JC17MLS366 AMC for Survey Audit Compressors Problem Diagnosis Repair Maintenance and Service of Step less Capacity Control System Installed in Makeup Gas compressor 9030-0006-KA-04B In HCU at Gujarat Refinery.

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RFQ ITEM 00010: AMC for Stepless System- HCU

00010: "Audit/ Emergency visit- Normal Working day: The job shall include the following a) Complete sutdy of stepless circuit (both in site & control room) for any abnormality and submit a report based on historical and current data, b) Minor settings/ adjustments (as per requirement) shall be done at site, c) 1D shall be considered as 8 hours on normal working days of IOCL, d) Party to visit as per the requirement of IOCL. This shall also include visit on emergency basis. Following shall be checked incase the machine is in idle condition, e) Checking the unloader rod depth as per manual and advise accordingly, f) Checking & confirming the Bus address of the newly installed Actuators, g) Supervising the termination of the new actuators, h) Checking the position and functioning of actuators through simulation, i)Downloading the HSS history from CIU and review the operational trends and decide Further activities accordingly, j) Checking the temperatures on the CIU and advice customer for valve operation, k) Checking Hydraulic Unit Oil & replace if required, l) Checking oil filter and replace if required, m) Reset pressure relief valve, n) Checking and reset Hydraulic oil pressure, o) Checking oil leakages in the hydraulic system, p) Supervising tightening of tubing, screw bolts, q) Checking external condition oil cooler and clean, r) Service Engineer shall monitor the systems thoroughly for any abnormalities during operation & submit service/ observation report, s) Check TDC Sensor working & set TDC sensor gap if required, t) To carry out minor repairs like arresting leakages, adjustments required etc. Immediately to ensure availability of Compressor/ Hydrocom, u) Supply of 2 barrel of hydraulic oil (per two years), v) Inspection of seal, valve & electronic housing.

00020: Audit for Stepless-Overtime charges: This shall includeall the jobs as per service item 10 which shall be carried out after normal working hours

00030: Reconditioning of Actuators(This shall be done as per requirement) Reconditioning of Actuators (This shall be done as per requirement)

00040: Valve Reconditioning-1st stage-HCU

00050: Valve Reconditioning-2nd &3rd stage-HCU

00060: Snapshot monitoring of 9030-0006-KA- 4 (HCU MAKE-UP COMPRESSOR- Model: 3 HF/3) Reciprocating compressor on quarterly basis or as per IOCLs requirement. 1) Vendor shall bring all the necessary transducers like pressure sensor, accleormeter, velometer, ultosonic probe, temperature sensor along with the analyzer required for data collection and analysis. 2) Health monitoring of piston rings, packings, crosshead, rod reversal, cylinder vibration, bearings, PV plot shall be monitored and trended. 3) Following parameters/ plots along with trend shall be analyzed and recommendation based ont he same shall be intimated. a) Main bearing high and low frequency vibration plots, b) Cylinder indicated pressure & volume and valve cover ultrasonic, c) Cylinders indicated pressure and valve cover vibration, d) Cylinder PV plot & log PV plots, e) Cylinder Rod Load plots, f) Crank angle correlation, g) Valve temperature an ultrasonics, h) Rod Drop. from the PV Diagram, f)VALVE LOSSES: To be calculated and expressed as percentage of total energy, g)THEORETICAL DISCHARGE TEMPERATURE: To be calculated, assuming isentropic compression of the gas, h)VALVE & PISTON RING LEAK DIAGNOSIS: Comments to be submitted regarding the suction and discharge valve leak as well as piston ring leak situation as indicated by the PV Diagram. 5) Preliminary and detailed report shall be submitted within 01 day & 7 days from the date of data colelction respectively. The report should include: a) Present condition of the Machine, b) Complete Performance Analysis, c) Outlines of defect and recommendation thereon. 6) The report has to be submitted as soft copy (in CD) as well hard copy. The Unit EA denotes for number of equipment (compressors)