ANNEXURE “A1”

SCOPE OF WORK

1. Introduction

The Petroleum Oil & Gas Corporation of South Africa, hereinafter referred to as
PetroSA, is the national oil company of the Republic of South Africa. PetroSA
owns, operates and manages the South African Government’s assets in the
Petroleum Industry.

PetroSA seeks to establish a three year or five year contract [commencing 01

July 2015] with a suitable and competent Supplier for the retubing of heat
exchanger bundles and / or for the manufacturing of complete heat exchangers,
i.e. shells and bundles. The majority of the exchangers are required to be
designed, fabricated or retubed in accordance with ASME VIII Div 1 and TEMA.
The contract shall be based on rates for labour / machining and cost plus
percentage mark-up for materials.

2. Services

2.1. Scope of work, but not necessarily limited to:

 Design, Procure, Manufacture, Inspect and Test

 Supply, Packing, Transport and Deliver to PetroSA Mossel Bay Site
 Supply of consumables / material to execute the Contract works
 Rigging and Rigging Equipment to load and off load equipment at
supplier’s works
 Project Management, Supervision and Quality Assurance
 Inspection and Testing through-out Construction
 Data Package
 Performance and Acceptance test of workmanship
 Defects Liability Period
 Any other items not covered by the foregoing, but forming part of
the Supplier’s obligations and responsibilities, including all ancillary
equipment and services required to make heat exchangers supplied
a fully comprehensive working system, until such time as the heat
exchanger has been Accepted by PetroSA.
2.2. Mechanical Scope

2.2.1. The Supplier shall supply PetroSA with, in the case retubing:
a) Off-loading, dismantle / strip tube bundle complete at
Supplier Works and clean components.
b) Inspect and assess material and tolerances, machining,
welding, heat treatment and associated fabrication testing
requirements. Submit detailed cost estimate to PetroSA.
c) Forming of U-tubes and heat treatment when applicable.
d) Assemble heat exchanger tube bundle, attaching tubes to
tube sheet(s), as per PetroSA approved Supplier QA/QC
procedures and PetroSA Engineering specifications and
other support documentation.
e) Preparation of tube bundle after reinstatement
 The Supplier shall take appropriate action to protect
and prevent internal and external corrosion of all tube
bundle components after final inspection and approval
by PetroSA.
 The Supplier shall take suitable precaution to protect
tube bundles from physical damage during
transportation and handling.
 The Supplier shall clearly and suitably mark the lifting
points and tube bundle weight shall be prominently
displayed.
 Each assembled tube bundle or new heat exchanger
shall be clearly identified with the tag number hard
stamped at a suitable location on the tubesheet[s].
 Specific painting requirements shall be completed
before delivery.

2.2.2. The Supplier shall supply PetroSA with, in the case

replacement heat exchanger:
a) Design new heat exchanger in accordance with existing
equipment information given, using the latest code of
manufacture, and submit to PetroSA for approval.
b) Compile new drawings and submit to PetroSA for
approval.
c) Compile QCP and accompanying QC documents, i.e.
WPS, technique sheets and submit to PetroSA for
approval.
d) Compile purchase specifications for materials and submit
to PetroSA for approval.
e) Purchase materials for new manufacture
f) Manufacture new shells and bundles as per PetroSA
Specifications.
g) Assemble heat exchanger tube bundle, attaching tubes to
tube sheet(s), as per PetroSA approved Supplier QA/QC
procedures and PetroSA Engineering specifications and
other support documentation.
2.3. Scope of Documentation

2.3.1. Level 4 MS project schedule within 3 working days of order

placement for the manufacturing, inspection and approval of
QCP hold points
2.3.2. Mandatory Requirements
a) Design and manufacturing document review and approval
b) Quality Control Plans
c) Material purchase specifications
d) NDE Procedures
e) Procedure Qualification Records
f) Weld Procedure Specifications
g) Fabrication Drawings
h) Kick-off and pre inspection meetings
i) Inspections at appropriate stages (See attached draft IAP)
j) Heat Treatment Charts
k) NDE applicable specifications, typically ASME Vlll, Div 1
and PetroSA specifications
l) Final documentation deliverables
 Per Tag or ID Number
 Original Code Data Book
 Certified copy of Code Data Book
 Original Code Data Book on CD
 Drawings in Microstation format (for new manfacture)

The Supplier shall supply PetroSA with data pack containing

the following information, not later than 2 weeks after Final
release of equipment from supplier’s works.

2.4. Summary of work excluded from the scope of this specification:

PetroSA will provide:

 Engineering drawings and data sheets of existing equipment
 Government approved inspection authority
 Loading or off-loading at PetroSA site
 Commissioning
 Thermal design, if required
 Finite Element Analysis (FEA), if required
2.5. APPLICATION PROCESS

Once the service contract (rates) is in place –

 PetroSA will issue the Supplier with a scope of work based on a
specific heat exchanger, complete with drawings and relevant
design information.
 The Supplier shall forward a detailed quotation, complete with cost
breakdown backup, per tag number, within 7 days of receipt of
scope of work / tube bundle at Suppliers Works.
 The Supplier shall clearly state exclusions from its scope of supply.
 Suppliers are at liberty to submit proposals that may deviate from
guidelines set by PetroSA. PetroSA shall be required to approve
these alternate proposals.
 The confirmation to perform the Services will be issued to the
Supplier by PetroSA's Engineering & Design Department, with an
order number, within 7 days of receiving Supplier's quotation.
 The Supplier shall then issue a level 4 MS project schedule within 3
working days which shall form the basis of the equipment delivery.
 Pre-inspection meeting shall be held at the supplier’s works to
clarify and agree on the scope of work (in detail) and align AIA
requirements.

2.6. REFERENCE DOCUMENTS

Air-Cooled Heat Exchangers SP/EA001S001

Exchanger Design Criteria SP/EZ001-S001
Metrication SP/MZ001S005
Technical specification painting – Part 2 –
coating system ISM/SD/MET/002
Requirements for post weld heat treatment ISM/PR/MET/002
Heat treatment SP/UZ006S005
Specification for Category 3 Pressure
Apparatus SP/VZ001-S001
Specification for Category 1 And 2 Pressure
Vessels SP/VZ001S010
Surveillance of suppliers’ manufacturing
program ISM/PR/AIA/001
PetroSA AIA scope and design verification ISM/PR/AIA/002
Supplier quality assurance requirement ISM/PR/AIA/003
Code Data Book Review ISM/PR/AIA/004
AIA coordination and Responsibilities ISM/PR/AIA/005
Mandatory Design, Inspection and Certification
of new/repaired/modified Boiler and Pressure ISM/PR/AIA/006
Apparatus
NCR's and Corrective Actions ISM/PR/AIA/007
Proof of Inspection (C.O.C.) Certificate of
Compliance ISM/PR/AIA/008
Pre-inspection meeting procedure ISM/PR/AIA/009
 PR/MRE/END/DRW/0
Engineering Supplier Drawing Supply 01
Specification Packing / marking protection and 2340-ZZ0000-21001-
storage S005
 DRAFT INSPECTION ACTIVITY PLAN (IAP) GUIDELINE

 THIS DRAFT IAP IS A GUIDELINE DEFINING THE MINIMUM EXTENT OF PetroSA AND/OR
OTHER PARTY ACTIVITIES
 TYPE AND EXTENT OF TESTS WILL BE STRICTLY COMPLY WITH CODES AND/OR
SPECIFICATIONS

CLASS: TYPE: DATE:

HEAT EXCHANGERS TUBE BUNDLES
TYPE
OF
DESCRIPTION OF ACTIVI CERTIFICATI
POS TY ON REMARKS
REQUIREMENT REQUIRED
Petro
SA
Material certificates for
1 tubes, plate, fixed and R Yes PetroSA might specify steels origin
floating head tubesheet
Welder and NDE operator Where welded construction is
2 R Yes
qualification employed
Workmanship and fabrication
3 Fabrication monitoring RI
progress observation
4 Shop major weld repairs O Yes If any
Non destructive
5 RI Yes
examination
U-Tube heat treatment after
6 R Yes Heat charts where applicable
bending
Pressure value and hold time to be
7 Hydrostatic tests W Yes
certified
Visual and dimensional
8 W Yes
check (final inspection)
9 Inspection Register R

Rev Date Approved By LEGEND

Review by Inspector
R
Random Inspection during fabrication – Notification
RI
not required

W Witness by Inspector – Notification required

SW Spot witness by Inspector – Notification required

Observed point – the specified inspector requires
notification of the time of inspection or test. The
O inspection or test is performed as scheduled, if the
specified inspector is not present, the Supplier may
proceed to the next step.
 TYPICAL VENDOR DOCUMENT REQUIREMENT LIST (VDRL)

PROJECT :
EQUIPT No. :

VENDOR DOCUMENT DATE :

REQUIREMENT LIST PREPARED :
PAGE :
REV :

THE VENDOR SHALL PROVIDE DOCUMENTATION TO SATISFY THE

REQUIREMENTS LISTED BELOW.
VENDOR'S ACCEPTANCE SIGNATURE:
.........................................................

COPIES REQUIRED
DESCRIPTION
WITH FINAL
FOR REVIEW
BID DISTRIBUTION

*AFTER PURCHASE ORDER DUE REPR

PRINT PRINT REPRO PRINT
DATE* O
Master Document List
Fabrication Schedule
Sub Vendor List
Material Technical Purchase Specifications
General Arrangement Drawings
Detail Fabrication Drawings
Design Calculations (Mechanical)
QC Plan (Typical With Bid) + Actual
NDE Procedures (To AIA)

Inspection and Test Plan

Welding Procedure Specification
Welding Procedure Qualification Record
Welding Consumables Certificates
Heat Treatment Procedures
Code Data Book Addendum
Material Test Certificates
NDE Reports / Certificates
Non Conformance Reports
Concession Requests
AIA Certification
As Built Drawings
As Built Calculations
Signed Off QC Plan
 TYPICAL ENGINEERING DOCUMENT LIST (EDL)
DOCUMENT REMARK
DOCUMENT TITLE REV
NUMBER S

1. DRAWINGS & DATA SHEETS

Data Sheet TBA Included
General Arrangement Drawing TBA Included
Detail Drawing C028100248 Included 0

2. SPECIFICATIONS
Shell & Tube Heat Exchanger Included
Exchanger Design Criteria Included
Metrication Included
Requirements for Vendor's Drawings & Documents Included
Painting Included
Heat Treatment SP/UZ006-S005 Included 03
Specification for Category 1 & 2 Pressure Apparatus SP/VZ001-S010 Included 00
Specification for Category 3 Pressure Apparatus SP/VZ001-S001 Included 05
Mandatory Design, Inspection & Certification of Boiler Included
SP/42001-S001 02
& Pressure Apparatus
Lad Project Engineering Bulletins 001 -009 Included

3. PROCEDURES
Vendor QA Requirements TI/P/00/027 Included
PR/MRE/END/DR Included
Engineering Supplier Drawing Supply
W/001

* Is supplied upon request