SCOPE OF WORK AND
SCOPE OF SUPPLY
DOCUMENT No.
A062-114-50-46-SP-03 Rev.0
Page 1 of 7
ERECTION OF CAT COOLER NEW
FCCU
10000294-HB-48009
SCOPE OF WORK AND SCOPE OF SUPPLY FOR
CATALYST COOLER INSTALLATION AT
HPCL-MUMBAI
0
06.01.2011
Issued with Tender
RSR
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SHAIL
JKM
S.RAINA
SCOPE OF WORK AND
SCOPE OF SUPPLY
DOCUMENT No.
A062-114-50-46-SP-03 Rev.0
Page 2 of 7
ERECTION OF CAT COOLER NEW
FCCU
Rev. No.
Date
Purpose
Prepared By
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10000294-HB-48009
Checked By
Approved By
SCOPE OF WORK AND
SCOPE OF SUPPLY
DOCUMENT No.
A062-114-50-46-SP-03 Rev.0
Page 3 of 7
ERECTION OF CAT COOLER NEW
FCCU
10000294-HB-48009
GENERAL
This tender specification cover modification works required in Regenerator at the time of Catalyst Cooler
installation in the Regenerator section at HPCL-Mumbai. Brief scope of modification work in each
equipment is as follows (but not limited to the following):
1) FCC REGENERATOR (Item No 114-R-1002)
a)
b)
c)
d)
e)
f)
g)
Dismantling/ re-assembly of existing structure required for the erection of catalyst cooler.
Cutting and removal of dished end of nozzle B41 & B45.
Installation of mitre section of nozzle B41
Erection of Catalyst Cooler shell and welding of its top nozzle with nozzle B41
Erection/installation of 2 nos spring hangers for supporting catalyst cooler.
Installation of debris screen assembly for nozzle B41.
Installation of Cooled catalyst standpipe (comprising of slide valve & expansion joint) connected
with nozzle B45 & H05.
h) Installation of cooled catalyst deflector in nozzle B45.
i) Installation of catalyst cooler tube bundle.
Note: All above modification works are to be carried out in strict compliance to UOP drawings/
specification enclosed with tender specification
The tender covers supply of all materials ( except those covered in Owner’s scope of supply), cutting all
items requiring removal and other components as per drawing, supply of all materials for temporary
supports, fabrication and installation of all temporary supports while dismantling/cutting/ removal of all
items, transportation of the same to area indicated by Engineer-in-Charge, (Items which are to be
reused shall be properly kept and care should be taken not to damage any component), supply of all
new materials as per specification, erection of the same in position, welding and carrying out all NDT
requirements, carrying out PWHT as per Code, hydro-testing, supply of all refractory materials,
anchors, applying all refractories, curing, drying etc., surface preparation, application of primer/paint,
dismantling of all insulation wherever required for carrying out site work, supply of new insulation
material/cladding etc., and installation of insulation etc., completing all the work as per code, standards,
specification, requirements of tender, instructions of Engineer-in-charge, including cleaning all debris,
and making the area to the original condition. All modification works shall be carried out with adequate
safety and barricading requirements for the operating refinery and agencies who have done similar job
shall be employed .
Owner’s Scope of Supply
1)
2)
3)
4)
5)
Catalyst Cooler (Item No 114-E-1002)
Mitre portion of nozzle B41 as per UOP/L&T drg., Debris screen assembly
Catalyst deflector for nozzle B45
Expansion joint & Slide valve for Cooled catalyst standpipe
Two number spring hanger support for Catalyst cooler
Contractor’s scope of Supply
Contractor’s scope shall include but not limited to the following items:
1) All metallic and non-metallic parts/items required for executing the job as per code, standards,
specifications, drawings, requirements of tender document and instruction of Engineer-inCharge.
2) All crane(s) for erection of equipments (The capacity of crane(s) shall be decided by
Contractor).
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SCOPE OF WORK AND
SCOPE OF SUPPLY
DOCUMENT No.
A062-114-50-46-SP-03 Rev.0
Page 4 of 7
ERECTION OF CAT COOLER NEW
FCCU
10000294-HB-48009
3) All transportation equipments, handling equipments, all tools, tackles etc. for execution and
completing the job.
4) All loading/unloading equipments.
5) All form/shuttering materials for application of lining.
6) All refractory mixing equipments, vibrators, application equipments, drying equipments etc. for
carrying all works with respect to refractory.
7) All material for temporary supports/structures required while cutting and dismantling/removal.
8) All material and consumables for welding procedures, welder’s qualification and performance
test, etc.
9) All Jigs, Fixtures and Trolley as per UOP specification required for bundle erection/removal and
future maintenance as well. The same are required to be handed over to HPCL after erection of
catalyst cooler assembly.
10) All refractory materials of approved specification, all anchors, edge bars, collars, punch tabs,
ceramic fibre, paper, hex mesh, SS reinforcing needless, etc. as per specification, drawing from
the suppliers indicated in the tender.
11) Blinds and tail blinds required are to be supplied by the contractor.
12) All materials for insulation work.
13) All equipments accessories etc. for gas cutting.
14) All items required for conducting non-destructive examination like radiographic examination, UT,
DP/MP examination, hydro-test, etc. and any other tests a specified, PWHT etc.
15) All consumables, industrial gases such as Oxygen, acetylene argon etc. all types of electrodes,
radiographic films etc. including all accessories for completing the job.
16) All tools, tackles, accessories, apparatus for shot blasting, application of primer/paint etc.
17) Providing all necessary safety equipments along with dedicated safety Engineer throughout the
Contract period.
18) All equipment required for proper ventilation and proper lighting during execution of work.
19) All primer/paint and equipment required for surface preparation.
20) All materials for all temporary structure/supports wherever required for dismantling/erection etc.
21) All materials required for replacement of any item/ component damaged during execution due to
contractor’s negligence, improper erection sequence/ erection method etc.
22) All drawings and documents as per Vendor Data Requirement.
23) All items (other than free issue items) covered in applicable EIL/ UOP specification, standards
and drawings.
24) Spare gaskets (200%) of each size and 10% spare bolting (minimum 2 nos.) of each size for all
blind flange connection, companion flange connection.
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SCOPE OF WORK AND
SCOPE OF SUPPLY
DOCUMENT No.
A062-114-50-46-SP-03 Rev.0
Page 5 of 7
ERECTION OF CAT COOLER NEW
FCCU
10000294-HB-48009
25) All internal distributor, along with supports etc. as per specification called out in the
drg./standard.
26) While welding new portion with the old portion dehydrogenation treatment (heating, upto 300
deg C for two hours) shall be carried out.
27) All personnel required to assist owner in making equipment and connected piping hydrocarbon
free, fit for executing revamping.
28) Any other items not specifically covered but required for completing all work as per
specifications, codes, standards and requirements of tender document/Instructions of Engineerin-charge.
CONTRACTOR’S SCOPE OF WORK
1) Preparation of all detailed fabrication drawings/working drawings and getting the same
reviewed/ approved by EIL/HPCL before start of work.
2) Preparation of dismantling and erection procedures/sequences including obtaining approval
from EIL/HPCL before start of any dismantling / erection activity.
3) Construction of hardstand for movement of all crane(s) and other equipments. Contractor shall
visit site, get familiarized with the site layout and check the adequacy of bearing strength of
area of the erection site. In case strength of ground is not adequate, contractor shall carry out
all strengthening activities and shall include the same in his scope and quoted price shall
include for the same.
4)
All hot works to be done in booth covered by asbestos cloth/GI sheets meeting safety
requirements of the operating refinery and as per the instructions of Engineer-in- charge.
5) Temporary supports are to be provided wherever required while dismantling the dished ends of
nozzles, structural members etc so as to remove safely these items that are to be dismantled
and to keep the other items to be retained in position are not disturbed from its original position.
6) Carrying out necessary spading for ensuring positive isolation of the Regenerator as per the
instructions of Engineer-in-charge. Making necessary hose connections for steaming out /
draining activities.
7) Opening of man-ways and nozzles wherever required, blinding/de-blinding as case
may be for the execution of the work, are to be done by the contractor.
8) Providing necessary assistance to HPCL/EIL for removal of loose catalyst from the
Regenerator.
9) Removal of existing insulation to the extent required for modification works.
10) Erection, assembly and welding of new catalyst cooler with Regenerator nozzles, conducting
all NDT examination, heat treatment etc. Chipping of refractory and hex-mesh to the extent
required for the attachment of new catalyst cooler and preparing the edges for welding shall be
included in the Contractor’s scope.
11) Contractor shall carry out all edge preparation and conduct 100% UT examination of prepared
edges for all shop/site joints (All edge preparation shall be compatible to adjacent component).
12) Conducting all welding procedure, welder qualification, performance test, etc.
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SCOPE OF WORK AND
SCOPE OF SUPPLY
DOCUMENT No.
A062-114-50-46-SP-03 Rev.0
Page 6 of 7
ERECTION OF CAT COOLER NEW
FCCU
10000294-HB-48009
13) Providing suitable ventilation and lighting arrangements for persons working inside the
equipment meeting all safety requirements.
14) Reinstallation of new insulation at places from where insulation has been removed
modification/revamping. Application of insulation on new equipment wherever required.
for
15) Dismantling of any platforms ( in sections / as a whole) without damaging any component which
are interfering with the erection scheme with prior approval of EIL/HPCL. After completion of
erection, the same shall be re-installed to the original requirement.
16) Contractor shall provide complete procedure for site seam examination and method of
application of refractory lining before start of work for review by HPCL/EIL. As a minimum all site
joints shall be 100% RT, 100% UT & 100% WFMT (from outside and inside both wherever
feasible) before and after PWHT (as applicable) are required.
For all site joints 100% DP check for root run and all subsequent passes of weld shall be carried
out (Contractor shall furnish all NDT examination requirement of shop/site fabrication for review
by HPCL/EIL).
17) Transportation and erection of catalyst cooler assembly as per approved erection/handling
scheme by HPCL/UOP/EIL.
18) Demonstration of tube bundle removal/insertion in catalyst cooler shell to HPCL/EIL as per
instruction from Engineer –in-charge.
19) Transportation of spring hangers from stores and erection of the same in position for load
condition specified in the tender elsewhere.
20) Conducting 100% UT examination of non-accessible joints and bevel edges of existing
components.
21) Engaging the services of UOP approved refractory inspection agency, refractory application
agency, refractory dry-out agency as called in the tender.
22) Application of refractory lining including cleaning of the surface by blast cleaning, installation of
anchors / hex mesh, preparation of proper refractory mix, installation of lining by qualified
personnel, proper curing and drying, inspection and testing of the lining as per specifications,
standards and to the satisfaction of Engineer-in-charge.
23) Surface preparation required as per spec./drgs., application of primer / paint to new surfaces.
24) All items which are fabricated / completed at shop shall be transported to site/ Storage
yard/stores duly packed.
25) Erection of temporary platform, scaffolding inside and outside of Regenerator/ Reactor riser
required for the execution of stipulated work and removal of the same after completion of work.
26) Transportation of used or replaced items which are required to be stored as per instruction of
Engineer-in-charge.
27) Adhering to safety and barricading requirement as instructed by the operation group of running
refinery.
28) Contractor shall take hot and cold work permit from HPCL before start of site activities.
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SCOPE OF WORK AND
SCOPE OF SUPPLY
DOCUMENT No.
A062-114-50-46-SP-03 Rev.0
Page 7 of 7
ERECTION OF CAT COOLER NEW
FCCU
10000294-HB-48009
29) After completion of all site activities, clearing the entire area as per requirement of Engineer-inIn-charge is the responsibility of the contractor. All personnel required for such activities shall be
provided by the contractor.
30) After award of contract, detail of activities proposed to be carried out at shop, at site prior to
shutdown and during shutdown along with the schedule must be submitted to HPCL/EIL for
review.
31) Rectifying and bringing the same to original requirement of any component/refractory damaged
during erection due to contractor’s negligence, wrong/improper method of execution shall be
carried out by the contractor without time and cost implication on the part of client.
32) All relevant drawings, standards and specifications are attached as per document no. A062-11450-46-LL-02. Any other drawing/document required by contractor shall be furnished during prebid meeting.
33) Refer doc no A062-114-50-46-SR0003 for schedule of rates for Erection works of catalyst
cooler.
34) Contractor shall visit the site and study the site conditions before quoting for the job.
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