SCOPE OF WORK (SOW)
Integrated Hydraulic & Pneumatic System, Tubing, Testing, Processing & Mechanical Services for
QAPCO
1. ABOUT SUNPOWER-GEN
Established in 1973, SunPower-Gen, Supertech Group started as product sales company that supplies
industrial products to various industries including Oil & Gas, Petrochemicals, and Food & Beverage.
Supertech Group have a vast stock of almost 50,000-line items from reputable manufacturers.
In 2001, SunPower-Gen was established to serve Engineering sectors. Today, we design, manufacture,
and install most of the engineered products and systems for our clients. We have been serving the
industries for over 49 years with a commitment to providing excellent Products and Services.
2. WHY QAPCO SHOULD CHOOSE SUNPOWER-GEN AS YOUR PREFERRED SERVICE CONTRACTOR
• SUNPOWER-GEN carries Parker Endorsement as preferred contractor’s – Reliability Assured
• We have done similar major projects in past with major key clients with ZERO leakage which
help complete the project on-time – Proven track records
• Parker Trained & Certified Engineer and Technicians for Tube Bending – Less Wastage of
material
• Parker Trained & Certified Engineer and Technicians for Autoclave Fittings, EO2 Form fittings
& Par Flange 37 – Assurance of International Standard
• SUNPOWER-GEN presence in local market for deeds – Assurance of reliable organization
• Parker has endorsed the competency of SUNPOWER-GEN Skilled technicians – Quality of
work Assured
• SUNPOWER-GEN has more than 20 Years’ experiences to handle similar projects – You are
dealing with expert.
3. OBJECTIVE
To deliver complete, reliable, and OEM-backed services for tubing installation, small bore piping,
leak detection and rectification, hydraulic and pneumatic system maintenance, flushing,
calibration, filtration, chemical cleaning, and comprehensive onsite support, specifically tailored to
the operational needs of QAPCO’s petrochemical production facilities.
Our goal is to ensure maximum reliability, safety, and operational efficiency for all critical systems.
4. FACILITY & PROCESS AREAS COVERED
Services are available for all QAPCO plant units and supporting facilities, including but not limited
to:
4.1 Ethylene Cracker Units
• Primary and secondary cracking furnaces
• Quench exchangers and towers
• Gas compression trains
• Heat exchangers and transfer lines
• Transfer line exchangers (TLE)
• Steam dilution and quench water systems
• Cracked gas compression stages
4.2 LDPE / Polymer Production Plants
• Polymerization reactors
• Extruder and pelletizing systems
• Reactor cooling circuits
• High-pressure piping and tubing
• Additive injection skids
• Product conveying and bagging areas
4.3 Cooling Water Systems
• Cooling towers and basins
• Supply and return headers
• Heat exchanger bundles and inlet/outlet lines
• Booster pump stations
• Chemical dosing points for anti-scaling and biocide injection
4.4 Process Gas Compression Units
• Main gas compressors (reciprocating / centrifugal)
• Suction and discharge piping manifolds
• Lube oil consoles and piping
• Seal oil systems and tubing
• Cooling circuits for inter-stage coolers
4.5 Furnace and Quench Systems
• Burner fuel gas lines and pilots
• Quench oil circulation and coolers
• Tube sheets and radiant coils connections
• Steam injection nozzles and tubing
• Combustion air supply systems
4.6 Utility and Steam Systems
• High-, medium-, and low-pressure steam networks
• Steam traps, drip legs, and condensate recovery lines
• Boiler feedwater pumps and tubing
• Desuperheaters and attemperators
• Utility stations for air, nitrogen, steam
4.7 Chemical Injection and Dosing Skids
• Acid, caustic, anti-foulant, anti-scaling injection skids
• High-pressure metering pumps and tubing
• Calibration columns and instrumentation lines
• Chemical storage tanks and day tanks
• Drain and vent connections for safe isolation
4.8 Air Separation & Instrument Air Units
• Air compressors and dryers
• Instrument air tubing and distribution headers
• Nitrogen generation or storage systems
• Air receiver tanks and safety relief systems
• Filter and regulator assemblies
4.9 Tank Farms & Offsite Storage Facilities
• Product and feedstock storage tanks
• Loading/unloading lines and manifolds
• Drain and sump systems
• Foam injection and fire-fighting water lines
• Vapor recovery units (VRUs)
4.10 Product Loading Bays & Pipelines
• Truck and railcar loading stations
• Ship loading arms and transfer lines
• Custody transfer metering skids
• Pigging systems and launcher/receiver stations
• Long-distance product pipelines
4.11 Fire Water & Safety Systems
• Fire water pumps and deluge skids
• Ring main piping and hydrant connections
• Foam systems and monitors
• Safety showers and eye wash stations
• Alarm panel tubing connections
4.12 Maintenance Workshops and Warehouses
• Hydraulic hose fabrication stations
• Spare parts storage for tubing and fittings
• Tool calibration and inspection areas
• Equipment maintenance bays
• Material quarantine and quality control zones
4.13 Shutdown, Turnaround, and Emergency Maintenance Support
• Entire plant unit isolation, depressurization, and cleaning
• Temporary bypass lines and jumpovers
• Critical path planning for tubing and SBP work
• On-call rapid response teams for leak repair
• Specialist manpower supply during peak workloads
• Field engineering support and technical documentation
• QA/QC inspections, test pack preparation, and system reinstatement
• Coordination with process, mechanical, electrical, and instrumentation teams
5. DETAILED SCOPE OF SERVICES
5.1 TUBING SERVICES – EXTENSIVE AND FULL-SPECTRUM
• Tube / Pipe Cutting, Deburring, and Cleaning
o Tube preparation in controlled manner to avoid contamination.
• Tube / Pipe Bending
o Onsite precision bending (manual and electric) of SS, Cu, Inconel, Duplex, Copper tubes
o Non-standard radius routing for tight space optimization.
• Tube Forming
o Positive-locking fitting with high operational safety.
o Approved for safety-important areas such as: hydraulic presses, cranes, lifts and hydraulic
steelworks.
o Ideal alternative to the welding connectors used in shipbuilding, offshore and heavy machinery
construction.
o Tube Size – O.D. - 6mm to 38mm
• Tube Flaring
o The Parflange F37 system provides a reliable connection without the need for welding, offering
cost and time savings.
o It uses a specialized orbital flaring process to create a 37-degree flare on the tube end, forming a
sealing surface.
o The system is designed to be interchangeable with other industry-standard flange systems
o It can handle a wide range of pressures (up to 420 bar) and tube diameters, from 1/2" to 10"
(12.7 mm to 273 mm).
• Coning & Threading (Autoclave Cone & Thread)
❖ High-Pressure (150,000 psi):
▪ Fittings and Tubing: Available in sizes 1/4", 5/16", 3/8", 9/16", and 1" tube size.
▪ Cone and Thread Tubing: Used for high-pressure fluid transport, available in sizes from 1/4" to 1
1/2".
▪ Materials: Typically made from 316 stainless steel, with options for over 50 corrosion-resistant
alloys.
❖ Medium Pressure (20,000 psi):
▪ Fittings and Tubing: Available in sizes from 1/4" to 1 1/2".
▪ Tubing Sizes: Specifically, sizes like 1/16", 1/8", 1/4", 3/8", and 1/2" are mentioned.
▪ Materials: Typically made from annealed stainless steel.
• Installation of Compression Fittings
o Single & Double Ferrule (Parker A-LOK, SwageLok, etc.).
• Impulse Tubing for Instruments
o Pressure, Flow, Temperature, Level transmitters.
• Junction Boxes, Tube Manifolds & Hook-Up
o Fabrication of hook-up assemblies, including multi-line junction terminations.
• Tubing Bundles (Pre-Fab or Onsite Bundling)
o Heated, traceable, or insulated options.
• Tubing Support
o Vibration-absorbing clamps (Stauff Clamps), color-coded markers, tray mounting.
• Bulkhead Panel Installation and Routing
o Custom penetration sealing for safe zone divisions.
• Loop Checking, Leak Test and Commissioning Support
o Full hook-up, Pressure Testing, Chemical Cleaning, Mineral Oil & Glycol Oil Flushing.
5.2 SMALL BORE PIPING (SBP) SERVICES – ≤3”
• Welding, Fit-Up, and Pipe Fabrication
o CS, SS316, Duplex, GRE/GRP, GRE Lamination & Molded joints.
• Pipe Spool Fabrication and Onsite Modifications
o Quick response spool manufacturing and site fit-up.
• Cold Cutting, Beveling, and End Prep
o Spark-free operations in classified zones.
• Pipe Hangers, Supports, and Bracketing
o Riser clamps, anchor guides, pipe shoes.
• Hot Tapping and Expansion Tie-Ins
o Integration with live systems.
5.3 HYDRAULIC SERVICES – ONBOARD AND WORKSHOP
• Component Servicing
o Hydraulic Cylinders – – Supply, Service, Installation, Testing & Commissioning - Seal kits,
honing, piston rods.
o Hydraulic Pumps – Supply, Service, Installation, Testing & Commissioning - Gear, vane, and
piston types
o Hydraulic Motors – – Supply, Service, Installation, Testing & Commissioning - Gear, vane, and
piston types.
o Directional Control Valves – Supply, Service, Installation, Testing & Commissioning -
o Proportional, Servo & Pressure Control Valves – Supply, Service, Installation, Testing &
Commissioning
o Accumulator Inspection, Bladder Replacement, Nitrogen Charging– Supply, Service, Installation,
Testing & Commissioning
o Valve Blocks and Manifolds – Rebuilding and performance testing. – Supply, Service, Installation,
Testing & Commissioning
• Hydraulic System Testing & Commissioning
o Full functional testing with data logging.
• Complete HPU Overhaul
o Tank inspection, heater testing, electricals, pressure switch tuning.
• Hydraulic Hose Replacement & Pressure Testing
o Crimping, testing, tagging, and routing.
• On-site Services
o Troubleshooting, Overhauling & Commissioning of Hydraulic systems
Hydraulic Cylinder Test Bench
Hydraulic Pump Test Bench
Hydraulic Accumulator Test Bench Hydraulic Valves Test Bench
Hydraulic Power Pack Unit Servicing & New Fabrication
5.4 PNEUMATIC SYSTEM SUPPORT
• Control Air Line Routing & Servicing -– Supply, Service, Installation, Testing & Commissioning
o For solenoids, valve actuators, pneumatic panels.
• Compressor Interface & Air Dryer Support– Supply, Service, Installation, Testing &
Commissioning -
o Leak check, filter replacement, water trap inspection.
• Line Blowing with Dry Air/Nitrogen – Supply, Service, Installation, Testing & Commissioning -
o Pre-commissioning service for clean delivery.
5.5 FILTRATION & VARNSIH REMOVAL
• Offline & Inline Filtration Skids
o Down to 1 micron, ISO 4406 Class 15/13/10 or better.
• Vacuum Dehydration Units (VDU)
o Water/moisture removal from hydraulic and lube oils.
• Electrostatic Oil Cleaners (EOC)
o Removes soft contaminants and varnish particles.
• Filter Element Supply & Performance Testing
o Replacement, sizing, DP checks, media validation.
5.6 FLUSHING, PRESSURE TESTING & CHEMICAL CLEANING
• Hydraulic Flushing
o High-speed turbulent flow with inline particle counters.
• Air/Nitrogen Blowing
o For pneumatic, gas, and low-pressure lines.
• Hydrotesting
o Up to 4500 bar using calibrated gauges.
• Pneumatic Testing
o Pressure decay, bubble, and soap tests.
• Helium Leak Detection
o Mass spectrometry sniffing/vacuum box.
• Chemical Cleaning & Pickling
o For SS316 and Duplex, ASTM A380/A967 compliant.
• Passivation
o Post-pickle passive film formation.
Hot Oil Flushing Pressure Testing
Chemical Cleaning Water/Moisture Removal from Oil.
5.7 CALIBRATION SERVICES
• Calibration, Testing & Certification of Field Instruments:
o Pressure Transmitters (PT)
o Temperature Transmitters (TT)
o Flow Transmitters (FT) & Flow Meters
o Pressure Gauges (PG)
o Level Gauges (LG), Radar and DP Level Transmitters
• Use of Certified Master Equipment (Deadweight, Calibrators)
• Tagged Instrument Documentation & Reports (In PDF & Hard Copy)
• Instrument Loop Checking Support
o Troubleshooting of non-responsive signals.
5.8 ON-SITE TROUBLESHOOTING & RECTIFICATION
• Hydraulic & Pneumatic Leak Detection and Repair
o Pressurized line repair, fitting replacement, sealing.
• Component Isolation and Swapping
o To maintain uptime during operations.
• Root Cause Analysis of Repeated Failures
• Inline Pressure & Flow Monitoring
• Remote Tubing Replacement/Hot Swaps
5.9 MATERIAL SUPPLY, STOCK MANAGEMENT & PROCUREMENT
• Supply of All Tubing, Fittings, Valves, Hoses, Seal Kits
o Including original Swagelok, S-Lok, Maximator, HIP, Eaton.
• Optimal Stock Maintenance
o Onsite kitting of frequently used sizes/types.
• Custom Tubing Kits & Termination Panels
o Pre-labelled and field-installable units.
• Rapid Response for Emergencies
o 24/7 support with buffer stock.
• Supply of Chemical Flushing Chemicals, Grease, Lubricants
o All with MSDS and certification.
5.10 MANPOWER SUPPLY, CERTIFIED EXPERTISE AND TRAINING CENTRE
• Mobilization of Competent & Certified Professionals
o Parker-Certified Hydraulic Technicians
o Instrument Tubing Fitters
o Flushing Engineers
o Calibration Technicians
o Mechanical Fitters
o Pressure Test Operators
o Project Engineers & Supervisors
• Certifications Held
o BOSIET / HUET / H2S
o OGUK Medical / Permit-To-Work / Client Onboarding
o Parker OEM Hands-On training with certificates from Parker
• Full Equipment & PPE Provided
• Standby Teams for Emergency Callouts
HYDRAULIC TRAINING CENTRE PARKER SBEX TRAINING
5.11 MECHANICAL SERVICE SUPPORT
• Valves, Filters, Strainers, Gauges – Supply & Installation
• Panel Assembly – Hydraulic, Pneumatic & Control
• Greasing, Bolting, Torqueing & Alignment Services
• Pump Skid Assembly & Hose Skid Testing
• Sealing Solutions & Gasket Supply
• Bladder Accumulator Pre-Charging & Testing
5.12 Sub-Structure Raising Cylinder (SRC) – Service & Overhaul
• Complete disassembly and inspection of cylinder barrel, piston rod, glands, and end caps.
• Detailed evaluation for surface scoring, ovality, wear, or misalignment.
• Honing, polishing, or hard chroming of rods and cylinder tubes as required.
• Replacement of seals and wear rings using OEM-compliant or Parker-certified seal kits.
• Reassembly under controlled conditions with torque and tolerance validation.
• Static and dynamic hydraulic testing for stroke verification and leak-proof integrity.
• Final painting, preservation, and packaging for storage or reinstallation.
5.13 Mast Raising Cylinder (MRC) – Repair & Testing
• Controlled dismantling and cleaning of mast raising cylinders.
• Inspection for rod straightness, cylinder roundness, pitting, and seal groove wear.
• Replacement of seals, guide rings, and wipers.
• Precision alignment during reassembly to avoid off-axis wear.
• Hydraulic pressure testing at operating and proof pressure.
• Final validation of actuation speed and smoothness.
• Generation of detailed service report and test certificate.
5.14 Catwalk Hydraulic System – Servicing & Functional Testing
• Visual inspection and function check of complete catwalk hydraulic circuit.
• Cleaning and flushing of hydraulic lines, manifolds, and control valves.
• Replacement of damaged hoses, cylinders, and fittings using Parker parts.
• Cylinder reconditioning including rod inspection, polishing, or replacement.
• Calibration of hydraulic controls for synchronized operation.
• Leak testing and end-to-end function validation for pipe handling sequence.
• Commissioning assistance and performance reporting.
5.15 Optional Rig Hydraulic Support Services
• Hydraulic Power Unit (HPU) preventive maintenance and breakdown support.
• Full-system flushing and varnish removal for old or contaminated circuits.
• Leak rectification and re-hosing of high-pressure connections.
• Onsite emergency repair response team deployment.
• Supply and installation of Parker Hannifin hoses, seal kits, valves, and fittings.
• Certified manpower supply: hydraulic rig technicians, troubleshooters, and supervisors.
• Commissioning, rig-up/down support, and shut-in testing.
6. COMPLIANCE AND STANDARDS
• ISO 9001 / ISO 14001 / ISO 45001
• ASME B31.3, API 6A / 17F, DNV, ASTM A380 / A967
• ISO 4406, NAS 1638, NORSOK M-501
• OEM and Project Specific Requirements
7. HSE, QUALITY & DOCUMENTATION
• Permit To Work Participation
• Pre-task Toolbox Talk, Risk Assessment, JSA
• Workpack & QA Dossier Submission
• Calibration Certificates, Flushing Records, Pressure Logs
• Material Test Certificates (MTC) for all components
• Final As-Built Documentation and Redlined Drawings
