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SCOPE OF WORK FOR ANNUAL MAINTENANCE CONTRACT FOR AUTO LPG DISPENSING STATIONS

ALDS are provided with two underground LPG Tanks of 7.5 KL / 10 KL water capacity each for storage
of Auto LPG, submersible pump / above ground dispensing pump, unloading pump & one or two
LPG dispensers.

Scope of Work:
1. Preventive maintenance in-line with OISD code requirements / equipment manufacturer recommendations
( visiting site once in a month - maintenance of all mechanical, electrical & electronic parts / sub assemblies)
2. Breakdown maintenance in case of any breakdown
( after receiving written or oral information by party - report to be submitted as per format agreed )
3. Testing of safety fittings / equipments as per OISD code requirements / equipment manufacturer recommendations
4. Supply of all spares / consumables / manpower for maintaining the ALDS
5. Refresher training to retail outlet personnel on correct / safe operations & upkeep of Auto LPG stations.

Records of all checks / maintenanace / tests done at the ALDS shall be maintained at the Auto LPG dispensing station
with second copy marked to Manager - Engineering, Regional Office.
Monthly report shall be submitted to HPCL

I. STATUTORY TESTING OF RELIEF / PROTECTION SYSTEM (as per OISD 210)

EQUIPMENT / FACILITY Frequency Agency


Emergency push button Trips Once in a month Competant / Authorized Person
LPG Hoses - both of LPG
dispenser & bulk LPG Once in 4 months Authorized Person
unloading hoses
Earth Pits By Licensed Electrical contractor
High level alarm of storage
vessel
Competant / Authorized Person
Remote Operated Valves Once in 6 months
LPG Pump
Breakaway Coupling
Authorized Person
Fire Extinguishers
Safety Relief Valve Competant Person (CCOE Approved)
Thermal / Hydrostatic Relief Once in a year Competant Person
Valve
Cathodic Protection System Authorized Person

II. LPG DISPENSER


Checking of the following components - Hydrostatic Relief Valve, High Pressure Releif valve, Vapor Eliminator / Filter,
Temperature probe, Differential valve, Back Check valves, Ball valves, metering system, recirculation valve, PLC boards
of dispenser, dispenser key pad & solenoid valve.
LPG dispenser shall be calibrated twice a year using Calibrated Mass Flow Meter (prior intimation to be given to HPCL)
III. SUBMERSIBLE PUMP & BYPASS VALVE
Inspect the pumping system for leaks, vibration, unusual noise etc. Check for Tank vapor pressure & pumpset discharge
pressue. Check current drawn by pump.
For Bypass - Check & record cracking pressure & pressure at full flow when bypassed
Checking proper working of pressure switch / pressure transmitter.

IV. LPG UNLOADING PUMP


Inspect the pumping system, checking for leaks from mechanical seal, vibration & unusual noises. Checking for tank
vapor pressure & pumpset discharge pressure, current drawn by pump & lubrication of pump & motor bearings.

V. CONTRACT EXCLUSIONS (not covered under contract)


1. Submersible Pump
2. Unloading Pump
3. Smart Hoses
4. Mass Flow Meter
5. Air Compressor
6. All type of ball valves / ROV's
7. Magneto restrictive type level gauge
8. Rochester gauge
9. Piston meter of dispenser

V. SUBMISSION OF REPORT
1. Copies of all Preventive Maintenance & Break down maintenance service reports
2. History sheets of all ALDS
3. Summary of Breakdown & Preventive maintenance
4. Reports of statutory testing of equipment carried out & T.C.
5. AMC scheduler intimating dates of visit every month & MISshowing complaint received v/s. attended.

VI. DELAY IN ATTENDING COMPLAINTS


Rs.500/- per day penalty as per Clause No.9.2 till the ALDS is restored

VII. PAYMENT TERMS


Payment shall be done on quarterly basis to respective regional office & shall be credited on or before 15 days
after bill reciept by HPCL.
commendations

pensing station

inator / Filter,
lve, PLC boards

be given to HPCL)
umpset discharge

cking for tank


HINDUSTAN PETROLEUM CORPORATION

LOG BOOK FOR MAINTENANCE CONTRACT FOR AUTO LPG D

LOCATION :

SR. CHECKED
MAINTENANCE DESCRIPTION
NO. YES/NO

Cleaning of LPG strainer /filters in the


1 YES
LPG dispensing system.
Water draining from the underground
2 YES
LPG tank

3 Checking of the breakaway coupling YES

LPG dispenser Hoses to be checked -


4 YES
visually, hydrotested

Checking of the LPG Dispenser Nozzle


5 and certifying that it dispenses only when YES
it is properly connected to the vehicle.

Checking of the over speed device of the


LPG Dispenser - to certify it shuts the
6 remote pump and solenoid valve YES
upstream of the hoses I case of an
emergency.

Checking whether density of the fluid is


7 YES
correctly entered in the Dispenser.
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Checking temperature compensation
8 YES
system of the LPG Dispenser
Checking the preset functions of the LPG
9 YES
dispenser
Checking the Low flow rate cutout of the
10 YES
LPG Dispenser
Leak tests of all the hydrauli joints of the
11 LPG Dispenser and the total piping YES
system

Checking control panel : checking of the


12 YES
circuit, cleaning of the contactors, etc.

Visual checking of the LPG piping both


13 YES
above ground and in trenches.

Checking level monitoring sysytem and


14 YES
alarms.
Pnuematic Circuit Air tubing to be
15 YES
checked for any kinks/leakas, etc
Functioning of ROV's and lubrication of
16 YES
the actuators

17 Leak tests for all manual valves YES

Cleaning of strainers/filterson the LPG


18 NO
line once in 3 months or if required

Functioning of the emergency shut down


19 YES
system to checked from all the 4 locations

20 Condition of the electrical cables YES


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Check condition of FLP & Non-FLP
21 NO
electrical fittings

Checking the condition of the pressure


22 relief valves, temperature relief valves YES
provided on the LPG tank and piping

Calibration of the Temperature and


23 NO
pressure gauges as per the norms

Calibration of the Differential Pressure


24 NO
switch
Calibration of all the sensors of the
25 NO
Gauging system.
26 Earth Pits YES

27 Thermal/Hydrostatic relief valves YES


28 Excess Flaw Check Valve YES
29 High Level Alarm of storage vessel YES
30 LPG Pump YES

31 Emergency Push Button Trips YES

32 Cathodic Protection System YES

33 Fire Extinguishers YES

34 Others -

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CORPORATION LIMITED

CT FOR AUTO LPG DISPENSING STATION

DATE :

Frequency REMARKS

Once in 3 Months

Once in 6 Months

Once in a year

Once in a Month

Once in 3 Months

Once in a month

Once in 3 months

8 of20
Once in a month

Once in 3 months

Once in a month

Once in a month

Once in 3 months

Once in a month

Once in a month

Once in a month

Once in a month

Once in a month

Once in a month

Once in 3 months
9 of20
Once in a month

Once in 6 months

Once in 6 months

Once in 6 months

Once in 6 months

Once in a year

Once in 5 year
Once in a year
Once in a year
Once in 6 months

Once in a year

Once in a year

10 of20
Scope of Work

1. Visual Inspection of Installations: gates, Fencing, Cleanliness, Painting, No Smoking, Hydrant Systems, Tanks,
Pipelines, LPG Fittings, Electrical Fittings, Vaporisers, Pumps

2. Soap Solution Test of Nozzles: All opening on the Tank, All Ball Valves, all Welded Joints, All Flange Joints

3. Operation Check up of the following Things: Roto Gauge, Slip Tube Gauge, Fixed Level Gauge, Ball Valves,
Pressure Gauge, Temp. Gauge, Vaporisers, Hose Pipe - Vapor Line, Liquid Line & Needle Valve

4. One visit Per Quarter with prior appt. with plant LPG/ maintaenance Incharge.

5. Safety Valve (SRV) Testing - to be conducted as per due date, in co-ordination with plant

6. Hydrotesting of Unloading Hose

7. Work to be done by Technicians; One Visit by Sr. Engg. For One day.

8. Charges for renewal of License

9. NO CHARGES FOR BREAKDOWN VISIT

10. Payment made after submission of Bill / Test report / Visit report

PAYMENT CYCLE: TWO CYCLES IN A MONTH i.e. 10TH & 25TH

On 10th Payment cycles all bill falling due (Net deduction after rejections / return) as per our terms upto 30th
of previous month will be captured for Payment

On 25th Payment cycles all bill falling due (Net deduction after rejections / return) as per our terms upto 15th
of current month will be captured for Payment
Systems, Tanks,

lange Joints

e, Ball Valves,

erms upto 30th

erms upto 15th


Sr. No. Location P.O. No. & Date Description & Specification Qty Unit
17003013/0 dtd
1 THANE 08.06.2016
17003055/0 dtd
2 JALNA 09.06.2016
17004505/0 dtd
3 WALUJ 14.07.2016
17004504/0 dtd
4 CHIKALTHANA 14.07.2016
Rate / Unit Amount
Monthly, Quaterly & Annual Maintenance of 2 x 20 MT Propane Above Ground Installation as per SMPV Rules

O & M of Propane Gas Station (From May 2017 to Dec 2017 - 8 Months)

A. MAINTENANCE

SCOPE OF SERVICE:
1. Preventive Maintenance Visits: periodical basis once in a month

Equipment / Facility Frequency


Periodic Hydraulic Testing of Once in 5 years
Vessel
Excess Flow Check Valve Once in 5 years
Safety Relief Valve Yearly
High Level Alarm of Storage Yearly
Vessel
LPG Pump Yearly
Fire Extinguishers Yearly
Earth Pits Half Yearly
Emergency Push Button Trips Half Yearly
Remote Operated Valves Quarterly
Claning of Vaporiser / Filter Quarterly
Cleaning of Strainer Monthly
Claning of Vaporiser / Filter Monthly

DETAIL SCOPE OF MAINTENANCE WORK


I. LPG VAPOURISER
Checking cleaning of Valves, Coil, Hydrotesting of Coil @ reqd. test press. (once in 5 yrs.) , cleaning of Electrical such as
thermostat, Solenoid Valve, heaters; Cleaning of Vaporiser internal & boxing up with recommissioning

II. PUMP & COMPRESSOR


Inspection /checking for leaks, vibration, unusual noise; checking of Tank vapor press. & pumpset set discharge press.
Checking for current drawn, run hoses & ambient tank temp.

III. TANK LEVEL SYSTEM


Testing of sensor on monthly basis, recalibrate all sensors & I/P's once a quarter & readjust when drift exceeds 5% of full
scale

IV. GENERAL DESCRIPTION OF MAINTENANCE WORK


1. Cleaning of filter / strainer in vapor eliminator of LPG Dispenser
2. Checking Temp. settings, preset functions, Low Flow rate O/P of LPG Vaporiser
3. Leak test of Hydraulic joints of LPG vaporiser piping & total piping system
4. Visual checking of LPG Piping - above grnd. & in trenches
5. Checking Level monitoring system & Alarms
6. Pneumatic Circuit Air line check for leaks
7. Functioning of ROV's
8. Condition of cables, PRV, TRV

B. OPERATIONS

I. SAFETY OPERATION: all safety norms to be followed as per SMPV Rules, safety harness for workforce & operators to undergo
training atleast once in a year.

II. TRAINED MANPOWER: Engineer - shall visit once quarterly, Technician - 24 hour basis
Total team of 4 people @ site.

III. OPERATIONS (trained Technician):


Unloading LPG product from Bulk road Tanker to Above Ground Tanks, Weighment of incoming product, Operating of pumps &
equipments, control panel, vaporisers & all satges of Regulators
(cost of Travelling local conveyance are inclusive of PO value along with site visit Rs 10,000/- )

IV. CONSUMABLES (inclusive in PO value)


All - 'O' Rings, Gaskets, Washers; Studs & Nuts; Earthing wire, Contactors, Relays, Earthing Jumpers (a set of consumables to ret
lation as per SMPV Rules

ning of Electrical such as

set set discharge press.

hen drift exceeds 5% of full


orkforce & operators to undergo refresher

g product, Operating of pumps & flameproof

pers (a set of consumables to retained @ site)


O & M OF PROPANE & AMMONIA STATION - 24 MONTHS

Propane Station: 1. 2 x 600 MT LPG / Propane Station


2. 2 x 63.5 MT LPG / Propane Station

Ammonia Station: 1. 2 x 10 MT Ammonia Station - I


2. 2 x 10 MT Ammonia Station - II

Details of Manpower:
Technicians 2 Nos.
Asst. Technicians 6 Nos.
Relievers 1 No.
TOTAL 9 Nos.

LPG PROPANE STATION:

A. OPERATION: 2 x 600 MT Propane station Regular 24 hrs a day x 7 days a week


2 x 63.5 MT Propane station Occasional Operation - depending on requirement or JSL instruction

OPERATION INVOLVES: i. Unloading of Tankers & Lorries into bullet as per SOP;
ii. Unloading compressors, Valves & associated equipments as per SOP / PESO norms

OPERATION OF DELIVERY ROUTE: i. Ops. Of valves, transfer pump, vaporisers & Press. Regulators as per SOP (1.5Bar - 1.8Bar @
ii. Ops. Of Natural vapor lines & co-ordinating with customers for smooth running
(Ferro-Alloy, SMS-Caster, HSM-Reheating Furnace, etc, CRM - HAPL Unit)

OPERATION OF OTHER SYSTEMS: i. Fire & Safety (Sprinkler, Hydrant, water monitor isolation valve upto Top of Gas station)
ii. Ops. Of steam line, PRS system & co-ordination with CRM for smooth propane ops.

B. MAINTENANCE:

PERIODIC / YEARLY Statutory test / inspection / calibration of SRV, PAV, EFCV, SERVO GAUGES, DECANTING HOSES for

Pop Action Servo Decanting


SRV Valve Gauges Hoses
2 x 600 MT Propane station 8 Nos.
2 x 63.5 MT LPG station 8 Nos. 10 Nos.
4 x 10 MT Ammonia Station 8 Nos. 14 Nos.
ement or JSL instruction

s per SOP (1.5Bar - 1.8Bar @ outlet)


r smooth running

upto Top of Gas station)


mooth propane ops.

CANTING HOSES for

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