Você está na página 1de 14

ANNEXURE-III

SCOPE OF WORK
Sub: Repair of Regeneration Columns C-1202 and C-1302 of GSU-12 and GSU-13 Plants at
ONGC Uran Plant, Uran
The GSU units of plant removes the shore content like H2S & CO2 from hydrocarbon gas before
extracting the LPG,C2C3,LAN and sweet lean gas.
During the turnaround inspection of the columns C-1202 and C-1302, it is found that there is
thickness loss at various location on columns from inside as well as outside also. The thickness
loss has to be repaired for the service of the remaining life of the columns.
The repairing of columns has to be done by lap band repair at some of the location, at other
locations by weld build up. At some location SS cladding (inside the column C-1302) is
damaged, hence an internal repair including the replacement at some portion and patch weld/
weld build up repair at some location of clad/column is to be carried out.
Details of columns(C-1202 & C-1302)
SL no.
Details
1
Design pressure (Ks/cm2g)
2
Operating
pressure
(Ks/cm2g)
3
Design temperature ( C)
4
Service
5
ID
6
Capacity
7
Thickness of shell (mm)
8
9
10
11
12

Specification values
5.7
0.5/0.7

97.3(top)/125.7(bottom)
Sulfinol-X solvent+H2S+CO2+hydrocarbon gas traces
2550mm(top)/3500mm(bottom)
129.2m3
12(9+3) top 3 mm clad up to 5 m from top,15mm in
middle,19 mm at bottom
columns 25.7+1.15

Max height of
(meter)
MOC of shell/clad
Insulation thickness(mm)
Joint efficiency
Code

SA516Gr.60/ SA516Gr.60+A240-321
105
1.0/0.85
ASME Sec.VII DIV.I 1986

A .Repair locations of C-1202:


Area of Corroded Zone
(mXm) of external surface of Shell
1.0X0.5
0.5X0.5
121 | P a g e

Fillet Weld patches area


(mXm)
1.2X0.8
Nil
UP14C15018

Weld overlay area ( mXm)


Nil
2.0X2.0

LOCATION

A/1ST
top
B/1ST
top
B/1ST
top
D/5th
top
E/5th
top
F/5th
top
G/5th
top
H/5th
top
I/5th
top

2
3
4
5
6
7
8
9

Nom
inal
thick
ness(
mm)

Observ
ed min.
thickne
ss(mm)

Area of Type of repair


corrod
ed
zone(m
xm)

shell from 12

6.4

1.0x0.3

shell from 12

4.5

shell from 12

7.0

2.0x1.2
5
1.0x1.0

shell from 15

9.4

1.5x1.0

shell from 15

7.7

1.0x1.0

shell from 15

8.6

1.0x1.0

shell from 15

8.9

0.2x0.2

shell from 19

13.4

shell from 19

12.0

Area
to
repaired

S.No

be

B. Repair locations of C-1302:

Area of Lap bands


8.6x1.0
(M X M) OD of shell2.74m
8.6x2.0
8.6x1.5

Internal
3mm
SS
cladding area
to
be
replaced (m
X m)
1.5 X1.0
2.5x1.5
1.5x1.0

Fillet weld patches 1.5x1.0


area M2
Fillet weld patches 1.5x1.0
area M2
weld overlay area m2 2.0

Nil

Nil

1.0x0.5

weld 1.0overlay area 2.0


m2
weld overlay area m2 1.5

0.2x0.2

weld overlay area m2

Nil

1.5

Nil
Nil

Nil

Detail scope of work:


1. Erection/dismantling of scaffolding at periphery of columns prior to the shutdown as per
the instructions of Engineer in charge is in the scope of contractor. Scaffolding material and
all tools/tackles including consumables like paint removers, Rustolene, Brass Wire brushes,
waste clothes is in the scope of contractor.
2. Erection/dismantling of scaffolding at inside of column, (if require,) shall be done as per the
instructions of Engineer in charge and same is in the scope of contractor.
3. The removal/installation of insulation shall be in scope of ONGC. The scrap of insulation
shall be removed by ONGC
4. The removal of composite coating shall be in scope of contractor (if required).

122 | P a g e

UP14C15018

5. After shut down blinding/DE blinding of columns shall be performed by contractor as per
instruction of EIC.
6. The repair is to be done at identified locations inside as well as outside of columns which
are at various height. The contractor may visit the site so as to get first hand details about
the job to be carried out.
7. The supply of all the material required (including logistics, loading/unloading etc.) to
execute the job as per SOW is in the scope of contractor.
8. The welder/welders deputed for the job shall be a qualified welder and requisite associated
manpower shall be made available at the site so as to complete the job within stipulated
time.
9. The procedure given for carrying out the repair shall be followed and as per the guidelines
of ASME Sec IX and ASME Sec II Part C.
10. The type of repair like lap banding, fillet weld of patch, weld overlay and clad (inside the
column) replacement have been provided above in the table but same is indicative only. If
needed repair work in more area shall be performed in addition to above. And the
contractor has to adopt the appropriate procedure to do all said repairing work accordingly.
11. Suitable NDT to be done after every root and final weld run. After completion of the
repair, radiography shall be done by the contractor as per the instructions of Engineer-incharge.
12. On completion of repair, two coats of high temperature & corrosion resistance
paint shall be applied over the repaired surface as well as on whole surface of columns after
properly cleaning and corrosion removing as per the standard procedure with minimum DFT
after each coat 20 microns.
13. The scrap generated during the execution of the repair job will become the property of
the contractor and shall be taken out of ONGC premises. Accordingly the bidder has to
quote the price for the safe disposal and comply all statutory requirement.
14. All the jobs to be carried out shall be executed as per the instructions of Engineer-incharge and within the given time period.
15. The columns shall be flushed and washed the whole column from inside properly by
contractor followed by oxygen test before taking repair job either from inside or from
outside of columns.
16. If needed the contractor has to remove nearly 7 trays, do the repair/replacement work
inside the column and then refit same trays properly.
17. Bidder has to do hydro test of column at test pressure for leak test at 1.5 times of design
pressure.
18. The contractor has to paint the railing, grating, ladder platform of the column with
suitable paint as per procedure.

123 | P a g e

UP14C15018

19. Contractor has to arrange PPE (Personal Protective Equipments) like safety shoes, safety
belts, helmets etc. for all his personals to be engaged during execution of job at site.
20. The contractor has to get gate pass for men and equipment himself. ONGC shall assist
him. Providing all required documents and police verification shall be responsibility of
contractor.
21. On accident if any for employees of contractor, ONGC shall not any responsibility for
same and ONGC shall transport the victim up to ONGC plant occupational health center.
Transportation of patient from ONGC premises to required hospital and treatment shall be
responsibility of contractor.
22. Following procedures of repairing of damaged at different portion of columns can be
adapted by bidder. Replacing the section or component containing the defect for clad
pad portion.
1. Damaged or eroded shell plates (reduced thickness) area may be repaired by
removing a section and replacing the plate as per required thickness and
material specification.
2. Full penetration groove weld to be provided.
3. The welds are radio graphically tested with applicable construction code.
Ultrasonic examination by an industry qualified UT shear wave examiner. May
be substituted by radiography if NOE procedure is approved.
4. All patch plates corners that do not extend to existing longitudinal or
horizontal weld shall be rounded having a 1 in. (2Smm) minimum radius. Weld
proximity to existing weld shall be reviewed by the engineer.
Fillet weld patches:
Following procedure should be used for fillet weld patches or weld build up:
Fillet weld patches may be used to make temporary repairs to damaged,
corroded or eroded areas of pressure vessel components. Temporary repairs
using fillet welded patches shall be approved by an inspector and engineer.
The use of fillet welded patches may be subject to the acceptance of the
governing jurisdiction.
Fillet welded patches require special design consideration specially related to
weld joint efficiency, filler welded patches may be applied to internal or
external surface of shell, heads and header provided that in the judgment of
the engineer, either of the following is true:- The fillet welded patches provide design safety
equivalent
to
reinforced
openings designed according to the applicable construction code.
a. The fillet welded patched are designed to absorb the membrane strains of
the parts so that in accordance with the rules of the applicable
construction code, the following result:

124 | P a g e

UP14C15018

b. The allowable membrane stress is not exceeded in the vessel part or


patches.
c. The strain in the patches does not result in fillet weld stresses that
exceed allowable stress for such welds.
Lap band repairs:
The band is designed to contain full vessel design pressure,
All longitudinal seams in the repair band are full penetration butt weld with the
design joint efficiency and inspection "consistent with the appropriate code,
The circumferential fillet welds attaching the band to the vessel shall are
designed to transfer the full longitudinal load in the vessel shell, using a joint
efficiency of 0.45,
Appropriate surface NDE shall be conducted on all attachment welds,
The band material and weld material are suitable for contact with the
contained fluid at the design conditions and an appropriate corrosion
allowance is proved in the band.
Welding procedure:
Following process may be used to obtain the finish weld.
Contractor
shall
establish
suitable
WPS
&
PQR
as
per
mandatory
requirement of ASME Sec. IX, Also applicability of suitable welding rod,
electrode and filler metal as per ASME Sec, II part C.
The process may be SMAW or GTAW.
Consumables for GTAW as per ASME SFA 5.18- AWS ER 70S2, for SMAW
as per ASME SFA 5,1 - AWS E7018.
The lap band can be partially or fully pre-fabricated according to design given
by designer in accordance with appropriate code.
Safe
installation
procedure
to
adopt
by
contractor
for
welding
of
circumferential fillet weld between band and shell. Pre heating to 150 deg. Or
higher to be maintained during welding.
Weld overlay of corroded area (clad repair procedure)
The SS clad has been removed by erosion. It needs weld overlay over CS plate to protect the
same. Following procedure shall be used
1. Mark clearly the area that needed to be repaired,
2. Ensure proper qualified welder who is doing welding jobs
3. Welding electrode used for SS are ER309 electrode by GTAW OR SMAW process.
4. Proper size electrode to be used and continuous run to be made over CS surface as per
required thickness of SS clad.
5. Current to be properly controlled as excess current may burn out the base metal.
125 | P a g e

UP14C15018

6. After complete welding of required thickness proper flushing (grinding) to be done


smooth surface.
7. NDT as MPI or LPT to be done on ground surface for defects.
Welding process:Following process may be used to obtain the finish weld. Contractor shall
establish suitable WPS & PQR as per mandatory requirements of ASME
Sec. IX. Also contractor has to establish applicability of suitable welding rod.
Electrode & filler wire as per ASME Sec. I! Part C.
1. SMAW
2. GTAW
Procedure:Surface cleaning: Care to be taken previously installed paint / insulation is
properly cleaned. Method like chipping, grinding can be used to achieve surface
preparation.
Marking: Prior to cutting, all affected members (where surface thinning is
observed) shall be properly marked with appropriate length. Cutting can be done
by gas cutter or by any other suitable method. During cutting method should be
such selected that during the process it should not lead to distortion of the
structure or any increase in joints.
Welding: Prior to welding edge preparation, bevelling shall be carried out using
grinding machine for proper joint preparation. Only qualified welders shall be
deployed for welding as per ASME Sec IX or equivalent. All weldings shall be in
minimum 2 passes. Welding shall be followed by suitable NOT (RT, UT and MPI)
etc. to ensure the quality of weld.
Precaution for repair: All sharp, rough, broken edges and the edge of joints shall
be cleared out so as to avoid defects and to install or fabricate equipment and
defect free joints. Precaution for repair shall be taken into consideration that it
does not alter the mechanical properties of the material.
In the ONGCs scope:
a. Low tension power supply and connections shall only be provided by ONGC.
b. Water and air at 4-6 kg /cm2 pressure shall be provided by ONGC.
c. Any power supply up to the column bottom for grinders etc. however, long cable from
bottom to top of column to be arranged by contractor.
Special Terms & Conditions:

Payment terms:
No advance payment shall be made. 100%Payment shall be made on successfully
completion of each column repair job as per Scope of Work and terms and conditions of the
contract.

126 | P a g e

UP14C15018

Bidder has to submit the bill/invoice in triplicate with all required documents in the name of
DGM (F&A), ONGC, Uran and should get tracking number from our HR/ER Section. The bill
after tracking no. shall be forwarded to concerned Engineer in charge by HR/ER for
certification, verification, and final release. Payment shall be released within 21 days from
the date of submission of bill to concerned Engineer-In-Charge.
Completion Schedule: Contractor has to complete the job of repair of each column within
20 days from the date of handing over the respective columns.
Mobilization: Maximum 15 days shall be allowed for mobilization of men, equipment and
machinery etc. from date of LOA.
Contract period: Contract period for the jobs will be 18 Months from placement of LOI.
Inspection: Inspection shall be carried out by ONGC representative/ TPI(arranged by ONGC)

Guarantee/Warrantee: Contractor has to furnish a guarantee/warrantee for a period of one


year from the date of completion of job. During the period if any defect is observed in the
executed job, the same shall be rectified by the contractor at free of cost within a minimum
possible time.

127 | P a g e

UP14C15018

128 | P a g e

UP14C15018

129 | P a g e

UP14C15018

130 | P a g e

UP14C15018

131 | P a g e

UP14C15018

132 | P a g e

UP14C15018

133 | P a g e

UP14C15018

134 | P a g e

UP14C15018