PWRJT20012/ Maintenance and Inspection of crude oil storage tank VT 02 at WRPL Viramgam.

SUPPLY ITEMS:

Supply & delivery of following materials along with required testing/ inspection as per applicable standards & technicial specifications indicated in the tender documents and submission of testing/ inspection documents to EIC for acceptance.

Pipes: seamless carbon steel Gr. B hot finished pipe as per ASTM A 106

NPS 1 [DN 25] Sch 80 [wall thk 4.55mm]

NPS 3 [DN 80] Sch 80 [wall thk 7.62mm]

NPS 6 [DN 150] Sch 80 [wall thk 10.97mm]

NPS 8 [DN 200] Sch 80[wall thk 12.70mm]

Valves

NPS 1 gate valve 150# (API 602)

NPS 1 check valve 150# (API 602)

NPS 1 Ball valves 150# (ISO 17292).

NPS 3 150# Ball valves

NPS 6 150# SS-316 Butterfly valve

NPS 6 dia 150# Dual Plate Check Valve

NPS 6 dia 150# F/F CS Gate valves as per API 600

NPS 8 dia ANSI 150# F/F CS Gate valves as per API 600

Pipe fittingsConforming ASTM A 105 / A 352 Gr. LF2 / A 216 Gr. WCB / A 234 WPB and dimensions as per ASME B16.9 / ASME B16.5

FLANGE WNRF, NPS 1, Class 150

FLANGE WNRF,NPS 3, Class 150

FLANGE WNRF,NPS 6, Class 150

FLANGE WNRF,NPS 8, Class 150

ELBOW, 45 DEG, NPS 3 Schedule 80

ELBOW, 45 DEG, NPS 6 Schedule 80

ELBOW, 90 DEG, NPS 3 Schedule 80

ELBOW, 90 DEG, NPS 6 Schedule 80

ELBOW, 90 DEG, NPS 8 Schedule 80

Concentric reducer, 8" x 6", Sch 80, 150#

Concentric reducer, 6" x 3", Sch 80, 150#

Concentric reducer, 3" x 2", Sch 80, 150#

TEE, Straight, NPS 3, Sch 80

TEE, Straight, NPS 6, Sch 80

TEE, Straight, NPS 8, Sch 80

Spiral Wound Metallic Gaskets (SWMG)-NPS 24

ASBESTOS FREE(AF) FIBRE JOINTING SHEETS - AF159-Oil/ AF110-water and their equivalents as per intended application

Steel Fasteners (Studs / bolts conforming ASTM A 193 B7 with two nuts conforming ASTM A 194 Gr. 2H, both heavy hex pattern along with two round washer)

3/4" dia x 4" long (8"-150#)

3/4" dia x 3.75" long (6"-150#)

5/8" dia x 3.5" long (3"-150 #)

1/2" dia x 2.5" long (1"-150 #)

1" UNC x 8" long to suit 24" shell manholes

1.25" Diameter X 10" long to suit 30" nozzle

1.5" Diameter X 11.75" long to suit stirrers and inet nozzle

M25 x 6" long to suit clean out doors

Other components of piping

8" Y-type CS strainers suitable for fire-water service. For Firewater line

Foam maker - Seamless SS 316L (Capacity 200 LPM)

Male instantaneous coupling conforming to IS:903 threaded with Non Return Valve suitable for foam pourer inlet connection (Size 63mm). Material of coupling, spring & nut shall be SS 316. Male coupling fitted with SS 316 flange.

1" 3000LB half coupling for fixing drain valve of foam line & Fire water line

Sprinkler nozles 1/2" SS 316L with K factor as approved by EIC

1/2" 3000 LB half coupling for fixing sprinkler nozzle

Miscellaneous

Flexible Joint / Flexible hose type Roof Drains (6" diameter) as per contract specification

Supply of primary seal system as per contract specification

Supply of secondary seal system as per contract specification

Supply of Galvanised Iron strips of 40 mm x 5 mm for earth pit to pit connection as per contract specification

Galvanic anodes for Cathodic Protection (CP) of Tank Bottom (product side):- Supply of Aluminium-Indium-Zinc Alloy Sacrificial Anodes as per contract specifications. All the material testing/ inspection as per tender specifications, applicable standard & material requirement shall be in scope of contractor and all the test/ inspection reports shall be submitted along with the supply of item.

Water for Hydrotesting: - Arrangement of potable water for hydro-test of tank under M&I and transporting the same to fire water pond or directly to tank under M&I as directed by EIC/ Site Engineer including supply of material, consumables, manpower, tools, tackles etc. complete on round the clock basis through tankers etc. as per the advice of EIC/ Site Engineer. Water shall be timely arranged by the contractor before the start of hydrotesting of tank to avoid any delay in hydrotesting & thereafter commissioning of tank.

COMPOSITE WORKS:

Dismantling works (steel plates / pipes / structural shapes)

Dismantling of steel plates and structural shapes (All sizes / all thicknesses / all heights): Dismantling of old plates including attachments, support structures / clamps etc by gas cutting / deseaming / unbolting etc, transportation to Owners yard and proper stacking. The scope shall include steel plates of all aizes and thicknesses installed on roof, bottom and shell at all heights.

Dismantling works (NPS - All sizes / all thickness / all heights) : Dismantling of old piping including valves, fittings, support structures / clamps etc by gas cutting / deseaming / unbolting etc, transportation to Owners yard and proper stacking. The scope shall include piping of all sizes upto schedule 80 installed at all heights. [Note: The unit of measurement shall be Inch-Meter]

Repair / Replacement / alteration – Tank bottom / shell

Repair by weld-on-patch on tank bottom: The scope of repair shall include but not limited to taking delivery of plates 5mm / 6mm / 8mm from Owners stock yard, transporting to site, cutting/ fabricating to required size, fitment, welding and NDE including supply of tools, tackles, consumables and other requisite resources. Repair scope includes weld on patches on bottom. NDE covered in separate SOR item

Weld on Patch repair on shell and wind girders:- The scope of contractor shall include taking delivery of new 8/10mm plates from Owners stock yard, transporting to site, cutting and bending to required dimensions of patch, fitment, welding and NDE including supply of tools, tackles, consumables and other requisite resources NDE covered in separate SOR item.

Fabrication and erection of annular plates : The scope shall include but not limited taking delivery of 14/16 mm owner supplied plates from owner's store & shifting them to tank, fabrication, fitment by lifting the shell along with structural, welding, testing of lap/ butt welds by soap solutions under 3 to 5 PSI vacuum for leak proofness, DP test of root & capping of radial butt weld joints in presence of site engineer, Oil-Chalk Test of shell to annular joint, including supply of labours, equipments, tools, tackles, supervision and other requisite resources to complete the work as per the technical specifications and instructions of EIC/ Site Engineer.

Fabrication and erection of bottom, primary and secondary wind girder plates :-The scope of replacement shall include but not limited to taking delivery of new 5mm/6mm/8mm/10mm plates from Owners stock yard, transporting to site, cutting/ fabricating to required size, jacking, stiffening, straightening, fitment, welding of plates including roof appurtenances and NDE (Non Destructive Examination) including supply of tools, tackles, consumables and other requisite resources. The payment shall be made on the basis of actual quantity of plates erected for roof repair/ replacement. NDE covered in separate SOR item

Supplying and filling coarse sand prior to bitumen carpeting including cost-of sand, royalty, transportation, loading , unloading, spreading in layers not exceeding 20 cm., watering, ramming, compacting, dressing and levelling etc. complete in all respects inclusive of cost of all labour, materials, tools, tackles etc. as per drawings, specifications and direction of Site Engineer.

Bituminous Carpet Rectification : Supply, laying as per profile and compaction of 50mm thk bituminous carpet (Premix bitumen layer consisting 80/ 100 grade black bitumen, coarse river sand and stone gravels in the ratio of 8:25:67) under Tank Bottom/ Annular Plates including removal & disposal of damaged bitumen padding. This shall include supervision, manpower, machinery, tools, tackles, consumables, non-consumables, equipments and other requisite resources.

Water draw-off sumps fabrication:- Taking delivery of owner supplied 10 mm/ 14 mm plates, rolling, fabrication of water draw off sump (1.5m dia. & 0.95m Ht.), carrying out oil chalk test of weld joints, dismantling of existing sump, fixing of new sump, compaction ramming of foundation including supply of equipments, consumables, labours, tools & tackles etc. to complete work in all respects as per direction of EIC/ Site Engineer.

Weld joint strengthening of tank bottom/ Shell/ Annular lap/ butt joints:- Strengthening of tank bottom/ shell/ annular lap/ butt/ fillet joints by depositing additional weld beads (with 3.15mm AWS 5.1 E7018) wherever required to restore the joints (butt / fillet) including supply of all equipments, consumables, labours, tools, tackles etc. required to complete the work in all respects as per the specifications and directions of the EIC/ Site Engineer. Testing of weld joints is to be done by vacuum box/ oil chalk/ DP test (covered in separate SOR items) as per site conditions and instructions of EIC/ Site Engineer.

Repair and alteration – Tank Roof (Section-3 of technical specification)

Design & Engineering of Double Deck Floating Roof having 5mm upper deck plates and 6mm lower deck plates indicating all roof appurtenances likes pontoons, manholes, roof legs, seals, rolling ladder track, other roof appurtenances and related/ required items as per API 650 standard (latest edition). Review & approval of detailed drawing & design from reputed consultant like EIL or as approved by EIC and submission of approved drawing to IOCL for final review and acceptance.

Double Deck Roof installation: Fabrication, asembling, erection and testing of new Double Deck Floating Roof (DDFR) including all appurtenances, attachments, penetrations, modification and re-installation of rolling ladder and track as per approved design. : Taking delivery and transportation of 5mm / 6mm /8mm / 10mm / 12mm plates from owner's storeyard to the work site; cutting, fabrication, erection, straightening of new plates by jacking or other means, welding of plates with AWS 5.1 /5.5 E-6013 / E7018 electrodes including rolling, bending, cutting, drilling etc. as per API 650 standard for double deck floating roof fabrication. This also includes fabrication, erection and welding of pontoons, manholes, auto bleeder vents, emergency drain, roof leg sleeves, roof legs, rim vents, roof drain sump, foam dam, all covers of pontoons, manholes & sumps, supply & installation of 06 (six) nos. of breather valves including flame arrestors and leg seals. This item also includes the supply all the required materials and consumables required for completion of this work. (C) Testing of lap weld joints with soap solution under 21 KPa or 3 PSI with vacuum (vacuum box test) as per latest edition of API-650, for leak proofness including supply of all equipments, tools, tackles, materials, consumables, labours etc. required for execution of the work, complete in all respects as per specifications, drawings & instructions of the EIC/ Site Engineer. (D) Roof floatation upto maintenance leg height by air/ water including supply of air/ water by the contractor (contractor shall arrange diesel engine/ electric motor driven water pumps where cost of diesel/electricity shall be borne by the contractor) along with necessary tools, tackles, equipments, consumables, labours etc. to complete the work in all respects as per instructions of the EIC/ Site Engineer. Note : Only plates shall be supplied by Owner. Rest all materials (viz pipes for roof legs / sleeves /bleeder vents/ breather valve, flanges and fittings for breather valve piping, breather valves, structural shapes, flanges, leg seals for emmision control, water for hydrotest, consumables etc to complete roof installation works shall be supplied by Contractor and the rate is inclusive of all these materials, water and consumables. Modification and re-installation of dip-hatch is covered under separate SOR item

Shell : Penetrations/ Modification /replacement:

Shell plates's replacement:- The scope of contractor shall include cutting or de-seaming corroded plates of shell, removal and transporting to Owner scrap yard, taking delivery of owner supplied plates from owners stockyard, transportation to work site, bending to required curvature, cutting fabricating to required dimensions, edge preparation, fitment, welding and NDE including supply of tools, tackles, consumables and other requisite resources. NDE covered in separate SOR item.

Installation of new nozzle: The scope shall include but not limited to cutting a hole on shell 1st course, fabrication of 6” nozzle similar to existing design, installation, providing reinforcement plate at shell penetration joint, welding, carrying out post weld heat treatment including supply of manpower, tools, equipment, machinery, consumables and any other resources

Blinding old nozzle: Scope of work to include but not necessarily limited to blinding of existing 8” diameter nozzles including supply of manpower, tools, equipment, machinery, consumables and any other resources

Piping works: Scope of work to include but not necessarily limited to transporation and proper stacking at Owners yard, taking delivery of Owner supplied materials (if any) from Owners yard, transporting to work site, fabrication, asembling, testing and installation of new piping including supervision, manpower, equipment, machinery, transportation, tools, tackles, consumables and any other resources:

Erection of roof drain system: Assembly, installation and hydrostatic testing of new roof drain piping system (comprising pipes, fittings, valves, flexible joint type roof drain, gaskets and fasteners) including supervision, manpower, machinery, tools, tackles, consumables and other requisite resources. Test pressure shall be as recommended by the manufacturer [Note: supply of pipes, roof drain, valves, fittings etc under separate SOR item. Fabrication of pipe spools for roof drain system shall be paid under separate SOR item. This item is only for erection of roof drain system i.e. from roof sump to inside shell nozzle]

Fabrication works (NPS - All sizes; carbon steel) : Design (if required) and fabrication of piping including fittings etc. The scope shall include piping of all sizes upto schedule 80 and installed at all heights [Note: The unit of measurement shall be Inch-Dia. Supply of pipes and fittings covered under separate SOR]

Erection (NPS - All sizes; all heights; carbon steel/stainless steel) : Assembling, hydrotesting and installation of piping systems (comprising pipe, fittings, valves, gaskets, fasteners etc) and support structures. The scope shall include piping of all sizes upto schedule 80 and installed at all heights. [Note: The unit of measurement shall be Inch-Meter]

Fabrication works (NPS - All sizes; stainless steel) : Design (if required) and fabrication of piping including fittings etc of sprinkler and foam lines of all sizes upto schedule 80 and installed at all elevations [Note: The unit of measurement shall be Inch-Dia. Supply of pipes and fittings shall be in Owners scope]

Foam Guard Plates:- The scope of repair and / or replacement of foam pourer system shall include but not necessarily limited to dismantling by cutting / de-seaming of existing foam pourer system (piping, foam guard etc), shifting to Owners’ scrap yard, fabrication and installation of new foam pourer system as per drawing / existing design including supply of manpower, tools, equipment, machinery, consumables and other resources as may be required to complete the work with all safety precautions.

Funnels for Water Draw Off/ Roof drain:- Dismantling existing funnels of Water Draw Off/ Roof drain, taking delivery of owner supplied 8mm/ 10mm steel plates from owner’s store yard, transporting steel plates from owner's store yard to the work site, fabrication of new funnel for water draw off lines by rolling, fitment, cutting, welding etc. and Installation of new funnel including all required equipments, manpower, tools, tackles, consumables, non-consumables to complete work in all respects.

Structural Works:

Structural Works (shapes/sections/bars ):- The scope of structural steel work shall include supply, fabrication and erection of shapes/sections/bars of roof, staircases, rolling ladder, railings, curb angle, roof rim angle, support structures of wind girders / cooling rings / foam lines / foam dam / peripheral seals, clamps, handles etc including supply of manpower, equipments, consumables, tools & tackles etc. complete as per drawings / existing design .

Structural Works (Stairway and Rolling Ladder steps):- Supply of pre-fabricated GI (thickness of Zinc coating shall be minimum 100µm ) gratings and installation of the same, inclusive of welding, supply of manpower, equipments, consumables, non-consumables, tools, tackles etc. to complete the work in all respects as per tender specifications.

Stairways/wind girder/rolling ladder hand rails:- Supply of 40 mm nominal diameter heavy class pipes as per IS-1239 part-I (latest) for staiways, wind girder and sch. 80 pipe as per SA-106 GrB for rollig ladder. The pipes shall be galvanised as per IS-4736 (Zinc coating shall be minimum 400g/m2), fabrication, welding and erection of stairways/ hand rails including supply of all equipments, manpower, tools, tackles, consumables, non-consumables etc. to complete the job as per directions of EIC/ Site Engineer.

Submerged shunts : Design, supply, installtion and testing of submerged shunts made up of SS-316 as per API RP 545 and NFPA 780

Cable Tray for tank radar gauging:- Supply, installation & fixing of pre-fabricated ladder type GI cable trays of width 150 mm, 300 mm, 450 mm & 600 mm as per site requirement and with required fasteners & accessories for laying of cables with standard rung spacings. Load for support span of 2.5 meter as 30, 60, 75 & 90 (in Kg/m) respectively with concentric static load as 70 Kg at the centre, with materials, manpower, tools, tackles, consumables etc. as per directions of EIC/ Site Engineer.

Boxing up of the tank:- Boxing up of the tank including supply and fitment of all required gaskets, studs with two nuts and two washers of ASTM A 193 Gr.B7/194 2H, providing gaskets between flange connections, tightening as per direction of EIC/ Site Engineer. Supply and fitment of nuts/ studs/ bolts of all roof and shell manholes, clean out doors, roof drains, water drains, product drains, inlet & outlet nozzles, all body & manifold valves along with all necessary manpower, equipments, tools, tackles, consumables, non-consumables etc. shall be in scope of contractor. ( Note: Supply of nuts/studs/bolts / gaskets for cleanout doors and shell manholes is covered under seperate SOR items)

Hydrotesting of the tank:- Hydrotesting including making arrangement for filling water for hydrotest upto roof floatation height (2.5-3m) or shell height as approved by EIC, transportation of water from fire water pond/tank to tank under M&I by installing 2 nos. diesel engine/ electric motor driven water pumps [with a min. pumping capacity of min. 100 KL/hr, cost of diesel/electricity shall be borne by the contractor], holding the roof in floating condition for minimum 48 hours, inspecting all the joints, pontoon, manholes, ABP area, valves etc.; arrangement of all necessary equipments, pump(s) of sufficient capacity, laying of required pipings/ hoses, necessary connections, materials, consumables, non-consumables, manpower, tools, tackles etc. both for pumping the water into the tank and for emptying the water from the tank; attending leakages through flange joints/ any other joints, if any, adjustment of floating roof supports to operational height (separate SOR item), as per directions of EIC/ Site Engineer (Water shall be supplied by the contractor - separate SOR item). It shall be Contractor's responsibility for timely arrangement of water required for hydrotesting. After successful completion of hydrotesting, the water shall be drained out and shifted/ pumped to the fire water tank/ fire pond (using the above pump & piping) or to the OWS as per instructions of EIC/ Site Engineer.

Civil works

RCC Supports for the Sprinkler Line:- Providing and laying Reinforced Cement Concrete in foundation & column, as directed by EIC, including centering and shuttering where necessary and curing with water including supply of steel reinforcements, necessary labours, tools, tackles, consumables etc. to complete the work in all respect. (M200/ 1 : 1.5 : 3 - 1-Cement : 1.5-sand : 3-stone aggregate 20 mm nominal). (excluding cost of reinforcement)

PCC 1:3:6:- Providing and laying plain cement concrete of mix 1:3:6 for support of fire water piping system, repair of circumferential drain/ radial drain/ apron area, including centering and shuttering where necessary and curing with water complete including cost of materials, equipments, manpower, tools, tackles, consumables, non-consumables etc. to complete the work in all respects as per tender specifications and directions of EIC/ Site Engineer.

PCC 1:2:4:- Providing and laying plain cement concrete of mix 1:2:4 as directed for support of fire water piping system including, repair of circumferential drain/ radial drain/ apron area, centering and shuttering where necessary and curing with water complete including cost of materials, equipments, manpower, tools, tackles, consumables, non-consumables to complete the work as per tender specifications and directions of EIC/ Site Engineer

Restoration of the tank dyke wall, surface drains (radial/ circumferential), apron area etc. inclusive of supply of all required stones, bricks, sand, gravels, cement, manpower, tools, tackles, equipments, consumables, non-consumables etc. to complete the work in all respects as per directions of EIC/ Site Engineer.

Repair of dyke at fire line/ foam line crossing including necessary supply of all bricks, cements, gravels etc., manpower, tools, tackles, consumables, non-consumables etc. to complete work in all respects as per direction of EIC/ Site Engineer.

Tank Surface Preparation and Painting works: (refer Section-7 of technical specs)

Surface cleaning ST2 Roof deck internals and galvanised structures (Stairways, Rolling Ladder, Ladder Track, Gauging Platform) :- Surface preparation conforming to Swedish standard ST-2 (abrading by sandpaper). This item is inclusive of providing all required manpower, tools, tackles, consumables, non-consumables, equipments etc. to complete the work in all respects as per technical specifications and instructions of EIC/ Site Engineer.

Sweep blasting of tank internals (NACE No. 4):- Abrasive (Copper Slag blasting) blasting of the tank internals (bottom / shell / roof lower deck / leg supports etc) conforming to SSPC-SP 7/NACE No. 4. This item is inclusive of providing all required manpower, tools, tackles, consumables, non-consumables, equipments etc. to complete the work in all respects as per technical specifications and instructions of EIC/ Site Engineer.

Surface cleaning NACE No. 3 : Abrasive blast cleaning of plates and pipes conforming SA 2 standard. This item is inclusive of providing all required manpower, tools, tackles, consumables, non-consumables, equipments etc. to complete the work in all respects as per technical specifications and instructions of EIC/ Site Engineer.

Surface preparation NACE No. 2 (all structures plates / pipes / roof / shell / bottom/ attachments at all heights) :- Surface preparation using water washing (WJ4) with low TDS potable sweet water followed by copper slag blasting (conforming to SA 2.5 surface finish) and and profile of 40 to 70µm inclusive of all required water, abrasives, equipments, manpower, consumables, tools, tackles, consumables, non-consumables to complete the work in all respects as per specifications and instructions of the EIC/ Site Engineer. Note : For work at heights, separate SOR item exists for supply and fitting of double steel scaffoldings

Automated blast cleaning NACE No. 2- Tank Internals (Bottom / sketch /annular plates, sumps, nozzles, piping, shell up to 1.5m and other attachments) and Roof: Surface cleaning low TDS potable sweet water followed by blasting with iron Grit & steel shots using complete automated blast cleaning equipment inclusive of providing all required manpower, tools, tackles, consumables, non-consumables, equipments etc. to complete the work in all respects as per technical specifications and instructions of EIC/ Site Engineer. The prepared surface shall conform to SA 2.5 surface finish and profile of 40 to 70µm.

Primer application for Deck Internals:- Priming with Red Oxide Zn-phosphate primer 30-35microns per coat x 2 coats on internal portions of pontoon boxes, lower side of top deck, structurals in between the decks, structural supports of floating roof, including the supply of paints, equipments, tools & tackles, labours, consumables etc. to complete the work as per direction of EIC/ Site Engineer.

Supply and application of ONE coat @ 100µm of surface tolerant epoxy including the supply of paints, equipments, tools & tackles, labours, consumables etc. to complete the work as per direction of EIC/ Site Engineer.

Painting (Galvanised structures such as stairs, hand rails etc):- 1 coat x 50µm per coat of epoxy primer + 1coat x 100µm per coat of surface tolerant epoxy by brush / roller application followed by one coat of aliphatic polyurethane @ 50µm including supply and application of paints, strip coat on all weld joints projection and supply of all equipments, tools, tackles, manpower, consumables, non-consumables etc. as per specifications of paint manufacturer and directions of EIC/ Site Engineer.

Painting of roof upper deck with associated appurtenances, shell and wind girders :- One coat of inorganic zinc silicate primer to a dry film thickness of minimum 60-75Microns by airless spray application followed by intermediate coat (1 coat x 200µm per coat or 2 coats x 100µm per coat of Surface tolerant epoxy) and top coat (50µm DFT of Aliphatic polyurethane) by airless spray application, sealer coat on primed surface by airless spray, stripe coat of surface tolerant epoxy on all weld joints/ projections by brush including supply of all requisite resources (paints, equipments, tools, tackles, manpower, consumables, non-consumables etc.) to complete the work in all respects as per specifications and directions of the EIC/ Site Engineer. The total DFT shall be minimum 310 microns + sealer coat.

Primer only application - Tank Internals (Bottom / sketch /annular plates, sumps, nozzles, piping, shell up to 1.5m and other attachments) :- Final cleaning of prepared bottom surface by industrial vacuum cleaning, supply and application of 1 (one) coat of epoxy primer to a DFT of minimum 50 microns. The painting area also includes small patch plate assembly (for anode installation). The bolt stem to be covered with tape so that it does not get painted as it has to provide electrical connectivity between plate and anode. This item is inclusive of supply of all required resources ( paints, equipments, manpower, consumables, tools, tackles, consumables, non-consumables etc) to complete the work in all respects as per specifications and instructions of the EIC/ Site Engineer.

Finish coat of tank Internals (Bottom / sketch /annular plates, sumps, nozzles, piping, shell internal below roof lower deck and other attachments) :- After surface preparation and application of primer on entire tank internals, the primed surface shall be cleaned by industrial vacuum cleaner followed by supply and application of 2 (two) coats of solvent free epoxy to a DFT of minimum 200 microns per coat (grey and off-white shades for the 1st and 2nd coats respectively) or single coat of 400 microns (offwhite shade) by Airless spray, by brush for stripe coat, carrying out MIBK test, adhesion test, recording DFT, 100% holiday test to detect any pinholes etc. The painting area also includes small patch plate assembly (for anode installation). The bolt stem to be covered with tape so that it does not get painted as it has to provide electrical connectivity between plate and anode. The total DFT (including primer) shall be minimum 450µm. This item is inclusive of supply of all required paints, all equipments, manpower, consumables, tools, tackles, consumables, non-consumables to complete the work in all respects as per specifications and instructions of the EIC/ Site Engineer.

Radium sticker background:- Reflective radium sticker printing (background sticker) and apply including pasting and fixing with supply of all manpower, equipments, tools, tackles, consumables, non-consumables, scaffolding (separate SOR item) working at any height etc. as per instruction of EIC/ Site Engineer to complete work in all respects.

Radium sticker lettering:- Reflective radium sticker letter printing and apply in background stickering including pasting and fixing with supply of all manpower, equipments, tools, tackles, consumables, non-consumables, scaffolding (separate SOR item) working at any height etc. as per instruction of EIC/ Site Engineer to complete work in all respects.

Tank Bottom CP works:

Installation of Galvanic Cathodic Protection (CP) for Tank Bottom (product side):- Installation, Testing and Commissioning of Sacrificial Anodes Al-In-Zn Alloy including fasteners and Powercrete R-95 / Protal 7000 epoxy coating for carrying out the work of providing Cathodic Protection to Tank bottom plates as per terms and conditions of the Tender and instructions of EIC/ Site Engineer.

SERVICES:

Tank Inspection and Other Works:

Locking of roof (from operation legs to maintenance legs) including all required manpower, equipments, tools, tackles, as per the direction of EIC/ Site Engineer.

Locking of roof (from maintenance legs to operation legs) including all required manpower, equipments, tools, tackles, as per the direction of EIC/ Site Engineer.

Dismantling of secondary seal : Dismantling, transportation and storing of complete secondary seal assembly along with all its accessories in the owner's store yard or location as designated by EIC/ Site Engineer. This shall include all required tools, tackles, consumables, non-consumables, manpower and supervision etc. to complete the work in all respects.

Dismantling of primary seal : Dismantling, transportation and storing of complete primary seal assembly along with all its accessories in the owner's store yard or location as designated by EIC/ Site Engineer. This shall include all required tools, tackles, consumables, non-consumables, manpower and supervision etc. to complete the work in all respects.

Installation of Primary Seal: Installation of "liquid mounted" new PolyUrethane seal as per drawing / existing practise & specifications inclusive of tools, tackles, equipments, consumables, non-consumables, manpower and supervision for completing the work in all respects as per tender specification.

Installation of Secondary Seal:- Installation of secondary seal system with all related accessories etc. along with provision for insertion of nozzle of foam based rim seal fire protection system inclusive of necessary equipments, consumables, tools, tackles, manpower and supervision for completing the work in all respects as per tender specifications.

Residual crude oil transfer to other tank:- Installation of (steel/ flexible) piping (approx. 300 m), provision of suitable pump(s), installation, connecting and pumping of residual crude oil/ crude-water mix in the tank (approx. 5000 KLs) from all the water/ product draw offs to the nearest crude oil storage tank as per instructions of EIC/ Site Engineer along with required manpower, tools, tackles, equipments, consumables, non-consumables etc. to complete the work in all respects.

Opening all the shell & roof manholes (NPS 30 / 24) & flush-out doors as per instructions of EIC/ Site Engineer with all required manpower, tools, tackles, consumables, non-consumables, equipments etc. to complete the work in all respect.

Making of ramp at the flush-out doors to enable the placement of truck for loading of sludge and restoration after desludging as per instructions of EIC/ Site Engineer with necessary manpower, tools, tackles, consumables, non-consumables etc. to complete the work in all respects.

Arrangement & Installation of air driven flame proof eductor fan(s) for ventilation for gas freeing the tank, as per instructions of EIC/ Site Engineer along with all required tools, tackles, manpower, consumables, non-consumables etc. Suitable documents for the eductor fan indicating that the same is flame proof shall be submitted to the EIC for its approval prior to using it at the site. Double earthing of all the equipments like motors, eductor fan etc. shall be done. Degasification shall be done inline with API RP 2016.

Blinding of common inlet & outlet and its TRV: Blinding of flow lines including connected TRV lines (if any) as per directions of EIC/ Site Engineer and tender specifications along with all required manpower, tools, tackles, consumables, non-consumables, supervision etc. to complete the work in all respects.

De-Blinding of common inlet & outlet and its TRV: De-Blinding of flow lines including connected TRV lines (if any) as per directions of EIC/ Site Engineer and tender specifications along with all required manpower, tools, tackles, consumables, non-consumables, supervision etc. to complete the work in all respects.

Shifting of Sludge to Sludge lagoon: The scope shall include entry into tank, making manual / mechanical arrangement for collecting and shifting of sludge in trucks/trolleys placed at the clean out doors, transporting to sludge lagoon / pit located inside Owner’s installation including supervision, supply of all manpower, equipments, tools & tackles, PPE's, breathing apparatus, fire and safety appliances etc. to complete the job in all respects as per the direction of EIC/ Site Engineer and tender specifications. Explosive meter with calibration should be brought by the contractor to continuously monitor the LEL & oxygen level inside the tank. During transportation of sludge, the tractors should be covered properly to avoid any spillage of sludge oil mix inside the station.

Rim Seal Fire Protection System (Foam based) - Dismantling works:- Dismantling of automatic foam based rim seal fire protection system, impouline tubes, 1" dia SS piping, spray nozzles, cable trays cables, foam cylinders, junction box and all related accessories, shifting all the items to owner’s store yard or any other location in station premises designated by EIC and complete the works in all respect as per the directions of EIC/ Site Engineer inclusive of required manpower, tools, tackles, consumables, non-consumables etc.

Rim Seal Fire Protection System (Foam based) - Re-installation, Testing: & Commissioning - . After completion of M&I works, shifting & transporting of the dismantled system from owner’s store yard or the storage location in station premises designated by EIC to the designated tank and re-installation, Testing & Commissioning of the rim seal fire protection system including all required manpower, tools, tackles, consumables etc. to complete the works in all respects in line with the directions of EIC/ Site Engineer.

Tank bottom, shell internal & roof lower deck scraping:- Thorough scraping of the tank bottom, internal surface of shell upto 1.5 m from tank bottom, all pipings, roof supporting legs, water draw off sumps, lower surface of lower deck & other internals etc. as per direction of EIC/ Site Engineer including all required manpower, tools, tackles, consumables, non-consumables etc. to complete the work in all respects.

Dyke cutting:- Cutting of dykes to enable movement of truck to pick up sludge from tank for pumping the sludge and to enable movement of equipments, materials, etc. at site, inclusive of provision of piping for maintaining flow in storm water drain and cleaning, water flushing of all hume chambers inside the dyke area & its plugging, as per instructions of EIC/ Site Engineer with necessary manpower, tools, tackles, consumables, non-consumables etc. to complete the work in all respects.

Dismantling of cable tray for making approach inside tank dyke along with all required manpower, tools, tackles, consumables, non-consumables etc. to complete the work in all respects as per directions of EIC/ Site Engineer. The scope of work shall be inclusive of dismantling, transporation to owner's yard & stacking as per instruction of EIC/Site Engineer.

Installation of cable tray after dyke restoration (after M&I) along with all required manpower, tools, tackles, consumables, non-consumables etc. to complete the work in all respects as per directions of EIC/ Site Engineer.

Bottom & annular plate scanning:- Tank annular bottom plate scanning using the scanners based on MFL (Magnetic Flux Leakage)/ LFET (Low Frequency Electromagnetic Technique) technique inclusive all skilled/ unskilled manpower, tools, tackles, consumables and submission of detailed report of individual plates in hard copies as well as in soft copy with software (if any), the reports shall be approved by ASNT level-II inspector.

Shell scanning:- Tank surface scanning of secondary wind girder near weld areas covering 200mm width using the floor scanners based on Magnetic flux leakage (MFL)/ Low Frequency Electromagnetic Technique (LFET) inclusive of all skilled/ unskilled labours, tools, tackles, consumables and submission of detailed report of individual plates in six nos. of hard copies as well as in two nos. of soft copies with software(s) (if any) in DVDs, the reports shall be approved by ASNT level-II inspector.

Testing of weld joints:- Cleaning & buffing of weld joints for testing of the lap/ butt joints on the tank bottom/ top deck/ bottom deck surface/ shell patches/ shell replacement/ annular plate/ tank shell piping welds by Oil Chalk test/ Dye Penetration (DP) test/ Vacuum box test by soap solution under 21 Kpa/ 3PSI vacuum for leak-proofness, including supply of all manpower, tools, tackles, equipments, consumables, non-consumables etc. to complete the work as per API 650 latest edition and instructions of EIC/ Site Engineer.

Vacuum Box Test

Dye Penetration Test

Oil Chalk Test

Submission of Tank M&I Reports and Drawings:- Submission of tank M&I reports indicating as-built dimensional drawings, bottom/ roof/ shell plate repairs (i.e. position patch repair & plate's replacement), their dimensions, maintenance carried out in the tank, detailed earth pit drawings along with tank M&I reports of repair and maintenance as per the directions of EIC/ Site Engineer. Details of desludging works, foam pourer and sprinkler system, it’s as-built drawings, their bill of materials indicating pipe, flanges, fittings, fasteners etc. used, tank painting details indicating brand & type of paints used, flexible roof drain make, details & dimensions, any other repair & maintenance works shall be incorporated in report submitted by contractor. Contractor shall submit 2 hard copies and 2 soft copies of all the drawings and tank M&I reports to the EIC within 21 days of the completion of M&I works.

Tank calibration by EODR method:- Calibration of the tank by EODR method including all liaison work with the Competent Authority for approval of the calibration charts, preparation of the charts and payment of fees to the Competent Authority for approval, submission of charts in hard copies as well as soft copy, as per directions of EIC/ Site Engineer including all required arrangement for tank calibration, tools, tackles, consumables etc. to complete the work in all respects.

Dismantling & shifting of Stirrers and re-installation after M&I:- Dismantling of electric motors, stirrer assembly, gear boxes, coupling, belt etc. of the tank stirrers, shifting to the owner’s store/ workshop and shifting back all the components of stirrers to the work site after M&I and re-installation of the of electric motors, stirrer assembly, gear box, coupling, belts, supply of gaskets etc. and other accessories/ components upon completion of M&I, including alignment of stirrer. Supply of all required equipments, tools, tackles, labours, consumables, non-consumables etc. to complete the work in all respects as per direction of EIC/ Site Engineer.

Earth Work:- Earth work excavation in foundation trenches or drains upto the depth of 1.5 m including the dressing of sides and ramming of bottoms, including getting out the excavated soil and disposal of surplus excavated soil as directed, within a lead of 80 m including all required tools, tackles, manpower, consumables, non-consumables etc. to complete in all respects as directed by the EIC/ Site Engineer.

Double Steel Scaffolding:- Erection of Unit Frame type Independent Scaffold as per IS 2750 for working at heights in line with all safety guidelines, safety equipments, PPEs as indicated in the contract and as per instructions of EIC/ Site Engineer. Supply of all materials, equipments, tools, tackles, materials, consumables, manpower etc. for scaffolding erection works shall be in the scope of contractor. Erection of double steel scaffolding is to be done during dismantling, erection & welding of foam pourer piping, sprinkler rings/ piping, spiral stairways, primary wind girder & secondary wind girder, radium sticker works and during surface preparation and painting of tank shell.

Dehumidification of tank internals during surface preparation, priming and painting works:- Dehumidification of tank internals during (a) blasting surface preparation; (b) priming, and; (c) painting to maintain conditions as per technical specifications. Uninterrupted dehumidification conditions shall be maintained till the bottom and internal surface preparation, priming & painting activities are over; as per EIC's instructions. Supply of dehumidifiers, condensers and all equipments with required manpower, tools, tackles, consumables, non-consumables etc. to maintain the minimum required conditions during surface preparation, priming & painting activities shall be in the scope of contractor.

Transportation of various materials by tractor trailor for leads upto 3 Km or part thereof including loading & unloading, with necessary labours, tools, tackles etc. of items such as cement, sand, scrap, debris, metal, pipes, earth, refractory, insulation, furniture, plants etc. all such materials from one place to another place including battery area and outside battery area all complete as per the direction of the EIC/ Site Engineer.

Steeltech system

Expo Gas Containers Ltd