Scope of Work

Tender Title : Providing Annual Rate Contract for “LPG Bullet
cleaning, statutory inspection, painting, NDT & Hydro testing”

CRFQ No. 1000410329
at BDT,BPCL Bina Refinery.
NAME OF JOB:
Providing Annual Rate Contract for “LPG Bullet
cleaning, statutory inspection, Painting, NDT &
hydro testing” at BDT, BPCL, Bina Refinery.
SCOPE OF WORK
(CRFQ No–1000410329)
Page 1 of 31
CRFQ No. 1000410329
S. DESCRIPTION NO. OF
No. PAGES
1 COVER PAGE 1
2 MASTER INDEX 2
3 INTRODUCTION OF THE JOB 3
4 SCOPE OF WORK 3
5 BPCL’S SCOPE 10
6 CONTRACTOR’S SCOPE 10
7 SPECIAL CONDITIONS 15
8 ANNEXURE’S 19
9 LIST OF ATTACHMENTS 32
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CRFQ No. 1000410329
1) INTRODUCTION OF THE JOB:
The intent of this tender is LPG Bullet cleaning, statutory inspection, Painting, NDT & Hydro
testing of 6 (Six) Nos. of LPG Mounded Storage Bullets installed at BR, BDT BPCL under SMPV
(U) Rules 1981 and carry out repairing of same, if any.
The work shall broadly De-commissioning / De-gassing / Cleaning / including removing all fitting
and instrumentation, carrying out chicken test, supplying & providing blind flanges / spades /NDT
/hydro testing /mixture of shot & grit blasting & Painting/ de-blinding / boxing up the vessels after
completion of inspection with all instruments / Certification as per statutory as applicable. The
contractor shall organize all labors, consumables, fasteners, tools, tackles, material and
equipment for above operation and the rates quoted shall be inclusive of all.
2) SCOPE OF WORK:
As per SMPV (Static and Mobile Pressure Vessels), frequency of internal inspection & periodic
testing is once in five years for LPG mounded bullet.
Following is the list of BDT LPG mounded bullets for next Inspection
Sr. No . Bullet No Capacity in M3
1 70 - TT - TB - 01A 3295
2 70 - TT - TB – 01B 3295
3 70 - TT - TB – 01C 3295
4 70 - TT - TB – 01D 3295
5 70 - TT - TB – 01E 3295
6 70 - TT - TB – 01F 3295
Inspection and testing of LPG bullets shall be carried out by competent person (“Competent
person” means a professional organization comprising of at least two persons
recognized by the Chief Controller, for such gases and vessels and for such period as
may be specified as competent for carrying out tests, examination, inspections,
certification for installations). All the maintenance and inspection activities shall be included
in the scope of contract and job shall be carried out with witness of all the inspection activities /
testing by BPCL-BR inspection engineer along with competent person.
2.1) Internal Inspection
1. Carry out positive isolation, open all manhole covers of the bullet, and offer the bullet for pre-
cleaning inspection.
2. Provide proper lighting, ladders, exhaust fans / air ejectors, erect internal scaffolding and carry
out internal cleaning followed by inspection & thickness measurement (USTM) evenly spread
over the entire inner surface including both dish ends and the openings. For USTM minimum 48
points on each shell course, minimum 10 points per petal and crown for dish ends and 10 points
on each man way and nozzle above 4 inches and 4 points on nozzle up-to 4 inches shall be
taken.
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3. Remove internal coating, clean all the circumferential & longitudinal weld joints of shell & both
dish ends crown weld joints by power brushing covering 6” on either side of the weld and carry
out visual inspection and 100% WFMPI (Wet Fluorescent Magnetic Particle Inspection).
4. Remove coating, clean all nozzles to shell weld joints by power brushing and carry out visual
inspection followed by WFMPI and DP testing.
5. Remove coating, clean all the internal stiffeners to shell weld joints by power brushing and carry
out WFMPI and DP testing.
6. Carry out Ultrasonic Flaw Detection (UFD) of welds not less than 25% of circumferential &
longitudinal weld seams, 100 % T– joints of shell & both dish end crown and all nozzle joints.
7. Carry out hardness test randomly on circumferential and longitudinal welds including parent
metal and nozzle welds from inside, heat affected zone and the weld beads on all the plates and
joints.
8. Carry out Corrosion mapping of liquefied petroleum gas (LPG) mounded bullets at Bina Refinery
using robotic crawler based automated ultrasonic scanning System.
9. Remove external fire proofing from all the instrument nozzles, clean and carry out USTM &
inspection for external corrosion.
10. In case of any indication of defect or doubts about any defect in WFMPI, removal of the mound
cover may be required to expose the outer surface for necessary examination from outside.
11. While carrying out any Non Destructive examination (NDE) attention shall be given in areas near
supports, fittings, reinforcement rings, field welds, bottom nozzles etc.
12. Any major repairs (if required) shall be carried out only after taking approval from competent
authority.
NOTE: - ND examinations schedule to be submitted before start the NDT.
2.2) Internal Painting
Internal painting shall be restored in kind after Inspection and completion of any job (if
required) as per the following procedure:
1. Surface preparation: Surface preparation Sa 2.5 by mixture of shot and grit blasting.
2. One coat of two component High Build Epoxy Phenolic primer cured with polyamine adduct
hardener (F-15) @ 100 micron DFT/ coat.
3. One coat of two components High Build Epoxy Phenolic intermediate coating cured with
polyamine adduct hardener (F-15) @ 100 micron DFT/ coat.
4. One coat of two component High Build Epoxy Phenolic finish coating cured with polyamine
adduct hardener (F-15) @ 100 micron DFT/ coat.
5. Total DFT 300-micron minimum. (The above coating materials shall have minimum volume
solids of 62% to provide the desired DFT.)
2.3) Inspection of Connecting Lines
1. Provide proper scaffolding access for comprehensive inspection of LPG inlet, Vapour balance &
PSVs inlet lines for USTM at all elbows, all T sections, all Injection / Mixing points, all reducers
and at every 06 meters of straight length.
2. Remove fire proofing followed by cleaning of outlet lines up to insulation joint and carry out
USTM, Visual inspection and WFMPI of weld joints of outlet elbow.
3. Electrical shall carry out inspection of all insulation joints for its functioning.
4. Clean and carry out DPT of all the RTJ gasket grooves.
2.4) Mound External Inspection
1. On each bullet, make pockets of 2 feet x 2 feet on the mound surface at every 10 meter at the
location shown by Inspection engineers for inspection of Geotextile protection layer of the
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mounds. If found damaged, restoration shall be carried out in kind. After inspection restore the
mound as existing.
2. Remove all the vegetation from the mound and carry out filling of gap/voids at all damaged
locations
3. Visual inspection shall be carried out in the bottom sand drains for the bleeding of sand through
drains.
2.5) Hydro-Static Pressure Testing:
1. After completion of all NDTs and internal inspection carry out hydro-test of all bullets at 19kg/cm2
2. Reading of the foundation settlement shall be taken during water fill at 0%, 25%, 50%, 75%,
100% and again 0% after water draining.
3. Hydro testing of the bullet shall be carried out with all internals fitted inside and all the first
isolation valves in hydro test circuit. This may require all spades installed for entry of the vessel
to be relocated on downstream of isolation valve.
4. After completion of the hydro test, drain the water slowly after taking necessary precaution.
2.6) Vessel Settlement:
1. Settlement of the vessel shall be monitored at all the reference points and the readings shall be
compared with the original readings for identifying the overall and differential settlements.
2. The bottom nozzle supports shall be checked and if required to be adjusted so as to release
undue Stresses on it.
2.7) Cathodic Protection
1. The PSP (Pipe to soil potential) reading at the test lead points for vessel shall checked and The
PSP survey results shall be plotted graphically to identify and locate cathodic holidays.
2. The minimum PSP shall be more negative than (- 0.85) volts with respect to copper/copper
sulphate half-cell. In areas where anaerobic bacteria active minimum PSP shall be more
negative than - 0.95 volts instead of (- 0.85) volts.
3. Ensure that polarisation potential is below (- 1.2) volts with respect to copper/ copper sulphate
half cells. Polarisation potential shall be measured at a given location on a vessel by measuring
PSP immediately (within the first second or two) after simultaneously interrupting the current
output from all cathodic protection sources affecting that portion of the vessel.
4. The polarisation cell shall be checked for replenishing the liquid levels (KOH).
2.8) Pressure Relief Devices
Following relief valves shall be removed and sent for overhauling & testing at BPCL-BR
workshop. Test shall be witnessed by competent person and BPCL-BR inspection engineer.
Sr. No. PSV No Make Set Pressure Location

Kg/Cm2
1 70-PSV-1901A/B M/s MEKASTER 14.5 70 - TT - TB - 01A
2 70-PSV-1902A/B M/s MEKASTER 14.5 70 - TT - TB - 01B
3 70-PSV-1903A/B M/s MEKASTER 14.5 70 - TT - TB - 01C
4 70-PSV-1904A/B M/s MEKASTER 14.5 70 - TT - TB - 01D
5 70-PSV-1905A/B M/s MEKASTER 14.5 70 - TT - TB - 01E
6 70-PSV-1906A/B M/s MEKASTER 14.5 70- TT - TB - 01F
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1. All relief devices shall be externally painted as per following painting scheme
 Surface finish: ST-3, power tool cleaning
 Primer: 1coat of F-8 self-priming epoxy @ 100μDFT/coat
 Finish coat: 1coat of F-2 Polyurethane @ 40μDFT/coat
 Total DFT: 140 microns (RAL 5013 (Cobalt Blue) color)
2. The excess flow valves and the remote operated valves shall be inspected and tested.
2.9) Special Points Applicable for NDT Activities:
1. All pressure gauges used for testing shall be calibrated at NABL approved laboratory and valid
calibration certificate shall be provided at the time of testing. BPCL-BR reserve the right to check
the calibration of the gauges at instrument work shop before use of the same.
2. All pressure gauges’ calibration details shall be mentioned on the vessel certificate and gauges
calibration certificate shall be attached with vessel certificate.
3. All Non Destructive Examinations shall be carried out as per ASME Section V
4. Coating inspector NACE CIP Level 1 is required to monitor the painting and blasting activities.
5. All the consumable, equipment required for non-destructive examination shall be in the scope of
contractor.
6. Contractor shall deploy pneumatically operated equipment for working inside the bullets.
7. All the non-destructive examination equipment like WFMPI and UFD shall be battery operated
only. Sufficient spare chargeable battery back shall be kept available during the work.
8. All NDE activities shall be carried out by persons having minimum ASNT Level-2 qualification
with at least 2 years’ experience in particular NDE.
9. Ultrasonic thickness measurement equipment shall be Krautkramer / GE or Panametrics
/Olympus only, with valid calibration certificate.
10. For WFMPI, Aerosol can for fluorescent liquid shall be of Pmet or Magnaflux make only.
11. Only Aerosol CAN of Pmet or Magnaflux make shall be used for DPT.
2.10) Automated Ultrasonic Scanning (AUT):
The following shall be the minimum requirements for carrying out AUT:
1. Large structure inspection (LSI) automated ultrasonic scanning system shall be used for bullet
shell and both dish ends. Approx. area for scanning per bullet is approx. 1900 m2.
2. The automated ultrasonic scanning shall be done internally from inside the bullet, with confined
space entry.
3. The vendor shall mobilize minimum two machines to complete the job within the stipulated time
of 7 days for one bullet. If more machines are required contractor has to augment the same
accordingly.
4. Automated scanning crawler shall be capable of traversing the entire vessel shell from inside
without the effect of the inclination / curvature of the vessel.
5. The machine should be able to travel 360 degrees and shall be able to take all readings including
overhead positions (i.e. 11' o clock to 1' o clock) Vendor may use different techniques to capture
data in this area, if necessary.\
6. Water or any other suitable couplant may be used. The water Bullet shall be of moderate size
(Not more than 200 liters) and shall have one attendant to continuously monitor the water level.
Any additional requirement for makeup water shall be made.
7. The probe shall be capable of reading through the thickness of the paint film.
8. The system shall be used to perform A-B-C-scanning of entire vessel from inside with pre-
decided scanning resolution.
9. All the A-B-C scan data shall be digitally stored on computer as permanent record. This data
shall be submitted to BPCL-BR along with the final reports.
10. Initially coarse scanning shall be carried out with 50 mm index and 2 mm scan.
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11. Fine scan with 5 mm x 2 mm shall be carried out in the selective areas where corrosion / suspect
indications are found during Coarse scanning. This shall be limited to corroded zone only.
12. The vendor shall bring the following manpower as a minimum per system per shift of 12-hours
for automated ultrasonic scanning.
a. 1 x ASNT Level-II-UT engineer
b. 2 x Technical Assistants
c. 2 x Helpers
13. For Automated scanning (coarse/fine), the vendor has to quote on per square meter basis.
14. Scanning / Preliminary observations report shall be submitted after completion of the job on daily
basis and final report shall be submitted within five days after completion of the total job.
15. The final report shall be signed and endorsed by ASNT level III personnel.
16. The vendor shall indicate the prerequisites of surface preparation like shot blasting / power
buffing required to carry out AUT, if necessary.
17. Water storing and evacuation facility from the bullet along with necessary pumping arrangement.
18. All equipment required for AUT along with skilled manpower, consumables if any, protective
clothing and safety gears etc.
19. Any other item essential to carry out the job, but not explicitly mentioned in BPCL's scope of
supply.
20. Contractor shall bring necessary 30Amp ELCB Board, sufficient length electrical cables and
other required accessories for carrying out the job.
21. Only calibrated equipment with certificate shall be used whose validity shall not be more than
one year and should have proper records and traceability.
22. Job shall be carried out by persons qualified with valid certificate holders of ISNT / ASNT Level-
II in AUT.
23. Scanning / Preliminary observations report shall be submitted after completion of the job on daily
basis.
24. Submit the Final inspection report indicating the observations and findings duly marked on a
sketch, immediately after completion of job on each of the equipment as per ASME Sec V, duly
checked, reviewed and endorsed by ASNT level III personnel.
25. On completion of NDE, the inspected area shall be cleaned free of debris / grease / oil or any
other consumable used for the job.
26. On completion of scanning, the entire mapping of the bullet shall be completed as follows:
a. Results sheet showing corroded Location with details.
b. Graphic & color-coded C-scans with corresponding B-scans for corroded locations
c. A-B-C-scan data for entire vessel.
27. Submit two copies of all mapping reports in color and one soft copy in color containing findings,
observations and valid certificates of the personnel who has carried out and certified the job.
28. AUT equipment being deployed by Contractor should have capability to carry out Coarse
Scanning 50 mm X 2 mm grid (10 thousand thickness points per Sq. Mtr.) and also Fine
Scanning 5mm X 2mm grid (1 lakh thickness points per Sq. Mtr.) on curved shell plates having
thickness range from 22 mm to 45 mm.
29. Contractor should have carried out AUT scanning on similar comparable size, operating
equipment himself or his associates preferably in India or anywhere in the world. Clear
documentary evidence should be produced at the time of bidding.
30. Contractor shall submit a written declaration confirming capability of resource mobilization of
doing entire AUT of one vessel in 7 working days on round the clock basis by way of deploying
multiple number of machines along with dedicated operating team for each machine at site.
31. The AUT machine shall be capable of travelling 360 degrees all along the vessel inside shell
surface and shall be capable of collecting all the readings smoothly on overhead positions of the
vessel.
32. The Contractor shall submit verifiable details of their experience profile. Details shall include
plants name, address, contact person, nature of job undertaken, period etc.
33. The entire AUT activity shall be carried out under direct site supervision & written certification by
ASNT/ISNT UT Level 3 qualified professional and copy of his valid UT Level 3 certificate shall
be submitted.
34. AUT outputs along with Interpretations Report shall be submitted to BPCL in soft and hard copies
signed by UT Level 3 professional.
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2.11) Common Points:
1. All pressure gauges used for testing shall be calibrated at NABL approved laboratory and valid
calibration certificate shall be provided at the time of testing. BPCL reserve the right to check
the calibration of the gauges at instrument work shop before use of the same.
2. All pressure gauges’ calibration details shall be mentioned on the vessel certificate and gauges
calibration certificate shall be attached with vessel certificate.
3. All Non Destructive Examinations shall be carried out as per ASME Section V.
4. All the consumable, equipment required for non-destructive examination shall be in the scope of
contractor.
5. Contractor shall deploy pneumatically operated equipment for working inside the bullets.
6. All the non-destructive examination equipment like WFMPI and UFD shall be battery operated
only. Sufficient spare chargeable battery back shall be kept available during the work.
7. All NDE activities shall be carried out by persons having minimum ASNT Level-2 qualification
with at least 2 years’ experience in particular NDE.
8. Ultrasonic thickness measurement equipment shall be Krautkramer / GE or Parametric
9. /Olympus only, with valid calibration certificate.
10. For WFMPI, Aerosol can for fluorescent liquid shall be of Pmet or Magnaflux make only.
11. Only Aerosol CAN of Pmet or Magnaflux make shall be used for DPT.
2.12) Any Other Tests/ Jobs:
1. Any other testing / inspection job which is not described above and is required under SMPV (U)
Rules 1981 for certification and re-certification of the Mounded Storage Bullets are to be carried
out by the contractor and the same shall be deemed to be included in the total quoted rates and
scope of work. However, any licensing fee to be paid to CCOE, Nagpur for re-certification shall
be reimbursed by BOR: to the contractor at actual on production of proof/ receipt form CCOE,
Nagpur.
2. In case of any non-conformity / noncompliance of nay NDT reading(s) the same shall be
addressed with proper codes / standards / procedures / other approved documents and suitable
measures required to be undertaken to correct the non-conformity be suggested and evolved
for making the vessel suitable for further use including any liasoning work with concerned
authorities shall have to be done by the contractor.
BPCL Can engage at its own discretion and cost a third party inspection agency to witness and
monitor the inspection & testing jobs being carried out by the contractor.
2.13) Repair of Mounded Storage Bullets: (Optional)
1. All the repairs shall be carried out strictly in accordance with the requirements of SMPV (U)
Rules 1981 and the relevant codes / standards / specifications and it shall be the responsibility
of the contractor to ensure that all the repair relate jobs are done as per the procedures
mentioned in the relevant codes and standards.
2. The contractor shall also ensure that all the necessary preventive / safety measures are taken
in order to prevent any further damage to the bullet while carrying out repair jobs, if any.
A. Minor Repairs:
1. If any crack / flaw of minor nature has been noticed during the NDT / WFMPI Inspection,
the contractor shall undertake suitable repairs of the same.
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2. Once any crack / flaw has been noticed, the depth of the same shall be assessed by the
UT method with requisite sensitivity as per ASME code Section VIII Division 1&2. All the
cracks having depth lesser than the corrosion allowance provided for, shall be removed
by grinding.
B. Major Repairs:
If in the opinion of the CCOE / BPCL-BR Inspection / competent third party inspection
authority, any defects / cracks need to be repaired by welding and stress relieving, the
contractor shall carry out such repair jobs as per repair procedures duly approved by the
CCOE, Nagpur thro’ CCOE approved welders / fabricators. However, BPCL may at its
desertion can get these repairs done through any other repairing agency/ welder / fabricator
which are duly approved by the PESO.
NOTE: Any Repair will be taken care by BPCL, however all statutory approvals will be
in scope of vendor.
2.14) Reporting / Documentation:
All the documents and the final report shall be submitted in quadruplicate in properly bound
form for each LPG Bullet Without the submission of the final reports, the job shall be
considered as incomplete and payment shall be withheld as per relevant clauses of the
“payment Terms” referred in the SCC.
2.15) Activities to Be Carried Out: -
For fulfilling statutory requirement about Inspection / Hydrostatic Testing of Mounded Storage
Bullets the following activities as briefed below are to be carried out:
1. To provide positive isolation of Mounded Storage Bullets by installing blinds on inlet and
outlet lines of hydrocarbon liquid / vapour up to the first isolation valves by dropping spool
pieces or valves and to remove the Fire Proofing cement as per requirement. Removal &
normalizing of fire proofing and insulation as required to be carried by contractor.
2. To make the LPG bullet totally Hydrocarbon free by filling water and checking periodically
for settling of the Bullets during water filling. The settlement shall be noted after filling of
water at 0%, 25%, 50%, 75% & 100% of total volume.
3. To make necessary arrangements for proper lighting (flame proof fitting and Ventilation
inside the Mounded Storage Bullets, for safe movement and working.
4. To erect the scaffolding inside the LPG bullet as required for approach to the entire
circumference of shell and removal of scaffolding after completion of testing, inspection and
repair work (if any) is as per the detailed specification. All equipment & materials required
for the scaffolding at both dish end shall be arranged by the contractor. Scaffolding of
balance portion of the bullet will be executed by using trolley mounted platform type
scaffolding. BPCL standard Scaffolding procedure are to be followed.
5. Cleaning of bullet shall be done by hydro jetting.
6. To carry out necessary surface cleaning of weld joints or area as instructed by BPCL (by
mixture of shot and grit blasting) for NDT & repair works (if any).
7. The Inspection, Testing, Certification of the Mounded Storage Bullets included through
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visual inspection and inspection by various NDT methods such as UFD. WMPI, UFT,
Hardness Test, DPT whichever required etc. These will be subject for inspection and
clearance by BPCL Inspection representative.
8. To carry out minor repairs if any i.e. removal of cracks by grinding or any other approved
method as applicable.
9. To carry out major repairs if any (optional items) as per approved procedure by PESO,
Nagpur.
10. To carry out the grit blasting and painting at bottom 1/3rd portion or area as instructed by
EIC, as per specifications attached.
11. To carry out the Hydro-test in presence of the Competent Person as per approved procedure
and guidelines to the design hydro test pressure.
12. Carrying out external inspection on mound, retaining wall, inspection tunnel, bottom nozzle
& its suspension / support, accessible top nozzles etc.
13. Removal & shifting of pressure Relief Valves from mound top to loading at vehicle. (Vehicle
will be arranged by BPCL). Shifting of PRV’s from Vehicle to Mound top and Reinstallation
of the same.
14. To Carry out De blinding and boxing up of the LPG bullet and also do pre-commissioning
activities.
15. Submission of status reports and all supporting documents / NDT reports. All the documents
shall be submitted in quadruplicate in properly bound form for each LPG bullet.
16. Submission of final report with Certificate issued by PESO, Nagpur. The final report shall be
submitted in quadruplicate in properly bound form for each LPG bullet along with soft-form
(in CD) also.
3) BPCL SCOPE:
1. Power supply of 230 volts for NDT equipment’s and pumps, etc. up to Field junction box,
only.
2. Water Supply for Hydro test.
3. Degassing / Hydrocarbon free LPG bullet (Along with vendor support)
4) CONTRACTOR’s SCOPE: -
1. Pump along with all accessories for Hydro-test (flame proof design). CMRI certificate and all
associated certificates to be submitted before use.
2. Blinds & Gasket of required rating for conducting Hydro test. Gasket, flange Material, nut bolts
of all type shall by certified by BPCL Inspection department. Replacement of nut bolts / stud
shall also be certified by BPCL Inspection department. The procurement of nut bolts/studs
shall be as per drawing specification and is in the scope of contractor.
3. All gaskets required for LPG bullet will be provided by contractor.
4. Calibrated pressure gauges with certificate for Hydro test. (Any redundancy required)
5. DPT material & NDT equipment’s required for NDT testing.
6. All Consumable for any repairing work e.g. electrodes/cotton waste, etc. (Optional)
7. All the consumable like different type of gaskets (including metallic gaskets, spiral wound
metallic gaskets), blinds, washers, nuts, bolts, fasteners, angles, clamps etc. shall be of good
& standard quality and are in the scope of the party. Rates quoted by the party shall be
inclusive of all as above.
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8. All PPE’s / Safety gears for each individual labour including Dust Mask; Hand Gloves etc. to
be ensured, no deviation accepted.
9. Supply of grit slag/compressor and blasting gun (minimum 04 Nos) & skilled man power.
10. Supply of paint as per specification.
11. Provision of lighting equipment’s such as flame proof sockets, 24V Bulbs (Minimum 40 Nos.)
Braided / Armoured Cable only including panel for supply. Installation, extension and shifting
of the lighting equipment / arrangements as per job requirement. ELCB / trip switches to be
used for safety reasons. CMRI lab certificate of all FLP enclosures and test certificate of cable
and other accessories to be submitted before use.
12. In addition, the contractor shall note the following:
a. The equipment is required for use in hazardous environment as per area
classification Zone 1. All the equipment, tools and tackles shall meet the criteria.
Equipment, tools and tackles etc. not meeting the criterial shall not be allowed to be
used.
b. All the NDT Test equipment, Measuring Instruments, Gauges etc. shall be duly
calibrated having valid calibration certificate with traceability. Any equipment /
instruments not having valid calibration certificate shall not be allowed to be used.
c. The decision of Engineer-In-Charge regarding accepting any NDT Test equipment /
Measuring Instruments etc. shall be final and binding on the contractor. In case any
replacement is sought the same shall be arrange within 24 hours by the contractor.
13. Supply and erection of scaffolding by complying all the standards and safety norms. (may
refer attached photographs).
14. Electrical supply of 415 V & above is in the scope of contractor only by means of DG sets.
DG to be placed at a distance of minimum safe distance mentioned in OISD or as instructed
by BPCL & accordingly armoured cable to be arranged.
15. Contractor shall have minimum 03 numbers of IS mobile phones for communication with
prior approval by BPCL F&S.
16. Contractor to have his own Porta cabin site office in BDT area near E&P office.
17. Minimum two safety officer / safety supervisor shall be deployed by the vendor in each
shift. The minimum qualification of safety officer / safety supervisor shall be of graduate
along with diploma in industrial safety and having minimum 03 years of experience.
18. Following conditions shall be followed by the vendor for confined space entry inside the
Bullet specially for cleaning & Painting purpose
a. Only trained and experienced person/s shall be allowed inside the Bullet for the
sludge removal and cleaning purpose.
b. Vendor shall strictly follow BPCL HSE guidelines for confined space entry / inert space
entry, while executing the job.
19. Contractor shall arrange all the transportation to and fro & local, accommodation for their
manpower, materials, consumables, material handling equipment etc. The Contractor
shall arrange for all tool and tackles and other vehicles like dumper, crane to shift their
equipment into the Bullet farm as and when required. Diesel required for running diesel
driven equipment hired / owned by the Contractor.
20. Contractor shall monitor the atmosphere inside the Bullet for LEL, H2S, oxygen and other
toxic gases bymeans of gas detector for safe entry and maintain its records on continuous
basis. Separate portable meters shall be arranged by Contractor for each Bullet. Quantity
of these portable meters shall be sufficient to cater requirement at any time.
21. Any other consumables / equipment / materials required for completion of the job and not
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specifically mentioned in BPCL scope of supply shall be arranged by the Contractor.

22. During the execution of cleaning job of the Bullet, damaged fire protection systems due
to Contractor activity (Hydrant, Monitor, water spray, foam system and Rim seal fire
protection system, etc.) if any, contractor shall rectify, repair and restore the same up to
smooth functionality and acceptable level of BPCL fire and safety department.
23. Contractor has to get certified all Electrical equipment’s / tools by BPCL Electrical Department.
24. Vendor shall arrange all fire and safety gadgets required for the execution of job. All these
gadgets are required to be certified by BPCL Fire and safety department, before put into
use.
25. Contractor to submit tentative schedule (for cleaning and inspection jobs) during Bid
submission.
26. All Equipment’s & Manpower related to cleaning shall be in the scope of vendor. All the
charges towards mobilization of Manpower and equipment’s shall be in the scope of
vendor. Accommodation, conveyance & food expenses of the manpower shall be in the
scope of vendor.
5) PRECAUTION TO BE TAKEN DURING/ AFTER CLEANING (By Both Contractor &

BPCL)
1. Water shall be drained after regular visual inspection of discharge fluid.

2. Manholes to be opened for forced draft air circulation and making Bullet HC free.
3. Man entry will be done after clearance of EIC for manual scraping dry sludge and
further water washing.
4. Sludge to be manually mopped and shell plates to be cleaned to the satisfaction of EIC.
5. After cleaning & washing from manway, ensure that Bullet is free from water, emulsion
and sludge if any by draining the water into OWS and emulsion / sludge into barrels.
6. After the residual content free gas from the Bullet is totally pumped out, provide an
educator /exhaust blower to gas free the Bullet. Fit the exhaust fan to one of the roof
manhole manway cover and begin gas freeing. If exhaust / fan to be used for gas
freeing, then the motor and cable connections shouldbe of flame proof type.
7. Check the LEL and oxygen level inside the Bullet periodically.
8. LEL of CO / H2S should be ‘Zero’ while that of O2 should be >20.9 %. The Bullet is
considered ready for hand over for M&I when above condition get satisfied.
9. Continue to run the exhaust blower till the Bullet is free of hydrocarbon gas.
10. Use Breathing equipment’s for entering the inside the Bullet. Person must wear
protective clothes (helmet, Safety Shoes, Hand gloves, PVC apron, one person should
be always present near the manhole as stand by while others are working inside.
11. The sludge can be pyrophoric and is to be kept always wet with water.
12. Do not allow a single person to work continuously more than 30 minutes inside the Bullet.
13. In event of non- performance by the Contractor, suitable penal action can be taken by
the Engineer In- charge including termination of the contract and decision of Engineer
in charge shall be final. BPCL may engage any other agency to complete the balance
jobs at risk and cost of the existing Contractor.
14. Any equipment / material required to fulfil above mentioned requirements will be in
contractor’s scope only.
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6) OPERATIONAL SAFETY
1. The Contractor shall be required to work round the clock basis including Sundays &
Holidays. During the period of the contract, the Contractor shall not substitute / replace
man-power without prior consent of BPCL EIC. The Contractor has to submit proposed
manpower allocation plan & proposed manpower schedule along with the un-priced bid.
The workers shall be given weekly offs as required under the factory act. No worker
or supervisor shall work more than maximum of 12 hours a day on any day. All legal
obligation to employ skilled / unskilled workers as required under the law need to be
adhered to by the successful Contractor to the satisfaction of BPCL.
2. The Contractor shall give a declaration that all the equipment’s are intrinsically safe in
design and will not fail metallurgical, structurally etc. Statutory certificates for equipment
wherein required needs to be submitted as per MP Factory rules by the Contractor.
Discrepancies, if any noticed in Contractor’s equipment, the Contractor must take prompt
corrective action to the satisfaction of BPCL EIC. BPCL personnel will regularly visit the
Contractor’s plant and inspect all records and equipment health and number of
manpower deployed as and when required by him. Adequate spares shall be available
with the Contractor at site for maintenance purposes.
3. The Contractor must comply with all safety and environmental related requirements
as per the advice of BPCL during the entire stage of contract. BPCL will have the right
to terminate the contract at any time if the safety performance of the Contractor is not
satisfactory in any area of activity.
4. The Contractor shall observe all the safety precautions and obtain necessary work
authorizations and e-permits from BPCL before starting the work particularly in the
Bullet area.
5. The Contractor shall maintain proper housekeeping at the site at all time and shall
satisfy all the requirement of BPCL EIC in this regard. All the Contractor employees
shall wear 05 mandatory personal protective equipment failing to which BPCL
reserves the right to invoke financial penalties as per the laid down procedures of
BPCL for penalizing Contractors for not adhering to BPCL safety rules.
Service Provider's PPE Quality & Issuing Frequency
S.
No. PPE Type Specification Quantity Frequency
Safety Helmet EN:397 1 Yearly
1 IS:2925
2 Safety Goggles EN:166 1 Quarterly
ANIS:2925
Safety Hand
3 2 pairs Weekly
Gloves Polka Dotted
4 Boiler Suit Cotton 3 Sets Yearly
5 Safety Shoes EN-345 1 Pair Yearly

IS:15298
6. Contractor shall maintain a daily log and record for all their activities and make its copy
available to BPCL on daily basis. Any abnormalities which have safety and / or
environmental implications must be reported to BPCL immediately. Contractor shall
submit monthly report of all the activities giving all the necessary details as advised by
BPCL from time to time. The monthly report shall be submitted in the first week of
succeeding month.
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7. Obtaining all permits before start of the job including the Bullet entry permit as per
BPCL safety rules and Regulations and work permit system.
7) ELECTRICAL SAFETY
1. All equipment brought to the site by the Contractor shall be suitable for hazardous
area (Area classification: Class I, Division I, Gas group IIA & B as per CENELECEN
50014).
2. Contractor shall arrange one flameproof panel or DB from where all the loads shall be
connected as per load and equipment rating. From this panel power supply distribution
shall be given to all the equipment (Motors, lighting connection, single phase DB,
Starter for motors, etc.) used during Bullet cleaning job.
3. The flameproof panel supplied by the Contractor should be having 4 pole MCCB with
earth fault protection or SFU contactor feeder with earth fault protection or ACB with relay
in the INCOMER. All the outgoing feeders should be having 3 pole / 4 pole MCB &
RCCBs or MCCB with earth fault protection or SFU contactor feeder with earth fault
protection.
4. The outgoing motor feeder supplied by the Contractor should be of appropriate rating
as per the motor power requirement and it should have suitable overcurrent and earth
fault protection facility.
5. All the flameproof motors shall have independent push button stations with start and
emergency stop facility near motor itself.
6. All electrical equipment (Panels, starters, motors, light fixtures etc.) shall be suitable
for operation in Hazardous area of the Refinery.
7. All cables required for 3-phase / 1-phase power connections should be armored /
braided and should not be damaged at any place and should not have any joints.
Supply of all size and ratings of cables along with Flameproof Panel or DBs/machines
shall be in Contractor’s scope and all the equipment shall be certified from BPCL
workshop before usage.
8. The Contractor shall bring sufficient nos. of flame proof distribution boards (3-phase /
Single phase) as per the job requirement.
9. All cables terminations should be done using Flameproof double compression cable
glands and terminations done using proper sized cable lugs.
10. Work permit system is compulsory to be followed by Contractor as per BPCL policy.
11. All electrically powered flame proof machines should be certified from BPCL
workshop, after they had brought inside refinery. The shortcomings in machine are to be
rectified by Contractor at his cost immediately.
12. The Contractor shall deploy full time electricians having industrial wiremen certificate
for all the electrical jobs.
13. All the flameproof equipment and its accessories required for maintaining flameproof
integrity of Motor, Panel, Starter, Light fixtures, etc. required during Bullet cleaning
work shall be in Contractor scope.
14. All manpower required for cable laying, connection, disconnection, shifting of hand
lamp sets / flood lights / Power DB / all electrically operated machines shall be
completely in the scope of Contractor.
15. Earthing connections as per IS standard should be given to all machines / equipment.
Earthingwire shall be used for equipment Earthing with proper connection.
16. All necessary spares like HRC fuses, relays etc. required for replacement purposes
shall be maintained by the Contractor at site.
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17. Flood lights and Hand lamps- Contractor to bring sufficient flame proof flood light / hand
lamps EX-d IIA/IIB/IIC as per work area classification with all accessories.
18. All the equipment, accessories required during entire Bullet cleaning work shall be in
Contractor scope.
19. Contractor has to arrange for power by their own i.e. DG set etc.
20. 24 volts’ flame proof hand lamps and flame proof transformer for lighting purposes
shall be in Contractor scope.
8) OTHER CONDITIONS OF THE CONTRACT
1. The job shall be carried out for Bullet cleaning & Inspection as per the schedule and shall
complete within schedule by deploying sufficient resources. BPCL may facilitate round the
clock working if found necessary. However, our estimated time is based on general shift
timing of 08:30 hrs to 18:00 hrs working only.
2. Safety precautions to be taken as per BPCL Safety Guide lines while executing the jobs
3. Inspection and testing of LPG bullets shall be carried out by competent person
(“Competent person” means a professional organization comprising of at least two
persons recognized by the Chief Controller, for such gases and vessels and for such
period as may be specified as competent for carrying out tests, examination, inspections,
certification for installations). All the maintenance and inspection activities shall be
included in the scope of contract and job shall be carried out with witness of all the
inspection activities / testing by BPCL-BR inspection engineer along with competent
person.
4. Coating inspector NACE CIP Level 1 is required to monitor the painting and blasting
activities.
5. All NDE activities shall be carried out by persons having minimum ASNT Level-2
qualification with at least 2 years’ experience in particular NDE.
6. For Automated Ultrasonic Scanning (AUT) vendor shall mobilize minimum two machines
to complete the job within the stipulated time of 7 days for one bullet. If more machines
are required contractor has to augment the same accordingly.
7. Contractor has to mobilize minimum 3 nos of diesel operated air compressors for blasting
and painting job. (Diesel for compressors are in the scope of Contractor).
8. Contractor has to access the site conditions and submit the bar chart before start of job
for completion of M&I activity for each Bullet within 90 days immediately after mobilization
at site.
9. Contractor is required to submit organization chart along with details of experience &
qualification of engineer & supervisors.
10. Contractor shall engage specialized skilled manpower for the jobs as per work
requirement. The contractor shall be responsible for deployment of experienced
manpower in related field and to maintain quality of all painting jobs as per specifications/
instructions of EIC.
11. Contractor has to deploy breathing air systems (Minimum 04 nos.) for supply of fresh air
as approved by BPCL F&S at site for confined space entry and internal / external shot
blasting and painting job.
12. The time period of contract shall be 24 months including mobilization from the date of
award of PO/FOA or instruction to commence the work given by Engineer-In charge
whichever is later. Bidder can be facilitated for parallel working on 02 bullets from date of
handing over of LPG mounded storage bullet, free of hydrocarbon but same is on
discretion of EIC. EIC decision will be considered as final.
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13. Providing all the paint material, consumable materials, airless spray system, brushes,
cleaning tools, manpower, supervisors, scaffolding material and other necessary
arrangements required for the cleaning & Inspection job has to be done by the contractor
with in quoted rates. The payment will be certified, based on the joint measurements of
actual job carried out as per relevant SOR items and specifications.
14. Preferably airless spray system for painting job will be used. Contractor shall provide &
deploy sufficient number of such machines & spray arrangements for painting job.
15. The Material procured for the job shall be accompanied by inward challans/bills, duly
stamped by BPCL security at main gate and shall be submitted to EIC. No payment shall
be processed in absence of duly authorized inward challans/bills.
16. Material receipt register shall be maintained and record produced to EIC as per
instructions. Material Test Certificates shall be obtained & submitted to BPCL.
17. Shot blasting by mixture of grit & shots only. Copper Slag is not Permitted.
18. After surface preparation, removal of dust particles from metal surface by Industrial
vacuum cleaner before starting primer application.
19. Housekeeping of site on regular basis and after completion of job is in the scope of
contractor. Suitable penalty may be imposed, if housekeeping is not carried out.
20. Dedicated and skilled supervisor(s) at site should be deployed by the contractor at each
location with each group for monitoring safety & quality of job.
21. The contractor’s manpower shall be medically fit. Each worker / labour / supervisor /
engineer shall have to undergo safety training and medical check-up prior to commencing
of the jobs. All medical records shall be kept available for ready reference as per
requirement.
22. Contractor shall obtain medical fitness certificates & Form-32 for his workers & supervisors
at his own cost as per BPCL safety department guidelines for getting gate passes and
work permits.
23. Meeting on Weekly Progress report along with EIC for progress review.
24. Tool box talk to be given on daily basis before start the job.
25. Contractor has to submit the waste disposal (Sludge/Scrap) procedure.
26. If the contractor fails to carry out the job in accordance with the terms and conditions of
the contract, BPCL has option to get the job done through the other agencies at risk and
cost of the contractor. This amount shall be deducted from security deposit/ bills of the
contractor.
27. The contractor shall make his own arrangement for transportation of material and
manpower within refinery premises.
28. The contractor shall fulfil all the obligations arising under the contract and shall not enter
into sub- contract with any other party/ parties.
29. The painting work shall be carried out as per BPCL painting manual, manufacturer’s
specifications / Indian standard specifications and as per instructions of EIC.
30. BPCL will not make any payment for idling of manpower & resources due to any reason
whatsoever, such as due to delay in issue of work permits / non – availability of clear work
front / any other reason etc. It will be contractor’s sole responsibility to arrange & deploy
sufficient resources to complete the job with in time schedule.
31. Daily progress report & planning shall be submitted in approved format to EIC, and level-
II qualified primavera engineer should be available at site for monitoring.
32. Contractor shall maintain all joint records, inspection records, material procurement &
consumption registers, Bills & entry challans of the material duly stamped by BPCL
security at main gate, material test certificates, lab reports, PF/HR compliance etc and
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submit all these records to BPCL along with each bill for certification & release of payment.
33. The contractor shall maintain the whole area of his operation in a clean, tidy environment
and safe condition on a day to day basis. The EIC reserves the right, to charge the cost of
area cleaning/ housekeeping in case contractor fails to do so.
34. Contractor shall take due care of the BPCL material/assets, while handling/during
execution of jobs and shall be liable for recovery for the loss / damage occurred due to
mishandling/negligence.
35. Jobs done by contractor shall be inspected by BPCL inspection department as per
specification. If any non-conformity is observed, contractor will attend/ rectify/ repair the
same free of cost.
36. Contractor shall obtain insurance of his employees, workmen, equipment’s, tools and
tackles etc.
37. Contractor to obtain necessary work permit & safety clearances and observe all safety
regulations as per HSE norms/BPCL safety guidelines & shall follow conditions mentioned
in permits/RAs.
38. Contractor shall strictly follow all the safety norms established by BPCL HSE / Fire &
Safety Department, including the usage of all required Personal Protective Equipment’s
(PPEs), during, on & off the work, etc.
39. The quantity variation of individual SOR items may take place up to any extent on either
side. Contractor shall be able to carry out painting jobs as per BPCL requirement /
instructions of EIC. The payment shall be done on the basis of actual executed quantities
of various SOR items. Accordingly, contractor shall make arrangements of manpower &
material procurement of paint etc. to carry out painting job.
40. Contract may be terminated without assigning any reason and without giving any
compensation as per BPCL decision by giving one-month notice.
41. “A Hindrance Register shall be maintained by contractor in the enclosed format to record
all hindrances encountered during execution of works against the contract. The items of
work affected due to any hindrance shall be clearly recorded in the Hindrance Register.
Engineer-in-charge as well as the site representative of the Contractor will sign on the
register against the recorded hindrance. In case of encountering multiple hindrances
simultaneously over a period of time affecting the same item or different items, the net
period of hindrance will be worked out considering the overlapping period.” EIC decision
shall be final in this regard.
42. All material and services required to complete the bullet M&I activity, it is in the scope of
contractor.
43. PESO Clearance will be in the vendor’s scope.
44. HVAC (Portable) along with Duct (min.50 mtr) to be provided by contractor for LPG Bullet
M&I.
45. Exhaust/educators with magnetic stand to be provided by contractor.
46. Certificate and Credential of all employees to be submitted prior to start the job.
47. Safety violence’s should be nil any safety violence’s will be penalized strictly as per safety
guidelines of the contract.
48. All civil & mechanical material used for the jobs is to be as per the specification mentioned
below: -
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List of approved make of product for civil & mechanical work
Material supplied under this contract shall be ISI make or best quality available in the market or as
approved by Engineer – in-charge. Contractor shall also arrange manufacturer’s test certificates if
required by Engineer – in-charge. Tenderer should note that material supplied shall bear warranty as per
manufacturer’s warranty certificates against defects, supplied material shall be defects free and from
fresh stock. Only approved material by EIC shall be accepted & considers for payment.
Sr. No. Description Approved make

1. Cement ACC/ Ultratech /Grasim/JP
2. TMT/HYSD Steel reinforcement SAIL/ TATA/ GOEL
3. Weather Proof Exterior paint Asian/ Berger
4. Enamel Paint Asian/ Berger
5. Premium Emulsion Paint Asian/ Berger
6. Structural Steel Tata/ SAIL/ Jindal
7. Gaskets all sizes (Metallic and CHAMPION SEALS
Non Metallic as per requirement)
8. UT testing equipment’s Krautkramer / GE or Paramatric / Olympus
9. WFMPI Pmet or Magnaflux make fluorescent liquid
10. DPT Pmet or Magnaflux make fluorescent liquid
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Annexure –A
SURFACE PREPARATION & PAINTING
1. Paint Approval
The paint (or range of paints) to be used shall be approved by owner.
2. Contractor Responsibilities for Painting

The Contractor shall be responsible for:
i) The quality of workmanship, which shall be performed in accordance with this document
and all other relevant documents such as site regulations, safety rules, referred
standards and codes, etc.
ii) Obtaining the Owner's assurance that the equipment is certified safe and available and
that all appropriate tests are completed before starting any painting work.
iii) The protection of all equipment, structures and any other areas from mechanical
damage, environmental damage, damage caused by abrasives during blast cleaning,
paint droppings, or overspray.
iv) The earthing of electrical equipment.
v) Taking all necessary precautions to avoid interference with the execution of work of other
contractors.
vi) The characteristics of the paints and paint materials obtained from the paint
Manufacturer. The characteristics shall be obtained via the provision of separate
technical, and health and safety data sheets.
vii) Control of waste resulting from the Contractor's painting and coating activities, in
accordance with site regulations and specific contract requirements.
viii) Maintaining workshop facilities, tools and equipment in a good, clean condition. Spray
guns, brushes, rollers, paint pots and the like shall be regularly cleaned and shall be
suitable for their purpose.
ix) Preparation of appropriate work planning, which shall be in agreement with that of the
Owner.
3. Codes and Standards

The applicable codes and standards reference in this specification shall be as follows:
Code Description
IS:5 Color coding
IS: 101 Methods of test for ready mixed paints and enamels.
IS 2379:1990 Indian standard for pipeline identification- Color code
ASA A13.1-1981 Scheme for identification of piping system: ANSI
4. Surface Preparation Standards

In order to achieve the maximum durability, following methods of surface preparation shall be
followed, depending on condition of steel surface and as instructed by Engineer in charge.
Adhesion of paint film to surface depends largely on the degree of cleanliness of the metal surface.
Proper surface preparation contributes more to the success of the paint protective system.
Contractor shall ensure that surface is free from weld spatter, sharp or rough welds before start of
job and any such irregularities shall be brought to the notice of EIC before start of job.
Surface preparation for achieving SA2.5 shall be done by blasting mixture of iron shot 60% + grit 40%.
Page 19 of 31
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*Cu slag shall not be used.

Following standards shall be followed for surface preparations –
i) Swedish Standard - SIS-05 5900-1967 (Surface preparations standards for Painting
Steel Surfaces).
ii) Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP).
iii) British Standards (Surface Finish of Blast-cleaned for Painting) BS-4232.
iv) National Association of Corrosion Engineers, U.S.A., (NACE).
The paint manufacturer instruction shall be followed at all the times. Particular attention shall be
paid for the following: -
i) Instruction for storage to avoid exposures as well as extreme temperatures.
ii) Surface preparation prior to painting.
iii) Mixing & thinning.
iv) Application of paint and the recommended limit on time interval between coats.
5. Philosophy & Guarantee
i) Contractor shall stand guarantee for painting system as follows: -

a. For surfaces painted after Blasting as surface preparation 5 years
ii) For all internal lining / painting works, manufacturer’s laboratory test statement /
Laboratory Paint performance certificates to be checked for specified services at design
/ operating conditions. Material shall be procured from only those approved manufacturers
who will meet the above stated criteria.
6. Health and Safety

Most of the volatile organic solvents used in paints causes health and fire hazards. They are
harmful for the respiratory system, eyes and skin and also are potentially explosive. Hence,
the following general precautions are necessary while handling and application of paints.
i) Inhalation of solvent vapours or paint mist, contact with liquid paint with skin and eyes
should be avoided.
ii) Suitable approved respirators or face masks should be used during paint application and
handling.
iii) Since solvent vapours are heavier than air, they tend to accumulate at the bottom of
Bullets or of confined spaces. Care should be exercised while entering areas where this
might have happened.
iv) Food and drink should not be stored or consumed where paints are stored and smoking
should be prohibited in such areas.
v) All fire safety precautions are to be followed in areas where paints are stored and where
paint application is done.
vi) Cans holding liquid paints are to be handled carefully and should not be kept near or
above any hot surface or object.
vii) All scaffoldings, etc. erected for painting must be to the satisfaction of BPCL safety
requirements. Safety belts with lifelines are mandatory requirements, while painting at
elevated locations.
viii) If a Fire involving paint does occur, avoid sparks from electrical appliances or caused by
metal to metal contact.
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ix) Do not extinguish with water, as paint solvents float on water, & help Fire to spread.
x) Use a dry chemical, foam or CO2 extinguisher.
xi) Protect from the fumes with breathing apparatus
7. Tools & Equipment
i) All tools, brushes, rollers, spray gun, abrasive material, hand power tools for cleaning and
all equipment, scaffolding materials, shot/wet abrasive blasting, water blasting equipment
& air compressors etc. required to be used shall be suitable for the work and all in good
order and shall be arranged by the contractor at site and in sufficient quantity.
ii) Mechanical mixing shall be used for paint mixing operation in case of two pack systems
except that the Engineer-in-charge may allow the hand mixing of small quantities at his
discretion.
8. Storage
All paints and painting materials shall be stored only in rooms to be arranged by contractors and
approved by EIC for the purpose. All necessary precautions shall be taken to prevent fire. The
storage building shall preferably be separate from adjacent building. A signboard bearing the words
“PAINT STORAGE” – HIGHLY INFLAMMABLE” shall be clearly displayed outside.
i) As a rule, paint shall be stored in a well-ventilated room.

ii) All paint and thinner shall be stored in such a way that the manufacturer’s labels can be
readily identified.
iii) Paint stocks shall be controlled so that they can be used within their effective period of
use.
iv) For storage areas, provide prescribed protective measure and signs.
v) Paint exceeding the prescribed quantity shall not be stored.
vi) Care shall be taken while storing and handling to avoid breakage or marked deformation
of containers.
vii) When paint is stored outdoors, it shall be protected by using plastic/ tin sheets or other
appropriate measures, in order to prevent damage to containers or changes in the quality
of the paint.
When paint is temporarily stored in the working area, the amount equivalent to one day’s use or less
shall be stored. Paint shall be protected from rain, snow etc. using plastic/tin sheets.
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Annexure – B
INSPECTION AND TESTING OF PIPELINES & BULLET NON DESTRUCTIVE TESTING

1. ULTRA SONIC THICKNESS MEASUREMENT & FLAW DETECTION
a. The general requirements of thickness measurement by Ultrasonic Flaw Detection shall

confirm to the requirements of SMPV(U) Rules and relevant
codes/Standard/Specifications.
b. Ultrasonic thickness measurement equipment /Flaw detection equipment and
accessories as required shall be the responsibility of the contractor. The contractor
shall provide equipment and accessories of Kraut Kramer make or equivalent along
with recorder.
c. Ultrasonic thickness measurement shall have to be taken by using ultrasonic
Thickness meter. Ultrasonic Flaw Detection shall be done covering points/ location
so as to get profile or wall thickness to meet the requirements of SMPV (U) Rules
and relevant codes/standards/ specifications. Approximately 10-15 reading are to be
taken to get a representative profile of wall thickness of each petal and crow plates.
Each location of thickness shall be scanned and minimum thickness shall be marked
on Inspection Reports.
d. Thickness is to be measured on all the four side of all the nozzles including manhole.
Spot / Areas where thickness is required to be measured will have to be cleaned by
the contractor up to desired level of surface preparation.
e. Depending on the inspection results, more thickness reading may have to be taken
on all connected pipeline of the LPG bullet, as required.
2. ULTRASONIC FLAWs DETECTION
The ultrasonic flaw detection covering minimum of 25% of total weld seams shall have to
be done by the contractor and this has to include the following:
a) 100% of the “T” weld joints covering a straight length of 150-200 mm on either side
shall be checked for cracks/defects by ultrasonic flaw detection.
b) 100% of the nozzle welds of liquid / vapor lines and manhole shall be checked by
ultrasonic flaw detention.
3. WET FLUOROSCENT MANGETIC PARITICLES INSPECTION (WFMPI)
WFMPI is required to be carried out the detect all type of cracks / defects or such other
discontinuities and irregularities by using any / all the following:
a) Articulated A.C Magnetic yoke.
b) Fluorescent iron powder suspended in water /Kerosene
c) Ultraviolet Light.
WFMPI method used should meet the requirements of standard / recommended practices and
be in accordance with SMPV (U) Rules 1981 and relevant codes / standards / specification
including selection of equipment and magnetic powder. Equipment of Magnaflux or equivalent
make shall be used for the job that shall be having valid calibration certificates. All the
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CRFQ No. 1000410329
equipment accessories including the consumables required to carry out WFMPI shall be in the
scope of contractor.
Note: No permanent magnet will be allowed to be used for MPI testing.
a) 100% of the welds including circumferential and longitudinal seams, dish end petal
joints, nozzle welds fillet welds of stiffening rings, welding spot areas on which temporary
attachments i.e. brackets, clamps, 150-200 mm parent metal on either side of all weld
joints is to be covered WFMPI.
b) 150-200 mm parent metal either side of all weld joints is to be covered in WFMPI.
c) Depending on the inspection findings more area in the parent metal, if required may have to
be inspected and covered by WMPFI.
4. DYE PENETRANT TESTING

Hardness is to be measured as per the requirements of SMPV (U) Rules 1981 and
relevant codes / standards / specifications:
a) Hardness is to be measured on the welds joints, HAZ, parent metal / plate, nozzle weld,
and any leftover cleat and weld areas at random, Exact location / spot for hardness
measurement shall be decided on actual job at site.
b) Hardness shall be measured by high sensitive non indentation type measuring equipment
of Krautkramer make or equivalent. The Hardness measuring equipment to be used shall
have the facility of recording, storing and formatting the recorded readings.
The hardness measuring equipment as required above shall be providing by contractor

5. HYDROSTATIC TESTING
The hydrostatic testing shall be carried out as per SMPV (U) Rules -1981 for which the
procedure in brief is as follows:
After degassing and before hydro testing, all Pressure Relief valves, Radar gauges, main
level gauge, Servo level g\Gauges, high level alarms and other mountings have to be
safely removed and openings are to be blanked off with blind flanges of appropriate
ratings. This sophisticated equipment are costly and hence have to be handed with
enough & proper care to avoid any damages. The same are to be fitted back on the
vessels in their original position & condition and to be ensured that all are back in normal
working condition. In case of any type of damage to any of these equipment, the cost of
the same shall be recovered from the contractor’s payments. Blind list is required to be
prepared before starting Hydro testing.
Initial level reading of vessel foundation have to be noted with respect to any fixed
structure / bench mark.
a) Hydrostatic test of Mounded Storage Bullets is required to be conducted at a pressure as
specified / stipulated by the requirements of SMPV (U) Rules 1981 and relevant codes /
standards and as directed by Engineer-In-Charges.
b) Necessary arrangement including blinding of entry & exit nozzles, Instrumentation
Connections, Water Connection, Water Filling, providing calibrated pressure gauges
(Range 0-35 Kg/cm2 and 0-40 /cm2 etc.) are to be done facilitate hydrostatic testing.
c) Two calibrated pressure gauges one near the test pump and other at the top of the LPG
bullet are to be provided by the contractor. Also two pressure gauges are to be kept at
site as stand by Certificate copies shall be attached along with the report submission.\
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d) Settlement of the bullet is to be checked and noted during water filling by suitable means
for which arrangement shall be made by contractor. Settlement to be noted after filling at
25% interval of the bullet and further steps of 10% each. Proposed arrangements shall
have to be discussed with Engineer-In-charges before starting the work of filling water for
Hydro testing.
e) Pressure should be raised up to 50% of test pressure and held for 30 minutes and then
gradually raised at a step of 10% up to the rest pressure. Test will be witnessed by BPCL
/ Competent Person approved by CCOE / Inspection dept. and should be done to their
satisfaction.
f) Entire inspection work shall be done as per the instruction of Engineer-In-Charge.
Procedure and Methodology shall be discussed with Engineer-In-Charge for consent /
approval before staring any NDT and hydro test.
g) Suitable filling and pressure pump for above hydrostatic testing shall be arranged by
contractor.
h) All connected pipe lines / valves to be hydro tested.
6. RADIOGRAPHY (OPTIONAL)
a) Radiography shall be carried out for confirming the defects if any observed during the other
NDT inspection of the Bullets or as directed by Engineer-In-Charges.
b) In the radiographs, location of weld joints (circumferential / Longitudinal) are to be clearly
marked for future reference.
c) Once the radiography job is over the films used shall be handed over the Engineer-In-
Charge along with the report interpretation of the findings.
In case during Inspection and NDT, any cracks / defects are noticed then the contractor has to
undertake the repair of the same, after the permission to undertake such repairs has been accorded
by PESO Nagpur, which shall have to be arranged by the contractor.
7. ANY OTHER TESTS/ JOBS:
a) Any other testing / inspection job which is not described above and is required under
SMPV(U) Rules 1981 for certification and re-certification of the Mounded Storage Bullets
are to be carried out by the contractor and the same shall be deemed to be included in the
total quoted rates and scope of work. However, any licensing fee to be paid to CCOE,
Nagpur for re-certification shall be reimbursed by BOR: to the contractor at actual on
production of proof/ receipt form CCOE, Nagpur.
b) In case of any non-conformity / noncompliance of nay NDT reading(s) the same shall be
addressed with proper codes / standards / procedures / other approved documents and
suitable measures required to be undertaken to correct the non-conformity be suggested
and evolved for making the vessel suitable for further use including any liasoning work with
concerned authorities shall have to be done by the contractor.
c) BPCL any engage at its own discretion and cost a third party inspection agency to witness
and monitor the inspection & testing jobs being carried out by the contractor.
Page 24 of 31
CRFQ No. 1000410329
Annexure – C
ERECTION OF SCAFFOLDING AND ITS REQUIREMENTS:
SCAFFOLD & LADDER SAFETY
Scaffolds are temporary structure/ work platforms that are constructed to provide support for
workmen, plant and materials etc. used in building, construction, maintenance, repair and
demolition work etc.
Competent Persons shall be responsible to inspect & tag the scaffolding prior to use by site
personnel. It shall be inspected periodically (every seven days) or in the event when the
condition
/ structural modification is carried out.
Fall of person from height, fall of material, collapse of scaffold etc. are the common type of
incidents that are reported. The following section details the general safety requirements that
shall be implemented at BPCL Refinery.
Selection of Type and Design of Scaffold
Decide the type of scaffold and its bay length based on the nature of activity to be performed,
load of man, material tools-tackles, work location, length of platform etc. Use following table for
the purpose.
Maximum spacing
Type of Scaffold Scaffold loading per Maximum number of
between
m2 working platforms
Standards
Very light duty 1 working platform
75 kg 2.7 m
independent (Person)
Light duty
150 kg 2 working platforms 2.4 m
independent
2 working platforms
General purpose 200 kg 2.1 m
and 1 at very light
independent
duty
2 working platforms
Heavy duty 250 kg - 300 kg 2.0 ml. / 8 m
and 1 at very light
independent
duty
Special purpose To be stated after risk assessment
Note: Scaffolding shall be erected with a factor of safety not less than 4.
Safety Aspects:
 Scaffolding erection shall be done from bottom to top.

 Place the base plate (size: 6x6 inches, thickness: 6 mm) as per the design criteria
maintain the spacing.
 The footing of scaffold shall be placed on levelled & sound ground capable enough of
carrying
 maximum intended load without settling or displacement.
 Don't use concrete blocks, barrels, boxes, loose bricks etc. for support of scaffolds
 After reaching to the first horizontal level, place one temporary bracing on one side of
Page 25 of 31
CRFQ No. 1000410329
scaffold before proceeding further.

 The height of scaffold should not be more than four times of its minimum base dimension
unless guide
 ropes, ties or braces are used or properly supported laterally. It is applicable if fixed
structure support is not available.
 Ensure that first horizontal member on either side of scaffold is at 2-meter height from
ground.
 Platform shall be made at least 46 cm fastened securely. & Gratings shall not extend
beyond 6" from the end.
Joints in standards should not occur in the same lift. Joints should be arranged so that they
occur as near as possible to a ledger. All standards shall be vertical. Ledgers shall be securely
fixed to standards and shall be horizontal. Joints in ledgers should be staggered,
i.e. joints in adjacent ledgers should not occur in the same bay.
 Gratings shall be laid with no openings more than 1 inch (25 mm) between adjacent
guards or scaffold member.
 Guardrails and toe guards shall be fitted to the inside of standards to prevent outward
movement. If guardrails and toe guards are removed for the movement of materials, they
shall be restored as soon as practicable (ex. heat exchanger jobs).
 Provide guard rail (1200 mm), mid rail (600 mm) & Toe guard (100 mm). on all open sides
and end of the platform above 2 m height.
 Use of monkey ladder to access working platforms on scaffolds is not recommended, as
it will obstruct free entry through the ladder cage.
 Scaffold should be vertical & checked with plumb. So that bracing will fit without forcing.
 Scaffold shall be braced at all four sides.
 Always keep 3-meter distance from overhead high tension line and get counter sign by
relevant electrical engineer on the work sheet/permit.
 Safe & convenient means of access to be provided: portable ladder, fixed ladder, ramp
or runway. It is the duty of supervisor to provide safe access and safe work location
through the use of permanent platforms, temporary platforms and lifelines.
 Scaffold having more than 10 m height shall be secured with fixed structure for stability
at first & then at every 8 m, where ever provision of fixed structure.
 No worker should be expected to expose himself to an unprotected fall while getting to
the work location or while working.
 Ladder shall be installed immediately after completion of second horizontal plane or 6
Mtr. scaffold.
 Ladder shall extend at least 3 rungs from the platform and oriented at 900 to the landing
platform.
 Scaffolding shall be erected with a factor of safety not less than 4.
 Use of full body harness with double lanyard with scaffolding hook by all scaffolder's
after completing first horizontal plane.
 Vertical member shall be connected with horizontal member by using fix clamp (right
angle) only.
 Only bracing can be connected with vertical member by using swivel clamp at ground
end. Other end of bracing shall also be connected with horizontal member by using fix
clamp as far as possible.
 While erection or dismantling of scaffold the spanner shall be used with proper string in
hand so that it will not fell down.
 Accumulation of water nearby scaffolding area to be avoided.
 In case of very high scaffolding, proper mean of communication between person at
Page 26 of 31
CRFQ No. 1000410329
ground level and at top shall be ensured.
Safety in Use of Scaffold

 Display the copy of Permit at work location.
 Ensure adequate and competent supervision during the course of activity.
 After completion of work close the work permit and submit to the area owner for record.
 Before using the scaffold check the inspection tag marked on it and ensures that it is
safe for use.
 Before climbing up check that it is not under dig, all bracing members are in place.
 Wear hand gloves while climbing the ladder and wear safety harness while working at
height.
 Upon climbing the work platform, first hook up lanyard of your Full body harness with
guard rail or suitable structure so as to restrict fall in case of loss of balance.
 No loose material shall be left on the platform. Place the tools in tool box & other items
in basket.
 Don't climb up on the rails of scaffold to over reach job location.
 Take care of overhead electric lines always keep yourself 3 meter away from the same.
In such case clearance from electrical engineer is must and get counter signature on
work permit prior to begin its use.
 Don't overload scaffold. Working platform when fully loaded shall not deflect more than
l/60ofthespan.
 Provide barricading so that it will not be hit & run by any vehicle or equipment & also will
be free from man movement.
Safe Dismantling of Scaffold

 Display the copy of permit at work location and Scaffolding Tag with the wording "DO
NOT USE SCAFFOLD" should be fixed to the scaffolding at all access points.
 Barricade the area of work and restrict the entry of unwanted personnel.
 Ensure that scaffolding to be dismantled by the scaffolder’s in presence of supervisor.
 After completion of work close the work permit and submit to the area owner for record.
 Scaffolding removal shall be from top to bottom plane wise.
 First remove bracing and then remove all horizontal members in one plane.
 After reaching to second last horizontal plane, first install bracing of 3 m for ground level
plane & then only remove the horizontal members at second level.
 Loose scaffolding member shall be lowered down by rope & not by using man chain or
throwing.
 Loose member shall be segregated and stacked properly. Removal of ladder may be
done after reaching to the second horizontal plane from ground level.
 While erection or dismantling of scaffold the spanner shall be used with proper string in
hand so that it will not fell down.
Page 27 of 31
CRFQ No. 1000410329
Annexure – D
Photographs for Reference
FLP Lighting Arrangement inside LPG Bullet
Track arrangement for movement of portable trolley or scaffolding
Page 28 of 31
CRFQ No. 1000410329
Arrangement for shifting of Scaffolding
All photographs are just indicative only to expedite the job, however as per site conditions and
safety guidelines requirement may differ. In any ambiguity with reference to photographs. EIC
decision shall be considered as final and contractor will abide to follow the same.
Page 29 of 31
CRFQ No. 1000410329
Annexure- E
Details of Mounded Storage Bullets
1. The major dimensions of the LPG Mounded storage bullets are as follows:
Sr.
Description Details
No.
1 Equipment Name Mounded LPG storage Bullet
2 Tag no 70-TT-TB-01 A/B/C/D/E/F
3 Shell thickness in mm 35
4 Dish end thickness in mm 18 (Min) 20 (Nom)
5 Internal shell diameter in mm 7000
6 Overall length in mm 88040
7 Erection weight in kgs 720000
8 Operation weight in kgs 2370000
9 WL / WL length in mm 81240
Sr.
Description Details
No.
PD :5500 (Latest), OISD-150 (Latest) & SMPV Rules
1 Design Code
1981 (Unfired)
2 Shell BSEP 10028-3 P275NLI
3 Nozzle Flange SA 350 Gr. LF2 CL.I
4 Nozzle neck SA 333 Gr. 6
5 Pipe fittings SA 333 Gr. 6
6 External studs/bolts/nuts SA 320 GR L7, SA, 194 GR 7
2. Other design parameter:
Sr.
Description Details
No.
1 Manufacturer Name G.R. Engineering Private Ltd.
2 Year of Commissioning 2010
3 Design Pressure in Kg/cm2 14.5 (INT)
4 Design Temperature in Degree centigrade 55/ (--) 27
5 Corrosion allowance mm 1.5
6 Capacity M3 3295 (NOM) 2800 (stored)
7 Hydrostatic test pressure (kg/cm2) 19.0 Horizontal (At top vessel)
8 Cathodic protection Yes as per 6893-642-CP-002
Page 30 of 31
CRFQ No. 1000410329
3. Blinds required for Hydro testing of mounded storage bullets:
Details of Flange
Rating
Sr.No. Mark Services Size Sch Type Face
Cl.
1 F Feed line 150 NB (6") SCH-80 300# SRWN RF
2 T Vapour balance line 200 NB (8") SCH-60 300# SRWN RF
3 S Spare + B.F. 101.6 ID 22.22 thk 300# LWN RF
4 SV Safety valve 200 NB (8") SCH-60 300# SRWN RF
Level Switch High
5 LSHH 100 NB (4") SCH-120 300# SRWN RF
High
6 LSLL Level Switch Low Low 100 NB (4") SCH-120 300# SRWN RF
7 LT 1 Level Transmitter 150 NB (6") SCH-80 300# SRWN RF
8 LT 2 Level Transmitter 150 NB (6") SCH-80 300# SRWN RF
Multi Point Temp.
9 TE 50.8 I.D 16.65 thk 300# LWN RF
Element
Man hole + B.F. with
10 M1 800NB (32") 14 thk 300# SRWN RF
Davit
11 PT/PI Pressure Transmitter 38.1 I.D 15.9 thk 300# LWN RF
12 D Outlet (Pump Suction) 350 NB (14") 14 thk 300# SRWN R.T.J
Man hole + B.F. with
13 M2 600 14 thk 300# SRWN RF
Davit
Details of Gasket
Sr.No. Mark Services Size Rating Cl.
1 F Feed line 150 NB (6") 300#
2 T Vapour balance line 200 NB (8") 300#
3 S Spare + B.F. 101.6 ID 300#
4 SV Safety valve 200 NB (8") 300#
5 LSHH Level Switch High High 100 NB (4") 300#
6 LSLL Level Switch Low Low 100 NB (4") 300#
7 LT 1 Level Transmitter 150 NB (6") 300#
8 LT 2 Level Transmitter 150 NB (6") 300#
9 TE Multi Point Temp. Element 50.8 I.D 300#
10 M1 Man hole + B.F. with Davit 800NB (32") 300#
11 PT/PI Pressure Transmitter 38.1 I.D 300#
12 D Outlet (Pump Suction) 350 NB (14") 300#
13 M2 Man hole + B.F. with Davit 600 300#
All gasket material shall be certified by BPCL – Inspection Department.
Page 31 of 31

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Tender Title : Providing Annual Rate Contract for “LPG Bullet

cleaning, statutory inspection, painting, NDT & Hydro testing”

3 INTRODUCTION OF THE JOB 3

1) INTRODUCTION OF THE JOB:

Sr. No . Bullet No Capacity in M3

2.1) Internal Inspection

NOTE: - ND examinations schedule to be submitted before start the NDT.

2.2) Internal Painting

2.3) Inspection of Connecting Lines

2.4) Mound External Inspection

2.5) Hydro-Static Pressure Testing:

2.6) Vessel Settlement:

2.7) Cathodic Protection

2.8) Pressure Relief Devices

Sr. No. PSV No Make Set Pressure Location

2.9) Special Points Applicable for NDT Activities:

2.10) Automated Ultrasonic Scanning (AUT):

2.11) Common Points:

2.12) Any Other Tests/ Jobs:

2.13) Repair of Mounded Storage Bullets: (Optional)

2.14) Reporting / Documentation:

2.15) Activities to Be Carried Out: -

specifically mentioned in BPCL scope of supply shall be arranged by the Contractor.

5) PRECAUTION TO BE TAKEN DURING/ AFTER CLEANING (By Both Contractor &

1. Water shall be drained after regular visual inspection of discharge fluid.

5 Safety Shoes EN-345 1 Pair Yearly

8) OTHER CONDITIONS OF THE CONTRACT

List of approved make of product for civil & mechanical work

Sr. No. Description Approved make

2. Contractor Responsibilities for Painting

3. Codes and Standards

4. Surface Preparation Standards

*Cu slag shall not be used.

5. Philosophy & Guarantee

i) Contractor shall stand guarantee for painting system as follows: -

6. Health and Safety

7. Tools & Equipment

i) As a rule, paint shall be stored in a well-ventilated room.

INSPECTION AND TESTING OF PIPELINES & BULLET NON DESTRUCTIVE TESTING

a. The general requirements of thickness measurement by Ultrasonic Flaw Detection shall

2. ULTRASONIC FLAWs DETECTION

3. WET FLUOROSCENT MANGETIC PARITICLES INSPECTION (WFMPI)

4. DYE PENETRANT TESTING

The hardness measuring equipment as required above shall be providing by contractor

7. ANY OTHER TESTS/ JOBS:

 Scaffolding erection shall be done from bottom to top.

scaffold before proceeding further.

ground level and at top shall be ensured.

Safety in Use of Scaffold

Safe Dismantling of Scaffold

FLP Lighting Arrangement inside LPG Bullet

Track arrangement for movement of portable trolley or scaffolding

Arrangement for shifting of Scaffolding

2. Other design parameter:

3. Blinds required for Hydro testing of mounded storage bullets:

All gasket material shall be certified by BPCL – Inspection Department.

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