Internal cleaning, inspection, repair and painting of transmix tank (nominal capacity of 1000 kl, 12 m dia. and 9 m height) at PRRPL Jatni, Odisha

Amount

SUPPLY ITEMS

Supply of MS structural steel for all internal structures of Double Deck Floating Roof like rafters, truss, compartment, rim, ring, leg supports etc. and for manual gauging platform near dip gauge, railing on primary wind girder, rolling ladder, stairway, supports of wind girders, foam dam etc. as per approved drawing and requirement i.e. angles, channels, beams, flats, square rods, round bars, chequered plates, MS pipes, cotter pin, etc. of reputed make as approved by EIC/Site-Engineer.

PIPE (ASTM A 106 Gr. B): Supply of pipes of following sizes for tank level gauge sytem:

1" Nominal pipe size x Sch 80

2" Nominal pipe size x Sch 80

3" Nominal pipe size x Sch 80

6" Nominal pipe size x Sch 80

8" Nominal pipe size x Sch 80

20" Nominal pipe size x Sch 80

SWMG (Spiral Wound Metallic Gasket) (As per ASME B 16.20 - Latestedition): Suitable for raised flanges of bores as per ASME B 16.5 for flanges of the following sizes:

SERVICE ITEMS

Opening of roof manholes

Dismantling, transportation and storing of primary and secondary seal along with weather sheet plates and related material in the owner's store yard or location designated by EIC.

Barricading for height upto 10 m around the tank by GI corrugated sheet and supported by structural steel for carrying out hot work in the tank location.

Installation of temporary flame proof eductor in shell manholes and roof manholes (dia 30 inch) and operating it for ventilation and gas freeing of the tank as per the directions of EIC.

Blinding for isolating the tank and de-blinding after the completion of M&I works of tank inlet/ outlet/surge line. Scope of work includes blinding the inlet/outlet/surge (6", 6", 12" dia.) line with contractor supplied BLRF, gaskets, etc. along with the retrieval of residual product between tank body valve and flange joint. After the completion of M&I works, the inlet/outlet header line is to be connected to the tank (part of Boxing up of the tank under separate SOR item) as per the directions of EIC.

Desludging- Measurement of sludge quantity in line with tender specifications and instructions of EIC. Removal of sludge admixed with water as per technical specifications and instructions of EIC / Site Engineer. Cleaning of tank / sludge disposal through a combination of mechanical / manual processes including making necessary arrangements using contractor supplied flame proof pump and associated piping system. Taking all safety precautions and degasification of the tank to make it 100 % gas free including supply of all equipments, manpower, tools, tackles, consumables, non-consumables, PPEs, fire and safety appliances, breathing apparatus etc., to complete the job in all respects as per the direction of EIC/ Site Engineer and tender specifications. Calibrated explosive meter should be brought by the contractor to continuously monitor the LEL & oxygen level inside the tank. Double earthing of all the equipments like pump, sludge tank, exhaust/ eductor fan, truck mounted tank etc. shall be done. The work shall entail the complete evacuation of sludge & water mix present in the tank and making arrangement for its storage by supplying properly sized closed container as per the instructions of EIC/site engineer. The evacuated sludge may be thereafter transported to another location for processing (separate SOR item for sludge transportation).

Thorough scraping of the inside of the tank including tank bottom, roof leg supports and shell internals and appurtenances etc. alongwith the supply of tools, tackles, labor, etc., to complete the work in all respects and make the tank safe to carry out hot works as per direction of site engineer/EIC.

Thorough scraping of the inside of the tank lower deck, alongwith the supply of tools, tackles, labor, etc., to complete the work in all respects and make the tank safe to carry out hot works as per direction of site engineer/EIC.

Transportation of evacuated sludge admixed with water retrieved from the tank and placed in properly sized container through truck or other transportation means and its disposal for further processing to a distance upto 150 km from tank location as per the directions of EIC/site engineer. All the arrangements for sludge transportation viz. vehicle, container, manpower, etc. to be provided by the contractor. (approx sludge admixed with water- 40kL)

Dismantling of existing fire water riser, sprinkler ring, foam line above ground level by opening flange joints / U clamps etc, bringing it to ground level and transportation to owner's store yard. Re-installation of the same piping & fittings after the completion of tank maintenance works. The job includes retrieval of old pipes and fittings, shifting to the designated location within the station premises, and reinstallation of the same after the completion of shell and wind girder repair job. The item including supply of all materials labours, consumables etc. necessary to perform the job and complete the job in all respects as per the drawings, specifications and direction of the EIC/ Site Engineer. Approx length of pipes to be dismantled & re-installed : 3" line= 40 m, 2.5" line =40m, 1" line =65m (Supply of SWMG is covered under separate SOR item)

Testing of weld joints: Cleaning & buffing of weld joints for testing of the newly fabricated joints on the tank top/ bottom deck surface by oil-chalk test/ DP test/ vacuum box test by soap solution under 3PSI vacuum for leak proofness, including supply of all manpower,tools, tackles, equipments, consumables etc. to complete the work as per API 650 and instructions of EIC/ Site Engineer.

Oil Chalk Test

Dye pentrant Test

Vacuum Box test

Erection of double steel scaffolding for working and painting at heights in line with all safety guidelines indicated in tender and instructions of Engineer-in-Charge/Site-Engineer. Supply of all tools, tackles, materials, consumables, labours and erection works shall be in the scope of contractor.

Scanning and inspection of the surface of bottom plates by floor scanners based on Low Frequency Electromagnetic Technique (LFET) and submission of detailed report of bottom plates as per the instructions of Engineer-in-Charge.

Calibration of the tank by Survey method including all liaison work with the competent authority for approving the calibration charts, preparation of the charts and payment of fees to the competent authority for approval and submission of the charts in hard copy as well as soft copy.

Submission of 3 sets of approved as built dimensional drawings as per the repair and maintenance carried out in the tank and detailed earth pit drawing along with reports of repair and maintenance as per the directions of EIC. Contractor shall submit 2 hardcopies and 2 softcopies of all drawings and reports within 15 days of the completion of M&I work.

Providing at least 20 TON capacity mobile crane service to ensure stability of the double deck floating tank roof during gas cutting operation of the portion of the roof stuck with gauge well pipe. (maximum weight of the floating roof is 15 Ton including all the components & rolling ladder). The item includes the subsequent lowering of tank roof & locking of leg supports. (distance from road to tank center is 16m, width of road is 6m, tank dia. is 12m). The tank roof can be lowered on leg supports after cutting 20 SQM of the tank outer rim area)

COMPOSITE ITEMS

Partial dismantling of damaged portion of existing platform structure provided for tank gauging, spiral staircase, rolling ladder, resting platforms, landing platforms, hand railings, foam dam supports, pipe supports and supports, curb angle, foam extension plates etc. After partial dismantling of these damaged structures, the contractor shall fabricate and erect new platform/parts of stairway/parts of rolling ladder structures as per the directions of EIC/Site-engineer. The item includes the supply of labour, equipment, consumable, tools and tackles etc to complete the job as per directions of Site Engineer / EIC. (Supply of structural steel for this work is covered under separate SOR item)

Retrieval of electronic level gauge system including asociated cables etc. and dismantling of existing dip hatch piping system for tank of height 9 m (system consists of one 8" dia pipe & one 20" dia pipe enclosing 1 nos each of 1", 2", 3" dia pipe & 2 nos. of 6" pipe). Fabrication & erection of new dip hatch system including supply & installation as per requirement/ design, inclusive of the supply of 25mmthick neoprene rubber sheet, guide rollers, brass roller with brackets,neoprene rubber 20mm thick (1mx1m), CAF gasket 3mm thick, nut bolts,etc., as per design/ drawing & specifications and inclusive of all tools & tackles, consumables, labours etc. to complete the work as per design/technical specifications and as per the direction of EIC/ Site Engineer. The scope of work also includes installation of the earlier retrieved electronic level gauge system with associated cables in the newly constructed piping system as per the directions of EIC/Site-engineer. (1. supply of pipes for gauging, 2. dismantling, fabrication & erection of gauging platform under separate SOR items)

Dismantling, retrieval & re-erection of Aluminium dome already installed in the tank ( tank dia-12m). The scope of work includes dismantling of the already existing Aluminium dome and retrieval of the structural components (structural frame and roof panels) of the dome and its transportation to the owner's stock yard as per the instructions of EIC. After the completion of M&I works of the tank, the Aluminium dome shall be re-erected for the tank with the earlier retrieved structural components(structural frame and roof panels) of the dome. The vender shall furnish all labor, materials and equipment required for successful erection of aluminium dome structure. As the sealant, gasket material, bolts, fasteners, etc are likely to get damaged during the dismantling operation, the work entails the supply of sealant, gasket material, bolts, fasteners, etc by the contractor as per API 650 Appendix-G for "Structurally-Supported Aluminum Dome Roof". All aspects of the work shall meet the minimum requirements of API 650 Appendix-G and as additionally specified in the technical specification for Aluminium dome. Supply of all materials, consumables, labor, equipment, machinery, crane for erection, tools and tackles, to complete the work in all respects as per specifications, standards, codes, and instructions from Engineer-In-Charge shall be in the scope of the contractor. If any of the structural components (structural frame and roof panels) of the dome is damaged during the dismantling operation, the same are to be provided at the risk and expense of the contractor.

Strengthening of tank bottom & roof weld joints, annular plate, sketch plates, shell to bottom plate joint, primary wind girder, secondary wind girder joints by depositing additional weld beads (one run with 4 mm AWS 7018) wherever required to restore the joints to the required fillet size of 8 mm including supply of all labour, equipments, consumables, etc., required to complete the job in all respects as per the instructions of Site Engineer / EIC.

Dismantling of buckled/damaged portion of existing shell plates & shell appurtenances in approx. 40% shell area. Thereafter, erection of owner supplied shell plates (6 mm thickness for first shell course & 5 mm thickness for 2nd to 6th shell course) including bending as per the tank curvature, edge preparation, hoisting, fitment, welding of shell plate by E-7018 electrodes, stress relieving treatment (PWHT) of welded portion, complete radiography testing of the welded portion, carrying out dye penetrant test etc as per instruction of EIC . (Around 40% of the total shell area shall be replaced. Fabrication of shell appurtenances like stairway, primary wind girder, secondary wind girder, gauging platform,manholes, etc. is covered in separate SOR item)

Dismantling of Roof & other related appurtenances: (A) Dismantling of the roof plates by gas cutting/gouging only along with dismantling of breather valves, roof legs, ladder track assemblyetc. as per instructions of EIC/ Site Engineer including the supply of all tools, tackles, equipments, labours etc. to complete the works in all respects. After dismantling the ladder track, the rolling ladder shall either be supported with shell by fabrication, erection & weldingof suitable temporary supports or shall be dismantled as per the instructions of EIC/ Site Engineer. The Dip hatch shall be supported by shell by installing/ fabricating temporary supports. (B) Use ofoxy-acetylene gas cutter with NRVs at both ends for gouging/ cutting.The plates and other items should be cut/ dismantled in a suitablemanner for easy handling & transportation. (C) Transportation of all the materials to Owner's storeyard or location as designated by EIC withinthe station premises and proper stacking of all the materials as perinstructions of EIC/ Site Engineer.

Gouging (from primary & secondary wind girder/ shell weld location and cutting of old wind girder plates of wind girder and both sides of wind girder support, toe-board, dismantling the wind girder completely or partially as per the requirement, taking delivery of owner supplied plates (5-6 mm thick plates) from the owner's stockyard to the work site, fabrication, making perforations, erection at existing position including modification required for sloping outwards, testing of weld joints, supply of equipments, labours, tools, tackles, consumables, non-consumables etc., to complete the work in all respects as per directions of EIC/ Site Engineer and tender specifications. Testing of weld joints is to be done by vacuum box/ oil chalk/DP test (covered in separate SOR item) as per site conditions and instructions of EIC/ Site Engineer. The payment shall be made on the basis of actual quantity of plates erected for repair/ replacement.

Fabrication of Double Deck Floating Roof(DDFR): (A) Design & Engineering of Double Deck Floating Roof having 5mmupper deck plates and 6mm lower deck plates indicating all roof appurtenances likes pontoons, manholes, roof legs, seals, rolling laddertrack, other roof appurtenances and related/ required items as per API 650 & API 653 standard (latest edition). (B) Taking delivery and transportation of owner supplied 5mm & 6mm plates from owner'sstoreyard to the work site; cutting, fabrication, erection,straightening of new plates by jacking or other means, welding of new5mm & 6mm plates with 3.15mm AWS 6013 electrodes including rolling,bending, cutting, drilling etc. as per API 650 standard for double deckfloating roof fabrication. This also includes fabrication, erection and welding of pontoons, manholes, bleeder vents, emergency drain, roof leg supports, roof legs, rim vent, ladder track, roof drain sump, foam dam,all covers of pontoons, manholes & sumps. The rolling ladder supported with shell by temporary supports shall be installed back to its original position on the track after proper dismantling of thesupports or if dismantled, the rolling ladder shall be assembled back and installed. This item also includes the supply all the required materials and consumables required for completion of this work.

Fire water line, foam line, and sprinkler ring surface preparation : Surface preparation using hand tool cleaning including removal of oil, grease and other contaminants by solvent cleaning followed by removal of defective paint, loose millscale, loose rust, loose paint, weld flux, slag from the metallic surfaces, by hand chipping, hand brushing, hand scrappers / chisels,steel wools, final cleaning with high pressure ( 10000 PSI ) low TDS fresh soft water jet cleaning and drying with compressed air as per thespecifications and directions of Site Engineer. Prepared surface shall conform to WJ-4 /ST-2as per NACE no.5/SSPC SP-12 standards.

Fire water line, foam line, and sprinkler ring painting: Supply application of High build, self priming, rust encapsulating polyamido amine cured epoxy mastic coating (80%min.solid by vol.) with 100 microns DFT (min) by sprayapplication.Second Coat: One coat of Epoxy MIO (80% min. solid by vol.)with 100 microns DFT (min) by spray application Third and FourthCoat: Recoatable acrylic isocyanate aliphatic Polyurethane coat (50%min. solid by vol.) with each coat 50 microns DFT (min) by sprayapplication (Gloss retention minimum 80 % under 1000 hours of QUV lamp).Colour of paint shall be aluminium for tank shell and apputenances. The scope of work includes supply and application of paints, supply of all equipments, tools & tackles, labour etc as per tender specifications anddirections / instructions of Site Engineer/ E-I-C. Stripe coat to beapplied on all weld joints/ projections before application of above painting. (Color code: Yellow for foam line- approx 30 sqm area. Red for fire water line & sprinkler ring-approx. 50 sqm area)

Surface preparation by dry abrasive blasting (conforming to SA 2 1/2 surface finish- sand is not allowed as abrasive). The blasted surface shall have surface profile of 50-70 microns. Supply of all equipments, tools & tackles, consumables, labour, etc. to complete the work to all respects shall be in scope of contractor. Area of work: Tank bottom, Roof- foam dam and foam dam area, roof appurtenances, rolling ladder, track, etc, , inside shell, outside shell, roof drain pipe, water draw off pipes, staircase, primary, secondary wind girders, cooling ring supports, and other structures attached to shell, roof, bottom plate as per requirement and as directed by EIC/Site-Engineer.

Application with one coat of High Build epoxy Zn Phosphate DFT 75 Microns, Supply of all consumables, tools, tackles, equipment and labour shall be in the scope of contractor. Area of work: all newly fabricated top deck plates(bottom side), inside compartment plates and structural steel members of pontoon boxes, and as identified by site engineer etc as per instructions of Engineer-in-Charge/Site-Engineer. Surface preparation for the area is covered in a separate item of the SOR.

Tank shell & tank roof surface preparation : Surface preparation using hand tool cleaning including removal of oil, grease and other contaminants by solvent cleaning followed by removal of defective paint, loose millscale, loose rust, loose paint, weld flux, slag from the metallic surfaces, by hand chipping, hand brushing, hand scrappers / chisels,steel wools, final cleaning with high pressure ( 10000 PSI ) low TDS fresh soft water jet cleaning and drying with compressed air as per thespecifications and directions of Site Engineer. Prepared surface shall conform to WJ-4 /ST-2as per NACE no.5/SSPC SP-12 standards. (This item is to be executed for the shell & roof area which is not being dismantled)

Tank roof & external shell painting: Supply application of High build, self priming, rust encapsulating polyamido amine cured epoxy mastic coating (80%min.solid by vol.) with 100 microns DFT (min) by sprayapplication.Second Coat: One coat of Epoxy MIO (80% min. solid by vol.)with 100 microns DFT (min) by spray application Third and FourthCoat: Recoatable acrylic isocyanate aliphatic Polyurethane coat (50%min. solid by vol.) with each coat 50 microns DFT (min) by sprayapplication (Gloss retention minimum 80 % under 1000 hours of QUV lamp).Colour of paint shall be aluminium for tank shell and apputenances. The scope of work includes supply and application of paints, supply of all equipments, tools & tackles, labour etc as per tender specifications anddirections / instructions of Site Engineer/ E-I-C. Stripe coat to beapplied on all weld joints/ projections before application of above painting. (The area includes external shell, primary & secondary wind girders, shell appurtenances, floating roof, roof appurtenances, foam dam area, supports, etc.

Supply and application of one coat of high build epoxy zinc phosphate primer to a DFT of minimum 75 microns followed by two coats of high build solvent free epoxy phenolic paint to a DFT of minimum 200microns per coat or single coat of 400 microns by Airless spray, by brush for stripe coat, carrying out MIBK test, holiday test to detect any pinholes , The total DFT shall be minimum 475 microns, inclusive of labour, tools & tackles to complete the work in all respects as per specification and instructions of the site engineer / EIC. (area of painting-tank bottom & tank internals)

Surface preaparation of stairway, gauging platform, rolling ladder: Surface preparation using hand tool cleaning including removal of oil, grease and other contaminants by solvent cleaning followed by removal of defective paint, loose millscale, loose rust, loose paint, weld flux, slag from the metallic surfaces, by hand chipping, hand brushing, hand scrappers / chisels,steel wools, final cleaning with high pressure ( 10000 PSI ) low TDS fresh soft water jet cleaning and drying with compressed air as per thespecifications and directions of Site Engineer. Prepared surface shall conform to WJ-4 /ST-2as per NACE no.5/SSPC SP-12 standards. [Area- straiways, roof rolling ladder, ladder track, railing on primary wind girder, etc] (tank dia-12m, height 9m)

Painting of stairway, gauging platform, rolling ladder: Painting with One coat of epoxy zinc phosphate primer (60%volume solid) to a dry film thickness of minimum 50 microns, two coats of high build coal tar epoxy with minimum 50 microns DFT each by supply of all equipments, tools and tackles, labour etc as per specifications of manufacturer and direction of EIC. including necessary labours, tools, as per directionof EIC. [Area- straiways, roof rolling ladder, ladder track, railing on primary wind girder, etc] (tank dia-12m, height 9m)

Supply & Installation of Neoprene seal (2.5mm thick X 1250mm width X255000mm length) along with octagonal PU Block (018 Grade, 300 x 300 x2000, with 18Kg/Cu.M density confirming to ASTM 1564), including thesupply of stainless steel fastners, etc. as per attached drawing &specifications; labours, tools & tackles completing the work in allrespects as per direction of EIC/ Site Engineer.

Supply and installation of secondary seal (continuous membrane),including of supply of SS fastners, SS weather plates, Al-channels etc.,labours, tools & tackles completing the work in all respects as pedirections of EIC/ Site Engineer. (Refer SCC for material specifications, approx. peripheral length of rim seal is 113 m). The item also includes required modifications, such as fixing of channels/ anglesetc., for installation of secondary seal.

Boxing up of the tank including supply and fitment of gaskets (as per API 601) between all flange connections, tightening as per direction of site engineer/EIC. Fitment of nuts/studs/bolts of all roof and shell manholes, water drain, Inlet / Outlet nozzles, all body & manifold valves, sprinkler line, foamline etc. as per the instructions of EIC.

Making temporary arrangements by supplying pipe, flange joints, nuts/bolts, gaskets, NRV etc. for water filling in tank, complete hydrotesting upto maximum level for tank height of 9 m, attending leakages through flange joints if any, adjustment of floating roof supports to operational height, draining out of water after hydrotesting etc. as per direction of site engineer (Supply of water & associated corrosion inhibitor shall be in the scope of the contractor & details regarding mixing ratio & approved brands shall be duly taken from the EIC)

Painting of tank number & other identifications on the tank shell: Painting of tank number, capacity, service, shell nozzles, numbering of foam pourer, spray nozzle designation, earthing nos., owner's name (Indian Oil) with 3 monograms painted on the tank shell at 120 degrees to each other, asper instructions of EIC/ Site Engineer.

SKI ENGINEERING