Attachment to PR

SRU TRAIN 1 & 2 TESTING & INSPECTION JOBS-IBR-SHUTDOWN-DHDS

Job scope & Notes to Vendors
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DHDS: - ANNUAL RATE CONTRACT FOR CLEANING AND TESTING OF ( IBR ) WASTE HEAT BOILERS
75E101/201 & SULPHUR CONDENSERS 75E102/103/202/203 & OTHER MISCELLENIOUS JOB RELATED TO
THE FR DHDS SRU TRAIN 1 & 2 SHUT DOWN JOBS.

Provide necessary skilled Manpower, Tools & Tackles, Equipment, Consumables & non-
Consumables material(Unless Specified Otherwise), transportation, erection/dismantling of
Scaffolding as required and supervision to carry out Cleaning and Testing of Waste Heat
Boilers (WHBs) 75E101/201 & sulphur Condensers 75E102/103/202/203 at SRU, DHDS FR, & all
other miscellaneous job as per Job scope, SHE guidelines & other terms & conditions as
detailed below:-

PO VALIDITY PERIOD: - As given in tender OR Revised PO validity period OR 100% utilisation

of PO Financial Limit, whichever is earlier.

PO End Date:- As given in tender OR Revised PO validity period

Extension of Delivery Period or enhancement of Financial Limit of the Contract shall be

basis Vendor's performance and at the sole discretion of HPCL.

HPCL reference Drawings:

These Drawings are available at FR T&D section/DHDS Field Maintenance for reference, if
required.

1. Equipment no. 75E101/201; Drawing no. DB5-32880-75-15134, Rev.3, Sheet 3 of 3

2. Equipment no. 75F101/201; Drawing no. DB5-32880-75-15154, Rev.3, Sheet 2 of 3
3. Equipment no. 75E102/202; Drawing no. DE5-32880-75-15334, Rev.2, Sheet 1 of 4
4. Equipment no. 75E103/203; Drawing no. DE5-32880-75-15335, Rev.2, Sheet 1 of 4

SCOPE OF JOB:
Line Item no. 1
Cleaning & Testing of Waste Heat Boilers, 75E101/201, with IBR co-ordination
1. Install & remove the necessary blinds for the isolation of furnace before commencing
the jobs & after the completion of Waste heat boiler or entire SRU train-1 or 2
repair jobs respectively after obtaining permit from the HPCL supervisor. The
payment for spading & de-spading shall be done separately as per relevant PO line
item.
2. Isolate / remove all the existing Waste Heat Boiler mechanical / electrical /
instrument auxiliaries/ facilities / connections, clean, service, reinstall / hook-
up as instructed by HPCL supervisor and restore back the original working conditions
without making any damage to the existing equipment / facilities.
3. Make arrangement for entry into Shell & tube side by opening channel cover, Man-head
cover & and drop entire burner block after obtaining necessary entry permit. Erect
the scaffolding (as per the procedure attached in the attachment SC) at north side &
all other location wherever there is entry point of the vessel / exchanger or as
instructed by the HPCL engineer. Vendor to note that this scaffolding must be done
as per given in the attachment. Vendor must get the scaffolding approved from the
Fire & safety department. For scaffolding vendor to strictly follow instructions
from executing engineer for field requirement and erect the same. All the
scaffolding erected to be as per attachment and multiple vendors shall use the same
based on the nature of shutdown job and the scaffolding shall be available till
completion of all the jobs. Once the vessel/ exchanger is hand over to vendor,
vendor shall erect the scaffolding & shall remain their till all job as per HPCL
engineer is completed. Vendor shall also provide Fixed / Rope Ladders for Inspection
approach, as required. All types of Scaffolding materials is in the scope of the
vendor. Vendor shall be paid separately for building of scaffolding.
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4. Clean the MR nos. punched on the shell & offer to HPCL Inspector & IBR Inspector.
5. Wire brush / grind / file / clean & make necessary arrangements for the thickness
measurements on the West heat boilers, shell, and tube & at the specified locations
shown by the concerned HPCL Inspection Authorities.
6. Remove the insulation on the mouth of the refractory plug & keep at a safe place to
re-use the same.
7. Pull out the Refractory plug. Take necessary precaution while removing & installing
back the refractory plug to the location. Hammering to the Refractory plug for
removal or installation is strictly prohibited. Hammering leads to break the
castable refractory of the plug. Vendor has to fabricate the fixture to remove or
install plug. Material required for fabrication of fixture shall issue by the HPCL
as the free issue. Fabrication of the fixture is in the scope of the vendor without
any extra cost to the HPCL. After use vendor shall surrender the fixture to HPCL for
future use.
8. Keep the plug at safe site as per instruction of the HPCL engineer.
9. In case of Waste Heat Boilers 75E101/201, remove Burner Housing assembly from the
Thermal Reactor 75F101/201, Removal of burner assembly is not included in the scope
of the vendor under this line item.
Note: Dropping, cleaning and re-fixing back of Burner Housing assembly shall be
paid separately as per the applicable PO Line Item no. 8.
10. Install Eductor Rings (to be issued by HPCL on Loan basis), with Air supply
connection, at Man heads for proper Air circulation inside the Equipment. Vendor has
to collect the educator ring from FR tool room or any other place as directed by the
HPCL engineer.
11. Remove Demister Pads. Clean it with steam / air & water. All the sulphur & other
impurities to be removed out. After completion of the cleaning job offer it to the
PAD & Inspection department. After getting clearance from the PAD/Inspection &
operation vendor shall re-fix it back.
12. Internal steam coil, clean thoroughly & hydro-test it as directed by the HPCL
engineer. If required disconnect the internal steam coil & re-weld as per
instruction by the HPCL engineer. Any repair work in coil to be carried out by the
vendor. Repair work shall be paid under relevant PO line item no.
13. Remove fallen Refractory, Hard Sulphur, etc. from ends Channels, as well as from the
75F101/201 internal areas.
14. All types of Exchanger cleaning shall be approved by HPCL Inspection/PAD/operation
department. After HPCL approval, IBR approval is required for cleaning of the
Exchanger. HPCL shall arrange IBR Inspector visit at site. However, Vendor to co-
ordinate with IBR Inspector for approval of Cleaning. Carry out Hydro test of the
Shell side for IBR certification & tube side if required & ask by HPCL for any
flange leak identification. Tube test shall be witness by the HPCL inspection or
Maintenance or operation department. Vendor to pressurize the Shell side or tube
side, with sweet Water. Vendor shall made a testing gauge fixture for installation
of the pressure gauge. All material except the Teflon tape shall be given as the
free issue material If during test tube leak is found then marked it & show to HPCL
Maintenance & Inspection department. After getting approval from HPCL engineer plug
the leaky Tubes. The PLUG shall be issued as a free issue item from HPCL. All types
of co-ordination with IBR inspector, is a part of the job without any extra cost to
the HPCL. However, HPCL shall arrange the visit of IBR Inspector to site. Vendor
shall remain careful while hydro testing, that pressure should not go beyond the
specific test pressure. Vendor shall first satisfy himself the testing , after this
vendor shall offer the test for HPCL inspection department , after getting the
clearance from HPCL, vendor shall release the pressure up to 5 kg/sq.cm & shall
raise the required test pressure one hour before the IBR inspector arrival to the
site or as instructed by the HPCL engineer. All above activities are under scope of
the job without any extra cost to the HPCL. During testing if tube gets leak &
vendors plugged it then it shall not be considered as repeat test as this shall be a
routine job & it is in the scope of the vendor. After completion of all job vendor
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has to prepare the Shell side for Steam / Air / Nitrogen Test or leak test
Note: Replacement of Tubes and repair of Refractory lining, if any, is NOT included
in this Scope of Work. However, after Tube replacement/repair is carried out,
Vendor to carry out Shell Hydro test and obtain necessary IBR approval.
15. The internal steam coil Hydro test is a IBR test & vendor must get clearance from
the IBR. Any repair in the coil shall be carried out by the vendor. Repair payment (
welding ) shall be done separately as pre relevant line item.
16. Vendor shall unplug all Nozzles by Roding/Air blowing, up to the satisfaction of
HPCL Engineer.
17. Any minor structural repair work or the modification work to facilitate the entry in
the equipment or facilitate to expedite the job is in the scope of the vendor
without any extra cost to the HPCL. e.g. to facilitate the entry from the north side
, it is required to cut the railing & re-welding the same.
18. Vendor shall note that sometime this steam coil needs to be cut to facilitate the
other vendor to work for some other job. In this case vendor has to cut the coil,
re-weld & hydro testing to be carried out afterwards. Payment for re-welding job
shall be done as a butt-welding as per relevant line item of the PO.
19. After verification & approval of HPCL/IBR, Vendor to release the Water pressure and
gradually drain Water/ Condensate.
20. Safety Valve & all other types of valve to the first isolation irrespective of type,
rating & location with all valves on the exchangers, west heat boilers deck, of the
Equipment shall be removed & brought to Workshop by Vendor for servicing / repairing
or calibration. Repairing & calibration of the Valves are not in the scope of the
vendor & same shall be carried out by HPCL. Vendor shall collect back all the
valves from Workshop and re-install in position at Site. All valve removal,
shifting to work shop, bringing it back to site & installation is in the scope of
the vendor without any extra cost to the HPCL.
21. After completion of all related jobs, button-up the Equipment, remove Blinds and
hand over to HPCL for commissioning.
22. Any other associated activities to facilitate the above jobs, shall be a part of the
job.
23. Provide stand-by Crew for 10 Days after commissioning of the Equipment, for Hot
bolting, etc. on round the clock basis.
24. If Hydro test fails due to any reason other than leaks at Flange joints which
Vendor has attended during the job execution & as instructed in point no. 15,
Vendor shall be paid for Repeat Test corresponding Line Item. Such additional
payment shall be made by quantity adjustment of the applicable PO Line Item.

Line Item no. 2

Cleaning & Testing of Sulphur Condensers, 75E102/103/202/203, with IBR co-ordination
Scope of the job remain same as the line item no.1

Line Item No. 3

Cleaning & Testing of Waste Heat Boilers, 75E101/201, without IBR co-ordination
1. Scope of the job remains same as the line item no.1 except that IBR co-ordination,
which is not required under this line item.
2. All OK shall be given by the HPCL engineer.
3. Pl. note that vendor must get prior written permission from HPCL engineer to carry
out this job.

Line Item No. 4

Cleaning & Testing of Sulphur Condensers, 75E102/103/202/203, without IBR co-ordination
1. Scope of the job remains same as the line item no.1 except that IBR co-ordination,
which is not required under this line item.
2. All OK shall be given by the HPCL engineer.

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Job scope & Notes to Vendors
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3. Pl. note that vendor must get prior written permission from HPCL engineer to carry
out this job.

Line Item No.5

Dropping, Cleaning & Re-fixing back Channel Cover(s) of 75E102/202.
1. Open the Channel Cover(s) and clean thoroughly from inside and replace the Gasket.
2. Water jet all tubes from inside with available water jetting point nearby. Vendor
has to arrange the pipe & jet nozzle for this purpose. It shall be vendor job to
arrange the water connection from the point shown by the HPCL engineer up to the
site without any extra cost to the HPCL.
3. After cleaning offer it to the operation / PAD person for checking. Re-fix the
Channel Cover(s) after necessary approval of HPCL Operation/Maintenance Supervisor
in-Charge.
4. Refractory repairs, if any, shall be arranged by HPCL separately and the same is NOT
included in Vendor's Scope of Work.
5. This operation shall be carried out as & when required in running unit. During Shut
down period this item shall be in the scope of the vendor without any extra cost to
HPCL.

Line Item No. 6

Dropping, Cleaning & Re-fixing back Channel Cover(s) of 75E103/203
Scope of the Job remains same as the line item no. 5 except the exchanger no.

Line item No.7

Opening & Re-fixing back Inspection Cover of 75E102/103/202/203
1. Inspection Covers on the Channel Covers of exchanger 75E101/102/103/201/202/203
shall be opened and re-fixed back with necessary Gasket replacement, etc. as advised
by the concerned HPCL Supervisor in-Charge.
2. The internal cleaning possible without opening the main cover shall be carried out
by the vendor. This operation shall be carried out as & when required in running
unit.
3. During Shut down period this item shall be in the scope of the vendor without any
extra cost to HPCL.

Line item no. 8

Dropping, Cleaning & Re-fixing back Burner Housing
1. In case of Waste Heat Boilers 75E101/201, remove Burner Housing assembly from the
Thermal Reactor 75F101/201, clean Burner Tip , pipes and inside of Reactor.
2. All loose refractory material to be removed out & it shall be in the scope of the
vendor without any extra cost to the HPCL.
3. After necessary approvals of HPCL, re-fix the Burner Housing assembly.
4. HPCL shall provide the crane for removal but vendor has to arrange the rigging
tools & tackles for the same. Vendor shall arrange the Dimra(wooden block) from any
place inside/outside the refinery which shall be included into the scope of the
vendor.
5. Vendor to note that all spading, de-spading required shall be paid under line item
no. 9 & 10, once only. However if any spade which requires repeated operation for
removal & installation of the burner, all such repeated operations shall be carried
out by the vendor without any extra cost to HPCL.
6. Any refractory repair work is not included in the scope of the vendor. However
breaking of the refractory if required or as directed by the HPCL engineer shall be
in the scope of the vendor & shall be paid under relevant PO line item.

Line item no. 9

Spading or de-Spading or Gasket Replacement of 150 # Pressure Rating Class, for all Sizes
and at any Elevation

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1. Carry out Spading or De-spading or Gasket replacement jobs at Flanges of various
Sizes and Ratings, as per HPCL advise, using appropriate Gasket and with necessary
servicing of all Bolts for re-use to the maximum possible extent. In DHDS Plants, if
required and as per advice of the concerned HPCL Supervisor in-Charge, Vendor shall
have to use Torque Wrenches.
2. Payment shall be made as per the relevant PO Line Item.
3. All bolts must be de-greased before using. All final gaskets must be offered to HPCL
inspection department & must get signed on the gasket as well as on register for
payment purpose.
4. Without the valid signature on the register no payment shall be done for any de-
spading or gasket replacement job.

Line item no. 10

Spading OR de-Spading, 300 # Pressure Rating Class & above, for all Sizes and at all
Elevation
Scope of the job remains same as per line item no. 9

Line item no. 11

Filling of dry sulphur powder inside the Hydraulic seal piping.
1. There are 9 nos. Hydraulic seal in each DHDS SRU unit. This job normally comes after
each shutdown. However it may also come if the hydraulic seal is replaced during
normal running of the plant.
2. Vendor shall manually pulverize/smash the solidified Sulphur mass from the available
dry sulphur solid mass/stone in the dry sulphur pit area to prepare dry sulphur
powder.
3. The manual pulverized/smashed dry sulphur powder shall be offered to the DHDS
operation department for approval before filling it inside the Hydraulic seal
piping.
4. The same dry sulphur powder shall be filled inside the hydraulic seal.
5. Vendor shall fill the dry sulphur in a planned manner i.e. the powder shall be
filled uniformly.
6. Vendor shall manually compact the powder inside the seal using a metallic tamping
rod while filling to ensure complete filling of seal.
7. The tamping rod MUST be removed out after complete filling of the dry sulphur powder
in the hydraulic seal.
8. The hydraulic seals are Insulated from outside as a result vendor shall neither be
allowed to hammer the hydraulic seal piping nor allowed to vibrate the piping.
9. Vendor shall obtain a written approval for payment purpose from DHDS operation
department for the filling of Sulphur powder.

Line Item no. 12

Removal / cleaning / testing & installation of gas Ejector
1. Remove the ejector piece from its position to ground level.
2. After removal of the ejector put Blind Flanges to cover the open ends of ejector
piping, as a part of the job at no extra Cost to HPCL.
3. HPCL shall provide crane assistance for removal & installation, but all types of
rigging equipment & rigging shall be in the scope of the vendor.
4. Vendor shall carry out the jacket testing with the help of hydro testing.
5. Hydro testing of jacket shall be done with procedure given in the Line item No. 15
6. After jacket hydro test, carry out vacuum test of the inner pipe with the help of
the steam.
7. For vacuum puling test vendor shall connect steam connection at bottom of the
ejector & vacuum pressure (mercury) gauge at the other end.
8. The necessary arrangement for steam connection is in the scope of the vendor.
9. HPCL shall provide the mercury gauge to vendor for vacuum pulling test, however
vendor has to bring the vacuum gauge from FR inspection department & return the same
after completion of the job.
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10. Vendor shall bring his own gauge for jacket hydro test.
11. Any repair that comes during testing shall be not in the scope of vendor.
12. All testing must be certified by the HPCL MI.
13. After completion of testing install the ejector back to its position.

Line Item no. 13

Opening , Cleaning & testing of the Drum with steam coil of 75-D-101/201
1. After getting permit carry out spading as required as per process.
2. Dismantle the piping from the top cover.
3. Open the top cover of the drum.
4. Clean it from inside.
5. Hydro test the coil. Hydro testing to be done as per procedure given in the piping
hydro test in the same PO.
6. Carry out any repair of the coil. Repair of the coil (welding) shall be paid under
relevant PO line item.
7. Cut the new Asbestos gasket & install top cover.
8. Hydro tests the drum.
9. Re - connect the drum piping.
10. De-spade the drum.

Line Item No. 14

Removal, Unplugging, Hydro testing and re-installation of complete Hydraulic Seal Assembly
in Hydraulic Seal Pit
1. Remove all roof sheets, metallic cover plates of the hydraulic pit for removal of the
hydraulic seal & storage at a safe place & in a proper manner.
2. Remove complete Hydraulic Seal Assembly one by one or as required by HPCL engineer.
3. Crane shall be provided by HPCL. However the Vendor shall provide necessary Rigging
assistance & rigging equipment. Vendor shall provide necessary certificate for
rigging equipment.
4. Dismantle and unplug all inner Pipes and Jackets.
5. If required & as per HPCL MI / engineer request vendor has to remove the insulation &
clean the surface to the satisfaction of the HPCL MI.
6. For unplugging, vendor shall install steam connection from the nearest point. All
fabrication of rigid connection shall be in the scope of the vendor without any
extra cost to the HPCL. Rigid piping material shall be issued by HPCL as a FIM.
7. If required, heating with torch shall be allowed. However the same shall be in the
scope of the vendor without any extra cost to HPCL. Vendor shall use only HPCL
approved LPG cylinder for this purpose.
8. For detail unplugging scope vendor has to refer line item no. 21
9. Offer the piping to HPCL inspection department.
10. Carry out Hydro testing of Jacketed Piping of the Hydraulic Seal and obtain approval
of HPCL MI, re-assemble and re-install them inside the Hydraulic Seal Pit.
11. For this Item, Hydro testing is considered as a part of the job and no separate
payment shall be made for the same.
12. If any leakage found up to the 2 inch diameter size pipe shall be rectified by the
vendor payment shall be done under relevant line item. Repair work of the seal above
2 inch diameter is not cover under this line item.
13. Install hydraulic seal inside the pit.
14. By complying to all safety measures, install all roof sheets back to their position
with the fastener.
15. Vendor shall note that whether he is awarded the hydraulic seal job or not, he must
carry out the blowing procedure as a shut down starting activity without any
additional cost to the HPCL. For this, vendor shall provide a steam connection; open
the end cover or any other miscellaneous job etc. After blowing the liquid sulphur
as blow down to atmosphere, all remaining sulphur shall be cleaned/cleared from the
site by the vendor as a Good Housekeeping requirement,

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16. Payments shall made for entire job on each Hydraulic seal:- Blowing , spading ,
opening of the flanges , removal of the hydraulic seal from the pit , un-plugged,
clean, hydro tested and re-installed including re-installation of the roof sheet &
metallic cover plates.

Line item No. 15

Opening and cleaning of Liquid storage pit ( De-gassing pit , Main storage pit , pumping
pit ) , Hydraulic Seal Pit & Rundown line pits of each train per metric ton of sulphur
removed.
1. Once the train is shut down, the bottom of pit is filled with the solid sulphur. It
has been observed that the de-gassing Pit to the main pit pipe always gets plugged.
2. Remove Covers of Pit (concrete slab) and store at safe place with proper
identification tags for putting them back with ease.
3. HPCL shall provide Crane / Hydra assistance for removal of concrete slab from the
Sulphur storage pit.
4. As a part of degassing pit cleaning, vendor to open the pit cover and remove the
baffles plate to facilitate the cleaning and removal of sulphur from the pit.
Vendor to clean degassing and sulphur storage pit coils external surface to remove
sulphur traces as a part of hydro test preparation.
5. Vendor shall barricade all entry with the help of the Scaffolding for safety purpose
6. Enter into pits after obtaining necessary Entry Permit.
7. Vendor must provide a good condition ladder at both end for entry inside the pits &
fasten it with nylon rope for safety purpose.
8. Personnel entering the Pit must wear necessary Personal Protective Gears. All types
of PPEs (Personnel Protective Equipments) & any other safety equipments are in
Vendors scope.
9. Provide all Cleaning / Scrapping Tools for cleaning and scooping out Solid Sulphur
from inside the Pits. .
10. Remove all Sulphur out of the Pit by digging, scooping & lifting and then finally
transport/unload all Sulphur taken out in to the Sulphur Solidification Basin.
Providing arrangement for transporting & unloading Sulphur into the Solidification
Basin is in the scope of the vendor without any extra cost to the HPCL.
11. Remove all debris from the PIT.
12. Debris may contain of Insulation wool, foil, sheet, wooden pieces, metallic pieces,
water & dry sulphur. All debris to be sorted out & same to be shifted at designated
location inside the refinery.
13. If the hydraulic seals are not removed then vendor has to clean the area where it is
possible to access as per HPCL engineer direction.
14. Removal of the hydraulic seal is not included in the scope of the vendor under this
PO line item.
15. The dry sulphur removed shall be paid separately on per Metric Ton of solid sulphur
removed from the pits. Under relevant line item PO line item. (Density of Solid
Sulphur is 1960 kg/m3)
16. All inside piping / coil shall be clean thoroughly up-to the satisfaction of the
HPCL engineer.
17. Vendor shall take care that the piping of inside the pit shall not get damaged while
removing the sulphur.
18. Remove / install the de-gassing pits sulphur transferring valve for servicing
purpose. Payment shall be done under relevant PO line item.
19. The sulphur removal should be done up-to bottom of the PIT & must be certified from
the HPCL engineer.
20. The pumping pit should be clean up-to the bottom & pumping coil to be seen clearly.
21. Final cleaning should be done by brooming / sweeping of the bottom to the
satisfaction of the HPCL engineer.
22. All coils/piping/ floor/wall/seal to be clean thoroughly up-to the satisfaction of
the HPCL engineer.

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23. All transportation required to complete the job in all respect is in the scope of
the vendor without any extra cost to the HPCL.
24. The weighment for measurement purposes shall be done at HPCLS weighbridge prior to
disposing the sulphur at the solidification basin. The vendor to arrange all types
of transportation required for the same. The weight has to be certified by HPCL site
in charge.

Line Item No. 16

Unplugging of piping both jacketed, non-jacketed & coil piping
1. Vendor to note mainly all plugging of lines is due to solid hard sulphur.
2. Open the required flanges of the steam Jacketed piping , as required to identify
internal leak or for un-plugging.
3. If required bring the piping at grade level/Deck where workability access is
available. Crane shall be provided by HPCL, if required
4. Before removal of the Piping, match mark for identification of sequence of Piping.
5. Vendor shall connect rigid steam connection (for rigid steam connection piping
material shall be issued as a free issue material to vendor) to Steam Jacket or
inside piping and carry out unplugging. or 1 inch pipe & its fitting shall be
given by the HPCL as a free issue material.
6. Vendor has to fabricate the piping for steaming purpose. Steam Hose shall not be
issued by HPCL.
7. If HPCL gives the steam hose for unplugging, then Rs. 50 shall be charge per Hour &
the same shall be recovered from Vendors bills as quantity adjustment or the
Vendor may be advised to Pay the charges at Refiners cash office upon instructions
from the Field Maint. In-charge.(Not below the Rank of a Sr. Manager)
8. If during steaming, Steam hose gets damaged then vendor has to replace same with new
Steam Hose as per specification & make as advised by HPCL. If vendor fails to do so
then HPCL may cut the appropriate amount from his bill with quantity adjustment.
9. Steaming shall be done for minimum 1.5 Hours or till Steam Jacket/inside piping is
completely unplugged. Vendor may have to use heating torch if required for
unplugging purposes. Heating torch & its required accessories with heating gas to
complete the job is in the vendor scope of the job.
10. If vendor uses LPG gas for the same then vendor must use industrial gas cylinder
approved by HPCL fire & safety department.
11. Vendor shall open insulation on the Piping, if required in case of Steam Jacket is
not getting unplugged satisfactorily. However, the Box Clamp (insulation) has to be
kept intact for re-use. In this case carry out steaming externally also, so as to
unplug the Piping. If the insulation is damaged due to other reason than after
removal vendor must shift the insulation in insulation scrap yard on same days.
12. For removing the plugging in the internal pipe vendor may have to use suitable
rods/brushes, pneumatic brush etc. which is in the scope of the job without any
extra cost to HPCL. Vendor may be allowed to use the scrapper rod if available in
scrap yard. Otherwise vendor has to make his own arrangement for the same.
13. All dirt, Sulphur/insulation material, etc. shall be removed to a designated place
as advised by HPCL Supervisor in-Charge on daily basis.
14. At any point of time while unplugging, vendor shall keep Collecting Pots for Molten
Sulphur & ensure that no liquid sulphur should fall on the ground.
15. Collect all removed solidified sulphur and dump in to the Sulphur Solidification
Basin. All transport required is included in the scope of the job.
16. Opening & installing of one or both ends or dead ends for unplugging is in the scope
of the job without any extra cost to HPCL.
17. This job may come during running plant. Vendor has to carry out this job during SRU
S/D as well as during the running plant up to POs validity period.
18. Vendor shall be compensated for the above jobs as follows:
a) For unplugging of line vendor shall be paid Inch Meter basis (i.e. nominal
diameter of the pipe in Inches multiplied by the length of pipe in meter)
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b) For jacketed piping the unplugging of inner and outer pipe shall be
compensated separately.
c) For removal and re-installation of any piping sections removed for unplugging
purposes from its position to ground level or deck level compensation shall be
made on Inch Meter of the piping sections removed.
d) All final calculation shall be made on quantity adjustment basis.

Line Item no. 17

Hydro testing of Pipes / coils (Except Jacketed pipes)
1. Carry out Hydro testing of the Pipeline, as per Procedure and at a given Test
Pressure recommended by the Material Inspection Department of HPCL.
2. Piping shall be Hydro tested (along with its Branch connections, if any) shall be
de-pressurized by HPCL and handed over to the Vendor for necessary Spading/De-
Spading. Spading/De-Spading shall be paid separately as per the relevant PO line
item rate. Flushing and Gas freeing of the Circuit shall be carried out by HPCL.
However, Vendor shall provide assistance, like providing necessary connections, etc.
for the same. Vendor to note that for 600# and above rating Flanges, as advised by
HPCL Supervisor, Torque Wrenches may have to be used for tightening purpose
3. Vendor to carry out checking of all Vents and Drains on the line and make operable
all these Bleeders (including tightening of Valve Gland leak and minor repairs of
Bleeders to make them operable). This shall be done before taking up the Pipeline
for Hydro testing.
4. If any Bleeder is found broken/damaged or not operating (even after efforts to make
it operable), the same shall be informed to the concerned HPCL Supervisor and as per
advise of HPCL Supervisor, Vendor shall replace the Bleeder, etc. While
replacing/repairing Bleeders on the line, Gussets must be provided for all Vents &
Drains (providing Gussets shall be a part of Bleeder replacement job and no extra
payment shall be made for the same). If the Bleeder assembly is of Threaded
Fittings/Valves, no separate payment shall be made for the job. However, for Welded
Bleeder replacement jobs, Vendor shall be paid separately as per the relevant PO
line item rate. Welding Joints shall be of Radiography quality. It may be noted that
in case of any SR requirements for the Welded Bleeder replacement, etc. as advised
by HPCL Inspection, HPCL shall make separate arrangements for the same. However,
Vendor to provide necessary assistance for the same.
5. In case of rupture of any Section of the line during Hydro test, HPCL shall arrange
for necessary repair/replacement of the Section by deputing other Agencies.
Thereafter, as per advice of the concerned HPCL Supervisor, Hydro testing of the
entire line shall be carried out again by the Vendor (additional payment shall be
made to the Vendor for repeating the Hydro test). However, in case of failure in
Hydro testing due to poor workmanship by the Vendor (like leaks from the Welding
carried out by the Vendor, etc.) and reasons attributable to Vendor, rectification
of the same and re-Hydro testing of the entire circuit shall be carried out by the
Vendor at no extra payment by HPCL.
6. Vendor to prepare separate Isometrics of each of the Hydro tested Pipeline Loops /
Sections with all relevant details like Length, Line size; Flanges, etc. properly
indicated on the Drawing and submit the same to HPCL Supervisor.
7. After Hydro test completion, drain out Water and provide necessary assistance to
HPCL Operations for flushing the line with Compressed Air, etc. as per advice of
HPCL Supervisor.
8. On final approval of HPCL Supervisor, carry out necessary Spading/De-Spading and
provide assistance for commissioning of the line.
9. Vendor shall provide Pressure Gauges of range of 2 times the Hydro test Pressure at
the required number of points as per HPCL MI advice. Vendor to note that Pressure
Gauges calibrated within last 6 Months shall only be used and correlating
Calibration Certificate shall be produced by the Vendor for checking as advised by
the concerned MI/Maintenance Supervisor in-charge of HPCL.
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10. As per the advice of HPCL Supervisor, Vendor to replace Gaskets of various Flange
Joints in the Piping Loops/Sections taken before Hydro testing (or as advised by
HPCL Supervisor). Vendor shall be paid separately as per relevant PO line item rate.

Line Item no. 18

Hydro testing of Jacketed Pipe / Coils
General scope of the job remains same as the line item no. 14
1. In case of the Sulphur lines, if the lines is through & through but with some traces
or lumps inside the line , then in this case vendor has to remove the solid sulphur
from the line. This job shall be a part of the job scope without any extra cost to
HPCL.
2. If after opening the lines , it is found that the line is completely plugged then
vendor has to un-plugged it and payment shall be made under relevant PO line item
no.
3. Payment purpose Jacket pipe diameter shall be considered. In jacketed pipe line
testing, vendor shall test jacket of the piping. Whenever possible vendor shall
connect all intermediate jackets before testing without any additional cost to the
HPCL. The rigid connection material shall be issued as free issue material to vendor
for fabrication purpose. Vendor can fabricate this line with threading at site.
4. It may require that jacketed pipe has to take out from the position e.g. sulphur pit
vent line etc. & lay down at some other location for steaming or heating connection.
In this case the rigging shall be in the scope of the vendor.
5. HPCL may or may not give the crane , hydra, fork lift assistance to carry out the
job. The final decision in this regards shall be of HPCL & binding to the vendor.
Opening of the flanges shall be paid under line spading de-spading PO line item.

Line Item No. 19

Replacement of Threaded Items (Valves etc.)
1. Whenever required & as directed by the HPCL engineer vendor shall replace the
threaded valve in the unit.
2. This job requires prior permission of the HPCL engineer.

Line item no. 20

Replacement of Bonnet/Cover Gasket of Valves
1. Whenever required & as directed by the HPCL engineer vendor shall replace the bonnet
/ cover Gasket of valves. For this purpose vendor may have to replace entire
bonnet / cover of the valve.
2. In this case vendor shall remove the bonnet / cover of the some other valve shown or
given by the HPCL engineer for replacement purpose.

Line Item No. 21

Welding of SS Refractory Anchors/Lugs
1. As per advise of HPCL Engineer, Vendor to weld the required SS/SS304/SS310 anchors
/ lugs as required on the shell plate or channel plate or wherever required in SRU
train 1 or 2 or as directed by HPCL engineer.
2. Vendor shall first mark the required pitch as per drawing or as suggested by the
HPCL engineer & should offer to HPCL inspection department.
3. The SS anchors / lugs supplied by the HPCL may required some modification work &
same shall be in the scope of the vendor without any extra cost to the HPCL. e.g.
cutting the excess length.
4. After getting approval from HPCL Inspection department, vendor shall weld the anchor
/ lugs. Use E-309 Mo. Electrode / wire for welding SS anchors / lugs or as per HPCL
MI decision.

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Line Item No. 22
Item C: Fabrication of Bends for up to 2 Dia Line Sizes
1. Provide necessary services to carry out Cold Bending of the above sized Pipes, where
required, using Cold Bending Machine.
2. Vendor shall take all due precaution while bending so that bending portion shall not
get damaged. For this portion vendor shall use fine sand as filling material & cold
bull plugged both the opening After bending both the bull plug & sand should be
removed & line must be blow off with steam or air.
3. Supply of Cold Bending Machine shall be in Vendors Scope as a part of the Job.

Line Item no. 23

1/2 Inch to 2 Inch Socket Weld Joint, all schedules, of CS piping.
1. This line item is specifically added for Welded Valve (CS, up to 2 Dia size)
replacement, Steam Leak Jobs and Small Bore Pipeline (CS) Replacement job.
2. Piping shall be de-pressurized by HPCL and handed over to the Vendor for necessary
Spading/de-Spading. Spading/de-Spading shall be paid separately as per relevant PO
line item.. Flushing and Gas freeing of the Circuit shall be carried out by HPCL.
However, Vendor to provide necessary assistance for the same for valve operations if
required. Fabrication of temporary lines, if any, for de-pressurizing the Circuit,
cleaning, flushing is included in Vendors scope of job. Vendor shall fabricate the
temporary CS line, generally from Scrap Pipe (to be collected from the available
materials in the Scrap Yard, or as advised by HPCL Supervisor). Payment for such
temporary Piping shall be made separately on Inch Dia basis as per relevant PO line
item. After completion of jobs, such temporary connections shall be removed and
shifted back to the Scrap Yard or as directed by the HPCL engineer.
3. The existing piping to be cut or disconnected and removed. Vendor may have to carry
out Cold cutting, depending upon the Site condition. New Piping shall thereafter be
installed after proper fabrication. This includes fabrication/replacement of to
2 Threaded / Welded Piping, provision of Bleeders/Vents on Pipelines, along with
Gussets, as per requirement and as advised by HPCL Supervisor (Back welding of
threaded joints of Pipe & Valves, if required, is included in the scope of job). In
case the existing Piping is not to be removed and only new Piping is to be
fabricated & installed, then 90% of the applicable Line Item Rates shall be paid
(This shall be applicable to all fabrication Item Rates only. This shall however
exclude Items like Spading/de-Spading, Excavation & backfilling, Stress Relieving,
Radiography, Cutting of Slip Blinds & Dewatering Pump Operation). Calculation of the
amount payable shall be arrived at by Quantity Adjustment.
4. As a part of the job, Vendor shall carry out disconnection/reconnection of any Tie-
in Piping or Electrical/Instrumentation Fittings (like Thermocouples, etc.) and
provide suitable temporary Supports. As a part of the job and as advised by the
concerned HPCL Supervisor, Vendor shall provide Plugs and Caps on Vents and Drains.
Plugs and Caps shall be supplied by HPCL as FIM. Without any additional cost to the
HPCL.
5. Erection/dismantling of Scaffolding, wherever required for the job, shall be within
Vendor's scope of job. This shall be paid separately as per relevant PO Line Item
6. Only HPCL approved Welding Electrodes shall be used for the entire jobs under this
Contract, as per the list provided in ANNEXURE WE.
7. Vendor shall depute only approved & Coded Welders for all Welding jobs. Jobs shall
be awarded to Vendor only after the Welders are duly approved by HPCL's Material
Inspection Section.
8. The entire job shall be subjected to stage-wise Inspection and Approval by HPCL MI
Department. Mainly HPCL MI shall check the Fit-up of a line which is completely new
one or replaced with new one. But small repair work in unit at site location itself
shall not required HPCL MI certification for fit-up. But hydro test (wherever
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possible) of all repair work shall be witnessed by HPCL MI. & certification is
required for the payment purpose. Failing to which the line joint shall be
considered under temporary line weld joint basis. Though for small repair work HPCL
MI witness is not required it shall be vendors responsibility to inform the HPCL MI
that he shall carry out the repair work on the line & hydro test shall be offered to
them. All Weld Joints must be of X-Ray quality. Weld Joints may be subjected to
Radiographic checks at HPCLs cost. However, if welding does not meet the X-ray
quality, Vendor shall bear the charges of necessary repair and re-radiography
thereof without any extra cost to the HPCL and shall bear the re-Radiography
charges..
9. In case of CS, for Welding of Thickness <12mm, AWS E6010 shall be used for Root
Welding and AWS E6013 Electrodes shall be used for subsequent Passes. For Welding of
Thickness >=12mm, AWS E6010 shall be used for Root Welding and AWS E7018 Electrodes
shall be used for subsequent Passes. For Fillet Weld & Socket Weld Joints, AWS E6013
Electrodes shall be used.
10. Fabricate Steam Tracing lines, as per the Field requirements/as advised by HPCL. Fix
Steam Tracing lines with the help of Holding Lugs (provision of Holding Lugs shall
be in Vendors scope, including Materials, Electrodes, etc. as required for the same
and no separate payment shall be made). Also, bend the Steam Tracing lines as per
Site condition/as advised by HPCL. Payment for Bending the Steam Tracing lines shall
be made as per relevant PO line item.
11. Vendor to carry out DP check of socket welds for ensuring quality. Scope includes
all
i. Necessary equipments, materials, skilled personnel, etc required to
carry out DP Test as per
ii. Advise of HPCL Supervisor. Only MAGNA FLUX or P-MET DP material is
acceptable.
iii. Cleaning of the area to be tested, by buffing etc. as required, is part
of the scope of work.
iv. No separate payment shall be made for carrying out such DP Testing.
12. Welded Valves and small bore pipelines (up to 2 NB size) shall be replaced as per
approved procedures in the Refinery. Necessary Gusseting is included in the scope of
the job of Vendor and no separate payment shall be made for the same.
13. Hydro testing for Weld Joints of the Welded Valves and pipeline replacements, if
necessary, shall have to be done by the vendor. Vendor shall carry out Hydro
testing as per the procedure and at the Test Pressure as recommended by HPCL MI
Department. Pressure Gauges required should be provided by Vendor at required
locations as per advise of concerned Supervisor-in-charge of HPCL. Vendor to note
that Pressure Gauges calibrated within last 6 months shall only be used and
correlating calibration certificate shall be produced by the Vendor for checking
etc. as advised by concerned Supervisor-in-charge of HPCL. Fresh Water, Sea Water,
DM water or Soda Ash Solution, as required and as per advise of concerned HPCL
Maintenance Supervisor to be used for Hydro testing. Vendor shall make arrangements
for taking necessary connections from the near-by available points at the Work /
Fabrication Site. In case of any leak from the Weld Joints carried out by Vendor,
repair of the joint and re-Hydro testing the Fabricated Section / Circuit shall be
carried out by the Vendor. It should be noted that Hydro testing shall be part of
the Vendors job and separate payment shall be made as per relevant Line Item Rate
in PO. However, in case of re-hydro testing due to leak from weld joints and other
jobs attended by Vendor, no payment for such re-hydro testing shall be done. Re-
hydro testing shall only be paid if re-hydro testing is required to be carried out
for reasons not attributable to Vendors workmanship etc.
14. The job includes transportation of new Valves and other materials to the site.
Transportation of old Valves and piping etc. to a designated area inside the
Refinery premises is also Vendors responsibility

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15. Any Spading / De-spading required for the jobs involved above shall be paid
separately, as per the relevant PO Line Item Rates.
16. As advised by HPCL Supervisor, For nipple/pipe of vent/drain bleeder connections,
vendor to offer Fit up of all socket welded Joints & offer these welds for
inspection / DPT examination for checking integrity after completion of welding.
Vendor to carry out DP check of socket welds for ensuring quality. Scope includes
all necessary equipments, materials, skilled personnel, etc required to carry out
DP Test as per advise of HPCL Supervisor. Only MAGNA FLUX or P-MET DP material is
acceptable. Cleaning of the area to be tested, by buffing etc. as required, is part
of the scope of work. No separate payment shall be made for carrying out such above
jobs including DP Testing. The HPCL MI inspection check shall be done for complete
new line fabrication only.

Line Item No. 24

1/2 Inch to 2 Socket Weld Joint, all schedules, SS/KCS/AS Piping:-
Job Scope remain same as PO line item no. 23

Line Item No. 25

1/2 Inch to 2 but Weld Joint, all schedules, CS Piping
1. Job Scope remain same as PO line item no. 23 but inspection is compulsory , if for
any repair work at site HPCL may not check the fit up then vendor must show the
Hydro test whenever possible & as per instruction of the HPCL engineer.

Line Item No. 26

1/2 Inch to 2 but Weld Joint, all schedules, SS/KCS/AS Piping
Job Scope remain same as PO line item no. 23 but inspection is compulsory , if for
any repair work at site HPCL may not check the fit up then vendor must show the
Hydro test whenever possible & as per instruction of the HPCL engineer.

Line Item no. 27

Temporary Piping weld joint
1. Carry out fabrication and erection of temporary piping as per requirement. Collect
required materials from Scrap Yard or any other issuing location, as per advice of
the concerned HPCL Supervisor
2. After completion of the job if required vendor has removed the piping from unit area
& store or send to scrap as per direction of the HPCL Engineer.
3. This work is included in the job scope of the vendor without any additional cost to
HPCL.

Line item no. 28

1/2 Inch to 2 inch CS Corrosion Pad or Patch work.
1. Weld Corrosion Pads, as required, beneath the Piping sections, which shall be
resting on the Sleepers. Size and orientation of the Corrosion Pads should be as
follows - 12" Long Corrosion Pads, covering 1/3rd of the Pipe, circumferentially at
the Bottom. Due to location constrain pad length may be cut to suit at site with
prior permission from the HPCL executer.
2. Payment shall be made on Nominal Bore Pipeline Inch Dia basis.
3. Whenever required vendor should carry out the patch work to arrest the leak from the
piping , in this case the length of the patch shall depends on the leaky portion of
the line & payment shall be done on Nominal Bore Pipeline Inch Dia basis
irrespective of the length of patch.

Line item no. 29

1/2 Inch to 36 Inch CS Reinforcement Pad

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1. Vendor may have to carry out Branching of Pipelines, as required, in case Tees are
not available. Payment of the Joint shall be made on the basis of NB Diameter of the
Branch Pipeline.
2. Provide Reinforcement Pads as per Refinery Standard (2D, where D is the NB
Diameter of Branch Pipeline), wherever direct Tapping is taken from the Pipeline.
3. Payment for Reinforcement Pad Welding shall be made on the basis of NB Diameter of
Tapping.

Line item no. 30

6mm Thick CS Fillet Welding
1. The rates given in the SOR are for 6 mm thick welding.
2. For any other Thickness of Fillet Welding, Payment shall be made on pro-rata basis.
3. Calculation of the amount payable shall be arrived at by Quantity Adjustment.

Line item no. 31

6mm Thick SS Fillet Welding
1. The rates given in the SOR are for 6 mm thick welding.
2. For any other Thickness of Fillet Welding, Payment shall be made on pro-rata basis.
3. Calculation of the amount payable shall be arrived at by Quantity Adjustment.

Line item no. 32

Removal of CS/KCS/AS/SS Pipeline and reinstallation of the same after
repairs/modification only.
1. Scope of this Item includes removal of the line that is to be repaired / modified by
de-Bolting and/or Cold/Hot cut, as per advice of the concerned HPCL Supervisor.
2. Blinds the open ends, blinding of the open ends shall be in the scope of the vendor
without any extra cost to HPCL.
3. Vendor to cut the line in such a way that re-fixing of line is done with the minimum
number of Weld Joints. Reinstall the line by Bolting and/or Welding, as per the Site
requirement or as advised by the concerned HPCL Supervisor.
4. Vendor shall be paid for removal and reinstallation of line on Inch Meter basis.
This Rate shall be inclusive of Bolting/de-Bolting and no separate payment shall be
made for the same.
5. Weld Joints, Corrosion Pad, Reinforcement Pad, Corrosion Pad with Shoe Support,
Spading/de-Spading, etc. carried out for modification jobs shall be paid extra as
per the applicable PO Rates.

Line item no.33

Fabrication & Installation of MS Structural Supports
1. Cut and remove the old Structural as per instructions of the concerned Supervisor
in-Charge of HPCL.
2. The scope includes fabrication and installation of new Structural support as
required or as advice by HPCL engineer, or minor repair work in & around the SRU/ARU
unit.
3. Structural replacement Rate includes cutting & removal of old Structures, shifting
it to the scrap yard and fabrication & installation of new Structures.
4. Structural Material shall be provided by HPCL as free issue material
5. Vendor shall collect the structural material from the location as advised by HPCL
engineer e.g. Warehouse or scrap yard etc
6. For cutting and removal of existing Structures from Height, Vendor shall ensure
appropriate rigging arrangement for safe removal & bringing down such Structures to
Ground level.
7. Payment shall be made basis Metric Ton of the installed Weight of structural

Line Item No. 34

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Removal or Installation or replacement of the flanged valves of all rating, types &
at all elevation.
1. After necessary de-pressurization by HPCL and handing over to the
Vendor, carry out Spading/De-spading where required for isolation of
Vessel/Pipelines, to facilitate removal of the Flanged Valve.
2. Remove the existing Valve (if the job is at elevation, Vendor to bring
the Valve to Ground Level with the help of Chain-Pulley Block, etc.), tag the Valve
properly and transport the same to the designated Scrap Yard or Mechanical Workshop
or any other location, as advised by the concerned HPCL Supervisor for
servicing/reclamation purpose (Servicing/reclamation of any Valve is NOT INCLUDED in
Vendors Scope of work, which shall be separately arranged by HPCL).
3. HPCL shall provide Crane/Forklift assistance, at its sole discretion,
depending upon Valve Size and where assessed that it would not feasible to carry out
the jobs by manual rigging arrangements, like Chain-Pulley Blocks, etc.
4. After removal of the existing Valve, if new Valve cannot be installed
immediately in position, put Blind Flanges to cover the open ends of
Vessel/Pipeline, as a part of the job at no extra Cost to HPCL.
5. Transport new or serviced/reclaimed Valves and other Free-Issue
Materials from Warehouse/Mechanical Workshop/other location and install the same
with necessary servicing of all Bolts for re-use to the maximum possible extent.
Transportation of materials from Ware House/Mechanical Workshop or any other
location inside the Refinery premises is a part of Vendors Job scope.
6. Carry out necessary Spading/De-spading for commissioning of the
Vessel/Pipeline, using appropriate Gaskets, as per the instruction of HPCL
Supervisor. Payment for Spading/De-spading shall be made separately as per the PO
Line Item no. 9 & 10.
7. Payment for complete removal & installation of any Flanged Valve shall
be made as per the PO Line Item Rate. In case of only removal or only installation
of any Flanged Valve, 50% of the PO Line Item Rate shall be payable, by Quantity
adjustment. Calculation of Inch-Dia payment for Flanged Valves shall be based on one
side Flange NB Diameter only.
8. Pl. note that the valves which is on the first deck of the exchanger
or on the deck of the 75E101/102/103/201/202/203 or first isolation valve of these
exchangers/condenser are not covered under this items as these valves are in the
scope of the vendor under line Item No. 1. Without any additional cost to HPCL.
9. Due to un-sufficient manpower or any other reason , if vendor fails or
delays the work then HPCL shall carry out this job by some other vendor & cost shall
be deducted from the vendors bill. In this regards HPCL decision shall be final &
binding to the vendor.
10. Welded Valves shall not be paid under this Item as they shall be
included in the Weld Joint Rates under relevant PO line item.

Line Item No. 35

Leak Test (of the entire SRU train 1 or train 2 unit.)
1. The payment unit mentioned in the SOR is for the entire Train unit 1 or Entire
Train Unit 2.
2. Normally this activity shall be carried out after s/d is completed & before start-
up.
3. Identify the flanges which were open for some work during the S/D or repair work in
the unit.
4. Put/fix masking tape on all flanges which are open in the unit for any reason by
anybody.
5. Give Nitrogen / air connection as per DHDS operation officers requirement with
pressure gauge minimum at two places as directed by the DHDS operation officers.
6. Pressurizing shall be done by the HPCL DHDS operation people.

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7. Once the pressurizing is done, check the pressure gauge if pressure dropped out the
check all the flanges with soap solution.
8. During check if the leaky flange is noticed then tighten it properly if required
replace the gasket
8.1 If the leaky flange is from the vendor touched flange , then vendor shall not get
any payment for the repair work
8.2 If the leaky flange is not from the vendor touched flange, then vendor shall get
additional payment with respect to the spading rates of the line for repair work.
9. To attend the leak, vendor may be required to replace the gasket in this case vender
shall get only de-spading ( one time ) rates with respect to point no.6.
10. Vendor shall deploy enough & skilled manpower for this, else the job shall take more
time.
11. All material required for completing the job e.g. masking tape; Soap solution, soap
bottle etc. are in the scope of the vendor without any extra cost to HPCL.
12. For payment purpose HPCL operation people shall sign the check list. No payment
shall be given to vendor, if vendor fails to submit the duly signed check list by
HPCL operation people.
13. The leak test is carried out to confirm the all flanges are tighten properly & to
avoid the again shut down of the plant to replace the gasket. However even after
this test during actual start up or within a 10 days period any leak is noticed then
vendor has to attend it with respect to point no.6.

Line Item No.36

Blowing Test
1. This test is carried out for
1.1 To check thoroughness of the lines (whether line or equipment is plugged or
not)
1.2 To check the leaky portion of the jacketed line.
1.3 To remove the dirt , dust etc. from the lines
1.4 After completion of the repair work before start-up activity as per operations
requirement.
2. As per requirement of the Operations people, carry out steam / nitrogen / air
connection.
3. Carry out spading at one end & Open the other end flange.
4. Carry out the blowing of the line (valve opening shall be done by the HPCL, vendor
shall assist them).
5. If the lines are found to be plugged, then vendor has to open the flanges one by one
& to carry out the blowing to identify the plugged portion. In this case opening of
the flanges shall be paid separately as per relevant PO line item.
6. After identifying the plugged portion, vendor has to un-plugged the line, payment
for un-plugging shall be given separately under relevant PO line item.
7. After unplugging the lines box-up the same.
8. In case of Jacket pipe blowing (either by blowing the jacket or by blowing the main
pipe) ,spade one end of the line or jacket & open other ends of the lines i.e.
Jacket ends as well as main pipe end.
9. If some time Jacket line is found to be leaky then vendor has to carry out spading &
de-spading of each jacket line to find out the leaky jacketed portion. In this case
spading & de-spading shall be paid separately under relevant PO line item.
10. After completion of the work box the line.
11. For payment purpose, HPCLs concerned operation department shall sign the check
list. No payment shall be given to vendor, if vendor fails to submit the duly signed
check list from HPCLs concerned operation department.

Line Item No. 37

Concrete ( RCC ) or refractory breaking

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Vendor is required to break the concrete / RCC or Sulphur layer or refractory for
variety of purpose e.g.
A. For opening of the liquid sulphur pit vendor has to break the Concrete (RCC)
/ PCC sealing to lift the Concrete slab.
B. For Inspection purpose
C. As advise by the HPCL engineer
D. Inside the west heat boiler or condenser as advise by the HPCL engineer.
E. The Wall refractory of liquid sulphur pit etc.
F. Inside the exchanger 75E101/102/103/201/202/203 or 75B101/201 or 75F101/201

1. Break the existing RCC Paving, at the marked location, to enable Excavation.
2. Vendor shall be permitted to use Pneumatic Concrete breaking Tool only if DHDS
operation authority permitted. Supply of the required Diesel operated Air Compressor
shall be in Vendors scope as a part of the job.
3. Carry out segregation of broken Steel Rods. Segregated Steel Rods shall be shifted
to designated area inside the Refinery only, Sulphur should be transfer to the dry
sulphur pit immediately, transportation is in the scope of the vendor without any
extra cost to HPCL.. Concrete & refractory to be store at one place as shown by the
HPCL engineer. HPCL shall arrange for disposal separately for removed concrete only.
4. The location of the job shall be entire SRU / ARU connected unit.
5. In running unit some time rundown line un-plugging is done by HPCL at that time
Liquid sulphur is overflow in the ground. After sulphur becomes dry same should be
break transferred to the dry sulphur pit nearby.
6. Payment shall be made on per M3 basis of RCC broken / excavated. & for Sulphur on
weight MT basis

Line item no. 38

Diesel driven Dewatering Pump Operation (per Shift of 8 Hours) (using approx. 5 HP
pump).
1. As required and advised by the concerned HPCL Supervisor, carry out Dewatering
jobs, using Diesel operated Dewatering Pump (with Operator).
2. Ensure proper draining of Water, as advised by HPCL Supervisor.
3. Draining shall be done in the OWS or open nullah , the arrangement for this
purpose shall be in the scope of the vendor without any extra cost to HPCL. Vendor
to note that in any case water should not drain directly on the unit floor.
4. Vendor shall supply diesel pump with suitable accessories along with safety
devices, competent supervisor and operator to pump out water from designated sites
within DHDS on round the clock basis. Scope includes maintenance of all the assigned
equipment & supply of diesel, suction and discharge hoses, suction foot valve and
associated clamps and fittings.
5. Payment shall generally be made basis Rate for 8 Hours Shift operations. However,
in case of usage of Pump for less than 4 Hours, minimum of 4 Hours shall be paid. In
case of usage more than 4 Hours, payment shall be made on pro-rata basis as per the
relevant Rate in PO. Calculation of the amount payable shall be arrived at by
Quantity Adjustment.

Line item No. 39

Box-type Scaffolding (Erection + Dismantling)
1. Pl. carry out the scaffolding strictly as per the annexure attached with this PO.
2. Vendor to note that the scaffolding is being erected for their own job but as this
job is of Shut down nature job , other agencies / vendor shall also working at the
same place e.g. Insulation vendor , piping vendor , refractory vendor etc. All these
vendors require the scaffolding at different places. Some times it may be at the
same place, but physically it is not possible for two vendors to build the
scaffolding at the same place.

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3. Vendor shall build the scaffolding strictly as per PO & hold it till the complete
Shutdown is not completed. In this regards HPCLs decision shall be final & binding
to the vendor.

Line item no. 40

Standby Services :-
1. To attend the flange leak.During start up few flanges which are not touched by the
vendor gets leak , same to be attended on priority basis.

2. The start up activity of SRU unit may get delay due to

2.1 The main fluid of SRU unit is sulphur which is very corrosive in nature due to
which surprise leaks may occur during the startup. due to this leak operation has to
repeat the shut down & start up procedure.
2.2 SRU unit has many steam jacketed lines. These jacketed lines may leak during
start up. Operation needs to repeat the shut down & start up procedure
3. SRU unit can not be started in one shift & requires minium 5 to 6 days ( as per
recommendation of its Licensor )
4. It is observed that The Dirt legs, rundown line, seal pot & strainer get plugged
during start up .

Due to the aforesaid & other unexpected jobs, stand by services of semiskilled workers
are required to attend to these jobs.

Vendor shall note that during the stand by period if any flange leak or any job occur,
if same is attended by the vendor which was due to his own poor workman ship than he will
not get the stand by payment for that particular shift.

It is expected to start the Stand by services shift after 6 days, after all jobs having
been completed as per Job list & de-spading & as per PO line item is over.

Vendor shall not be eligible for payment,if repeat job occurs due to his own poor
workmanship during the stand by period.

Vendor shall arrange the standby services within 24 hours of notice from HPCL.
Minimum 1 shift of 8 hours per worker shall be paid evenif HPCL do not assign any job or
assigns jobs for less than 8 hours of actual work.

For jobs done beyond any 8 hours shift's actual work, payment for such Extra hour's work
shall be done against separate Line item.

Shift shall be counted basis "Reporting Time" and "Leaving Time" at Site, certified by
HPCL Maintenance.
Vendor shall follow all statutory rules regarding payment of Minimum wages, PF, ESIC,
duble wages for each extra hours work, etc. to the workers and submit documentary evidenc
to HR dept. as per rules.

HPCL's SCOPE OF SUPPLY:

1. Hardware like Nut Bolts, Gaskets, Gasket sheets, Cotton Rags, Grease will be
issued free of cost from Main Warehouse.
2. Slip Blinds, Eductor Rings and Air/Water/Steam Hoses will be issued on Loan
basis from Tool Room.
2. Electrical Power points will be provided, if required, for illumination purpose
only.
3. Crane/Fork-lift/Flat Bed Truck, with Operator, for
removal/installation/transportation of Exchangers components/Burner assembly. Note
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that such assistance will be provided only for heavier components and where felt
necessary by HPCL. Otherwise, Vendor to arrange necessary Chain-Pulley Block,
Tripod, etc. to carry out the jobs in a safe manner.

Vendors SCOPE OF SUPPLY:

1. All tools & tackles required to carry out the above jobs like Chain-Pulley
Blocks, Spanners, Hammers, Fixed/ Rope Ladders, Hack Saw Blades, Teflon Tape,
Clamps, etc.
2. All Testing arrangement and facilities like Hydraulic Pumps, calibrated
Pressure Gauges, etc.
3. Transportation assistance for to & fro shifting of components in case of
repairs/replacement.
4. 24V Hand Lamps, Cables & portable Switch Box for illumination.
4. Supply of Metallic Scaffolding materials and erection of the same as per job
requirements.
5. Any other arrangement required for carrying out the jobs which are not specifically
covered under HPCL's Scope of Supply.

NOTES TO VENDOR:
1. Before submission of his tender, the vendors/bidders shall thoroughly study the
entire tender document, visit the site, assess the full scope of work & seek
Technical clarification(s), if any, from Maint. Planning/Field Maint. And all non
technical clarification(s) shall be sought from Purchase department.
2. After PO placement, no compensation of any kind shall be claimed by the vendor for
lack of any information whatsoever connected with the works.
3. All the tender documents like, SOR, Job scope & notes to Vendors, drawings & other
documents asked or demanded by the Purchase department etc. shall form integral part
of the Tender & the Purchase Order
4. Vendor shall ensure use of skilled Manpower and specialist Riggers to carry out the
job of this nature, which usually has to be carried out in the running unit.
5. All Bolts & Nuts shall be serviced, segregated and stored properly for re-use.
Wherever necessary, Vendor shall cut WR Asbestos Gaskets of Exchangers as a part of
the job from the material issued by HPCL. Hot/Cold cutting of Nut-Bolts during
stripping of Exchanger Components and cutting of Stud Bars to the required Stud size
during re-assembly of Exchangers are included in scope of the job.
6. Repairs of any Roll leak, if required, will be separately arranged out by HPCL.
7. Vendor must take utmost care while handling the Tubes so as not to cause any damage
to the Tubes.
8. Any Refractory repair work will also be carried out by HPCL separately.
9. Vendor shall keep dismantled parts of Exchangers in such a manner not to obstruct
any Crane and Fork-lift movement.
10. Dropping and reinstallation of related Pipelines, if required, are included in the
Scope of jobs. Crane will be provided as per the requirement approved by the
concerned HPCL Maintenance in-Charge.
11. Rigging Tackles and fabrication of Fixtures, if required, would be in Vendor's
Scope. Material for fabrication of the same will however be provided by HPCL as FIM.
12. Vendor must return all Loan materials back to the issuing Tool Room, within Two Days
of job completion. Material Reconciliation Report shall be submitted along with the
Delivery Challan.
13. Vendors are advised to go through the Job Description and visit Site before
submission of their offer for the job. For any clarification, Vendor may contact the
concerned Maintenance Section in advance.
14. Vendor shall start the jobs immediately after handing over of the Equipment by HPCL
and complete the entire jobs within the shortest possible duration, as agreed with
the concerned Section of HPCL. Depending upon Plant exigency, jobs may have to be
carried out beyond normal Working Hours, including on Sunday/Hoilday and/or Round-
the-Clock basis for completion of the same within the Schedule. However, no separate
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payment will be applicable for working beyond normal Working Hours/Round-the Clock
basis.

GENERAL NOTES:
1. Vendor to obtain proper Work Permit, issued by the competent Authority of HPCL,
before carrying out any job. Entire job will be subjected to stage-wise Inspection
and Approval by HPCL. All arrangements and materials for stage-wise Inspection, as
instructed by HPCL, are in Vendor's scope. Vendor will have to co-ordinate with HPCL
Inspection and Maintenance sections to expedite the job. Vendor to take up jobs as
per the priority set from time to time by HPCL Maintenance Engineer. Vendor shall
maintain proper documentation/record keeping, etc. of the jobs.
2. Transportation of materials from Warehouse/Planning Yard to the work site is in
Vendor's scope.
3. Fork-lift will be provided by HPCL for transportation of Exchanger Components and
shifting of scrap filled Drums.
4. Total job shall be carried out in a manner not to hinder any near-by activities.
5. Jobs shall be carried out in a manner not to cause any damage to the surroundings.
Damage, if caused while carrying out the job, shall be made good by the Vendor at no
extra cost to HPCL.
6. Vendor shall arrange adequate & skilled Manpower and Supervisor. Manpower deployed
by Vendor should be experienced in similar type of jobs. All Equipment, Tools &
Tackles used should be of appropriate Type and Size, approved by competent Authority
for its SWL. All Equipment shall be brought inside the Refinery with proper Gate
Entry only.
7. At any stage of work, if progress of the job is found unsatisfactory, HPCL reserves
right to carry out remaining portion of the job by hiring services of other Agencies
to meet the Job Completion Schedule and back charge the additional/incidental Cost
of such services to Vendor's Account.
8. Vendor must ensure that all good and re-usable materials are serviced and re-used.
9. Vendor to mobilise the manpower and other resources at short notice and carry out
pre-Shutdown activities, wherever possible and as advised by HPCL Site Engineer.
10. Vendor will be required to maintain Good Housekeeping during and after the
completion of the job until the job is satisfactorily accepted by HPCL. Vendor to
collect all Debris/Scrap generated from the work area and dump at designated places
inside the Refinery, as instructed by HPCL Site In-charge.
11. In case of doubt, the same can be inquired from the concerned HPCL Maintenance
Section.
12. In case of controversy, HPCL's decision will be final and binding on the Vendor.
13. Any minor changes in scope of work required for completion of work shall be carried
out by Vendor at no extra cost to HPCL.
14. Stand-by personnel shall be provided by Vendor during start-up/commissioning of the
Plant facilities.
15. In case of fabrication/machining requirement of any item outside the Refinery, Free-
issue materials, as per the Contract and based on requisition submitted by Vendor,
will be allowed through Shipping Memos (Returnable Gate Pass) on verification by
HPCL. On returning these materials in finished condition or while returning excess
material, Scrap generated by machining only, will be retained by the vendor and the
same to be considered while quoting for the job. Vendor must obtain necessary Gate
Entry stamping and submit the same to the executing Department for reconciliation &
records. Vendor should also give reconciliation statements of the all Free-issue
materials for each job executed.
16. For General Notes and Terms & Conditions related to Environment, Health & Safety
(EHS) for execution of jobs inside the Refinery premises, please refer to linked
documents provided along with the Tender.
17. HOW TO QUOTE: Please quote a single %age (+ or -), applicable to all the Line Item
Rates given in the Schedule of Rates provided in the Tender.

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*********************** End of document *******************

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