BRIEF SCOPE OF WORK

1. BACKGROUND

1.1 PURPOSE OF TENDER:

1.1.1 This tender is to appoint a CONTRACTOR for the works which consists of
engineering design, procurement and supplies, manufacturing, construction,
testing, commissioning, and services as specified in the scope of works to be
furnished, supplied, or performed by CONTRACTOR.

This PIKAP Project consists of a combination of 4 different projects:

i. Utility Effluent (UE) Pipe Replacement At U4820 And 4200
ii. Pipe Replacement At Neutralization Pit (Neut Pit) At Demin Plant
iii. KSV Installation For Acid Injection At 4820 And 4200 Neut Pit And
iv. Auto pH Correction At 6340 COC Receiving Pit (ETP)

1.1.2 This tender is to appoint a CONTRACTOR for the WORKS of PIKAP Project for
the period of 24 months (12 Months execution with sectional I.A + 12 Months
Defect Liability Period upon sectional I.A) of work execution.

1.1.3 For this tender, since it’s a combination of 4 different projects, CONTRACTOR
shall commence the Engineering Design at the same timeline for each package
whereas the execution of work and Initial Acceptance will be based on each
timeline for each package. The proposed timeline for each package can be
observed as below.

This PIKAP Project consists of a combination of 4 different projects:

I. Utility Effluent (UE) Pipe Replacement at U4820 And 4200;
II. Pipe Replacement at Neutralization Pit (Neut Pit) At Demin Plant;
III. KSV Installation for Acid Injection at 4820 And 4200 Neut Pit; and
IV. Auto pH Correction at 6340 COC Receiving Pit (ETP)

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 2.1 PROJECT BRIEF

2.1.1 Initially, there are 2 projects to be executed in FY2023, for projects Auto pH
Correction at 6340 COC Receiving Pit (ETP) and KSV Installation for Acid
Injection at 4820 & 4200 Neut Pit. As part of the cost optimization and project
acceleration, PMT propose to bring forward 2 projects, which are projects Utility
Effluent (UE) Pipe Replacement at U4820 And 4200 and Pipe Replacement at
Neutralization Pit (Neut Pit) At Demin Plant that were planned in FY2024 to be
executed together with the 2 projects mentioned earlier. All 4 projects combined
is called PIKAP Project.

Original Year PIKAP Project

Auto pH Correction at 6340 COC Receiving Pit (ETP) 2023 To combine 4 projects into
1 contract based on the
KSV Installation for Acid Injection at 4820 & 4200 Neut Pit 2023 similarities of project
Utility Effluent (UE) Pipe Replacement at U4820 And 4200 2024 disciplines/ nature and all
its project sites nearby
Pipe Replacement at Neutralization Pit (Neut Pit) at Demin Plant 2024 from one to another.

2.1.2 In addition, PIKAP project is a consolidation work program design to optimize

integration during Project Initiation stage as well the commercial in 2023 and
minimize potential cost escalation in 2024.

2.1.3 The combination of PIKAP projects is based on FEL readiness which has been
presented and endorsed to PRPC UF during Project Steering Committee (PSC)
on 13 July 2023.

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 2.1.4 The description for each project as follows:

SCOPE 1: UE PIPE REPLACEMENT AT U4820 AND 4200

Six (6) nos of leak have been reported along the UE transfer line from ISBL
U4820 to ETP.

Inspection survey reveals signs of welding defect/corrosion pattern and UT

corrosion mapping also discovered localized corrosion scattered along the
Carbon Steel UE pipe body with some sample indicating less than 1 year of the
piping remaining life left.

Project scope covers replacement of existing carbon steel API 5l Gr B ERW

piping for UE transfer line to non- metallic piping material.

Boundary of change:
a) From U4820-T-004 and U4820-T-005 to ISBL U4820
b) From U4200-T-005A and U4200-T-005B to ISBL U420

Picture 1: UE Pipeline Overview at U4820 Pit T-004 and T-005

Carbon
GR

GR

UE transfer line from ISBL U4820 to ETP

Current Piping Material: Carbon Steel API 5L

Length of CS pipe ≈150m

Pipe size: 6 inch

UE line to Neutralization Pit T-004 and T-005

New Piping Material: GRVE

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 Picture 2: UE Pipeline Overview at U4200 Pit T-005A/B

Carbon Steel

GRVE

GRVE

UE transfer line from ISBL U4200 to ETP

Current Piping Material: Carbon Steel API 5L
Length ≈216m
Pipe size: 6 inch
UE line to Neutralization Pit T-005A/B
New Piping Material: GRVE

Therefore, this project is to design, procure, install and commission of new UE

transfer line from:
i. ISBL U4200 to ETP
ii. ISBL U4820 to ETP

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Project timeline as below:

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SCOPE 2: PIPE REPLACEMENT AT NEUT PIT AT DEMIN PLANT
Incorrect piping material was used, resulting in the delamination of Glass Reinforced Vinyl
Ester (GRVE) pipes and subsequent clogging of the strainer. If the delamination and
clogging are not addressed, it will interfere with the smooth flow of acid and effluent mixture
into the neutralization pit.
The neutralization process will be prolonged, and the level in the neutralization pit will rise if
the neutralized water cannot be transported to the Effluent Treatment Plant.
This disruption will bottleneck the daily capacity of the demineralized water plant
(1380m3/hr) and cause disturbances in the supply to other plants.
The scope of modification is to replace piping inside neut-pit from GRVE to CS with PTFE
lining which involves 2 locations i.e at Pit 4820-T-004 involving replacement of line 250-UE-
4820-70592-1N103DC-N and Pit 4820-T-005 involving replacement of 250-UE-4820-
70597-1N103DC-N. The new pipe size is 10-inch CS with PTFE Lining, and the length is
25m for each pit.

Piping inside Neut Pit at U4820

Current Piping Material: GRVE
Length: 25m
Pipe Size: 10 inch
New Piping Material: Carbon Steel with PTFE Lining

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Project timeline as below:

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SCOPE 3: KSV INSTALLATION FOR ACID INJECTION AT 4820 AND 4200 NEUT PIT
The existing design check valve does not ensure a completely sealed isolation, thereby
failing to prevent the backflow of regen wastewater into the Sulphuric Acid injection line
during operation. To prevent a recurrence of acid leakage caused by material incompatibility
and corrosion, modifications to the pipe, specifically the installation of a KSV and self-
regulated PCV, are necessary.

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4820-T-004 Neutralization pit:
i. Modification of sulphuric acid (SA) injection line 25-SA-4820-70541-1C127DA in
to header 250-UE-4820-70592-1N103DC-N to include new KSV, check valve and
ball valve of.

4820-T-005 Neutralization Pit:

ii. Modification of sulphuric acid (SA) injection line 25-SA-4820-70551-1C127DA in
to header 250-UE-4820-70597-1N103DC-N to include new KSV, check valve and
ball valve of.

4200 Recycle line:

i. P04A/B: Modification of recycle line 25-SA-4200-72546-1C127DA-N to include
2nos PCV and 7nos ball valves.

4200-T-005A:
i. Modification of sulphuric acid (SA) injection line 25-SA-4200-71547-1C127DA in
to header 150-UE-4200-70571-1N103DC-N to include new KSV, check valve and
ball valve of.

4200-T-005B:
i. Modification of sulphuric acid (SA) injection line 25-SA-4200-70542-1C127DA in
to header 150-UE-4200-70574-1N103DC-N to include new KSV, check valve and
ball valve of.

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SCOPE 4: AUTO PH CORRECTION AT 6340 COC RECEIVING PIT (ETP)
ETP experienced pH min 6 of incoming COC influent from user cause presence of high level
H2S gas exceeding PEL (10 ppm) at COC receiving pit (6340-T-001). H2S release to the air
through checker plates gap at top COC receiving pit, it will have unpleasant smell and create
toxic condition. Hence automation of caustic injection is required to neutralize the COC
effluent to 9.5 pH.

Injection point

New pH Analyzer: 2 nos

New Control Valve: 1 no
New KSV: 1 no
DN40 (3/4“) piping installation: estimated 20 m (with hot tap for quill injection point)
Instrument air supply and cabling for control valve and KSV
Instrument cabling from pH analyser to JB, if have spare
DCS modification

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Project timeline as below:

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