TENDER FOR REPLACEMENT OF SINGLE BOTTOM PLATE OF ABOVE GROUND ETHANOL TANK AT BORKHEDI DEPOT

Replacement of single bottom plate of above-ground ethanol tank (TK03) at Borkhedi Depot

Short text Item description Unit Qty

FAB STOR TANK AG Shell opening: Cuting a "window" in the tank shell at a height of 600 mm from the bottom base plate. Window Size: Approximately

MODIFICATION 1800 mm (circumferential length) x 400 mm (height).

Fabrication, erection and welding of vertical AG tanks as per designed drawing (design is not included in the scope of this item) out of free

issue steel plates (Bottom, Shell, roof, Wind Girders, Re-enforcement Pads, Backing Strips for bottom plate, Dip Plates, Extension Plates

/ Platforms etc.as per site requirement)

The job includes:

1. Handling / shifting of steel plates meant for tank erection from storage point inside BPCL's project premises to the tank erection site;

preparation of fabrication drawing and obtaining approval from TPIA & BPCL as per our standard drawing and sizes of plates available at

site; cutting and edge preparation of the plates as required; rolling of plates for shell of the tanks; fabrication, assembling and welding as

per our standard / relevant specifications and as directed by the Engineer-in-charge.

2. Testing of tank bottoms, roof, deck (wherever required) using vacuum box test method as per API/BPCL standards. The rate shall

include all charges towards consumables such as Water, Electricity, tools and tackles, labour, lifting jacks & machinery required to

complete the job. Providing all temporary structure and labour for completion of the job as per drawing and accounting of unused scrap

material as per tender clause.

3.100 % Dye Penetrant Testing (DPT) of root runs and any other tests specified as per drawings and specifications and also

2 9007836 Fabrication:Material-BPCL submission of AS BUILT drawings. KG

4. Radiography of shell plate weld joints as per API 650 latest edition.Oil Chalk test for bottom shell joint and pneumatic test for

all reinforcement pads shall be carried out by contractor. Fabrication drawing shall be prepared and approved from TPIA & BPCL by

contractor based on the designed drawings. As built drawing shall be submitted by contractor during submission of final documents.

5. Inspection/supervision by BPCL recommended TPIA (as per list attached) and scope of work/QAP.

Tank fabrication and installation shall be as per API-650 (Latest edition) / BPCL standards.

Rate to be quoted in KG of steel plates used for tank fabrication.

Typical drawing enclosed for reference, however vendor to submit site specific drawing for approval from Engineer In charge prior

tofabrication. Vendor

Scope of Work- Installation Specifications (New Plate) Dimensions: 1500 mm (Width) x 6300 mm (Length) Thickness: Minimum 8 mm

Material: IS 2062 Fit-up: Must be lapped minimum 50mm with adjacent plates.

Surface preparation of steel storage tanks by abrasive blast cleaning using compressed and dry air to near white metal finish meeting SA

2.5or SSPC-SP-10 . The work shall be performed in accordance with technical specifications including all equipment, hoses, nozzles,

labour, abrasivematerials, deployment of dedicated personnel, measuring and testingequipment, documentation for implementation of

quality assurance etc.all complete. The rates shall be exclusive of scaffolding.

3 9033317 TK ABR BLAST SA 2.5 M2

Application Area: All Internal, External surface of tank shell, bottom,Fixed Roof, Floating Roof, Roof Truss, All Tank Appurtenances etc at

alllevels and positions as per directions of BPCL Engineer In-charge.

Copper Slag shall not be re- used for blasting.

Supply and applying one coat of weldable grade Inorganic Zinc Silicate Primer (of BPCL approved makes) of min DFT 25 microns. The

work shall be performed in accordance with technical specifications and paint manufacturer's recommended procedures including all

equipment, hoses,nozzles, labour, paint materials, deployment of dedicated personel,measuring and testing equipment, documentation

for implementation ofquality assurance etc. all complete. The rates shall be exclusive of scaffolding.

Application Area-

a. Underside of Bottom plate for all vertical tanks at all levels and positions.

4 9033390 TK PRIMER INORG WLD M2

b. Any other area not specified above but instructed by BPCL Engineer In-Charge.

Rates shall be inclusive of various losses such as profile loss, Distribution loss, Application losses, Wagtages etc. in order to achieve

specified DFT. All paint materials supplied at site shall be accompanied by a valid test certificate issued by Paint Manufacturer.

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Supply and applying two coats of Glass Flake Epoxy with phenalkamine hardner (of BPCL approved makes) of min DFT 200 microns per

coat i.e.total DFT in two coats shall be min 400 microns. The work shall be performed in accordance with technical specifications and

paintmanufacturer's recommended procedures including all equipment, hoses, nozzles, labour, paint materials, deployment of dedicated

personel,measuring and testing equipment, documentation for implementation ofquality assurance etc. all complete. The rates shall be

exclusive ofscaffolding. Shade shall be Cream - Close to RAL

Application Area-

a. External surface of Welded Structural supports, Staircase (excluding GI Gratings), Handrails, Rolling Ladders, Top Landing Platform,

Foam Pourer Maintenance Platforms, 300 mm Tank Shell from Bottom Annular Plate, Projected Annular Plates, Primary Wind Girder-cum-

5 9033394 TK GLASS FLAKE EP 40 walkwayplatform, Secondary Winder Girders etc.for all types of Above groundtanks at all levels and positions. M2

b. Underside of Bottom plate for all vertical tanks at all levels and positions.

c. Full Internal surface of Shell, Roof Truss, Underside of Fixed Roof, Bottom Plates etc. of FW Tanks at all levels and positions.

d. Any other area not specified above but instructed by BPCL Engineer In-Charge

Rates shall be inclusive of various losses such as profile loss, Distribution loss, Application losses, Wagtages etc in order to achieve

specified DFT. All paint materials supplied at site shall be accompanied by a valid test certificate issued by Paint Manufacturer.

Vacuum box testing of roof and bottom plates per RM as per API 650/653 and scope of work enclosed with the tender.

Testing pressure range limited to 0.35 kg/cm2. Rate shall be paid on Running metres of welding joint for which the testing shall be

. . . TANK VACUUM BOX done.Rate to include arrangement of all equipment like glass box,compressor rubber tubes, torch lights and mud packing complete as per

TEST specifications

To carry out third party Inspection during the tank fabrication/modifications/maintenance works as per the scope of work enclosed.(List of

approved TPIA's)

Copies of all approvals / certifications for above to be submitted to BPCL as directed by Engineer in charge. TPIA inspection shall be

done asper BPCL approved TPIA's only.

Rate shall be quoted as per the following details including boarding, travelling and all overheads etc complete.

This item is towards depolyment/engaging third party inspection agency for documents/drawing review to site inspections, preparation of

7 9016520 . APPT TPIA P/L LS

TPIA services are required for the tankage works. The scope of work also includes vetting/approval of design and drawing submitted by

the tankage vendor and continuous presence of TPIA at site till completion of all works including approval of as-built drawings in all

respect as per direction of BPCL site Incharge.

Party shall quote the rates accordingly on lumsum basis. TPIA shall be present from start of commencement upto completion of

hydrotesting and handing over of the last tank.

From IMIR (Incoming material inspection certificate, material identification of steel plate) all the daily check/inspections to becarried out in

presence of TPIA and documents to be furnished.

The list of TPIA enclosed with tender.

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HYDRO TESTING OF CONE ROOF/FLOATING ROOF TANK (Supply of water for hydrotesting is in vendors scope) -

Scope of job includes filling water inside the tank up to the curb angle for carrying out hydro testing of the tank. After hydrotesting,

dewatering and cleaning of the tank to be done by the contractor. During hydrotesting taking levels of the tank w.r.t TBM after every filling

of 1 Mtr is also in vendors scope.

Arrangement for necessary pumping for filling the water in tank shall also be made by contractor including manpower, tools, tackles,

decanting water from tank and disposal of water by contractor outside the BPCL premises irrespective of any lead is in vendors scope.

Water shall be of potable type.

. . . HYDROTEST AG For hydrotesting, necessary closing and opening of valves, boxing up of manholes with new gasket / high tensile stud-bolts are also in

TANK scope ofthis item. After hydrotesting, manholes will be opened to clean the tank and complete the exercise of diesel swabbing for the

shell surface whichis not painted. Boxing up will be done using SS304 or higher Spiral wound Mettalic gasket of Champion or equivalent

make for which no extra payment shall be made.

All the neccessary arrangements to be done for filling water inside the tank shall be covered under this item including temporary supply of

flanges, fittings, gaskets, stud bolts, pipes, etc.

The payment for this item will be done after successfull hydrotesting of the tank.

Testing and Inspection:

Inspection of welding by Radiography Method on all types, sizes, thickness of plate (Bottom, Roof, Shell welding joints) including

processing of Films and interpreting the same to the Engineer-In-Charge together with recommendation of sub-contractor as to the

acceptability of otherwise of the welds; submitting the finished radiographic films as may be approved or directed by Engineer-In-Charge

including supply of all personnel, labour, materials, equipments, consumables, radiographic films and other inputs and providing all

service complete in all respects as required to perform the work as per specification and instructions of Engineer-in-Charge.

(I) Payment shall be done on the running metre of the film of respective size.

9 9019868 . . . TANK RADIOGRAPHY (II) Repeat radiography of the individual weld due to defective films or repair of welds shall be done at Contractors cost. RM

Scope of the job includes carrying out spot radiography of shell joints using gamma ray as detailed in API650 & Appendix A / technical

Radiography shall be done as per BPCL technical specifications/API 650 enclosed with the tender.

Rate shall be paid in Running Metre of the length of the film

Dismantling of tank plates by gas cutting/gouging and removing so thatit is in usable condition, including charges of cutting gas, crane

,tralier and tool <(>&<)> tackles, shifting them to scrap yard/ BPCL designated place after physical weighment. Scope

includesdismantling of structures, pipeline, fittings, gauges, make up platesetc, required for completing the job of dismantling of

bottomplates/roof plates/shell plates and payment will be done on weightbasis.

. . . DISMTL TANK BTTM Payment will be made on the basis of actual weighment of the dismantledsteel plates. The scope also includes, TO <(>&<)> Fro

PLT transportationcharges from the BPCL location to nearest Govt. approved/certified WeighBridge facility, for shifting dismantled steel plates

for physicalweighment of plates as per the instruction of Engg in-charge.