Preliminary Works for the Statutory testing of Mounded Bullets and above Ground Storage Vessels

Mounded Bullets

Providing MS tubular scaffolding inside and outside the Bullets suitable for cleaning of inner surface and suitable for carrying out all inspections like ultrasonic testing, radiographic testing, MPI and other NDT's and all allied jobs for inspection at various places and around all welding joints, if necessary. On outer surface as directed by the third party agency approved by IPPL. Scaffolding arrangement should be provided with movable footrest / MS Grill type / pathway etc., for easy movement of personnel and for resting equipments. Wherever tubular pipe touches the shell plate suitable rubber pads to be provided to avoid damages to the shell. The scaffolding shall be retained till the completion of the Bullet testing. The Contractor has to provide scoffolding material for 2 bullets. Bullets will be handed over one by one after completion.(Lenght of bullet - 23.46 meters & height - 6 meters& for other clarrifications GA/P& ID drawings attached )

Disconnecting the inlet, outlet of the LPG liquid and vapour line, SRV, HLA, Manhole, servo/radar gauge, displacer, Water drain lines, Globe valve / Gate Valves, ROVs and other fittings, disconnection of electrical cables without any damage as per the directions of the IPPL officials/ Third party inspecting official. All the disconnected pipelines and manifold valves and nozzles etc., should be positively segregated by blind flanges of 300 lbs. class rating with fasteners, which have to be supplied by the contractor and which can be taken back by the contractor on completion of the entire work. The fasteners and dummy used should be as per IS standards. Any damage for the fittings or any equipments during removal & fixing to be made good by the contractor. All the removed items should be kept under safe custody till commissioning, any damage has to be made good by the Contractor free of cost. Job also includes packing and handing over of old studs and nuts at store as directed.

Degassing of 300 MT Bullet with water, filling up water gradually and making necessary connections for in and out flow with suitable pipeline and motorised arrangement / hose, pumping arrangements as directed at site. The water used for degassing should be disposed off safely in the drainage and the sludge if any coming along the water should be carefully removed and buried at a safe place including excavation, backfilling and disposing off the surplus earth as directed. A sample of the sludge collected should be handed over to the IPPL. Water shall be supplied by M/s. IPPL

Internal cleaning : Thorough cleaning of the inner surface with water jet and cleaning the sludge / rust materials followed by thorough cleaning of inner surface to remove the scale, oil and rust by rotary pneumatic wire brushes to expose the metal surfaces and thorough buffing of welding joints. (Minimum 10 mm on both the sides of each welding joints including nozzle welds by thorough cleaning using rotary pneumatic wire brushes to expose bare metal (shining surface) with care to remove rust from both the sides of the weld ripples and under cuts). In addition 200 mm on all the sides of the entire weld joints of the nozzles and weld area of the support legs and other area as directed at site. Localized grinding of the welds to be done if required. The Gaskets to be subjected to Third Party Inspection for application of the same for LPG usage confirming to ASME B 16.2 or equivalent for Gaskets.

Providing flameproof lighting arrangement and ventilation provision with flameproof exhaust fan inside the bullet for carrying out necessary inspection, cleaning and NDT tests. Contractor to supply the flameproof light fittings, junction boxes, required cables etc. as directed at site. Only one bullet will be handed over for testing at a time. IPPL shall retain the lighting arrangement till the completion of works in 2 bullets. Bullets will be handed over one by one after completion of all works in one bullet.

Hydraulic testing of Bullets after completion of all NDT using water and hydraulic test pressure shall be maintained as prescribed and directed by IPPL / Third party, by using motorised pump of required capacity and draining the water after competion of testing. Job includes arrangement for filling the vessel from supply source, pressurisation to the required pressure, holding the same for the required period,using FLP / Diesel driven pumps, fittings, tools and tackles, Pressure gauge with minimum 6inch dial, etc as directed. The entire Testing will be witnessed by Third Party Agency. The water used for hydrotesting one vessel has to be used for another vessel by making necessary arrangment. Work also includes checking of settlement with dumpy level at various stages of water filling and decanting viz 0%, 25%, 50%, 75% and 100% levels.

Pneumatic testing of Bullets after completion of all tests using plant air/Nitrogen for the Pneumatic test pressure as prescribed and directed by IPPL / Third party, by using motorised pump of required capcity and draining the water after competion of testing. Job includes arrangement for filling the vessel from supply source, pressurisation to the required pressure, holding the same for the required period,using FLP / Diesel driven pumps, fittings, tools and tackles, Pressure gauge with minimum 6inch dial, etc as directed. The entire Testing will be witnessed by Third Party Agency. Thorough internal cleaning has to be carried out before box-up.

Fixing back all the liquid and vapour lines after servicing of all the valves including EFCVs and fixing all removed fittings like HLA, Servo gauge, servo/radar gauge, SRVs, Pressure / temperature gauge, Manhole covers etc., including supply of asbestos filled spiral wound metalic gaskets and using dismantled thoroughly cleaned studs -bolts / new studs against damaged. This includes all the works pertaining to commissioning of the bullets after inspection and testing duly approved by CCOE approved third party and subsequent clearing of all debris and removing of scaffolding materials at site.

Purging (Gas in) of bullet after completion of all NDT tests using water/air/vapour and draining as directed by IPPL /Third party Inspection agency.

LPG Above Ground Storage Vessels

Providing MS tubular scaffolding outside the Storage Vessels suitable for cleaning of outer surface and suitable for carrying out all inspections and all allied jobs for inspection at various places on outer surface as directed by the third party agency approved by IPPL. Scaffolding arrangement should be provided with footrest / MS Grill type / pathway etc., for easy movement of personnel and for resting equipments. The scaffolding shall be retained till the completion of the Storage Vessel testing. The Contractor has to provide scoffolding material for 2 Storage Vessels. It will be handed over one by one after completion.

Disconnecting the inlet, outlet of the LPG liquid and vapour line, SRV, HLA, Manhole, servo/radar gauge, displacer, Water drain lines, Globe valve / Gate Valves, ROVs and other fittings, disconnection of electrical cables without any damage as per the directions of the IPPL officials/ Third party inspecting official. All the disconnected pipelines and manifold valves and nozzles etc., should be positively segregated by blind flanges of 300 lbs. class rating with fasteners, which have to be supplied by the contractor and which can be taken back by the contractor on completion of the entire work. The fasteners and dummy used should be as per IS standards. Any damage for the fittings or any equipments during removal & fixing to be made good by the contractor. All the removed items should be kept under safe custody till commissioning, any damage has to be made good by the Contractor free of cost. Job also includes packing and handing over of old studs and nuts at store as directed.

Degassing of 15 MT LPG Storage Vessel with water, filling up water gradually and making necessary connections for in and out flow with suitable pipeline and motorised arrangement / hose, pumping arrangements as directed at site. The water used for degassing should be disposed off safely in the drainage and the sludge if any coming along the water should be carefully removed and buried at a safe place including excavation, backfilling and disposing off the surplus earth as directed. A sample of the sludge collected should be handed over to the IPPL. Water shall be supplied by M/s. IPPL

Internal cleaning : Thorough cleaning of the inner surface with water jet and cleaning the sludge / rust materials followed by thorough cleaning of inner surface to remove the scale, oil and rust by rotary pneumatic wire brushes to expose the metal surfaces and thorough buffing of welding joints. (Minimum 10 mm on both the sides of each welding joints including nozzle welds by thorough cleaning using rotary pneumatic wire brushes to expose bare metal (shining surface) with care to remove rust from both the sides of the weld ripples and under cuts). In addition 200 mm on all the sides of the entire weld joints of the nozzles and weld area of the support legs and other area as directed at site. Localized grinding of the welds to be done if required. The Gaskets to be subjected to Third Party Inspection for application of the same for LPG usage confirming to ASME B 16.2 or equivalent for Gaskets.

Providing flameproof lighting arrangement and ventilation provision with flameproof exhaust fan inside the Storage Vessel for carrying out necessary inspection, cleaning and NDT tests. Contractor to supply the flameproof light fittings, junction boxes, required cables etc. as directed at site. Only one Storage Vessel will be handed over for testing at a time. IPPL shall retain the lighting arrangement till the completion of works in 2 Storage Tanks. Storage Vessels will be handed over one by one after completion of all works in one Storage Vessel.

Hydraulic testing of Storage Vessel after completion of all NDT using water and hydraulic test pressure shall be maintained as prescribed and directed by IPPL / Third party, by using motorised pump of required capacity and draining the water after competion of testing. Job includes arrangement for filling the vessel from supply source, pressurisation to the required pressure, holding the same for the required period,using FLP / Diesel driven pumps, fittings, tools and tackles, Pressure gauge with minimum 6inch dial, etc as directed. The entire Testing will be witnessed by Third Party Agency. The water used for hydrotesting one vessel has to be used for another vessel by making necessary arrangment. Work also includes checking of settlement with dumpy level at various stages of water filling and decanting viz 0%, 25%, 50%, 75% and 100% levels.

Pneumatic testing of Storage Vessel after completion of all tests using plant air/Nitrogen for the Pneumatic test pressure as prescribed and directed by IPPL / Third party, by using motorised pump of required capcity and draining the water after competion of testing. Job includes arrangement for filling the vessel from supply source, pressurisation to the required pressure, holding the same for the required period,using FLP / Diesel driven pumps, fittings, tools and tackles, Pressure gauge with minimum 6inch dial, etc as directed. The entire Testing will be witnessed by Third Party Agency. Thorough internal cleaning has to be carried out before box-up.

Fixing back all the liquid and vapour lines after servicing of all the valves including EFCVs and fixing all removed fittings like HLA, Servo gauge, servo/radar gauge, SRVs, Pressure / temperature gauge, Manhole covers etc., including supply of asbestos filled spiral wound metalic gaskets and using dismantled thoroughly cleaned studs -bolts / new studs against damaged. This includes all the works pertaining to commissioning of the Storage Tanks after inspection and testing duly approved by CCOE approved third party and subsequent clearing of all debris and removing of scaffolding materials at site.

Purging (Gas in) of Storage Vessel after completion of all NDT tests using water/air/vapour and draining as directed by IPPL/Third party Inspection agency.

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