Indian Oil Corporation Limited Tender

Removal of old muffle blocks (Burner Tiles) assembly from heater radiant section including lifting and pulling with all tools, tackles, lifting arrangement, refractory bricks supporting arrangement etc. all complete. EA shall mean complete set of burner tiles for one burner.

Lowering and shifting of muffle blocks (Burner Tiles) assembly from site position and disposal at scrap yard or other location within Plant. EA shall mean complete set of burner tiles for one burner.

Transportation of new muffle blocks (Burner Tiles) assembly from IOCL store to work site with necessary safety to avoid any damage during shifting EA shall mean complete set of burner tiles for one burner.

Lifting and installation of new muffle blocks (Burner Tiles) assembly properly and safely in CDU/VDU Heater including required refractory repair if any with tools, tackles, lifting arrangement etc. all complete. (Supply of Muffle block assembly and refractory material will be in IOCL Scope) EA shall mean complete set of burner tiles for one burner.

Gap filling between existing ceramic modules & bricks on walls/roofs of heater, boiler with ceramic blanket including removal of old filling, all tools and tackles as per direction of Site Engineer/EIC. Scaffolding, ceramic blankets shall be in scope of owner. Floor/wall/roof area shall be considered for measurement.

Dismantlling of refractory work, inside the heaters, of insulating blocks and insulation fire bricks, removing them carefully without causing damage and stacking the good pieces inside for reusing and taking out the damaged pieces outside the heaters, cleaning the salvaged materials for reusing, all labour, materials etc complete excluding the cost of scaffolding. Item includes disposal of debris to the directed place within 100m lead as per the instruction of the Engineer-in-Charge.

Dismantilling of refractory masonry work in walls, floors and other locations with fire bricks or refractory castables etc., removing them carefully without causing damage and stacking the good pieces inside for reusing and taking out the damaged pieces outside the heaters, cleaning the salvaged materials for reusing, all labour, materials etc. complete excluding the cost of scaffolding. Item includes disposal of debris to the directed place within 100m lead as per the instruction of Engineer-in-Charge.

Taking out loose fitted fire bricks from the floors of heaters etc. including stacking the serviceable fire bricks properly after cleaning and taking out the debris outside the heater and disposal of debris within a radius of 100M as instructed by the Engineer-in-Charge etc. complete but excluding cost of scaffolding.

Labour charges for repairing the burner arches and sides of size (0.8x0.4x0.4m) from inside the heater with Firecrete super or other repairing refractory materials including chipping off slag and other undulation, plastering the surface for bringing it to the design, dimension, curing etc. with all tools, tackles, labour etc. complete but excluding cost of scaffolding. Refractory shall be issued as a Free Issue material.

Labour charges for replacement of ceramic ferrules inside main Burner of SRU including removing damaged ferrules from tubes and replacing with new material, with all tools, tackles, labour etc. complete as per direction of Engineer-in-Charge. Ceramic ferrules shall be issued as a Free Issue material.

Labour charges for laying the fire bricks in the floors of heaters and burners with old/ new fire bricks loose without any joint after proper cleaning etc. including transporting bricks from Refinery Stores etc. complete but excluding cost of scaffolding. Fire Bricks shall be free issue material.

Labour charges for refractory masonry inside heaters, flare ducts, chimney, boilers etc. with fire bricks of different size and shape laid on fire clay refractory powder/ mortar etc. as per drawing, all labour, tools and tackles including transportation of material from store but excluding cost of scaffolding. Refractory bricks and mortars shall be Free Issue materials.

Removing and cleaning the fire deposits and scales on the surface of boiler tubes and other external surfaces of the walls of boiler, with wire brushes, coir ropes, gunny bags, chain etc upto the satisfaction of Engineer-in-Charge, cleaning the floor, throwing the debris outside the boiler upto 100M distance, all labour materials etc. complete excluding the cost of scaffolding. (Measurements will be based on surface area of wall, floor etc.)

Repairing the refractory lining including repair of cracks in floor and walls of refractory lining in heater and flue ducts by racking out the joints and pointing with refractory mortar including transporting of materials from store disposal of debris outside heater upto a distance of 50M etc. complete with all labour, tools and tackles, etc. complete (Refractory materials to be supplied free of cost), excluding cost of scaffolding. (Measurements will be based on surface area of wall and floor etc).

Concrete Lining with Refractory castables: Refractory concrete Lining with dense refractory castables or insulating castables or any other equivalent castables in any vessels, equipments, pipings, burner blocks, lining work inside heaters, boilers, chimney etc. as per manufacturer's specifications, drawings and directions of Engineer-in-Charge including curing, all labour and materials, all tools and tackles etc. complete but excluding cost of shuttering/ form work which shall be paid separately. Item excludes the cost of scaffolding. Only refractory materials such as castables shall be issued free of cost from Owner's stores. Item includes the transportation of such materials from Owner's stores to the work site and disposal of the debris within 100m lead to the directed place as per the instructions of Engineer- in-Charge.

API-936 Certified Refractory Inspectors: Deployment of API-936 Certified Refractory Inspectors during shutdwon of all process units of Refineries and providing the services as below, but not limited to, such as : *Inspection of installed refractory and provide recommendations. *To ensure that material and applicator qualification test results are line with job requirement and are fully documented *To inspect and physically verify that installation of hex-mesh, V-Bar S-Bars or other anchors has been carried out as per the design / drawing of refractory lining job. *To carry out physical verification of refractory materials before installation and ensure the same are in line with the engineering drawings/ datasheet. *To check and verify that accurate refractory installation procedures *To monitor, guide and assist owner and contractor to ensure desired progress of work *To assist owner and contractor in maintaining safety procedure / conditions *To check and verify accuracy of refractory Dry-out procedures *To inspect and test installed linings before Dry-out and after Dry-ou *To notify the owner and the contractor of any work deficiencies or potential deficiencies *To record all non-conformances and / or potential problems *To intimate conflicts, if any, between the specified execution plan and the actual installation procedures or installed refractory quality results *To prepare inspection report at suitable intervals *To certify that all the anchoring systems and refractory lining jobs including selection of all materials, installation, and Dry-out procedures have been carried out as per design / drawing / OEM / Manufacturer’s recommendation and direction of Engineer-in-Charge. with all manpower, material, tools and tackles, equiments, comsumables etc as per the direction of Engineer-in-Charge. Travel expenses: The rates are inclusive of To and Fro Travel expenses of the Refractory Inspectors prior to and after completion of deployment at the Refinery location. However, To and Fro transport facility from Stay accommodation to Refinery shall be arranged by the Owner Free of Cost during the period of deployment. "Accommodation expenses: The rates are exclusive of Hotel accommodation charges during the period of deployment. Stay accommodation for the Refractory Inspectors shall be provided by the Owner free of cost in their Guest House / Transit Accommodation / Nominated Hotel located near the Refinery. In case of non-availability of Owner’s accommodation, actual expenses towards Hotel accommodation for both the Refractory Inspectors in a single room (on double occupancy basis) in a Three-star or equivalent hotel from evening of one day prior to start of deployment up to next morning of last day of deployment shall be reimbursed on submission of valid documents. Note: EA stands for working for 12 Hours shift in Day or Night Separate Refractory Inspectors shall be deployed for Day and Night Shifts.