“JOB SCHEDULE AND SPECIAL TERMS AND CONDITIONS”
JOB : RETESTING AND PAINTING OF LPG CYLINDERS
– EX - PAHARPUR LPG PLANT
1.
The testing of cylinders shall be carried out as per the code of practice for
periodic inspection and testing of LPG Cylinders in use. Latest edition and
revisions there after to be followed strictly. Job includes depressurization, valve
removal, degassing, hydro-testing, valve fixing, painting and stenciling. Rate is
inclusive of to & fro transportation.
2.
All the other specifications shall be as per drawing LPG/C/RH/PKK/02
dated 12.12.2002. Latest edition and revisions there after to be followed strictly.
3.
All the safety messages, colour coding, tare weight shall be stencil painted
on the cylinders as per drawings No. LPG/C/RH/PKK/02 dated 12.12.02 and the
HP Gas Logo to be screen painted as per drawing no. LPG/D/KKK/01 dated
28.09.01 or the latest revision thereof.
4. Test Certificate and detailed list of cylinders tested shall be submitted to the
plant while effecting the delivery of cylinders.
5.
All the cylinders rejected during the tests and inspections shall be handed
over to HPCL along with the list of cylinders and their details. Such cylinders
shall be prominently marked by black paint (or as advised by BIS) for its
identification.
6.
The new Tare Weight shall be marked and screen painted on the cylinder
as per the drawing. The tare weight shall be within the accuracy of +/- 50 grams.
The tare weight shall be screen painted on shroud (shade no. 355 as per IS:5)
and shall also be screen painted in black paint on the inner side of the two
vertical stay plates. The quarter and the year of next test due date shall be
screen painted on the inner side of the third stay plate as per the color coding
mentioned in the LPG Cylinder drawing No. LPG/C/RH/PKK/02 dated 12.12.2002
or the latest revision thereof.
Any revision in the methodology of any part of the total job of this contract,
by HPCL or by any other statutory authority shall be complied with by the party
with out any extra cost.
7.
MARKINGS: The repairer will mark its abbreviated name, logo and the
test date on the third stay plate reproducing all the details of previous mandatory
testing and repair, including the abbreviated names of previous repairer and
testing party.
8.
VALVE FIXING: Valve fixing shall be done as per the procedure
applicable for the manufacture of new cylinders of HPCL. The valves shall be
fixed by using minimum two rounds of PTFE tape of ¾ th inch width, 40 micron
thickness, conforming to IS: 14643 of reputed manufacturers only. The valve
fixing torque will be at 145 + or – 15 ft-lbs. Proper torque wrench should be used
to ensure the correct torque and it shall be calibrated periodically.
9.
The primer and the synthetic enamel paint shall be conforming to IS: 2074
and IS: 2932. All the colour coding shall be as per the HPCL LPG Cylinder
drawing.
10.
The party should have the valid permission from CCOE and/or the BIS
License for carrying out statutory testing of LPG Cylinders during the contract.
11.
The cylinders shall be handed over to the party in fully depressurized
condition.
12.
The party shall submit statement of valves. All the valves removed from
the cylinders shall be salvaged and valves found to be good shall be used. The
rejected valves shall be handed over to the controlling plant. The storage of good
/ rejected valves shall be so as to avoid any physical damage.
13. Repairer shall maintain reconciliation statement on receipt of cylinders,
valves Vis a Vis dispatch and inventory of the same at their premises. The
statement shall be submitted to the controlling office/Plant on monthly basis.
14. HPCL reserves its right to inspect the repairer’s premises during the
reasonable time with or without prior intimation to the repairer to verify the quality
of repairing activity and for physical inventory verification of equipments
(cylinders, valves etc.) with the party.
15. In case of any shortage /loss of cylinders or valves by the party, the cost of
the same at the prevailing penal rate shall be recovered from the party.
16. In case of detection of first fill leakage (except Valve Leak/ Neck Leak)
in cylinders retested by you, a penalty of Rs. 1,800/- per cylinder shall be
recovered. In addition no charges shall be paid for those cylinders.
17.
Each cylinder should be tested as per IS-3196 (part II) and revisions
thereof,
a. Hydrostatic Stretch Test: Number of pressure gauge should be equal to the
number of testing points with positive segregation. Cylinders should be dried
totally and only after ensuring complete drying of the cylinder, test pressure
should be retained for minimum 30 secs. The HST fixture should be roller based
rotating type. Proper illumination to be provided. Arrangement to be made for
inspection of foot ring weld and bottom portion of the cylinder during test. The
water filling equipment preferably should be pneumatically operated and should
have auto fixing, auto filling and auto evacuation to avoid spillage of water on the
outer surface of the cylinder under test. A wooden / teflon mallet shall be used to
tap the cylinder specially at the C – Weld during HST to detect pin hole, porosity
and other weld defects if any.
b. Pneumatic Test: The inside of the tank for pneumatic test should be painted
with white paint. Proper illumination to be provided outside and inside the tank.
The cylinder should be filled with the air as specified in IS-3196 (latest) and
tested for minimum 60 sec for any leakage. Provision to be made for rotating the
cylinder during the test. Testing shall be carried out after fixing the safety cap on
the valve.
18. PAINTING SPECIFICATION:
A.
The surface of the cylinders are to be cleaned thoroughly using non –
ferrous wire brush and suitable cleaning agent like caustic soda solution of
proper density and drying the same.
B.
One uniform coat of Zinc Chromate Primer conforming to IS: 2074 (latest).
The minimum thickness shall be 15 Microns.
C.
Two coat of super synthetic enamel signal red paint (shade – 537 of
IS: 5) as per the specifications of IS: 2932 (latest) shall be applied.
The minimum thickness shall be 15 Microns.
D.
Tare weight shall be screen painted using black paint as per specification
IS: 2932 (latest) at three places inside the vertical stay plates. Screen
painting of tare weight in yellow paint (shade No. 355 as per IS: 5 (latest)
at three equi spaced locations on shroud. The size of stenciling to be 25
mm. Minimum paint thickness shall be 15 microns.
E.
Safety slogans shall be screen painted using white paint as per IS:
2932(latest) on shoulder of the cylinder namely check seal on delivery;
switch off regulator when not in use, for domestic use only in English as
well as Hindi as per our drawing.
F.
Net wt. 14.2 KGS should be screen painted using black paint as per IS:
2932 (latest). The size of the letter shall be 20mm.
G.
Two coats of blue enamel paint (shade no. 166 as per IS: 5 (latest) should
be used for painting at the shroud up to 63 mm radius from the bung of
cylinder, as per IS: 2932 (latest). The bungs should not be painted.
H.
HP Gas logo shall be screen painted in white colour at two places on the
body of the cylinder as per drawing LPG/D/KKK/99 rev 2 (latest) and at
one place on the 91 mm stay plate as per drawing no. LPG/D/KKK/01
dated 28.09.01 and revisions thereof.
I.
The next due date of re-testing shall be screen painted inside 91 mm / 52
mm stay plate as per drawing.
J.
Primer / Paints manufactured by only the following companies shall used
in all cases,
Asian Paint
3.
ICI Limited
5.
Shalimar Paint
K.
2.
Goodlass Nerolac
4.
Berger Paint
6.
Jenson & Nicholson
A drying time specified by the paint manufacturer shall be allowed in all
cases.
19.
All safety caps to be removed before execution of the job and only sound
safety caps shall be re-fixed ob cylinder valves after tying on one stay plate.
20. New thread / spring shall be provided on safety caps wherever the thread /
spring is damaged / missing. The nylon thread length shall be of 190 mm length.
21.
STAY PLATE STRAIGHTENING: The bend stay plates shall be
straightened wherever necessary using stay plate straightener.
22.
Repairer shall submit the statement on consumption of the valves. All the
valves removed from the cylinders shall be handed over back to the plant. The
storage of the new and the old valves shall be properly done to avoid any
damage.
23.
SEGREGATION OF DPT CYLINDERS: The party shall segregate
cylinders due for testing and painting from the conveyor/unloading point/ground.
Noting of cylinder serial and loading of the same in their truck are under the
scope of the party. Unloading of cylinders from truck to conveyor or in the
field/ground is also under the scope of the party.