Maintenance of Heat Exchanger

Tender Notice
Enquiry No. HOC/MECH/222/ HE ARC/137/
September17, 2011
Sub: Maintenance of Heat Exchangers (Annual Rate Contract)
Sealed tenders are invited from registered contractors with HOCL, Kochi for
Maintenance of Heat Exchangers (Annual Rate Contract).
Scope of Work
The scope of work includes maintenance and various exchangers on annual rate contract basis.
The Period of Contract of the work will be 18 months from the date of issue of work order issue of
instruction of start the work (or up March 2013). Therefore the rate quoted by the party shall be
valid for the above period (up to March 2013). The Exchangers will be released for cleaning as per
the requirement/ shutdown; party shall be ready to do the work at any point of time during the
period of contract. Minimum No. of exchangers released for cleaning can be one at a time and the
party has to mobilize the crew within 24 hrs. from the time of intimation / instruction of start of
work.
General
1. Once the equipment is ready for maintenance, isolation of equipment by putting
blinds/spectacle blinds in feed and outlet nozzles and all other nozzles indicated for the
purpose and fix blind number tags.
2. Provide necessary hose connections for draining, purging, steaming and water washing and
airing of the equipment as the case may be as per the instruction of Engineer in Charge.
3. Record the blind tag Nos. in the blind register and obtain signature in the register by Engineer
in Charge.
4. Removal and refixing (including to and fro transportation to central workshop / equipment) of
Pressure safety valves (if required) on the equipment and connected pipe lines shall be in the
scope of work of the respective equipment in the schedule of rates unless otherwise
mentioned separately.
5. Maintenance of the exchanger as explained in Clause No. 1 (see next page)
6. Assisting the inspecting team engaged in the inspection of Heat Exchanger.

7. CRANE / DERRICK required for the successful completion of the entire work shall be arranged
by the contractors at his own cost. HOCL shall permit the contractor to hire the HOCLs mobile
crane on chargeable basis if it is available and the rate shall be 1000/hr. + tax for mobile crane
of capacity 18T.
8. Scaffolding material (pipe and clamps) and its erection if required should be arranged by the
contractor.
I.
Heat Exchanger Maintenance

Floating Head Exchanger (E 2006, E 2010, E 4507 A & B)
blinds/spectacle blinds in feed and out let nozzles and all other nozzles indicated for the
2. Open and remove channel head cover
3. Open and remove channel head
4. Open and remove shell cover and floating head cover.
5. Pull out the tube bundle as per the instruction of Engineer in Charge. (Pulling out of tube
bundles of E 4507 A & B are not envisaged.)
6. Clean the tubes and shell, channel head cover, channel head shell, floating head, floating head
cover and dish end cover using hydro blasting machine (Karcher Pump) available in HOCL and
all flange serration by scrappers / wire brushes. If Hydroblasting is required for cleaning, the
same will be arranged by HOCL at their cost.
7. Preparation for man entry if required ie. provide necessary hose connections for draining, and
water washing of the equipment as the case may be.
8. Blinding shell side and tube side in the required sequence and stages suitable for hydrotest of
tube side and shell side separately.
9. Assemble the tube bundle, channel head shell, channel head cover, floating head, floating
head cover and dish end cover in required sequence and stages suitable for Hydrotest of tube
side and shell side separately.
10. Hydrotest the exchanger on shell side and tube side and floating head gasket, dish end cover
gasket.
11. Leaking tubes if any noticed during hydrotest should be plugged using CS/SS/Brass plugs as per
the instruction of Engineer in charge. Required plugs will be supplied by HOC at free of cost.
Repeat the hydrotest if any leak at shell side / tube side.
12. You shall get the hydrotest witnessed by Engineer in charge / 3rd party Inspector.
13. Test rigs should be used for testing floating head type exchangers tube bundle. (Test rings are
available in main store yard / maintenance workshop, the same has to be identified, cleaned,
transported to the heat exchanger. After testing, the test rigs are to be transported back to
the original location).
14. Test pressure for hydrotesting should be as per the inspection of the Inspector/Engineer in
charge.
15. Removal of isolations (ie. blind, spectacle blinds, blind tags etc.) for normalizing the Heat
Exchanger.
16. Hot bolting of the flanges after putting the equipment in line if it is required. However, this
activity will not be counted for the completion time for the work.
17. In case of cleaning of heater tubes by hydroblasting (by HOCL through other agencies), there
will be a gap of 1 or 2days (for cleaning) in between opening / boxing up of exchanger.
However, this activity will not be counted for the completion of the work.
Note : 50% of the quoted rate only will be paid to the party if the tube bundle is not pulled out and
brought to the ground (ie. only hydro testing of the tube and shell side and plugging of the leaking
tube is done.) Pulling out of tube bundles of E 4507 A & B are not envisaged.
U Tube Heat Exchanger ( E 4509)
blinds/spectacle blinds in feed and out let nozzles and all other nozzles indicated for the
2. Open and remove channel head cover
3. Open and remove channel head
4. Open and remove shell cover if available.
5. Pull out the tube bundle as per the instruction of Engineer in Charge.
3
6. Clean the tubes, channel head cover, channel head shell and end cover using hydro cleaning
machine (Karcher Pump) available in HOCL and all flange serration by scrappers / wire brushes.
If Hydroblasting is required for cleaning, the same will be arranged by HOCL at their cost.
7. Blinding shell side and tube side in the required sequence and stages suitable for hydrotest of
tube side and shell side separately.
8. Assemble to tube bundle, channel head, channel head cover, shell cover (if available) etc., in
the required sequence and stage.
Leaking tubes if any noticed during hydrotest should be
plugged using CS/SS/Brass plugs as per the instruction of Engineer in charge. Required plugs
will be supplied by HOC at free of cost. Repeat the hydrotest if any leak at shell side / tube
side.
9. You shall get the hydrotest witnessed by Engineer in charge / 3rd party Inspector.
10. Test pressure for hydro test should be as per the inspection of the Inspector/Engineer in
charge.
11. Removal of isolations (ie. blind, spectacle blinds, blind tags etc.) for normalizing the Heat
Exchanger.)
18. Hot bolting of the flanges after putting the equipment in line if it is required. However, this
activity will not be counted for the completion time for the work.
19. In case of cleaning of heat exchanger tubes by hydroblasting (by HOCL through other
agencies), there will be a gap of 1 or 2 days (for cleaning) in between opening / boxing up of
exchangers. However, this activity will not be counted for the completion of the work.
Note : 50% of the quoted rate only will be paid to the party if the tube bundle is not pulled out and
brought to the ground (ie. only hydro testing of the tube and shell side and plugging of the leaking
tube is done.)
Taxes & Duties
Your quoted rate shall be inclusive of all taxes and duties whatever applicable to this job except
service tax. Service tax will be paid extra if the party produces service tax registration and other
relevant documents to HOC.
Liquidated Damages
In case the contractor fails to complete the work within the stipulated period, contractor shall be liable to
pay a LD of % (half percent) of the contract value per day for the delay or part thereof subject to a
maximum of 5% (Five percent) of the contract value.
Defect Liability Period

Contractor shall guarantee the work for a period of one year from the date of issue of completion
certificate. Any damage or defect that may arise or lie undiscovered at the time of issue of
completion certificate, connected in any way with the workmanship should be rectified by the
contractor at his own expense as deemed necessary by the Engineer in Charge.
Scope of Supply
HOCLs Scope
a. HOCL shall issue hoses, gaskets, fasteners, pressure gauges, tube plugs, air, water, electricity at
one point free of cost to the contractor.
b. HOCL shall provide only the gasket sheets (CAF) (free of cost) to the contractor. The contractor
has to make arrangements to cut the gaskets to the required size.
c.
Fasteners (if required) for the final box up work shall be issued by HOCL at free of cost.
Contractors Scope
a. All skilled & Unskilled manpower require for the work is to be arranged by the contractor. All
machines, tools, tackles, lifting equipments such as crane, chain pulleys, slings, D shackles,
Hydraulic test pumps and other tools and equipments required for the completion of the work
is to be arranged by the contractor.
b. Crane / derrick required for the successful completion of the entire work shall be
arranged by the contractor at his own cost. HOCL shall permit the contractor to hire
the HOCLs mobile crane on chargeable basis if it is available and the rate shall be 1000/hr. for
mobile crane of capacity 18T.
c. Scaffolding material (pipe and clamps) and its erection if required should be arranged by the
contractor.

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Tender Notice

Enquiry No. HOC/MECH/222/ HE ARC/137/

Sub: Maintenance of Heat Exchangers (Annual Rate Contract)

6. Assisting the inspecting team engaged in the inspection of Heat Exchanger.

Heat Exchanger Maintenance

Leaking tubes if any noticed during hydrotest should be

Defect Liability Period

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