Technical Specifications: Floating Roof (IFR) and Allied Civil Jobs at Panipat Refinery."
Technical Specifications: Floating Roof (IFR) and Allied Civil Jobs at Panipat Refinery."
Name of Work - “Mechanical and civil jobs to convert TK-21, 22 & 24 from External Floating Roof (EFR) to Internal
Floating Roof (IFR) and allied civil jobs at Panipat Refinery.”
TECHNICAL SPECIFICATIONS
INDEX
S. No. ITEM DESCRIPTION PAGE NO
1. General 4
2. Codes and standards 4
3. Brief scope of supply and work 5-7
4. Bidder Scope for site execution 7-11
5. Payment terms and conditions 11
6. Temporary power requirement 11-13
7. Contractor Data Requirements 13-14
8. Painting Works 14-16
9. Desired vendor List 16-17
10. Deviation Format 18
11. List of Third party Inspection Agencies 19
12. List of Third Party Consultants 19
13. Drawings of existing tank Attached
14. Existing tank layout drawing Attached
15. Technical Specification for Storage Tanks Attached
16. Supplementary Specification For Structural Plates For Tanks & Vessels Attached
17. Technical Specifications for Boiler Quality Steel Plates Attached
18. Technical Notes (General Specifications) of Valves Attached
21. Technical Notes (General Specification) For Seamless, ERW & EFSW Pipes Attached
23. Technical Notes for Butt Welded ,Socket Welded and Screwed Pipe Fittings Attached
25. Technical Notes (General Specification) For Flanges, Spectacle Blinds And Drip Attached
Rings
26. Quality Assurance Plan for flanges Attached
30. Attached
Specifications for fire protection system package for storage tank
31. Attached
Standard specification for foam chamber equipment for cone roof tank
32. Attached
Gauge hatch with cover
33. Attached
Foam system
34. Attached
Still-well for gauge hatch and temperature indicator
35. Attached
Still-well for level transmitters (servo/radar)
36. Attached
Earth Connections
37. Attached
Standard specification for water spray nozzle for cooling
38. Attached
Technical Notes for Swivel Joints
39. Attached
Job specifications for liquid mounted primary foam seal
40. Attached
Job Specification for non-destructive examination requirements of piping
41. Attached
Standard specification for fabrication and erection of piping
42. Attached
Standard specification for inspection, flushing and testing of piping system
43. Attached
Welding specification for fabrication of piping
44. Attached
Welding specifications charts for piping classes
45. Attached
Piping material specification(J2A)
46. Attached
Inspection & test plan for painting works
47. Attached
Inspection & test plan for structural steel works
48. Attached
Job specification for civil works
This document containing 'Terms and conditions of the Contract' shall be read in conjunction with the other
Technical Documents, Standards/codes mentioned herein and General Conditions of Contract (GCC).
Wherever any portion of the GCC and/or of other technical document and/or other standards/codes
mentioned herein is repugnant to and/or at variance with any provisions of this annexure, then unless
different intention appears, the provision(s) of this annexure shall be deemed to override the provision(s) of
GCC and other technical documents and/or other standards/codes mentioned herein only to the extent that
such repugnancy or variance cannot be reconciled with the provisions in GCC and other technical documents
and/or other standards/ codes mentioned herein.
This annexure shall also be considered as an extension or supplementary part to the 'Schedule of Rates'
(SOR). Wherever in this annexure a mention has been made for contractor to be liable to arrange for and/or
supply anything, and/or perform any work, it would be deemed that the contractor within the costs of the
SOR items should discharge such liabilities, without any extra financial implication to the owner. If any
contradiction appears between SOR and this annexure, the later will supersede and shall prevail over the
former, to the extent of such variance.
The Bidders are asked to read the tender documents carefully and understand the scope and intent of the
job before quoting.
1. General
Indian Oil Corporation Panipat Refinery intends to convert external floating roof tank (Tk-21,22,24) to fixed
cum floating roof tanks (IFR tanks). The fixed roof shall be self-supported cone roof (truss supported) cone
roof as per API-650 latest edition. The tanks shall have a facility for nitrogen blanketing to stop any ingress of
moisture. The scope of supply and works for the bidder includes following but not limited to complete
design of fixed cum floating roof tanks, verification of existing design of floating roof as per latest API and
OISD standards, supply of material, fabrication, erection, testing, calibration, painting, etc. including civil
design check for foundation, civil works like strengthening of tanks-foundation pads, dykes and supply,
installation, testing etc. of firefighting system in strict compliance with engineering drawings, specifications
and standards attached in this tender and further engineering documents/drawings provided by IOCL prior
to start of work.
The following latest edition of codes, standards and recommended practices shall be applicable:
Other International Standards may also be acceptable subject to their being equivalent or superior with
prior approval of IOCL.
For provisions not covered by the above codes and standards, applicable engineering practices and
norms shall govern.
The scope of work of the bidder shall include but not limited to:
i. Design, Engineering of the complete tank as per latest API-650 and OISD standards. The bidder shall carry out
the design of the complete tank for fixed cum floating roof and then verify the same with the design of the
existing floating roof tanks. Bidder shall mark out the changes and modification required for fixed cum
floating roof tank and shall prepare complete detailed design calculations, drawings, documents, data sheet
for carrying out the modifications and for complete tank.
ii. Design and engineering of the self-supported cone roof, all required cone roof apparatus.
iii. Design, engineering of nitrogen blanketing system for tanks in order to avoid any moisture ingress. There
should not be any ingress of moisture in the tanks.
iv. Design check for the existing shell, tank bottom, floating roof etc. as per latest codes and standards.
v. Preparation of plate cutting diagram for roof and shell.
vi. Design, engineering, fabrication and erection of still well for radar and servo gauge with nozzles.
vii. Bidder shall prepare all the drawings, design calculations and shall submit the same to IOCL approved third
party consultant (List attached) for approval. TPC approved drawings shall be submitted to IOCL for
comments/approval. Fabrication of the tank shall only start after getting the design calculation, drawings
approved by IOCL.
viii. Design, engineering, supply and engineering and execution of tank cooling water system, fire water sprinkler
system, foam system etc. The cooling water system and foam system shall be as per latest OIDS-116
standard.
ix. Supply of material such as plates, piping items such as pipe, flanges, fittings, gaskets, studs and bolts etc, still
wells, gauge hatch cover, all tank accessories, revolving nozzle, foam chamber with deflector etc. The items
to be supplied has been mentioned in the RFQ under line item no 30. The items to be supplied as per the
technical specifications for plates, piping etc. attached in the tender.
x. Bidder to supply the material as per approved drawings only. Bidder shall be admissible for claim of supplied
material for the quantity mentioned in IOCL approved drawings only.
xi. Inspection of all supplied material shall be carried out as per approved QAP only. Bidder to submit the
drawings, QAP of the material to IOCL for comments/approval.
xii. All the material supplied by the bidder shall be inspected by IOCL approved third party inspection agency (list
attached). The charges/fees for getting the material inspected by TPI shall in the scope of the bidder. Bidder
shall not be admissible for any extra charges against this point. Bidder shall submit the TPI inspection release
note and obtain the dispatch clearance from IOCL before dispatching the material
xiii. Adequacy check for existing civil foundation and tank dyke. Submission of detailed adequacy report to IOCL
approved TPC and then to IOCL for comments/approval. If required, construction and execution of civil jobs
as per approved drawings.
xiv. Welding, Fabrication, erection and execution of the job as per approved drawings and documents.
xv. Preparation and submission of tank GA drawings, fabrication drawings
xvi. Preparation of tank As-built drawings
Prepared By Checked By Approved By
Ms. Sandeep Kaur, Mr. Hemanshu Dhawan, Ms. Bobby R. Doley,
AM (ML-ES) SESM DGM (ES)
Page 5 of 19
Specific Requirements of the Contract-Mechanical
Name of Work - “Mechanical and civil jobs to convert TK-21, 22 & 24 from External Floating Roof (EFR) to Internal
Floating Roof (IFR) and allied civil jobs at Panipat Refinery.”
xvii. Surface preparation and Painting of tank, piping as per IOCL painting specifications.
xviii. Supply, welding, fabrication and erection of tank nozzles as per SOR.
xix. Removal, installation and cabling for all instruments such as level indicators, temperature gauges, level
switch, level transmitter, RTD, etc.
xx. Supply, fabrication and erection of materials conforming to pipe specifications for auto bleeder vents, still
well for Gauge hatch, temperature gauge & Level transmitters (Servo & Radar), etc wherever shown, as per
drawings / studs.
xxi. Carrying out hydrostatic, pneumatic, vacuum and other tests as specified in code/specifications using
contractor’s own equipment’s.
xxii. Calibration of tank through strapping method/ other methods approved by owner and getting approval
from weights & measures/ and other statutory authorities. Contractor's must arrange strapping tapes and
all other material required for calibration. All fees for calibration of three tanks shall be in the scope of the
bidder.
xxiii. Carrying out all NDT such as radiography, heat treatment, DP etc. as per approved drawings and on advice
of IOCL inspection.
xxiv. Fabrication and erection of ladder, platforms etc. for accessing fixed roof nozzles and manholes.
xxv. Carrying out pneumatic testing for roof, bottom, shell as per approved drawings and IOCL inspection
xxvi. Erection of tanks will have to be carried out by jacking method & conventional method as required. Jacks
along with hydraulic pumps, material handling equipment’s including all accessories shall be arranged by
fabricator.
xxvii. Design, modification, fabrication of spiral stair case ladder.
xxviii. Dismantling of hydrocarbon and non-hydrocarbon piping (Fire water & foam piping etc) and erection of
the same as per detailed design and site requirements and as per EIC instructions.
xxix. Supply of diesel driven compressor including all fuel and consumables for carrying out painting jobs,
pneumatic testing etc. Chagres for supply of air compressor has already been included in SOR rates and no
separate charges shall be paid to the contractor against this item.
xxx. Dismantling of rim seal protection system consisting of piping and vessels it associated items
xxxi. Design, engineering, Supply, erection of breather valve/PVRV
xxxii. Installation, testing and commissioning of nitrogen blanketing line for tanks.
xxxiii. Erection of scaffolding with material in bidder scope.
xxxiv. Carrying out inspection of tank and witnessing of the same by IOCL inspection.
xxxv. Carrying out roof floatation test, puncture test etc. as per specification/code.
xxxvi. Submission of As-built drawings for complete tanks with all fabrication drawings (As-built). The complete
drawings folder shall be submitted in hard form (4 sets) and in soft form one set(in pen drive)
xxxvii. Submission of drawings required for PESO approval as per instruction of EIC.
xxxviii. Fabrication and erection of conical roof supporting structure as per the scope indicated above in the tender
documents and SOR.
xxxix. Hydrotest of tank
xl. Stage wise inspection of tank and witnessing of the same by IOCL inspection. Bidder has to submit QAP/ITP
for approval of IOCL. Inspection of tank shall be carried out as per approved ITP only.
Prepared By Checked By Approved By
Ms. Sandeep Kaur, Mr. Hemanshu Dhawan, Ms. Bobby R. Doley,
AM (ML-ES) SESM DGM (ES)
Page 6 of 19
Specific Requirements of the Contract-Mechanical
Name of Work - “Mechanical and civil jobs to convert TK-21, 22 & 24 from External Floating Roof (EFR) to Internal
Floating Roof (IFR) and allied civil jobs at Panipat Refinery.”
Execution of Tank jobs, Piping, Structural and other associated jobs including equipment erection (if any as per
the direction of Engineer-in-Charge (EIC).
Shifting and transportation of plates, piping materials, structural and equipment as required from
contractor/IOCL stores to site. Arrangement of required tractor trolley/ trailer/ City type double driving cabin
hydra / crane etc. shall be in the scope of contractor and the same is included in the SOR item rates.
Contractor shall not be admissible for any extra claim on account of this.
Blinding/ De- blinding, tail blind fabrication from the plate, flushing hose fitting (adapter) for connection etc.
as per instruction of EIC.
Fabrication and erection of all tank modification jobs as per approved drawings and documents
Fabrication and erection for pipe supports and structural platforms for valve operation at various locations as
per requirement.
Fabrication, lowering/lifting, erection, alignment, fitting and welding of pipe/Valves/ fitting/ flanges/PSV as
per scope of work mentioned in Contract.
Installation of control valves, instrumentation items, Thermowells and valves at all elevation as per
engineering drawings.
Painting of the tank, pipelines, equipment etc. as per the paint system given in the drawings/specifications.
Hydro-test of tank, old & new piping, at hydro-test pressure given in the drawings and as per instruction of
EIC. All Hydrotest equipment (Pump / Pressure Gauges etc.) shall be tested as per standard Engineering
practices. Its calibration report shall be arranged during the shutdown period. Contractor to arrange for at
least 1 no's of electronic high pressure pumps required for hydrotest. No manual pumps shall be allowed by
IOCL for hydrotest purpose.
Erection and dismantling of scaffolding. Safe work Practices shall follow as per "Permit to Work" Procedure of
IOCL.
All plates and piping shall be marked for clear identification of different piping to avoid mix up of different
materials, as per color code provided by IOCL.
Pneumatic testing of tank bottom, roof and piping. Contractor to arrange for air compressor for carrying out
pneumatic testing of piping, contractor to quote accordingly.
All required jobs to be carried out to complete the work as per instruction of EIC
Contractor scope of work given below (but not limited to) is in addition to execution of job as defined in scope
of work-
Contractor to deploy at least 01 (one) safety supervisor having minimum 2 years’ experience and which must
be having minimum qualification as diploma in safety/engineering.
After getting the job, Contractor should depute their planning engineers for understanding the job. Their role
shall be to make a site visit when the job is received and make assessment of material, prefabrication and
recourse planning etc. They shall also be responsible for assessment of site conditions, accessibility of cranes,
manpower planning, etc. The Contractor shall setup his office at site at his own cost.
As the job to be executed at height, Contractor has to mobilize sufficient nos. adequate skilled & unskilled
manpower and experienced supervisors for execution activities. The Contractor shall marshal his manpower in
a manner that ensures adequate deployment as well as adequate rest for the workers.
Scaffolding materials are required for the erection of scaffolding at all the locations and same to be mobilized
at site before shutdown or during normal unit operation. After getting the job, contractor has to visit the units
of Panipat Refinery and access the quantities of scaffolding materials required for the execution of job within
scheduled time line given in this tender document.
Contractor to note that wherever crane, hydra, forklift, tractor trolley is required for the erection purpose,
contractor has to bring their own crane / hydra for the erection of pipe & equipment's. Contractor shall not be
admissible for any extra claim against this. IOCL shall not provide any crane, hydra, tractor trolley, forklift etc.
for execution of the jobs. Contractor to quote accordingly
Contractor has to deploy dedicated Safety Supervisors with relevant qualification and experience in each shift
while working in rotating shift to whom training on safety shall be provided, in turns he will have to arrange
training for their staff and record of training has to be submitted to EIC.
All lifting tools & tackles, Jacks, wire ropes, blocks, shackles, slings etc. Including any special equipment
proposed to be used by the Contractor shall comply with the requirements of the appropriate BS/IS Codes and
shall carry valid test certificates. Contractor to submit details of all the lifting tools to be used (along with their
valid test certificates).
Contractor has to maintain "Inspection of Hand Tools Record" as per instruction of EIC. The defective tools
have to be replaced with new tools as and when required.
Contractor has to engage minimum 01 (one) qualified supervisor (minimum diploma in Mech. Engineering) for
having enough experience of reporting system. Site in charge/ supervisor has to report shift wise progress in
writing (in specifically designed format) to respective EIC. A progress report shall be published every day,
detailing the progress / constraints on every front of work. This monitoring shall continue till all activities are
completed to the satisfaction of the engineer-in-charge.
All consumables such as gas, welding electrodes, filler wire (IOCL Approved only) grinding wheels etc. and
other consumables being used at the time of mech. job are in scope of Contractor only. The welding rods/filler
wires and grinding wheels are to be used as per EIC/Inspection and consumables should be within the shelf
life.
All free issue material shall be issued either from unit store or main store. Contractor is required to collect and
transport the same to use at site. Material supervisors shall be deployed by the Contractor for preparing
requisitions based on drawing/scheme/site conditions, obtaining requisite signatures, coordination with
Stores, proper receipt of materials from IOCL and reconciliation and return of balance / unused materials after
completion of work.
IOCL shall provide land to the contractor free of cost for storage of materials and temporary office at site.
Contractor has to all arrangements for preparation of shed for safe storage of materials. Also contractor has to
bring their own pota cabin for setting up of the office at Panipat Refinery.
The Contractor shall maintain a high standard of housekeeping around the working area and shall provide any
covers, screens, etc to protect the adjoining areas not affected by the works. The Contractor shall, at all times,
keep the working area, including adjoining premises, in a neat, clean & safe manner. Upon completion of any
portion of the job, the Contractor shall promptly remove all his equipment, construction plant, temporary
works and surplus materials that are no longer required at that location.
Contractor has to deploy a site in-charge, fully conversant with oil & gas industries work practices and having
working experience in operating plant along with suitable/ required no. of discipline engineers. Contractor
shall deploy required qualified safety personnel. The site in charge must have enough experience of reporting
system & shall be responsible for liaison with IOCL.
Disposal of scrap into scrap yard /designated place as per instruction of EIC. The disposal shall be planned on
daily basis so that site is free from debris all time.
The party shall ensure good workmen practices like no short bolting, uniform tightening of bolts, proper
gasketing, proper cleaning of faces of flanges before box up, using brass hammers wherever required, proper
cleaning of studs before use, apply antiseize compound on fasteners, area cleaning etc.
IOCL's liability for medical assistance shall be limited to providing First Aid within the Refinery premises only.
Further medical treatment, if warranted, shall be the responsibility of the Contractor. IOCL shall have no
further responsibility in such matters.
To deploy suitable qualified supervisors and engineers in requisite numbers to assure execution of good
quality job as per best engineering practices and to the full satisfaction of EIC.
Pre- Site Visit: The Bidder is advised to make a visit to the location inside Panipat Refinery for a first hand
assessment of the quantum and nature of work, before preparing the bid. Once the bid is submitted, it will be
assumed that the Bidder is fully aware of the all the details involved in the execution of the work.
Contractor shall have to take responsibility for safety and security of their manpower and resources (i.e tools
and tackles, equipment's etc.) and free issued materials by IOCL. IOCL shall not be responsible for any loss or
damage to items and personal in custody of Contractor at site for any reason whatsoever.
IOCL reserves the right to fully or partially execute this contract. Payment shall be made to contractor as per
actual executed quantities of job. Contractor shall not be liable for any extra claim on this account. This clause
shall supersede all other clauses mentioned elsewhere in this contract.
TECHNICAL
It shall be entire responsibility of Contractor to procure and use welding electrode, filler wires as per approved
list of welding electrodes / filler wires.
The welding electrodes, filler materials, welding procedure and NDT as directed by inspection authority shall
be followed.
The Contractor shall be liable to engage only those welders, who are qualified and holders of valid certificate,
issued by Inspection Department of any of the IOCL Refineries. Contractor to have at least two IOCL approved
IBR CS TIG welder for undertaking the jobs.
Contractor should have at least 03 welding machines and 03 (three) nos. TIG welding sets. However
Contractor has to mobilize more resources as and when required upon the directions of the EIC.
The agency should have mother oven for proper baking of electrodes and temperature control.
The welding procedure qualifications (PQR) shall be carried out as per inspection requirement and related
testing charges and consumables required for the same shall be borne by Contractor. However, materials
required for test piece shall be provided by owner as free issue.
Welding procedure specification (WPS) to be approved by Inspection Department before starting any job.