IFR TANK CONVERSION PDP TML

API 5L Grade B 450 M — API 5L Grade B Pipe supply and delivery at site. Thickness 7.92 mm with TPI inspection. No negative tolerence allowed.

Tank GA Drawing Prep — "Preparation of General Arrangement (GA) drawings of existing CRVT tanks of 30.0 m diameter and 10.0 m height, based on detailed site survey, physical measurements and verification, including but not limited to shell courses, bottom, roof plates, roof structure, columns, rafters, wind girders, manholes, nozzles, stairway/helical ladder, platforms, walkways, appurtenances and all existing structural attachments. The GA drawings shall be prepared in AutoCAD format, complete with plan, elevation, sectional views and key dimensions, and shall be submitted for Engineer/Owner approval prior to commencement of painting works. The scope includes site visits, measurements, preparation, revisions (if any) and submission of final approved GA drawings for 2 Nos existing CRVT tanks."

SITC IFR SS-AL Hybri — "Supply, installation/erection, testing and commissioning of Stainless Steel–Aluminium Hybrid Internal Floating Roof (IFR) deck for the specified tank size, as per tender specifications, approved drawings, manufacturer’s procedures and API 650 Appendix H. Scope of Work Design, manufacture/fabrication, procurement, assembly, testing, painting, packing, inland transportation, inland transit insurance, unloading/loading and all activities required for delivery of materials up to tank site. Supply and installation of dual seal system complete with accessories including peripheral roof vents, center vent, anti-rotation devices, earthing (anti-static) cables, adjustable supports, pipe supports, vacuum breaker, deck drain, foam dam, etc., as per tender specifications and approved drawings. Supply and erection of all components and accessories, including items not specifically listed but required for safe, complete and proper functioning of the IFR system, shall be deemed included in vendor scope with no separate payment. Tank vendor shall provide all accessories and nozzles necessary for safe and correct operation of IFR. Welding <(>&<)> Quality Requirements All weld joints shall be fully welded. Partial/intermittent welding is prohibited. Pontoon weld joints shall be leak tested as per API 650 Appendix H. Engineering, Documentation <(>&<)> Approvals Vendor shall submit for HPCL approval: • GA drawings and fabrication drawings • Complete design calculations • Inspection and Test Plan (ITP) • Material Test Certificates (MTCs) • Manufacturer’s technical data sheets All work shall be executed as per approved GA/AFC drawings. Vendor shall submit after completion: • As-built drawings • Original test certificates • Warranties and performance guarantees in favor of HPCL Execution <(>&<)> Commissioning Includes erection, testing and commissioning of Hybrid SS–Aluminium IFR complete in all respects as per approved drawings, tender sp ecifications, job procedures and directions of Engineer-in-Charge (EIC). OEM representative of Hybrid SS–Aluminium IFR manufacturer shall be present during installation and, if required, during commissioning. Quoted rate shall include this requirement with no separate payment. Risk <(>&<)> Responsibility Clause In case of non-completion of works by manufacturer, all risks, responsibilities and costs shall be borne by bidder, who shall complete the work at own cost and risk without financial implication to HPCL."

HYDRO AND FLOATION T — "Scope: Testing of tank welding joints and carrying out hydro testing and internal floating roof (IFR) floatation and de-floatation test for tank of size 30 m diameter × 10 m height, as per Clause H.6 of API 650 (latest edition), tender technical specifications, codal provisions and directions of Engineer-in-Charge (EIC), complete in all respects. Hydro Testing Includes hydro testing of tank for minimum two (2) hours. Supply of water shall be in HPCL scope. Filling, holding and decanting of water including supply, transportation, installation and operation of pumps, hoses and accessories shall be in vendor scope. Any defects, leakages or deficiencies observed during hydro testing shall be rectified by vendor at no extra cost, including partial/full decanting, repair, refilling and re-hydro testing until acceptance. No additional payment shall be admissible for rework or re-testing. Floating Roof Floatation Test After hydro testing, floating roof floatation and de-floatation test shall be carried out as per API 650 Clause H.6. OEM authorized representative of Internal Floating Roof manufacturer shall be present during floatation and de-floatation test. Quoted rate shall include this requirement with no separate payment. During floating and de-floating at every 1.0 m water level interval, following shall be checked and recorded: • Plumb readings of floating roof • Rubbing/interference of roof components with tank shell, gauge pipes or appurtenances • Seal intactness and contact with tank shell • Roof rotation and earthing (anti-static) continuity • Any other checks recommended by OEM Repairs, Safety <(>&<)> Cost Responsibility If repairs/rectification/rework are required during or after hydro or floatation testing, all associated activities including decant ing/refilling of water, scaffolding, access arrangements, safety measures, manpower, tools, tackles and consumables shall be in vendor scope. All costs related to safety measures and access arrangements shall be borne by bidder and no payment shall be made under any PO line item. Documentation <(>&<)> Acceptance Combined Hydro Testing and Floating Roof Floatation Test Report shall be submitted incorporating observations, readings and acceptance records. Tank shall be considered successfully tested only after satisfactory completion and approval by HPCL/EIC. General Job shall be executed as per approved technical specifications, API 650 (latest edition), sound engineering practices and directions of Engineer-in-Charge, complete in all respects."

CALIBRATION OF TANK — "Carrying out calibration with flow meter for the entire height of the tank. Job includes preparation of calibration charts, getting the same certified by statutory authority (as directed by EIC) and hand over the certified calibration charts to HPCL. Job also includes making all necessary arrangements for the visit of representatives from statutory authority, payment of statutory fees, any other incidental expenses. Job also includes supply of calibrated strapping tapes (100 meters), all accessories, labour and complete the work in all respects as per is codes, specifications, standards and instructions of HPCL engineer-in-charge. Fees payment to Gov portal (Diractorate of legal metrology) will be paid by HPCL but bidder to arrange all other jobs included in scope and provide W<(>&<)>M approved calibration certificate for Tank."

Dismantling Tank Roo — Dismantling of Structural Steel Scope: Includes dismantling and removal of existing structural and tank components such as tank bottom plates, annular plates, sketch plates, shell plates, pad plates, roof deck plates, roof pontoons, roof buoys, wind girders, stiffeners and other structural parts identified by HPCL/TPIA during inspection. Work shall be executed safely as per API 653, API 650 (where applicable), OISD guidelines, statutory safety regulations and directions of Engineer-in-Charge (EIC), complete in all respects. of Work: Dismantling shall be carried out by gas cutting, gouging, mechanical means or approved methods without damaging adjoining structures. Measurement/payment shall be only for existing tank components. Scope includes: • Marking, cutting, supporting and safe removal of dismantled plates/components • Surface cleaning of cut edges • Protection of adjacent components from deformation/heat damage • Temporary supports, bracings, scaffolding and rigging arrangements All dismantling shall be executed as per approved dismantling plan under HPCL/EIC supervision. Measurement <(>&<)> Payment: Payment based on actual dismantled steel tonnage determined by weighbridge measurement (where available) or theoretical calculation using average thickness. UT thickness testing shall be carried out in presence of EIC for thickness determination. Temporary support structures erected solely for dismantling shall not be paid separately. All scrap/dismantled plates shall be handed over to HPCL after weighing and documentation. Execution Requirements: Vendor shall: • Submit dismantling plan and plate cutting diagram for HPCL approval • Ensure safe working conditions with required supports, rigging and scaffolding • Deploy qualified riggers, welders and gas cutters with safety supervision • Carry out dismantling sequentially ensuring structural stability • Maintain safe lifting using cranes, chain pulleys or tackles • Obtain hot work/confined space permits as applicable • Maintain records of dismantled components, sizes and weights Inclusions: Methodology and safety plan approval, tools, tackles, gas cutting sets, cranes, rigging equipment, consumables, safety gear, temporary supports, scaffolding, surface cleaning, stacking, weighing, scrap handing over, manpower, supervision and permits. Compliance: Work shall comply with API 653, API 650 (where applicable), OISD-129 / OISD-STD-105, HPCL Safety Manual and statutory safety regulations. Notes: Quoted rate includes all equipment, manpower, materials, tools, consumables, permits, safety arrangements, testing and documentation. No extra payment for temporary supports/scaffolding. Dismantling shall start only after HPCL approval. Vendor responsible for site safety, barricading and fire safety. HPCL reserves right to retain or reuse dismantled materials.

Sup/Inspctn of Steel — Supply and Inspection of Steel Plates Scope: Supply, inspection, transportation and delivery of steel plates conforming to IS 2062 Grade BR (minimum) of approved make, as per te chnical specifications, approved quality plan and HPCL scope of supply requirements, at designated HPCL depot/terminal, complete in all respects. Material Specifications: Material: Carbon steel plates conforming to IS 2062 Grade BR (minimum). Plate Sizes: • 6300 mm × 1500 mm, or • 6300 mm × 2000 mm, as per thicknesses specified in tender and approved fabrication drawings. Plates shall be manufactured, tested and certified by original manufacturer with Mill Test Certificates (MTCs) and Third-Party Inspe ction (TPI) release notes. Inspection <(>&<)> Testing: All plates shall be inspected by HPCL-approved TPI agency as per approved QAP prior to dispatch. TPI shall include visual inspection, dimensional checks, ultrasonic testing (UT) for lamination and mechanical property verification as per IS 2062 and HPCL specifications. MTCs shall indicate heat number, plate size, grade and test results. HPCL reserves right to reinspect materials at site before acceptance. Transportation <(>&<)> Delivery: Delivery shall be on door-delivered basis at HPCL depot/terminal including loading, unloading, transportation, transit insurance, ha ndling and freight. Vendor shall ensure safe transportation and stacking without bending, edge damage or corrosion. Each plate shall be marked with heat number, size, thickness, grade and manufacturer identification using non-corrosive paint. Weighment <(>&<)> Payment: Payment shall be based on actual weight of plates received and verified at HPCL weighbridge, if available. If not available, weighment shall be done at nearest Government/HPCL- approved weighbridge in presence of HPCL representative. Weighment certificate shall be signed by HPCL representative and consignment escorted to HPCL premises by HPCL representative or nominated person. Inclusions: Supply, inspection and testing of plates, TPI inspection and documentation, transportation, handling, loading, unloading, stacking, transit insurance and submission of quality documents including TPI reports, weighment slips and MTCs. Documentation: Vendor shall submit TPI release note, MTCs, HPCL- witnessed weighment certificate, delivery challan, packing list and heat number-wise reconciliation statement. Notes: Quoted rate includes supply, inspection, testing, documentation, insurance and delivery to HPCL site. Plates shall comply with IS 2062 Grade BR mechanical and chemical properties. No extra payment for transportation, testing or insurance. HPCL reserves right to reject non-conforming materials. Materials shall be handled and stored as per IS 800 and HPCL material handling standards.

Bottom repair with o — Fabrication of Bottom Overlay Patch Scope: Fabrication, laying and welding of carbon steel (CS) overlay patches on existing tank bottom and annular plates to restore integrity and prevent leakage/corrosion, as per HPCL instructions, approved repair drawings, API 653, API 650, OISD guidelines and HPCL safety procedures, complete in all respects. Material <(>&<)> Patch Specifications: Material: CS plates conforming to IS 2062 Grade E250 BR or equivalent. Thickness: As approved by Engineer-in-Charge (EIC) based on inspection/marking at site. Patch Size: Maximum 500 mm × 500 mm per location unless approved by HPCL. Patch size and location shall be HPCL approved. Weld Type: Lap joint fully seal welded on all sides. Weld Thickness: Root thickness matching parent plate thickness. Work : Includes: • Marking of corroded/defective areas as advised by HPCL • Surface preparation by grinding and cleaning to expose bare metal • Cutting, edge preparation and alignment of overlay plates • Fit-up, tack welding and full welding using suitable electrodes • Inspection <(>&<)> Testing – Vacuum box testing, visual and DP testing as per HPCL/API • Finishing – Grinding and cleaning of welded areas • Provision of temporary supports, scaffolding, lighting, ventilation and fire safety arrangements Inclusions: Manpower, tools, tackles, consumables, electrodes, gas, welding sets, grinders, equipment, cutting, grinding, fit-up, welding, testing and finishing. Vacuum box testing equipment and consumables, minor structural strengthening/modification, inspection, supervision and quality documentation as per HPCL QAP/ITP. Note: Supply of CS plates shall be paid under separate line item. This item covers fabrication, welding and testing only. Inspection <(>&<)> Testing: Testing shall be witnessed by HPCL and/or HPCL-approved TPIA. Vacuum box testing shall be as per API 650 Section 8.6. DP testing shall be carried out wherever required by EIC. Radiography of patch welds, if instructed by HPCL, shall be included without extra cost. Acceptance criteria shall be as per API 650/API 653. Execution <(>&<)> Compliance: Work shall be executed as per approved repair drawings, HPCL safety procedures and permit-to-work requirements and comply with: API 650, API 653, OISD-129 / OISD-STD-130, HPCL HSE Manual and Safety Guidelines. Notes: Overlay patches exceeding 500 mm × 500 mm require HPCL approval. Welders shall be qualified under HPCL/WPS/PQR. Repair areas shall be inspected by HPCL before patch placement. Vendor shall maintain repair logs indicating patch size, location, thickness and testing records. Work shall comply with confined space and hot work permit requirements.

Shell repair with ov — Shell Repair with Overlay Patch Scope: Repair and reinforcement of tank shell plates by removal of damaged, corroded or distorted portions and installation of carbon steel (CS) overlay or reinforcement pad plates in circumferential or spiral configuration as approved by HPCL Engineer-in-Charge (EIC). Work shall comply with API 653, API 650 (where applicable), OISD guidelines and HPCL technical and safety standards, complete in all respects. Material <(>&<)> Thickness: Material: CS plates conforming to IS 2062 Grade E250 BR or ASTM A516 Grade 60/70 as approved by HPCL. Minimum Thickness: 6 mm or as specified by HPCL. Overlay Type: Reinforcement pad or shell overlay plate in circumferential/spiral layout as directed by HPCL. Work : Includes: • Identification and marking of defective shell areas as advised by HPCL • Gouging/removal of existing pad plates, weld remnants, wind girder weld joints, support angles and old patches • Surface grinding to remove corrosion, paint, weld spatter and smoothen parent metal • Correction of local shell deformation before patch placement Fabrication <(>&<)> Welding: Cutting, edge preparation, fit-up, alignment and tack welding of overlay/reinforcement plates as per approved drawings. Full welding with fillet welds around edges ensuring complete sealing. Welding shall comply with approved WPS/PQR (ASME Section IX) and witnessed by HPCL/TPIA. Provision of tell-tale/weep holes wherever instructed by HPCL. Inspection <(>&<)> Testing: NDT including Dye Penetrant (DP) and Radiographic Testing (RT) wherever directed by HPCL. Visual inspection, dimensional verification and thickness measurement after completion. NDT and inspection records shall be certified by HPCL/TPIA. Finishing <(>&<)> Housekeeping: Grinding/dressing of welds, cleaning of work area and safe handling/disposal or handover of scrap as per HPCL HSE guidelines. Inclusions in Contractor Scope: All cutting, gouging, edge preparation, fitting, welding, NDT, testing, supply of electrodes, gases, consumables, tools, tackles, welding machines, grinders, testing equipment, manpower, supervision, permits, safety equipment, barricading, lighting, ventilation, fire protection and documentation including WPS/PQR, welder qualifications, NDT and repair logs. Note: Scaffolding shall be measured and paid under separate line item. Testing <(>&<)> Acceptance Criteria: Fillet welds shall achieve full throat thickness equal to patch plate thickness. Welds shall be continuous, leak-tight and free from porosity, undercut and lack of fusion. Acceptance shall comply with API 650 Section 8, API 653 Clause 11.3 and ASME Section IX. NDT results shall be accepted by HPCL before proceeding further. Compliance <(>&<)> Safety: Work shall comply with API 653, API 650, OISD-129/OISD-STD-130, ASME Section IX and HPCL Safety/Hot Work Permit systems including confined space entry protocols. Documentation <(>&<)> Deliverables: Submission of approved WPS/PQR and welder qualifications, NDT and inspection reports, as-built repair drawings indicating patch locations, size and thickness and final acceptance records signed by EIC.

Roof repair with ove — Roof Repair with Overlay Patch Scope: Repair of existing tank roof plates by providing carbon steel (CS) overlay patch plates of suitable thickness as directed by HPCL En gineer-in-Charge (EIC). Work shall comply with API 653, API 650, OISD guidelines and HPCL safety procedures, complete in all respects. Material <(>&<)> Patch Details: Material: CS plates conforming to IS 2062 Grade E250 BR or equivalent. Thickness: As advised/marked by HPCL. Patch Size: Maximum 500 mm × 500 mm per location unless approved by HPCL. Weld Type: Lap joint fully seal welded on all sides. Weld Thickness: Root thickness matching base plate thickness. Work : Surface Preparation: Identification and marking of damaged roof areas as directed by HPCL. Grinding and cleaning to expose bare metal removing paint, corrosion, rust or blisters. Cutting <(>&<)> Fit-Up: Preparation of patch plates including cutting, beveling and edge dressing. Window cutting, wherever required by HPCL, shall be included in scope with no separate payment. Alignment and fit-up of patch plates ensuring minimum distortion/gap. Welding: Lap welding on all sides using approved low hydrogen electrodes (E7018 or equivalent). Welding shall be carried out by qualified welders under approved WPS/PQR as per ASME Section IX. Preheat approx. 50°C and inter-pass temperature not exceeding 250°C shall be maintained. Testing <(>&<)> Inspection: Vacuum box testing and/or air pressure testing of welded overlay patches as per HPCL instructions. Additional visual and DP testing shall be performed wherever directed by HPCL/TPIA. Inspection results shall be documented and approved prior to closure. Finishing <(>&<)> Cleaning: Grinding/dressing of welds, removal of spatter, housekeeping and disposal of metal debris as per HPCL HSE requirements. Inclusions in Contractor Scope: All cutting, fit-up, welding, NDT, testing, supply of electrodes, gases, consumables, tools, tackles, welding equipment, testing accessories, temporary supports/fixtures, manpower, supervision, safety gear, permits for confined space/hot work, minor structural modification and documentation including WPS/PQR, welder qualifications and inspection reports. Note: Supply of CS plates and scaffolding erection/dismantling shall be paid under separate line items. Inspection <(>&<)> Acceptance Criteria: All welds shall be continuous, leak-tight and free from porosity, undercut or lack of fusion. Acceptance shall comply with API 650 Section 8, API 653 Clause 11.3 and ASME Section IX. HPCL/TPIA approval of test results and documentation is mandatory. Compliance Standards: API 653, API 650, OISD-129 / OISD-130, ASME Section IX and HPCL Safety/HSE/Hot Work Permit systems. Deliverables: Approved WPS/PQR and welder qualification certificates, NDT and vacuum test reports, as-built sketch showing patch locations/sizes and final inspection clearance certificate issued by HPCL.