.9.4.17 TURNER Completion of 12 years Secondary education. Must be adequately qualified with valid certificates to perform duties on lathes, milling, shaping and portable flange facing machines, grinders and drills. Minimum of 5 years refinery experience and be capable to identify and work with various types of materials. Must be equipped with safety equipment and tools required for precision measurement, i.e. micrometers, verniers, etc. Must be able to read manufacturing drawings and be familiar with the different types of tolerances and fits. Good command in speaking and written English& Hindi. 1.9.4.18 FOREMEN (Construction Workshop) Completion of 12 years Secondary education and have 10 years experience in a Refinery works. Be able to supervise fabrication and welding technicians and contractor personnel. Supervise shutdown and normal day to day activities in the workshop. Coordinate availability of materials and consumables. Should be computer literate with good command of English & Hindi speaking and written. 1.9.4.19 UNSKILLED LABOUR Must have worked in a technical environment previously and must be able to speak and understand Hindi.

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1.10 TEMPORARY UTILITIES 1.10.1 Temporary Potable Water Supply OWNER shall provide potable water free of cost at one point near the shutdown site for the cleaning and hydro- testing of the Refinery shutdown works as well as for drinking purposes. However, it is the CONTRACTOR'S responsibility to draw the water supply from the source point and make distribution arrangements as per work requirements & transport it to wherever required. Suitable facilities must be provided to direct waste water to plant drainages to prevent flooding of the work areas. The plant drainages will have to be cleared on a daily basis to ensure smooth flow. 1.10.2 Temporary Electricity OWNER shall provide free electrical power supply at four corners of the plant within 75 meter radius as construction power. The CONTRACTOR shall be responsible for making distribution arrangements including supply of power cables as per work requirements & BPCL electrical section instructions for welding, stress relieving and other purposes such as exhaust fans, AC/ventilation units etc. 1.10.3 Temporary Lighting The provision of all temporary lighting along with flameproof light fittings and hand lamps for maintaining the essential services within the shutdown site and all equipments (Furnaces, columns, vessels, heat exchangers....etc.) as well as CONTRACTOR'S site facilities shall be provided by the OWNER . However it shall be contractor’s responsibility to shift the lighting equipments to the respective location and maintain the lighting fittings provided in good condition and return the same to owner in good condition. Contractor shall make all arrangements for illumination wherever required.

1.10.4 Temporary Cooling and Ventilation The provision of all temporary cooling and ventilation equipment and appliances for maintaining the essential services within the shutdown area and equipment and the temporary site facilities shall be the sole responsibility of the CONTRACTOR. This includes provision of continuous air educators / Exhaust fans and air hoses inside the equipment (if required) to make it free of hydrocarbon smell. CONTRACTOR shall provide AC ventilation units for working inside the equipment as per detailed in individual equipment scope in volume III of this tender document. 1.10.5 Temporary Telephone OWNER may provide local MTNL telephone facilities at the CONTRACTOR'S site office and as well as at CONTRACTOR site offices based on availability of spare MTNL lines. The CONTRACTOR shall arrange for laying the telephone cables.

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1.10.6 Communication facilities by contractor

Contractor shall provide adequate on site communication facility such as VHF sets. Contractor shall obtain necessary prior approval from owner for use of these communication equipments. 1.10.7 Temporary Sanitary Facilities Temporary sanitary facility shall be provided by owner. 1.10.8 Temporary Site Infrastructure The CONTRACTOR is responsible to supply install and erect a temporary materials store with enough space to handle the volume of the shutdown work scope. The CONTRACTOR is responsible to supply, install and erect decent size porta cabins for site offices, temporary mess, rest areas for use of his direct staff and/or sub-Contractor’s staff. 1.10.8 Temporary Mobile Air Compressor The CONTRACTOR to be equipped with their own Mobile Air Compressor units with adequate distribution piping for air supply. The CONTRACTOR shall assess the total requirements for compressed air for the complete work list. In addition, the assessment must include for use of air line breathing apparatus (B.A.) sets, powering of air tools, needs of any temporary workshop, breakdowns/ maintenance, for the gas freeing of vessels and ventilation of vessels.

1.11 CONSTRUCTION AIDS 1.11.1 Hoists and Cranes The CONTRACTOR shall arrange for adequate numbers of certified heavy duty cranes with various capacities and exchanger bundle pullers to carry out the proposed Refinery shutdown Maintenance works within the given shutdown work programme. 1.11.2Tools and Tackles The CONTRACTOR should be well equipped with all the required tools and tackles including lifting tools such as chain blocks and slings to carry out the shutdown activities. A tool room with a caretaker to take care of the requirements around the clock is to be provided. Special tools such as Torgue Wrenches, bolt tensioning tools/sockets and machines and pneumatic tools are to be kept in the tool room in adequate numbers. The provision of the trolleys on the lifting beam provided at site shall be carried out by contractor. BPCL shall supply the trolleys of required size from the rigging yard. 1.11.3 Scaffolding and Platforms The CONTRACTOR shall provide all scaffolding required including, but not limited to, scaffold boards, rails, shackles, putlogs, fixing pieces, tubes, etc., all to

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the complete satisfaction of the OWNER site engineers and erected in compliance with the BPCL Refinery Safety Regulations. All scaffolding erected by the CONTRACTOR for the purpose of maintenance shall remain in position for Owner’s utilization till further notice of removal from the Engineer in charge. All scaffold tubes and fittings shall conform to IS1161 & IS 1362. No timber scaffold boards shall be permitted. Scaffolds are to be erected in accordance with BPCL Refinery Safety regulations. Any scaffolding which does not conform to the above requirements shall be immediately withdrawn from service, dismantled and re-erected such that the requirements are complied with. If the CONTRACTOR intends to use subcontract scaffolding, details must be provided in the CONTRACT TENDER. All the scaffolding work and scaffolder shall comply with following requirement. a) Contractor shall appoint competent person who is authorized to inspect and certify scaffolding as per OSHA std 29 CFR 1926, subpart L. b) Operating platform shall be fully covered with metal planks and adequately secured. If it is not require/possible to cover entire platform with metal boards/planks then in such case provide minimum three number of boards/planks in working area and remaining area shall be made inaccessible with hand rails, mid rails and toe boards to restrict the entry in that area. c) Toe boards shall be provided at all the side of operating platform of scaffolding. d) Hand rail and mid rail shall be provided at all the working platform level of the scaffolding. e) Ladder shall be provided to approach working platform. Length of the ladder shall not be more than 6 m. f) Ensure adequate stability of scaffold by use of adequate No. of cross bracings and other types of supports

‘Unsafe to use’ board shall be provided during erection of scaffolding. h) Only trained & certified scaffolders shall be allowed to work on g)

i)

scaffolding with ‘Unsafe to use’ board. After erection of scaffolding the authorized person contractor mentioned in Sr. No. 1 above, shall inspect & certify the scaffolding and after his full satisfaction that it is safe for use he shall put

‘Green Tag’ duly signed by him. The green tag shall have validity. The contractor shall also provide ‘Safe to use’ personally

board after approval of scaffolding by the competent person for visibility from distance. j)

Once scaffold is certified as ‘safe to use’, then nobody shall be allowed to alter/modify the scaffold for any purpose. If at all it is

altered / modified then their certificates as ‘safe to use’ stand cancelled. k) Joint coupler or sleeve coupler shall only be used for extending the scaffold pipes. l) Scaffolding shall be provided with base plates.

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

1.12 First Aid The 'First Aid' facilities will be arranged by the CONTRACTOR at site .However OWNER shall provide immediate medical aid at Owner’s medical centre free of cost based on requirement before taking the patient outside for further specialized medical assistance. However, the CONTRACTOR shall specify and list all his employees who have completed professional training in 'First Aid', H2S, and B.A self contained and air line. 1.13 SECURITY The CONTRACTOR shall provide adequate security measures to ensure full protection of the workforce, materials and other necessary equipment of the shutdown maintenance works and the property of the Refinery. The work shall be carried out in the OWNERS refinery premises and the CONTRACTOR'S personnel shall comply in all respects with such security instructions as may be issued to them from time to time by OWNER. Gate Entry passes shall be issued by the OWNER based on the information provided by the CONTRACTOR, however it shall be the contractor’s responsibility to ensure the good character of employed staff of its own as well as subcontractor. Application for the gate entry to the OWNER must be made in the prescribed manner and in sufficient time to allow mobilization on schedule and to meet the work commencement date. OWNER can advise on current requirements which could include permissions required as per statutory / GOVT. authorities for all employees.

1.14 ACCESS ROAD AND PARKING AREA The CONTRACTOR will be directed by Engineer in charge for the utilization of the access roads and parking area. 1.15 TEMPORARY CONTROLS 1.15.1

Plant Cleanliness The CONTRACTOR will be completely responsible for the daily cleaning all equipment and units after every shift as well as keeping the units and all equipment clean. The CONTRACTOR shall provide a sufficient number of waste skips and sufficient numbers of general workers meant exclusively for housekeeping purpose. The CONTRACTOR shall make arrangement for the collection and safe disposal to a Government approved municipal dump, of all waste materials used during the shutdown works. The CONTRACTOR shall ensure all waste

Page 16 of 36

skips are strategically positioned, emptied on a daily basis and re-sited as required, throughout the shutdown works duration to maintain the plant and work areas in a clean, safe and hygienic condition. All the insulation material shall be disposed outside refinery premises through MPCB / CPCB approved Insulation Waste Management Authorities without giving rise to any obligation from the local / statutory bodies. Necessary disposal slips / documents shall be submitted to BPCL. 1.15.2

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

1.16

TRAFFIC REGULATIONS AND ON SITE TRANSPORTATION The CONTRACTOR must comply with BPCL traffic& safety Regulations during the whole of the shutdown works period. The CONTRACTOR must provide onsite transportation for his own personnel, shutdown manpower personnel and subcontractor personnel. However OWNER shall provide the transport facility to

contractor employees from main gate to Worksite and back at the beginning of the shift and at the end of the shift respectively. 1.17

MATERIALS AND EQUIPMENT All materials and spare parts materials (Excluding CONTRACTOR supplied spares as specified in the Scope of Work and Bill of Quantity) will be provided to the CONTRACTOR free of cost. However, the CONTRACTOR must supply and provide all services (including the installation of spading & de- spading, temporary gasket for hydro testing), with no limitations as well as the following consumable materials. Welding electrodes, grinding wheels, grinding shields, welding screens, paints, lubricants, "general and lint free" fuel cleaning rags, lifting equipment, safety protective clothing, tags, pipe wrap, pipe covers etc. All CONTRACTOR supplied spares and materials (as specified in the Scope of Work and Bill of Quantity) must include "MATERIAL SAFETY DATA SHEETS". The CONTRACTOR is responsible to raise all necessary materials requisition vouchers and obtain the appropriate approval of engineer in charge for collection, transport, delivery and safe custody of all OWNERS issued materials. The CONTRACTOR may note that Owner’s Main Stores will be opened all seven days a week for all shutdown working hours. The CONTRACTOR is responsible to maintain a proper register indicating location of application and Material Issue Vouchers for all OWNERS free issue materials as well as the materials utilized in shutdown works for checking by OWNER Maintenance Engineers on daily basis. All surpluses OWNER issued materials must be returned to Owner’s Stores in their original condition. The CONTRACTOR must maintain and safe-guard all OWNWER issued materials in an appropriate temporary location as well as in a proper and correct manner.

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

1.18

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

1.19 1.19.1

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

1.19.2

SHUTDOWN MAINTENANCE RECORD DOCUMENTS The CONTRACTOR must maintain log sheets and registers, which contain the attendance of the CONTRACTOR's resources on a daily basis, commencing from the first day of mobilization period up to the final day of the demobilization period. All these attendance sheets must be verified by Engineer in charge every single shift .On completion of the shutdown works, a set of duplicate copies must be handed over to Engineer in charge. The CONTRACTOR must provide OWNER with a detailed Shutdown Project Close-out report prior to the issue of the "CERTIFICATE OF COMPLETION”. The Close-out Report must include the following information:-

1.19.3

1.

CONTRACTOR Shutdown Policy

2.

CONTRACTOR PERSONNEL statistics, e.g. Number of personnel per discipline and supervisor, engineer, management level utilized including actual and overtime hours worked.

3.

CONTRACTOR safety statistics, e.g. number of incidents and accidents including seriousness.

4.

Final scheduled planned and actual Execution Plan statistics.

5.

Scope of Work statistics, e.g. number of each type of equipment worked on including all types of valves.

6.

Major unplanned work done.

7.

Problems experienced during Mobilization, Execution and De-mobilization.

8.

Recommendations.

SPARE PARTS AND MAINTENANCE MATERIALS The CONTRACTOR shall return all the surplus free issue materials to OWNER ‘s

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Stores and the CONTRACTOR's storekeeper must ensure that all the relevant materials issued requisitions covering all the surplus spare parts and maintenance materials are verified and endorsed by Engineer in charge prior to the CONTRACT close-out. 1.19.4

DISPOSAL OF SCRAP / DEBRIS

Metal scrap shall be deposited after segregation / cutting to required size to Owners disposal yard in warehouse. Debris such as surplus earth after backfilling, RCC / PCC material, wooden scrap, cleaning consumables, empty paint drums to disposed out side the OWNERS premises without giving any complaints from Local / statutory bodies / Government authorities. All the insulation / refractory material shall be disposed outside refinery premises through MPCB / CPCB approved Insulation Waste Management Authorities without giving rise to any obligation from the local / statutory bodies / Government authorities. Necessary disposal slips / documents shall be submitted to BPCL. 1.19.5

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

1.19.6

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

1.20.1 EQUIPMENT AND PIPING GASKETS The CONTRACTOR shall identify the equipment and piping gasket including material specification based on the PMS / drawings while installation of the gaskets.. 1.20.2 OWNERS WAREHOUSE INVENTORY CHECK The CONTRACTOR shall carry out physical checking of all the free issue material in Owners warehouse during planning stage before commencing the pre / main shutdown jobs.

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ANNEXURE -A

PROJECT PLANNING, SCHEDULING, MONITORING & CONTROL SYSTEM FOR

TURNAROUND JOBS FEB-MAR 2017

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CONTENTS CLAUSE

DESCRIPTION

1.0

INTRODUCTION

2.0

DOCUMENTS ALONG WITH BID

3.0

AFTER AWARD OF WORK

4.0

TURNAROUND SCHEDULES

5.0

UPDATION OF TURNAROUND SCHEDULES

6.0

REVIEW MEETINGS

7.0

PROGRESS REPOERTING

8.0

PLANNING PACKAGE

9.0

CONTROL ROOM DISPLAY

10.0

SOFTWARE PACKAGES

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1.0

INTRODUCTION To ensure timely completion, the Contractor shall establish and maintain an effective Planning, Scheduling, Monitoring and Control system, including mobilization of required number of professionally qualified and experienced Planning Engineers for evolution of adequate preventive actions for likely slippages, and formulation of suitable catch-up schedule for delays, if any, that have occurred. Schedules, reports and documents shall be prepared and submitted by the contractor for review of OWNER at various stages and details of meetings shall be held are described here. The CONTRACTOR shall be responsible for submitting adequate planning data (Primavera P6.2 format or latest version) with regard to the development and maintenance/update of the CONTRACTOR'S detail Work Scope Execution Programme for the approval of the Engineer in Charge. (Refer to Appendix H, Annexure 1) The CONTRACTOR shall use Primavera P6.2 or latest version for Shutdown Planning and Scheduling Software.

2.0

DOCUMENTS ALONG WITH BID The bidder shall submit following documents along with the bid: a. Proposed Overall turnaround Schedule in network form showing details of all units. b. Write up on turnaround Planning, Scheduling, Monitoring and Control system (proposed ) c. Organizational set up for Planning, Scheduling, Monitoring & Control at Contractor’s Site Office. d. Turn Around execution methodology. e. Function wise Resource Deployment Schedule (manpower & construction equipment) inclusive of subcontractor jobs schedule f. Statement confirming compliance to the “Planning, Scheduling, Monitoring and Control System” requirements regarding contents of the documents to be submitted to OWNER.

3.0

AFTER AWARD OF WORK

3.1

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

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3.2

KICK OFF MEETING A Kick off Meeting shall be organized within two weeks of award of contract. The meeting shall be attended by OWNER’s representatives. During the meeting the following with respect to Planning, Scheduling, and monitoring and Control system shall be discussed and finalized. 1.

4.

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

5.

Any other document as required.

2.

3.

3.3

PROGRESS MEASUREMENT METHODOLOGY Contractor shall submit during Kick off Meeting, the detailed methodology of progress measurement of Ordering, Sub-contracting, Construction and Commissioning for review by OWNER. Contractor shall also furnish the methodology of progress measurement for sub-contracted packages such as furnace decoking, dry ice blasting, and AFC foam cleaning etc. and integration of the same with the overall progress. Progress figures at Unit / Function/Discipline level shall be summarized from deliverable level and indicated in the functional schedules. Contractor shall develop the Turn around schedule for arriving at resource leveling up to level 4 identifying the resources in terms of manpower as well as tools/tackles & construction equipment/machinery required to complete the job. During the execution of the job contractor’s planning engineer shall issue the job order for each activity indicating resource requirement and compare the same with actual used one before closing the job order .For completion of each job/ activity , the completed job order shall form the basis.

4 TURNAROUND SCHEDULES Following schedules shall be prepared and submitted by contractor to OWNER for approval. 4.1

OVERALL TURNAROUND SCHEDULE Contractor shall submit a network based overall turnaround schedule on time scale in ‘AO’ size, shutdown activities including all activities in the package and all functions of the work along with a Work Breakdown Structure indicating unit wise workload The schedule shall highlight Page 23 of 36

interface activities in the scope of OWNER and clearly reflect strategies and philosophy of execution. Major milestones for each unit shall be depicted at the beginning of the network. The turnaround schedule shall be developed for contractual duration. The schedule shall be reviewed by OWNER and the comments if any shall be incorporated and the schedule shall be issued for if any shall be incorporated and the schedule shall be issued for implementation with one week from the receipt of comments. The Turnaround Master Schedule depicts in general the key activities and milestones and the duration allotted. This schedule must include all preshutdown activities such as recruitment, interviews and mobilization of manpower and equipment. The CONTRACTOR shall be required to plan, perform and coordinate the WORK with that of other direct contractors to meet the time requirements of the Shutdown. 4.2

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

4.2.1

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

4.2.2 CATCH-UP SCHEDULE Contractor shall generate and submit catch-up schedule for completion of all balance activities including the unidentified activities at the preparation of overall schedule without change in contractual completion date with detailed resource reinforcement as and when asked by OWNER. The catch-up schedules shall be submitted for OWNER review. Accordingly the “S” curves for catch-up schedules shall be made and shown along with the original schedules and actual “S” curves. During updation of overall project schedule and construction schedule, the catch-up schedule shall be shown in bar charts along with the original schedule.

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5.

UPDATING OF TURNAROUND SCHEDULES The various schedules as described herein shall be updated for submission to OWNER. Updation of the schedule is to determine the Turnaround trend, with the objective of taking preventive/ corrective action. While updating, the following shall be considered: -

-

6.0

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

REVIEW MEETINGS Contractor shall present turnaround status, turnaround highlights and action plan as applicable at various review meetings as described below..

6.1

Management level Review Meeting Level of participation Contractor. Agenda frequency and venue

: Senior management of OWNER and : To be decided by OWNER.

6.1.1 Daily review meeting for Site Activities Level of participation: OWNER & LSTK Contractor along with Subcontractor Agenda:

7.0

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

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

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7.1

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











Programme v/s Progress for the day Programme for next day Critical areas Action taken / to be taken for slippages Front available Constraints, if any Resources deployed against planned with reasons for shortfall in resources deployment Important achievements for the day Materials receipt for the day Man power / Machinery deployment report – Required v/s Deployed

8.0 PLANNING PACKAGE Details of time submission, frequency of submission and tentative number of copies for all documents to be submitted by the LSTK contractor shall be decided mutually. Once the majority of the schedules are finalized, the LSTK contractor shall compile the same and submit in the form of a Planning Package. The Planning Package shall consist of the following: -

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

LSTK Contractor shall submit reports, updated schedule, programmes etc. as described till the completion of all work in the scope of the contract. No chapter/annexure of any report shall be deleted without prior written approval of OWNER. 9.0 CONTROL ROOM DISPLAY LSTK Contractor shall display charts featuring salient static information of the project, schedules, status of progress, resource deployment Hindrances if any , block flow diagram, plot plan, work break down structure etc. in contractors control point office .The status shall be updated at least on weekly basis.

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10.0

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

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ANNEXURE 1 - CONTRACTOR PERSONNEL

A) CONTRACTOR REPRESENTATIVE None of CONTRACTOR PERSONNEL listed here shall be removed or relocated from the positions indicated or replaced without the prior written approval of OWNER. Personnel removed shall be immediately replaced with new personnel who, in the sole opinion of OWNER are of, at least, an equivalent standard as the personnel removed. CONTRACTOR REPRESENTATIVE shall be Name

: NNNNNNNNNNNNNNN.

Position

: NNNNNNNNNNNNNNN.

CONTRACTOR REPRESENTATIVE nominated deputy (ies) shall be a ________ Engineer who will be in permanent pay roll of CONTRACTOR, for at least last three years, with a minimum of ten (10) years relevant experience. Name

: NNNNNNNNNNNNNNN.

Position

: NNNNNNNNNNNNNNN.

Address

: NNNNNNNNNNNNNNN.

Telex No

: NNNNNNNNNNNNNNN.

Telephone

: NNNNNNNNNNNNNNN.

The above nominated deputy (ies) cannot be changed during execution of the CONTRACT. The above nominated deputy(ies) is/are authorised to act on behalf of CONTRACTOR REPRESENTATIVE on the following matters under the CONTRACT:(a)

NNNNNNNNNNNNNNN.

(b)

NNNNNNNNNNNNNNN.

(c)

NNNNNNNNNNNNNNN.

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

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ANNEXURE2 - FACILITIES. PLANT AND EQUIPMENT

CONTRACTOR states below the details of its resources and facilities intended to be utilised for this CONTRACT. CONTRACTOR design office, design facilities, expediting and procurement agencies, fabrication yard (location and facilities) etc. are listed. CONTRACTOR states below the details of the main items of constructional plant and equipment, which it proposes to use for this CONTRACT. Details of all equipments etc. are specified. This list is the minimum that CONTRACTOR will be required to provide on WORKSITE. CONTRACTOR states whether the tool or equipment is already in CONTRACTOR ownership or will be purchased or hired. Details of any special tools should be highlighted. Description

Capacity and present Whereabouts

Manufacture and year of manufacture

No. of Units

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

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ANNEXURE3 - SUBCONTRACTORS

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

CONTRACTOR shall furnish in following format, the names and addresses of all SUBCONTRACTORS from whom it proposes to obtain services. CONTRACTOR is not permitted to change any SUBCONTRACTOR named in this list without first obtaining OWNER written approval Full technical submissions are required for all services rendered under the CONTRACT as required by the General Conditions of Contract & special conditions of contract and the Specifications.

EQUIPMENT

ACTIVITY

SUBCONTRACTOR / PRINCIPLE CONTRACTOR

REMAKRS

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ANNEXURE4 - SUPPLIERS CONTRACTOR states below the names and addresses of all suppliers from where it proposes to procure goods. CONTRACTOR is not permitted to change any supplier named in this list without first obtaining OWNER written authority. Full technical submissions are required for all goods procured under the CONTRACT as required by the General Conditions of Contract and the Specifications.

Supplier

Goods to be supplied

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ANNEXURE 5 - CONTRACTOR COMPANY ORGANISATION CHART CONTRACTOR inserts a copy of its organization chart which clearly shows the Company structure with respect to Subsidiaries and Joint Venture Partners, if applicable. The organogram indicates positions of Company Directors, Managers, Partners, etc.

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ANNEXURE 6 - CONTRACTOR PROJECT ORGANISATION CHART CONTRACTOR provides the proposed organization chart for this CONTRACT (including key SUBCONTRACTOR personnel, where applicable, and the person responsible for QA/QC, safety, execution etc.). The C.V's of all the personnel identified under this Annexure shall be submitted.

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ANNEXURE 7 - QA/QC PROCEDURES CONTRACTOR Quality Assurance and Control System dedicated for this CONTRACT shall confirm to OWNER Quality System Requirements. CONTRACTOR shall develop “Shutdown Quality Plan" following the guidelines set out in above document to implement the activities relevant to the Scope of Work; The Quality plan should be accompanied by a complete package of supporting documentation. CONTRACT EXECUTION PLAN

Under this Appendix CONTRACTOR shall include the following annexure highlighting the method of execution and programme for the WORK. Annexure 1 : EXECUTION PROGRAMME, Manpower Histogram and Progress S- Curve. Annexure 2 : CONTRACTOR Method Statement ANNEXURE - 2 - CONTRACTOR METHOD STATEMENT CONTRACTOR shall provide a detailed method statement and procedures detailing the proposed method of executing the WORK, in accordance with CONTRACT EXECUTION PLAN.

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UNDERTAKING TO BE SIGNED BY THE BIDDER REGARDING MOBILIZATION AND HOUSEKEEPING

In case of award of contract, we (the bidder) undertake to comply with following conditions for mobilization and housekeeping activities, over and above all the other contract terms and conditions mentioned in the tender. 1. Sub-contracting of the entire scope of work or majority of the scope of work is not permitted. Contractor can sublet only parts of the work on prior approval from BPCL and the sub-contractors credentials shall be submitted to BPCL for approval. Contractor is responsible for supervision of all sub-contracted works. Any sub-contracting does absolve contractor of any of its contractual obligations. 2. The contractor shall employ staff from his own organization for key positions such as the Shutdown Project Leader (site in-charge), Planning coordinator, Piping coordinator, Equipment coordinator, Quality Assurance coordinator, civil coordinator, safety coordinator and housekeeping coordinator. Contractor shall submit resumes of these staff to BPCL for approval. The key personnel shall conform to educational qualification and experience requirements as mentioned in the clause 1.9.1 Mobilization. The organization chart shall be submitted for BPCL approval within 15 days of award of contract. 3. Contractor shall maintain Attendance Register for his staff for key positions as mentioned in the above para. The contract staff shall mark their attendance by putting a signature against the date at the beginning of each shift. This Attendance Register shall be maintained in BPCL site office. BPCL Engineer incharge / his representative shall verify the attendance on random basis. 4. Inadequate mobilization and shortage of supervisory staff with respect to the agreed organization chart shall be treated as violation of contract and there will be penalty deducible from contractor invoices as under. Sr No. 1 2

3

4

5

Violation Non availability of Shutdown Project Leader (Site in-charge) at site Non availability of any one of the Coordinators (as defined in clause 1.9.1. of Attachment 1) at site Inadequate number of safety engineers

Failure to maintain Contractor coordinators attendance and Contractor safety supervisors attendance register for both shifts in BPCL site office. Delay in removal of scrap or debris more than 48 hours of scrap generation, due to reasons attributable to the contractor.

Penalty Rs. 15,000/per day. Rs. 10,000/per day per person. Rs. 10,000/per safety engineer per shift. Rs. 15,000/per day

Rs. 15,000/per day.

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6

Non availability of updated report from Contractor Planning on daily basis at specified time or submitting incorrect reporting.

Rs. 15,000/-per day.

The above penalties are in addition to the penalties for violation of HSE norm attached separately in the tender document and also in addition to the Liquidated Damages clause for delays in achieving contractual completion. 6. Contractor to provide exclusive manpower and coordinator for housekeeping activities. Delays in housekeeping activities shall result into penalties as above. Contractor shall maintain their site office and temporary storage place neat and clean. Only box type porta cabins or sheds covered from all side with high quality pre-coated sheets (blue in colour) are permitted. Temporary sheds with GI sheet / tarpaulin covering etc are banned. 7. In case of repeated deviations by the contractor to the clauses regarding mobilization and/ or inadequate number of safety engineers and/or repeated violations of work permit safety conditions, BPCL will initiate penal actions against the contractor, which may include Holiday Listing of the contractor.

All the above clauses are understood and agreed.

____________________________ Bidders Signature and seal

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APPENDIX A: ATTACHMENT 2 SCOPE OF WORK: COLUMNS 1.

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

2.

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

3.

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

4.

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

Page 1 of 6

c. Contractor shall provide air conditioners as per work package scope. d. Provide adequate lighting inside the column using 24 volt flame proof hand lamps and transformer. 5.

DISMANTLING & RE-FIXING OF INTERNALS: a. The contractor shall dismantle & remove the equipment internals wherever required as detailed under equipment specific work scope in Attachment 11: – Section A. The equipment internals shall include trays, tray components, demister pads, structured packing, random packing, Distributors, steam coils, grids, and structural items used for supporting the internals. b. The contractor shall mark legibly using permanent marker and non tearable tags on tray sections, tray manways, distributor piping and all other removable internals before dismantling for better identification during re-fixing. c. Wherever distributors are removed out of the column, it shall be cleaned including all nozzles and branches, assembled out side the column and shall be checked for blockage if any. All the nozzles shall be tested at competent testing laboratory for spray pattern testing. For distributor which are not possible for removal out side the equipment , all the nozzles shall be removed , cleaned and carry out spray pattern testing of all the nozzles at competent testing laboratory. d. The contractor shall open the tray manways of all the trays for columns having trays. e. All the demisters wherever applicable shall be removed and replaced with new one. Removed demisters shall be cleaned with hot water to make them suitable for disposal. The demisters shall be installed with the assistance of suppliers if required. Services of the supplier shall be arranged by Owner. f.

Remove the structured packing, random packing in part or full and carryout necessary replacements in presence of original packing supplier. Services of packing supplier shall be arranged by Owner.

g. The contractor shall re-fix, either repaired internals or with replacement materials after obtaining necessary clearance from operations/, Inspection and technology. 6.

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

Page 2 of 6

b. Servicing of fasteners includes cleaning by kerosene, wire brushing and application of antiseize compound like Molysulf etc. 7.

SCAFFOLDING a. The contractor shall provide necessary scaffolding or Ladder inside the equipment at the required locations to access trays /, internals /, internal surface of the shell, top and bottom dish end, or any other location as per EIC (Engineer In charge) instructions. The Contractor shall also provide scaffolding externally surrounding the equipment as required for inspection of nozzles, column piping and removal of instruments etc. b. Erect scaffolding inside the skirt for inspection of the bottom elbows / dish end of the columns. c. The contractor shall dismantle & remove the scaffolding or ladder after completion of all the maintenance work.

8.

CLEANING a. The contractor shall clean the internal surface of the equipment and internals including down comers, seal pans, distributors, its nozzles , support grids, etc., thoroughly free from scales, rust, coke, deposits using mechanized cleaning system wherever possible and cold work cleaning methods viz scrapers, wire brush in areas inaccessible by mechanized tools. b. The contractor shall clean the internal surface of the equipment in such a way as to prevent debris falling on any of the troughs / seal pans / down comers / tray decks. c. The contractor shall carry out shot blasting / power brushing of the weld seams 6” on either side of the weld joints to carry out Wet fluorescent magnetic particle inspection (WFMPI) wherever required and spot buff the parent metal surface of the equipment for ultra sonic thickness gauging. d. The contractor shall clean the internal stainless steel lining & weld seams using Stainless steel wire brush only. e. The contractor shall clean the tray valves / bubble caps / fasteners / clamps, etc., and replace with new one wherever found missing as per scope of works. f.

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

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

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9.

UNLOADING & LOADING OF RANDOM PACKING / RASCHING RINGS a. The contractor shall erect necessary temporary shelter using scaffolding pipes & tin sheets , brick work near the equipment for safe storage of the packing, raschig rings etc and dispose it on immediate basis at owner designated place after necessary cleaning and making them hydrocarbon free. b. The Contractor shall unload all the random packing and rasching ring by providing necessary chute / hopper arrangement. Crane, pneumatic / electric winch required for loading / unloading of the packing shall be arranged by the contractor. c. All the random packing to be reused or otherwise shall be cleaned properly using high pressure water jet to make it free of all the deposits, muck and foreign material.

10.

UNLOADING & LOADING OF STRUCTURED PACKING a. Remove structured packing from the equipment as detailed in scope of work in presence of original packing supplier. b. Stack the packing near designated place, clean the same to make it hydrocarbon free using hot / cold water and dispose. c. All the removed structured packing shall be either replaced with new one or old packing shall be reused as per instruction from site in charge. Packing loading shall be carried out in presence of original packing supplier. The services of packing supplier shall be provided by BPCL. d. Dispose the damaged packing on immediate basis at owner designated place after necessary cleaning and making them hydrocarbon free.

11.

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

12.

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

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13.

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

14.

EQUIPMENT FIRST ISOLATION VALVES:

a. The contractor shall service all the first isolation valves except those which are planned for removal, dismantling and testing. b. Valve servicing includes opening of the valve, cleaning stem, greasing the stem, flushing the valve through nozzle using water hose , making valve free for opening / closing and gland repacking / pull up. 15.

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

16.

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

17.

MULTIPLE WORK FRONT:

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

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18.

INTERNAL REPAIRS: a. The contractor shall carry out minor repairs to equipment internals and the equipment parent surface as required. All these repairs / replacements shall be done using cold work or hot work including but not limited to straightening & bend removal of tray segments, removal of cracks by grinding & welding, repairing of equipment internal lining & tray support ring (TSR) as required. The entire repair by cold work is part of lump sump scope. b. In case of major repairs to trays, the contractor shall shift the trays to construction shop and provide manpower assistance for carrying out repairs to the trays. This is part of LS scope. c. Tray valves and fittings shall be replaced wherever found missing as per the EIC instructions. d. Payment for repairs using hot work like removal of cracks by grinding and welding, internal lining replacement, TSR welding will be made as per applicable SOR based on the actual measurements.

19.

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

20.

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

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APPENDIX A: ATTACHMENT 3 SCOPE OF WORK: HEATERS 1.

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

2.

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

3.

PANELS/COVERS/DOORS/MANWAYS/PEEP HOLE COVERS: a) The contractor shall dismantle all removable panels, covers, doors, man ways, etc, as required and place them at the respective grade level or to ground level as per site conditions. b) Carry out necessary repair / rectification including welding of refractory anchors and re-install on completion of work. c) The contractor shall ease out the furnace explosion doors / peep hole doors, keep them in open condition during execution of work inside the furnace and refix back on completion of all activities. d) Replace all the damaged bolts of the man way covers/ panels e) The contractor shall weld refractory anchors wherever required. f)

The contractor shall carry out patch repair or fabricate panels, covers, door, man ways, etc., wherever required.

g) Cutting of necessary gasket, packing ropes / tapes etc for panel installation shall be carried out by contractor.

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4.

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

The contractor shall re-fix the serviced burners or with new ones, obtain clearance from operations and box up on completion of all activities.

g) Burner gun assembly shall be carried out in presence of BPCL Energy and Environment section engineer. h) After Installation, burner shall be offered to Energy and Environment section engineer for inspection i.e. for measurement of tip distance from reference point, nozzle angles, pilot positioning etc.

5.

i)

Cutting of necessary gasket, packing ropes / tapes etc for burners installation shall be carried out by contractor.

j)

If burner assembly is not dropped, carry out covering of the burner from inside the heater with solid metal plate to avoid damage to burner assembly. SCAFFOLDING

a) The contractor shall erect scaffolding inside the heater in radiation section up to a full height. b) Planks shall be laid & tied properly with the scaffolding pipes at every 2 metres height interval with two plank widths along the radius of heater tubes and the arrangement shall be made in such a way that cleaning & inspection of all the radiant tubes & bottom row of convection section tubes are comfortable. c) The contractor shall also provide aluminum ladders at two locations for the full height of the scaffolding for easy climbing. d) The contractor shall also provide scaffolding inside the stack up to the stack damper level. e) The contractor shall also provide scaffolding externally for removal of convection panels, inspection of cross over piping between radiation and convection section , heater shell man way opening, soot blower removal , air pre heater man way

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opening, FD and ID duct man way opening , inspection and overhauling all dampers / guillotines and stack painting . f)

Contractor shall also erect internal scaffolding in air pre heater duct, FD duct, ID duct for inspection and repair.

g) After completion of the repair / inspection work, remove scaffolding. 6.

EXTERNAL PASSIVATION OF TUBES: a) Prepare the Passivation solution as per standard procedure given in Attachment 12 for pickling and Passivation. b) The Passivation of the hand reach tubes shall be carried out immediately on entry inside the heater and on completion of the internal scaffolding for balance tubes. c) Carry out spraying of the solution on the external surface of the tubes and ensure that the entire tube surface is applied with the Passivation solution. d) In case spraying is not possible, then carry out the mopping of the tubes with the solution.

7.

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

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8.

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

9.

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

10.

THERMOCOUPLE REPLACEMENT


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

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11.

HYDRO TEST: a) The contractor shall carry out hydro testing of heater radiant, convection & super heater steam coils to the specified test pressure. b) The contractor shall fabricate necessary manifolds, laying temporary piping, providing hose connections from the source of water supply to the heater coil / temporary storage tank, etc., for preparing hydro test. c) Contractor shall arrange booster pump and temporary / piping up to heater coil for filling water in all the coils simultaneously. d) The contractor shall fill up the water in the heater coils, vent entrapped air, pressurize to the required hydro test pressure with necessary test pumps, and offer the coils for inspection. e) Pressure gauge shall be provided on individual coil vent and drain. f)

The contractor shall drain the filled water on completion of hydro test and displace the entrapped water using compressed air / nitrogen.

g) Steam super heater / Boiler feed water coil hydro test wherever applicable shall be offered to Boiler inspector along with the steam generator circuit in addition to BPCL inspection. Note: To ensure the sufficient service water pressure during filling the hydro testing circuit, contractor shall provide booster pump with temporary water hold up tank. 12.

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

13.

SERVICING OF PNEUMATIC CYLINDERS a) Remove pneumatic cylinders. b) Dismantle and clean the actuators. c) Replace consumables such as `O rings, Piston seals, Oil seals and Cylinder end cover gaskets / O rings. Supply of all consumables is in your scope. d) Carryout repairs such as servicing of Piston clamp, Cylinder mounting clamp, rod clamp swivel joint, Piston rod machining, chrome plating, Cylinder barrel honing and chrome plating. e) Assemble the actuators, test and carryout painting.

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14.

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

15.

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

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16.

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

17.

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

18.

TRANSFER LINE

Transfer line means line coming out from the individual pass of heater and going to the main column either as individual or as single line after joining to common header. a) Erect scaffolding / boson chair arrangement for inspection of the line. b) Remove insulation at all the bends of all the transfer lines. c) Make insulation pocket / window at every 10 meter interval in four compass directions on straight line. d) Clean and make spot on the line for UT gauging / scanning. e) Open the end blind flanges on the transfer line including that for the nozzles and offer line for inspection. f)

Offer line for UT gauging.

g) After completion of the inspection, insulate the line as per BPCL insulation procedure and remove scaffolding / bosom chair arrangement.

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19.

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

20.

STACK INSPECTION AND PAINTING a) Open stack man way. b) Make boson chair arrangement for internal inspection of the stack. Boson chair shall be supplied by BPCL, however contractor shall arrange necessary steel wire rope winch. c) Carry out fabrication of the structural beam for mounting on the stack top for guiding and supporting the boson chair and its wire rope. d) Boson chair arrangement shall be offered for load test to BPCL safety inspector before its actual use. e) Operation of the boson chair during inspection and repair of the refractory is included in your scope. f)

Carry out repair to internal refractory lining as per scope of work. Refractory repair shall include removal of old refractory and anchors, welding of new anchors and refractory lining.

g) Carry out external scrape cleaning and painting of the stack with 2 coats of zinc dust graphite using rope access technology / equivalent method. Painting of stack with conventional box scaffolding shall not be allowed. h) After completion of inspection, remove the boson chair arrangement and box up stack man way. 21.

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

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22.

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

23.

DUCTS

Ducts includes all the following ducting,
Hot air duct
FD suction and discharge duct
Flue gas ducting
Individual burner combustion duct & wind box . a) Open all the duct man ways including FD discharge to individual burners. b) Erect scaffolding internally. c) Carry out internal cleaning of all the ducts and FD ducts up to burners including cleaning of individual burner mesh. Removal and installation of the baffles inside the duct shall be carried out. d) Scrape clean the duct plate internally and paint as per BPCL painting specification AES 5430. e) Carry out cleaning of Individual burner combustion duct & wind box to remove the oils accumulation if any. f) 24.

After completion of the painting, remove scaffolding, box up man ways.

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

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APPENDIX A: ATTACHMENT 4 SCOPE OF WORK: HEAT EXCHANGERS & AFC 1. GENERAL a) Contractor shall carry out all the jobs on heat exchangers as detailed below including specific job detailed under Attachment 11 Section C. 2. PREPARATORY JOBS / BLINDING / DE-BLINDING: a) The contractor shall carry out all preparatory works & blinding for isolation and testing. The blind shall be installed on the inlet and out let side of the shell and tube side nozzles and all process connection to the heat exchangers. b) The Contractor shall erect necessary scaffolding, wherever required to facilitate removal of covers and shall dismantle / remove on completion of all activities. c) The contractor shall also provide necessary rigging facilities for lifting & lowering the heat exchanger component to the respective structural platforms near the equipment. d) The contractor shall service the test rings intended for the equipment including all fasteners before starting the exchanger maintenance work, clean all ring on completion of testing activities and secure it on the test ring stand firmly. e) Contractor shall ensure that all dismantled parts of heat exchangers are segregated & painted with proper identification marks including the fasteners in order to eliminate mix up of parts. Contractor shall store all the fasteners in separate bins. f)

The contractor shall carry out de-blinding on completion of all maintenance activities, box up the flanges with new gaskets and tightening of studs (replace the defective studs / nuts) to ensure zero leak of joints including hot bolting.

3. REMOVAL OF COVERS & TUBE BUNDLES: a) The contractor shall open the exchanger channel cover, channel box, shell cover, floating head cover, etc de-bolting by pneumatic tools / torque wrench (cold / gas cutting if required), and place the covers at the grade level. b) In case of Fin fan coolers with plug design, the contractor shall remove the 2 nos. plugs each on inlet and out let side of each pass of Air Fin cooler. Wherever retubing is required all plug shall require opening.

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c) In case of Fin fan coolers with cover design, the contractor shall remove and drop all the end covers of air fin coolers at both ends using chain pulley blocks/ crane wherever applicable. d) All exchangers with float head type & U tube design, the contractor shall pull out the tube bundle from the shell using bundle pullers and crane / escort / hydra in safe manner and take the tube bundle at ground level and load on the low bed trailer ( Trailer wheel diameter not more than 300 mm ) e) Contractor shall select the suitable capacity of bundle puller and crane / escort / hydra based on bundle weight and exchanger elevation. f)

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

4. TRANSPORTATION OF TUBE BUNDLES: a) After loading the tube bundle on the trailer, bind the bundle using load binder. b) The contractor shall carry out to & fro transportation of tube bundles from the work site to following locations for executing work as detailed below: •

Tube bundle cleaning yard or the designated place for cleaning

•

Exchanger shop for tube bundle re-tubing.

Note: All the tube bundles requiring re-tubing at BPCL shop, shall be cleaned internally / externally carry out inspection activities like ECT / RFET and then shall be sent to shop. 5. CLEANING OF EXCHANGER TUBE BUNDLE, COMPONENTS & FIN FAN COOLER TUBES: a) The contractor shall carry out cleaning of exchanger tube bundle, its components & fin cooler tubes as detailed below. 5.1 In-Position Cleaning a) The contractor shall carry out in position to bare metal cleaning of the following component of exchanger using hydro jetting / Power lance machine ( Electric driven only ) having capacity to develop at least 20,000 psi hydraulic pressure at the nozzle.

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o

Internal tube cleaning of the fixed tube sheet design heat exchanger

o

Internal cleaning of air fin cooler tubes.

o

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

5.2 Cleaning of Pulled out Tube Bundles: The contractor shall clean the tube bundle (internally and externally) using hydro jetting machine / Power lance (Electric driven only) having capacity to develop at least 20,000 psi hydraulic pressure at the nozzle. 5.2.1 Tube internal cleaning: Hydro jetting / Power lance : The exchanger tube internal surfaces are to be cleaned to bare metal using hydro jetting / Power lance machine (Electric driven only ) having capacity to develop at least 20,000 psi hydraulic pressure at the nozzle. . 5.2.2 Tube external cleaning: Hydro jetting / Power lance: The exchanger tube external surfaces are to bare metal using hydro jetting machine (Electric driven) having capacity to develop at least 20,000 psi hydraulic pressure at the nozzle. Note: For all the hydro jetting machines, machine mounted water tank supply line shall be provided with the ball & float arrangement to avoid the wastage of the water. No overflow of the water shall be allowed from the water tank. The contractor shall carry out the cleaning of fire water sprinkler nozzle of respective AFC/exchanger. The scope includes removal of the nozzle, cleaning and fitting back the same or new nozzle. 6. REPLACEMENT OF HDPE / METALLIC INSERTS:a) All coolers in sea water service are having either HDPE or Metallic inserts at their inlet and outlet. These inserts shall be removed completely before cleaning the tube bundle and shall be replaced with new one as existing. Flaring of the new metallic inserts shall be carried out by the contractor. 7. REPLACEMENT OF ANODES:a) The sacrificial CS / Zinc / Magnesium anodes welded / fastened to the channel head, floating head & covers are to be removed & shall be replaced with new one.

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b) If anode holding studs are found damaged, then carry out replacement of the same. 8. PAINTING OF THE HEAT EXCHANGER COMPONENT: a) For all heat exchanger with cooling water service on tube side other than those identified for glass flake coating, following component shall be painted with Coal tar epoxy paint as per BPCL painting specification AES 5430. o

Both tube sheet

o

Channel box

o

Channel cover

o

Float head cover

9. SHOT-BLASTING/ POWER BRUSHING FOR WFMPI OF SHELL WELD JOINTS:a) Contractor shall carry out shot blasting / power brushing of the weld joint covering 6 inch area on either side of the weld joint of shell and other component of exchanger as detailed against each equipment (Attachment 11 Section C) and offer for WFMPI testing. 10. INSULATION REMOVAL: a) Remove insulation for spading, de-spading, opening of heat exchanger. b) Remove Insulation around all the nozzles up to first flange or 250 mm from the shell to assess CUI / UT gauging. c) Remove Insulation at insulation support rings for all exchanger shells to assess CUI d) Make insulation pockets for taking UT gauging at every 2 meters on shell (In all four directions), dish ends / covers (4 directions) for UT gauging. e) If no insulation windows exist on the shell, then contractor shall cut the insulation window as per insulation standard procedure. The removable window shall be of the same basic material and thickness as the rest of the insulation and of sufficient rigidity to withstand handling.

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f)

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

Notes: 1. Point (c) related to Insulation rings shall not be applicable if not mentioned against specific equipment. 11. COLD & WELD REPAIRS: Following jobs on the heat exchanger component shall be carried out as detailed against each equipment task list or as recommended during course of inspection of equipment. a) The contractor shall rectify the transverse baffle edges, tie rods, spacers, impingement plates, longitudinal baffles, sacrificial anodes, etc., by grinding / bend removal / weld repairs, etc., b) The contractor shall carry out weld repairs on shell, tube bundle & components like channel box, channel cover, floating head cover, shell cover, sacrificial anodes holding studs , in-situ machining. c) The contractor shall carry out weld reinforcement to the eroded / corroded portions on tube sheet, gasket seating surfaces of components & on tube seal welds. d) The contractor shall replace the channel head pass partition plate wherever required. 12. IN-SITU RE-TUBING OF FIXED TUBE EXCHANGERS / AIR FIN COOLER INCLUDING SEAL WELDING:The contractor shall carry out •

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

•

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

as per following procedure.

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a) After removal of all the covers, channel box, opening of the plugs, make necessary working platform arrangement by erecting scaffolding and planks to facilitate the tube removal. b) Remove seal welding of the tubes by grinding / suitable means if applicable. c) Carry out cutting of the tubes at one end as required using pneumatic / electrically operated internal tube cutter. d) Using appropriate puller remove the tubes from tube sheet. e) Remove the left out ends of the tubes on other end of the tube sheet. f)

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

g) Shift all the new tubes to site / at equipment installed grade level. h) Clean the tube holes in both the tube sheet. i)

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

j)

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

k) Roll leak if any found during hydro testing shall be rectified by the contractor. Note: Wherever the tube bundles are being sent to BPCL shop, the retubing shall be carried out by BPCL. 13. RE-INSTALLATION OF TUBE BUNDLES & COMPONENTS: a) The contractor shall re-install the tube bundles after cleaning / re-tubing & obtaining clearance from BPCL Maintenance, Inspection and Operations Departments by using bundle puller , crane , chain pulley block , trolley etc, b) The contractor shall re-install the components of heat exchangers after cleaning & obtaining clearance from BPCL Maintenance, Inspection and Operations Departments in a stage wise manner to facilitate hydro testing. c) The contractor shall renew all the gaskets pertaining to the exchanger components and disturbed flanges while re-assembly.

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d) The contractor shall clean & salvage all the RTJ Gaskets and re-use. Cary out necessary lapping of the RTJ flange groove to obtain leak free joint. 14. HYDRO-TEST: a) The contractor shall carry out hydrostatic testing of the exchanger to the specified test pressures after re-installing the tube bundles & components as detailed below. Note: To ensure the sufficient service water pressure during filling the hydro testing circuit, contractor shall provide booster pump with temporary water hold up tank. 15.1 SHELL TEST: Shell test is applicable for all types of exchangers as detailed below. •

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

•

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

•

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

Hydro test Procedure: •

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

•

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

•

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

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•

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

•

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

15.2 TUBE TEST:Tube test is applicable for fin fan coolers and all types of exchangers as detailed below •

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

•

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

•

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

•

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

•

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

•

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

•

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

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•

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

TUBE TEST FOR AFC •

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

•

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

•

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

•

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

15.3 COMBINE TEST:Combine shall be conducted as detailed below. •

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

•

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

•

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

16. JOB COMPLETION & DE-SPADING: •

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

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•

Carry out insulation in standard on all the locations from where the insulation is removed. ***********************

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APPENDIX A: ATTACHMENT 5 SCOPE OF WORK: VESSELS 1.

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

2.

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

3.

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

4.

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

5.

DISMANTLING & RE-FIXING OF INTERNALS:

a. The contractor shall dismantle & remove the equipment internals wherever required as detailed under equipment specific work scope in

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ATTACHMENT 11 sections E. The equipment internals shall include catalyst, sand, filter element, demister pads, rasching ring , distributors, steam coils, grids, and structural items used for supporting the internals. b. The contractor shall mark legibly using permanent marker and non tearable tags on all the internals, distributor piping and all other removable internals before dismantling for better identification during refixing. c. All the demisters wherever applicable shall be removed and replaced with new one. Removed demisters shall be cleaned with hot water to make them suitable for disposal at owners designated place. All demisters shall be installed with the assistance of suppliers. d. The contractor shall re-fix either with repaired internals or with replacement materials after obtaining necessary clearance from Operations / Inspection. e. In case of Dosing tanks, contractor shall remove the agitator assembly wherever applicable and fit back the same after cleaning. 6.

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

7.

SCAFFOLDING a. The contractor shall provide necessary scaffolding or Ladder inside the equipment at the required locations to access internals / internal surface of the vessel. The Contractor shall also provide scaffolding externally surrounding the equipment as required for inspection of nozzles, removal of instruments etc. b. Erect scaffolding inside the skirt for inspection of the bottom elbows / dish end of the vessels. c. The contractor shall dismantle & remove the scaffolding or ladder after completion of all the maintenance work.

8.

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

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wherever possible and cold work cleaning methods (viz) scrapers, wire brush in inaccessible area. b. The contractor shall clean the internal surface of the equipment in such a way as to prevent debris falling on any of the nozzles. c. The contractor shall carry out shot blasting / power brushing of the weld seams 6” on either side of the weld joints to carry out Wet fluorescent magnetic particle Inspection (WFMPI) wherever required and spot buff the parent metal surface of the equipment for thickness gauging. After WFMPI, carry out the painting of the shot blasted/power brushed surface as per AES 5430 Rev 1, wherever applicable. d. The contractor shall clean the internal stainless steel lining & weld seams using SS wire brush and pickling. e. The contractor shall clean and service fasteners / clamps, etc., and replace with new one wherever found missing as per EIC Instructions. 9.

UNLOADING & LOADING OF CATALYST , SAND & RASCHIG RINGS a. The contractor shall erect necessary temporary shelter using scaffolding pipes & with tin sheets near the equipment for safe storage of the catalyst / sand, rasching rings etc and dispose it on immediate basis after necessary cleaning and making them hydrocarbon free. b. All the catalyst / sand etc ring shall be replaced with new one.

10.

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

11.

INSLUATION REMOVAL a. Remove Insulation at insulation support rings for all insulated vessels to assess CUI wherever mentioned against specific equipment. b. Remove insulation around all the manways and nozzles up to first flange / 250 mm from the shell for UT gauging. c. Make insulation pockets on the shell for taking UT gauging at every 2 meters on shell in all four directions, dish ends (4 directions) for UT gauging.

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d. If no insulation windows exist on the shell, then contractor shall cut the insulation window as per insulation standard procedure. The removable window shall be of the same basic material and thickness as the rest of the insulation and of sufficient rigidity to withstand handling. e. After completion of the job, carry out insulation and cladding as per BPCL insulation procedure given in Attachment 12. The same also includes painting with 2 coats of Zinc dust Graphite(2 x 30 micron) Notes: 1. Point a related to Insulation rings shall not be applicable if not mentioned against specific equipment. 12.

EQUIPMENT FIRST ISOLATION VALVES: a. The contractor shall service all the first isolation valves except those which are planned for removal, dismantling and testing. b. Valve servicing includes opening of the valve, cleaning steam, greasing the stem, flushing the valve through nozzle using water hose and making valve free for opening and closing.

13.

MIXER / STIRRER ASSEMBLY FOR CHEMICAL TANKS / VESSLES

a. The contractor shall remove the mixer / stirrer assembly and over the same to site in-charge for overhauling of any. After replacement / repair, assemble the mixer assembly. 14.

EQUIPMENT GAUGE GLASS :

a. The contractor shall remove all the gauge glass from the vessels along with manifold/stand pipe wherever applicable and carry out repair as per procedure detailed under Attachment 12. b. The contractor shall carry out the hydrotest of the stand pipes at vessel hydrotest pressure 15.

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

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16.

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

17.

HYDRO TESTING OF VESSEL

a. Carry out hydro testing / water fill up test of the vessels as per test pressure. b. During hydro testing all the spades installed for entry of the vessel shall be relocated on downstream of isolation valve for including the entire first isolation valve in hydro test circuit for body test. c. Hydro testing of the vessel shall be carried out with all internals fitted inside. d. During hydro testing, initially all the flanged isolation valve shall be kept in open condition to check the integrity of the valve body. On completion of hydro test with all valves in open condition, close the entire valve, open the downstream flange of the valve and check the valve for seat passing / testing. Seat testing shall be witnessed by inspection / Process engineer of Owner. e. After completion of the hydro test, drain the water slowly after taking necessary precaution. f.

In vessels having sand, charcoal, etc hydrotest shall be done prior to filling of san , charcoal back inside the vessel and again manway shall be opened for filling of sand, charcoal, etc.Final box up of manway shall be after filling sand, charcoal ,etc inside the vessel. Note: To ensure the sufficient service water pressure during filling the hydro testing circuit, contractor shall provide booster pump with temporary water hold up tank.

18.

MULTIPLE WORK FRONT:

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

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19.

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

b. The contractor shall carry repair to the vessel internal / internals by hot work like removal of cracks by grinding & welding, repairing of internal / external surface pits by welding and grinding, removal and welding of cracks on support ring (TSR), replacement of nozzles as required. c. Payment for repairs using hot work shall be made as per applicable SOR based on the actual measurements.

20.

JOB COMPLETION & STARTUP COVERAGE:

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

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APPENDIX A: ATTACHMENT 6 SCOPE OF WORK: EJECTORS Contractor shall carry out all the jobs on ejectors as detailed below. List of ejectors is given in Attachment 11 section F. a) Erect necessary external scaffolding. b) Carry out spading on steam inlet and process fluid inlet and outlet. c) Entire shell of the ejectors shall be offered for external UT gauging / scanning. d) Make necessary rigging arrangement for removal of the steam nozzle assembly. e) Open the ejector steam nozzle flange and remove the assembly out of the shell/ mixing chamber. f)

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

g) Clean and offer the steam nozzle for inspection and dimensional check to Inspection / Technology h) Make necessary scaffolding / ropes ladder arrangement for inspection of the throat diameter. Throat diameter check shall be carried out by BPCL technologist. i)

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

j)

Necessary repair / replacement based on inspection recommendation shall be carried out by the contractor.

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

De-spade and box up all the flanges.

m) Remove scaffolding after completion of the job.

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APPENDIX A: ATTACHMENT 7 SCOPE OF WORK: PROCESS / CW VALVES

Following procedure shall be followed for servicing of the process valves / cooling water piping valves. A) ISOLATION VALVES FOR COOLING WATER SERVICE (LIST OF VALVES IS GIVEN IN ATTACHMENT 11 section J) (Type of valve: Gate / Check and Globe) 1. Removal of valve a) Erect necessary scaffolding. b) Provide metal tag on the valve and pipe nozzle indicating the location of the valve and original mounting direction like stem position Vertical or horizontal on North/ South/East/West etc. c) Open and remove both the flange bolts. d) Make necessary rigging arrangement. e) Lower the valve from pipe line to ground level. 2. Transportation of valve a) After removal, load the valve on hand cart / low bed trailer. b) If required, use load binder to avoid falling of valve from cart / trailer during transportation. c) Shift the valve to central hydro testing / repair area. 3. Dismantling of valves a) Dismantle the valve completely. b) Clean all the component of valve like, body, bonnet, gate, stem, seat, seat rings free of foreign material using raw water high pressure jet after removal of the FRE lining.

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4. Inspection of valve a) Offer the entire component of valve to inspection. b) Based on inspection finding / recommendation valve shall be assembled or reconditioned as per procedure given in Attachment 12. 5. Assembly of valves a) After inspection, carry out FRE lining on the wet part of the body, bonnet and gate / check valve as per procedure given in Attachment 12. FRE lining on gate for non ferrous trim valve is not applicable. b) For globe valve, carry out glass flake coating on all wet part as per EIL specification no. 4691-0642-01 given in Attachment 12. c) Cut the bonnet gasket from compressed asbestos fiber sheet. d) Assemble the valve. e) Replace the gland packing. f)

Grease the stem.

g) After final assembly, operate the valve and check for its free ness / operability. 6. Installation of the valve a) Shift the valve to respective location. b) Make necessary rigging arrangement. c) Place the valve in position. d) Check the valve mounting direction on the tag. . e) Fit back the valve in position accordingly and tighten the flange bolts. Use new gasket while installation of valve. f)

Remove scaffolding.

B) ISOLATION VALVES FOR COOLING WATER SERVICE (LIST OF VALVES IS GIVEN IN ATTACHMENT 11 section J) (Type of valve: Butterfly valve)

1. Removal of valve a) Erect necessary scaffolding.

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b) Provide metal tag on the valve and pipe nozzle indicating the location of the valve and original mounting direction like wheel position, Vertical or horizontal on North/ South/East/West etc. c) Open and remove both the flange bolts. d) Make necessary rigging arrangement. e) Lower the valve from pipe line to ground level. 2. Transportation of valve a) After removal, load the valve on hand cart / low bed trailer. b) If required, use load binder to avoid falling of valve from cart / trailer during transportation. c) Shift the valve to central cleaning area. 3. Dismantling of valves a) Open the gear box cover for 10 inch and above valves. b) Clean the internal component, grease/ oil them. c) Clean all the component of valve like, body externally and internally, seat, seat rings, and disc free of foreign material using raw water high pressure jet. d) Replace the rubber seal ring “O “ring of the valve with new one. Supply of O ring is in contractor’s scope. 4. Inspection of valve a) Offer the entire valve for visual inspection. b) Incase valve is found damaged and not serviceable; same shall be repaired / reconditioned as per procedure given in Attachment 12.

5. Installation of the valve a) Shift the valve to respective location. b) Make necessary rigging arrangement. c) Place the valve in position. d) Check the valve mounting direction on the tag.

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

Remove scaffolding.

C) ISOLATION VALVES ON PROCESS (LIST OF VALVES IS GIVEN IN ATTACHMENT 11 section G) (Type of valve: Gate, Globe, Ball, Plug, Check, Butterfly) 1. Removal of valve a) Erect necessary scaffolding. b) Provide metal tag on the valve and pipe nozzle indicating the location of the valve and original mounting direction like stem position Vertical or horizontal on North/ South/East/West etc. c) Open and remove both the flange bolts. d) Make necessary rigging arrangement. e) Lower the valve from pipe line to ground level. 2. Transportation of valve a) After removal, load the valve on hand cart / low bed trailer. b) If required, use load binder to avoid falling of valve from cart / trailer during transportation. c) Shift the valve to central hydro testing / repair area. 3. Cleaning of valves a) Open the valve gate. Dismantling of valve is not required. b) Clean the valve body internally / externally, seat free of foreign material using raw water high pressure jet or steam / hot condensate for heavier hydrocarbon service valves. 4. Inspection of valve a) Offer the valve in clean condition to inspection for visual inspection. 5. Hydro testing of valves a) After visual inspection and clearance from inspection authority, replace the gland packing of valve.

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b) Carry out body and seat hydro test as per applicable standard and offer to inspection. c) Blind flanges required for hydro testing to be provided by the contractor. d) If valve is found leaking from the bonnet gasket, then opening of the bonnet and replacement of the gasket shall be carried out. e) Hydro test of valve shall deem to be completed, when it complies with the requirement of referred testing code. f)

However if the valve is found passing excessively beyond permissible limit of the code, then it shall be taken for repair/ reconditioning as per procedure given in Attachment 12.

6. Installation of the valve a) After hydro testing/ repair shift the valve to respective location. b) Make necessary rigging arrangement. c) Place the valve in position. d) Check the valve mounting direction on the tag. e) Fit back the valve in position accordingly and tighten the flange bolts. Use new gasket while installation of valve. f)

Remove scaffolding.

GLAND PACKING MATERIAL FOR PROCESS VALVE REPACKING Packing material :- NON ASBESTOS METALLIC EXPANDED PURE GRAPHITE ( > 99.5% ) PACKING REINFORCED WITH MULTIPLE INCONNEL WIRE AND FURTHER JACKETED WITH INCONNEL WIRE MESH IN EACH YARN. ( MIN. 3 & MAX.5) or Equivalent packing material satisfying all the following specifications. 1.) Packing shall be suitable for use in all types of Valves in handling fluid media containing Hydrocarbon / Hydrogen Sulphide / Hydrogen / Steam / Thermic Fluid / Hot Oil/ BFW/ Condensate /catalyst/ Fire water/ Raw cooling water/ sea cooling water/Air/ N2/Gases or any other kind of chemicals handled in refinery to withstand Temperature range from 50°C to + 650°C, Working Pressure up to 250 Kg/cm2 and PH range 0-14. 2.) For gland packing with inconel wire mesh / reinforcement , vendor shall submit test Certificate from any reputed Metallurgical Testing Laboratory that Inconnel wire material confirms to the specifications as per "UNS Nickel material grade having Min. Nickel 76% and Chromium Min 18%". The Test is to be witnessed and reviewed by 3rd Party Inspection Agency.

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3.) Surface of the packing has to be smooth enough and no wire should be visible on surface. 4.) Packing has to have Type Test Certificate as per API 589 (Fire Test for Evaluation of Valve Stem Packing) and API 607 (Fire Test for Soft -Seated Quarter-Turn Valves). A copy of the sample Test Certificate shall be enclosed along with the offer. The Test should be conducted at Yarmouth Laboratory USA or any other Laboratory approved by API. 5.) Packing must have Fugitive Emission Test Certificate to Tightness Class B as per SHELL MESC SPE 77/312 and API 622 latest edition or equivalent certification from any reputed 3rd Party Laboratory. GLAND PACKING MATERIAL FOR SEA WATER VALVES REPACKING Packing material: - Corrosion resistance Aldehyde braided square packing having break in lubricant to work under ph range 2-14 suitable for handling sea water to withstand temp upto 100 deg C and pressure upto 10 bar The material meeting above specification for repacking of Process valves and cooling water valves shall be sourced from vendor / manufacturer like BUMA, CHESETERTON, SPITMAN, JAMES WALKER INMARCO, CHAMPION or any other reputed vendor. The material shall have the related test certificates and shall be submitted to BPCL for review. NOTE: Reconditioning of valves: Final decision for reconditioning of the valve shall be in consultation with the owner. Owner reserve the right to issue new valve if available instead of going for reconditioning. Payment for reconditioning of the valves shall be as per applicable schedule of rates and reconditioning of the valve is not included in lump sum scope. Also note that in case of MOV (Motor operated valve), remove the actuator assembly and make temporary wheel arrangement for testing of valve. Fix the actuator back at site after valve fitment.

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APPENDIX A: ATTACHMENT 8 SCOPE OF WORK: RELIEF VALVES / RUPTURE DISC For removal, testing, repair and reinstallation of Relief Valve (RV) / Safety Valve (SV) / Rupture Disc (RD) , following procedure shall be followed. List of RV is given in Attachment 11 section H. a. Erect the scaffolding wherever required. b. Make necessary rigging arrangement such as chain blocks, crane, slings, and temporary structure. c. Provide Aluminum tags on RV / SV's / RD and punch the tag no on them. Also provide tag no. on nozzles from where the valves / RD have been removed. d. Open the inlet and outlets flanges bolts and remove the safety valve / relief valve & RD as per the list enclosed. In case of rupture disc, before removal of the disc, remove all the connection such as pressure gauge & all the attached tubing. e. Lower the relief valve using suitable rigging arrangement like crane, chain block. f.

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

g. Prepare job request to machine shop for servicing / testing of the individual valve as per RV/SV tag no in SAP, punch the job request no on the aluminum tag and transport the valves to machine shop. h. After completion of the repair, servicing and testing of the valves at machine shop which shall be carried out by OWNER, transport the valves back to the site. i.

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

j.

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

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

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APPENDIX A: ATTACHMENT 9 SCOPE OF WORK: ISBL PROCESS PIPING GENERAL: List of process piping requiring Hydro testing is given in ATTACHMENT 11 section I. However scope also applies to all the balance process piping inside the battery limit which shall be offered for inspection. Based on inspection & subsequent recommendation for repair shall be given. Necessary repair shall be carried out by contractor as per BPCL requirement. Payment towards repair shall be made as per applicable SOR unless explicitly mentioned in the specific scope. 1. Offer all the process pipelines inside the battery for visual inspection, Ultrasonic thickness gauging, scanning, Hammer testing. 2. Provide scaffolding for all the piping inspection. 3. For CDU-3 / VDU/ NHGU / LOBS / SRU /HCU complex the process piping are classified under three tables as below, Table A: - Insulated lines whose operating temperature falls in CUI range i.e. below 120 Deg C. These lines shall be offered for comprehensive inspection after removal of the insulation as below. For Vertical section: 1 meter Insulation band shall be opened after every 10 meters of straight length. Insulation shall also be opened at all the branches, support locations, elbows, T sections, reducers, drains and vents. For Horizontal section: 1 meter insulation band shall be opened at every support location. Insulation shall also be opened at all the branches, elbows, T sections, reducers, drains and vents. Table B: High temperature insulated line. These lines shall be offered for comprehensive inspection after removal of the insulation as below. Open insulation pocket at every support location, all elbows, all T section and one insulation pocket at every 10 meter of straight section of the line. Note:- Insulation pocket shall be of 6” x 6” size. On the nozzles the pocket can be smaller depending on nozzle size. Incase making pocket is not feasible on nozzle then full insulation to be removed. On elbows of pipelines the pocket shall be made on the outer radius. On Tees pocket shall be on outside of top stroke of T. On horizontal straight sections of pipelines the pocket shall be provided on the 6 o clock position Tables C: Bare lines Lift the pipe line at beam support locations and offer for inspection 4. Removal of insulation on all insulated pipe wherever applicable shall be in your scope.

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

EXTERNALLY INSULATED

PRESSURE

150 #

NO

18.0 Kg/cm2g

150 #

YES

22.0 Kg/cm2g.

300 #

NO

36.0 Kg/cm2g.

300 #

YES

45.0 Kg/cm2g.

600 #

NO

65.0 Kg/cm2g.

600 #

YES

85.0 Kg/cm2g.

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

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19. All the trenches are to be cleared free of congealed products / muck / salt water stagnation. 20. Remove all the damaged FRP coating on pipelines wherever applicable, clean and offer lines for inspection. After Completion of inspection and repair, carry out FRP lining as per procedure. 21. Make Boson’s chair arrangement / provide scaffolding for taking pipe wall thickness measurements on all the column over head and heater transfer lines. 22. After completion of the inspection / repair job remove the scaffolding. Note: To ensure the sufficient service water pressure during filling the hydro testing circuit, contractor shall provide booster pump with temporary water hold up tank.

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