Indian Oil Corporation Limited Tender

80 mm NB, Schedule upto 40

100 mm NB, Schedule upto 40

150 mm NB, Schedule upto 40

200 mm NB, Schedule upto 20

250 mm NB, Schedule upto 20

300 mm NB, Schedule upto 20

CARBON STEEL PIPING JOINTS FOR HYDROCARBON SERVICE (WITH WELDING ELECTRODE E-6010 / E-7018) Transportation of all piping items from owner's storage points to work site and/ or pre-fabrication yard and to site after pre-fabrication; cutting, grinding, edge preparation of pipes and fittings, like flanges, elbows, tees, reducers etc. to match the mating edges of different thickness; fit-up, bending, welding using approved welding electrodes as per owners quality requirements etc. as per codes/specifications, drawing etc., threading, laying, erection and alignment of pipes at ground level i.e. upto a height of 5 meters on sleepers, pipe racks etc. or upto 5 meters depth in trenches; connecting with equipment, nozzles, steam traps, strainers, orifice assemblies (including tapping upto first block valve), spray nozzles rotameters; tapping for instrument connections like pressure gauges, thermowells, sample connections, vents, drains etc. including fixing of all types of SW valves, gaskets, nuts and bolts, all inline instruments, elbows, tees, flanges, reducers, full coupling or half coupling, earthing strip wherever required; welding prefabricated shoes and supports (including alignment) as per the drawings, including preparation small bore isometric upto 1.5 inch NB, specifications, codes etc. and as per the instructions of the Engineer-in-Charge to his entire satisfaction including supplying of all types of tools and tackles, lifting arrangements, equipment, machineries, all consumables and labour etc. to complete the work in all respects in a workman like manner including area preparation for hot jobs, area cleaning after completion of work, flushing wherever required, cleaning of pipes externally off all foreign materials like weld beads, clamps fixtures etc. used in fabrication as directed by the Engineer-in-Charge. NOTE : Proper safety arrangements for carrying out the job is under contractor's scope and the same has to be complied with as per the dire ctions of the Engineer- in-Charge. NOTE: For piping beyond 5 Mtr. elevation above and below ground piping and upto 10Mtr. rates is to be escalated by 20%. For more than 10 Mtr. but upto 15 Mtr. rates is to be escalated by 30%. For more than 15 Mtr but upto 20 Mtr. rates to be escalated by 40% respectively. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately. NOTE: For piping where TIG welding is used for root run only, the rates to be escalated by 15% and where TIG welding is used for entire joints the rates to be escalated by 20%. NOTE: Payment of tapping points will also be made extra on joint basis, as the measurement is on joint basis.

Full TIG welding, 25 MM NB, SCH ABOVE 80 BUT UPTO 160

80 mm NB, Schedule upto 40

100 mm NB, Schedule upto 40

150 mm NB, Schedule upto 40

200 mm NB, Schedule above 20 but upto 40

250 mm NB, Schedule above 20 but upto 40

300 mm NB, Schedule above 20 but upto 40

Transportation from owner's storage points to work site and/ or pre-fabrication yard and to site after pre-fabrication; cutting, gr inding, edge preparation as per the instructions of the Engineer-in-Charge to his entire satisfaction including supplying of all types of tools and tackles, lifting arrangements, equipment, machineries, all consumables and labour etc. to complete the work in all respects in a workman like manner including area preparation for hot jobs, area cleaning after completion of work, pneumatic testing, cleaning of pipes externally off all foreign materials like weld beads, clamps fixtures etc. used in fabrication as directed by the Engineer-in-Charge. NOTE : Proper safety arrangements for carrying out the job is under contractor's scope and the same has to be complied with as per the dire ctions of the Engineer- in-Charge.

Branch size 4 inch

Branch size 6 inch

Branch size 8 inch

Branch size 10 inch

FABRICATION OF CARBON STEEL MITRE CUT BENDS (45 DEG BENDS) - THREE PIECES (TWO JOINTS) WITH WELDING ELECTRODE E-6013 Preparing drawings and fabrication of the 45 deg. carbon steel mitre bends (Three piece, two joints) including transportation of materials from owner's storage points to work site and / or shop, cutting, edge preparing, welding using electrodes as per owner's quality requirements including supply of all necessary equipment, consumables, labour, tools, tackles and supervision. Work shall be carried out as per the specifications, drawings, codes, and instructions to the full satisfaction of the Engineer-in-Charge.

150 mm NB, Schedule upto 40

200 mm NB, Schedule upto 20

250 mm NB, Schedule upto 20

300 mm NB, Schedule upto 20

FABRICATION OF CARBON STEEL MITRE CUT BENDS (90 DEG BENDS) - THREE PIECES (TWO JOINTS) WITH WELDING ELECTRODE E-6013 Preparing drawings and fabrication of the 90 deg. carbon steel mitre bends (Three piece, two joints) including transportation of materials from owner's storage points to work site and / or shop, cutting, edge preparing, welding using electrodes as per owner's quality requirements including supply of all necessary equipment, consumables, labour, tools, tackles and supervision. Work shall be carried out as per the specifications, drawings, codes, and instructions to the full satisfaction of the Engineer-in-Charge.

150 mm NB, Schedule upto 40

200 mm NB, Schedule upto 20

250 mm NB, Schedule upto 20

300 mm NB, Schedule upto 20

WRAPPING & COATING OF VESSELS/ UNDERGROUND PIPING ETC. Providing wrapping and coating as per the specifications including supply of all materials, tools and tackles, etc. The detailed spe cification for wrapping and coating is as under: 1. The surface preparation of pipes shall be done by grit/ shot blast cleaning to Swedish standard SA-2. 2. The grit/ shot blasting operation shall be carried out in the day time. Blast cleaning operation shall not be under taken in humid condition. 3. Only approved quality grit/ shot shall be used for grit/ shot blasting. The grit/ shot used shall be dry and free form any other impurities. 4. The grit/ shot blasted surface shall have a shining and near white metal appearances. 5. After grit/ shot blast cleaning, the surface shall be dry brushed to remove deposits. 6. The grit/ shot blasted surface should be inspected by quality control/ Inspection agency of owner/ contractor. COATING SYSTEM Following steps shall be followed: 1. Application of one coat of primer. 2. Application of one coat of coal tar enamel. 3. Wrapping fibre glass. 4. Application of 2nd coat of coal tar enamel. 5. Wrapping of craft paper/ coal tar impregnated outer wrap. PRIMING 1. Single coat of coal tar primer shall be applied manually with good quality brushes. Following precautions shall be taken during application of primer. 2. Primer drum shall be inspected for manufacturing date batch No. etc. 3. Primer drum shall be rotated before opening for proper mixing. 4. Primer shall be applied within 12 hrs. of completion of sand blasting. 5. Primer shall be applied evenly all along the pipe surface. 6. Any holiday or bare pipe left over during priming shall be primed again. 7. Primer will not be applied during rainy/ moist weather. 8. After application of primer and before drying, adequate precaution shall be taken to avoid contact of dust/ sand etc. with primed surface. 9. Normal primer requires 1 hr. time for proper drying and becomes dead after 24 hrs. of its application. 10. Coating shall be completed within these limits failing which dead primer shall be cleaned and fresh primer shall be applied again. COATING AND WRAPPING i) When the priming coat has dried and the surface of the primed pipe has been cleaned preferably by clean white rags to remove the settled dust just preceding of the coating operation. The pipe shall be coated with hot application of one coat of coal tar enamel to give a minimum thickness of 2.5 mm and to be securely bonded to the primer. ii) The coal tar enamel shall be cut into lumps preferably at the storage place upon a clean platform with side boards and due care must always be exercised by the contractor to keep the broken enamel absolutely free form dirt, grass, water or any other foreign material up to the time when enamel is charged into the melting kettle. iii) The coal tar enamel shall be slowly heated on reduced fire and maintained to the even temperature recommended for application i.e. 220 deg. C to 240 deg. C. iv) Constant stirring shall be necessary in continuously operating melting kettles. v) Melting kettle should have proper insulation. vi) The melting kettle should be of movable type i.e. wheel mounted and have towing arrangement. vii) The melting kettle should be kept near the work site. However, in no case the molten enamel shall be carried in bucket for more than 50 meter distance. Viii) During pouring of molten enamel, fine wire mesh filter shall be used to avoid the flow of impurity/ dirt/ sand. ix) During temporary interruption of the work the temperature in the kettle not shall be reduced by at least 50 deg. C below the normal specified temperature. x) Any enamel heated to temperature in excess of the maximum allowable temperature shall be rejected and suitably disposed off by the contractor. xi) Melting kettles/ pots shall always be maintained clean and in good working order and must be cleaned whenever deposits form on the heating surface. xii) A uniform thickness of 2.5 mm of enamel shall be applied to the surface of the primed pipe. xiii) A uniform thickness of 2.5 mm of enamel shall be applied to the surface of the primed pipe. xiv) The enamel shall be then reinforced by a spirally wrapped fibre glass wrap, pulled and embedded into the hot coating with an over lapping of edges of the wrap not less than 1/2" and not more than 1" xv) This will be followed by another coat of hot coal tar enamel application with a uniform thickness of 1.5 mm followed by craft paper/ coal tar impregnated fibre glass covering. xvi The coating and wrapping must be absolutely free of wrinkles in the wrappers, pinholes, bubbles, holidays voids thin spots or foreign matter. xvii Rolls of wrapping material shall not be kept along the right of way and shall be stored properly and brought to site. xviii) Wrapping material shall be so hauled and handled as to prevent injury to the packages. xix) No packages shall be handled with hooks or thrown form trucks. xx) Any such material which shows evidence of deterioration due to weather or any other cause, shall be rejected. COATING THICKNESS Minimum thickness of first should be 2.5 mm whereas total thickness should be approx. 4.5 mm. TESTING Following testing shall be undertaken: I) Physical Inspection: All the coated surface shall be visually inspected and all the wrinkles, bubbles, lack of overlap etc. shall be marked for repair. Ii) Sound Test: The coating adhesion can be checked easily with small wooden hammer by soft striking on coated surface. Change in sound indicates coating defects and same can be checked there by peel test. iii) Peel Test: The field bond test for coal tar enamel adhesion shall be preformed at 50-80F normal operating temperature of steel piping. If the coating temperature is above 80 °F or below 50 deg. F, pour cold or hot water over the test area to adjust the enamel temperature within this range. Using a knife, heated if necessary make two parallel cuts through the coating about 4 inch in length and 3/4 inch apart. With the edge of knife blade cut under the enamel strip at one end and loosen the enamel form the pipe the full width of the strip for about a 1/2" place the knife blade under the loosened end and apply a slow, steady pull upward on enamel strip. iv) If the peel length exceeds 1/8" the test is a failure and two additional tests shall be made at two different locations on the same section. If the additional tests are satisfactory then the section shall be approved. If the either additional test fails, the pipe section shall be rejected. SPECIFICATION OF COAL TAR PRIMER The primer consists of processed coal tar pitch and refined coal tar oil suitably blended with a solvent without pigment or inert filler or other substances (to be applied cold) for brushing or spraying as liquid coat to the clean surface piping as provided for in AWWA specification C-203-73. The primer should have no tendency to settle down in the container and when applied without producing bubbles, becomes dry and hard to touch within specified time ensuring and effective bond between the metal pipe surface and the enamel coating. The main characteristics of the coal tap primer should be as follows: 1. Drying time to touch dry, at normal humidity at 32 deg. C is less than 1 hr. 2. Max Boiling point of solvent 25 deg. C. 3. Penetration of residue at 25 deg. C. 4. Softening point of residue (ASTM-D-36) 104 deg. C. 5. Flash point of (ASTM 1310) 37 deg. C. 6. Pigment 7. Solvent Benzol solvent or highly toxic volatile solvents excluded. Reputed Indian Supplier (for Coal Tar Enamel and Coal Tar Primer). i) M/s Shalimar Tar Products, Calcutta. ii) M/s Lloyd Insulation (India) Ltd., New Delhi. 2. SPECIFICATION FOR COAL TAR ENAMEL The enamel shall be a WWA coal enamel type-I conforming to AWWA standard, AWWA C-203-86. The enamel be composed of a specially processed coal tar type blended with an inert mineral filter, properly graded, cleaned, dust free and without asphalt of either petroleum or nature base, to be applied to a recommended temperature. The main characteristics of the enamel shall be as follows: S. No. Test Enamel Type - 1 Min Max. 1. Softening Point, ASTM-D-36 140 deg.C 116 deg. C 2. Filter(ash) ASTMD-71 25% 35% 3. Fineness fillet through 90% Through 200 mesh. ASTM-D-54G 3. SPECIFICATION OF FIBRE GLASS INNER WRAP The fibre glass inner wrap of high tensile long monofilament, chemically inert glass fibre in jack straces patterns mat reinforced by longitudinal continuous stands of glass fibre yarn blended with insoluble inert resinous binder compatible with hot coal tar enamel and should conform to the following specifications: Tensile Strength (transverse) Kg/cm 0.50 + 0.10 Weight 41gm/sq.m Reputed Indian Supplier for Fibre Glass paper and Kraft Paper: i) M/s united paper product, Saharanpur, U.P. ii) M/s FGP limited New Delhi. iii) Specification of craft paper. The craft paper shall be smooth bituminised to be supplied in rolls. The average weight of a composite bituminised craft paper shall be a minimum of 120 gms/sq. Meter. A negative weight tolerance upto 5% of the composite weight may be permitted at the discretion to the owner, (bituminised craft paper with average weight less than 120 gms/sq. Meter in not acceptable). The bituminised craft paper shall be composed of two layers of craft paper shall be composed of two layers of craft paper and each weighing not less than 45 gm/sq. Meter and laminated with a layer of bitumen approachments weight 50 gms/sq. M to have a proper bond between the two layer of paper. He bituminised craft paper for field application shall be able to resist penetration. Specific Gravity at 25 deg. C ASTM D-71 1.4 1.6 Penetration, ASTM-D-5 10 a) At 25 deg. C 100 gms. Weight 5 secs. High temperature test at 71 deg.C 1/32 (Sag O AWWA C-203. Sec. 2.8.9 Low temperature test at 23 deg. C (Cracking), AWWAC-203 sec. 2.8.10 Peel Test, AWWAC-203 sec. 2.8.11 No peeling Electrical Resistance test at 17000 Volts and low amperage (1.5 mm thickness) Other Requirements (For wrapping and coating) 1. Third party Inspection certificate for all materials by EIL/ DNV/ LRIS/ MECON or providing IOCL approved manufacturers test certificate shall be in contractors scope. 2. Holiday testing machine shall be arranged and provided by contractor. 3. Vendor to submit transportation and Handling procedure T avoid wrapping and coating of pipes. 4. Vendor to submit and Get quality assurance plan (QAP) for wrapping and coating approved by owner/ Inspector. 5. The wrapping and coating surface must have machine finish in workmanship. Note: Additional payment for earth excavation and wrapping coating will be made extra for underground piping.

150 mm NB

200 mm NB

250 mm NB

300 mm NB

DISMANTLING OF CARBON STEEL/ ALLOY STEEL PIPING BY HOT WORK (INSULATED/ UNINSULATED) Dismantling and removal of above ground, overhead under ground (upto depth of 5m) redundant, steam traced pipelines, insulated and u ninsulated, of carbon steel / alloy steel by gas cutting or by grinder from various locations such as pipe racks, columns, pump house, vessels, heaters, heat exchangers, desalter etc. upto a height of 5 meters including, removal of insulation material, all on line instruments, fittings, flanges, valves, vents, drains, branching etc.; lowering down the same to ground level with due care so that no other piping, equipment#s, machinery#s etc. is damaged; cutting into pieces if required; segregating for reclaiming useful fittings such as bends, flanges, valves, instruments etc. by unbolting, gas cutting, cold cutting etc.; transporting and stacking the salvageable useful materials to workshop / instrument workshop/ store or as per the direction of the Engineer-in-Charge and shifting the scrap pipes etc. to scrap yard or any other location within refinery premises and completing the job as per the instructions of Engineer-in-Charge. Job also includes supplying of all types of tools and tackles, lifting arrangements, equipment, machineries, all consumables and labour etc. to complete the work in all respects in a workman like manner including area preparation, taking clearance for hot jobs, blinding and de-blinding, area cleaning after completion of work, flushing wherever required as directed by the Engineer-in-Charge. NOTE : 1. Proper safety arrangements for carrying out the job is under contractor's scope and the same has to be complied with as per the d irections of the Engineer- in-Charge. 2. Salvaging of useful fitting from redundant pipe, if done, will be paid under separate item. 3. Civil works (excavation and back filling) for underground dismantling shall be paid under separate item from Civil SOR. Note: For piping beyond 5 Mtr. elevation above and below ground piping and upto 10Mtr. rates is to be escalated by 20%. For more than 10 Mtr. but upto 15 Mtr. rates is to be escalated by 30%. For more than 15 Mtr but upto 20 Mtr. rates to be escalated by 40% respectively. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately.

100 mm NB

150 mm NB

200 mm NB

250 mm NB

300 mm NB

DYE PENETRATION TEST FOR PIPING WORKS Performance of dye penetration test including supply of all necessary materials, penetrant, developer etc. along with all equipment#s, labour, for carrying out the work as per specification & direction of engineer -in-charge at all elevations. Test has to be carried out in all metallurgy the test has to carry out on all schedules of pipes. NOTE: Since inch dia unit is not available in SAP, hence for estimate unit is to be taken as " dia.

For Pipes (Per Inch Dia)

HYDROTESING OF PIPING WORKS Hydrostatic testing of pipelines at the specified pressure including blinding/deblinding, fabrication and fixing of testing connections, pressure gauge installation. Hose pipe connection and making all other arrangements as required and dewatering, flushing and boxing up after fixing proper gaskets with supply of all labour, tools andtackles, instruments and instruction of the Engineer-in-Charge. The job has to be carried out at all elevations.

25 mm

80 mm

100 mm

150 mm

200 mm

250 mm

300 mm

RADIOGRAPHY OF PIPING WORKS Performance of radiographic inspection on all type & sizing of piping/ pipe fittings in position at all heights inclusive of providing sources, film, chemicals, & all necessary equipment#s, consumables etc. complete in all respect as per specification & instruction of the Engineer-in-Charge. NOTE: Since inch dia unit is not available in SAP, hence for estimate unit is to be taken as " dia.

For Pipes (Per Inch Dia)

HYDROTESTING OF GATE/GLOBE/ CHECK VALVES Job involves collection of valves from stores, go-down etc. transportation to testing bay or contractors' own premises, test the val ves for seat, body and backseat at recommended pressure including cleaning and greasing, transport back as per instruction and satisfaction of the Engineer-in-Charge.

100 mm

200 mm

250 mm

300 mm

DISMANTLING OF STRUCTURALS LIKE PIPE SUPPORT / STAIRWAY / DEVIT ETC. Removal of existing platforms / pipe supports / davits / stairways etc. along with adjacent fittings / members by cutting / debolting or by any other means without damaging the remaining unit and lowering down to the ground including erection of scaffolding, retrieving of all the usable materials and transportation to the storage point as directed by the Engineer-in-Charge.

INSTALLATION OF FLANGED / RTJ VALVES Transportation of all types of flanged / RTJ valves, gaskets, nut bolts etc. either from owner's storage point to workshop and / or worksite and installation of valves at ground level i.e. up to a height of 5 meters on sleepers, pipe racks etc. or up to 5 meters depth in trenches including assembly of valve accessories, cleaning of flanged faces, lapping of RTJ rings, cutting the gaskets to proper size, placing the gaskets / RTJ ring properly, tightening of studs, providing earthing protection by way of fixing strips, all complete as per drawings and direction of the Engineer-in-Charge including all labour, tools, tackles, consumables and supervision etc.

For Valves (other than RTJ)

INSTALLATION/ REMOVAL OF LEVEL TROLL, FIRE HYDRANT, MONITORS, SAFETY VALVES ETC. The job involves opening of flanged and removal of all types of level troll, fire hydrant and monitor by debolting/ cold/ hot cutting of fasteners wherever required, cleaning, or flange facing, lapping of RTJ rings, level troll, fire Hydrant, monitor, in position with correct direction and providing new gasket (IOCL supplied) including cutting of gaskets if required and finally tightening of the gland to ensure zero leak including hot bolting wherever applicable.

Installation (same as 7.1), CME0701001

Removal (same as 7.2), CME0701002

WELDING OF CS PLATES Transportation of all items including plates etc. from owner's storage point to work site and / or prefabrication yard and welding of CS plates including cutting / grinding / edge preparing and required testing to prove soundness of weld joint with supply of all consumables, manpower, tools as per technical specification and direction of the Engineer-in-Charge.

Above 3mm & upto 5mm thick.

Above 5mm & upto 6mm thick

CS / AS PLATE CUTTING Cutting of CS / AS plate by gas/ grinding or any other means as per direction of the Engineer-in-Charge according to suitability including transportation from stores to site with supply of all tools, tackles, consumables, equipment, labour etc.

5mm thick

6mm thick

HB Epoxy Zinc Phospohate Primer - 1 Coat

Acrylic Polyurethane Paint - 2 Coat

Fire Water Network Phase III (Civil)

Earth work in excavation by mechanical means (Hydraulic excavator) / manual means in foundation trenches or drains (not exceeding 1.5 m in width or 10 sqm on plan) including dressing of sides and ramming of bottoms, lift up to 1.5 m, including getting out the excavated soil and disposal of surplus excavated soil as directed, within a lead of 50 m.

All kinds of soil

Filling available excavated earth (excluding rock ) in trenches, plinth, sides of foundations etc., in layers not exceeding 20cm in depth: consolidating each deposited layer by ramming and watering, lead up to 50m and lift upto 1.5m

River sand

Providing and laying in position specified grade of reinforced cement concrete excluding the cost of centring, shuttering, finishing and reinforcement. All work upto plinth level.

1:1.5:3 (1 cement : 1.5 coarse sand : 3 graded stone aggregate 20 mm nominal size)

Providing and laying in position cement concrete of specified grade excluding the cost of centring and shuttering -All work upto plinth level.

1:4:8 (1 cement : 4 coarse sand: 8 graded stone aggregate 40 mm nominal size)

Centering and shuttering including strutting, propping etc. and removal of form for :

Foundations, footings, bases of columns etc. for mass concrete.

Columns, Pillars, Piers, Abutments, Posts and Struts

Steel reinforcement for R.C.C work including straightening, cutting, bending, placing in position and binding all complete upto plinth level as well as above plinth level.

Thermo-mechanically treated bars

Structural steel work in single section fixed with or without connecting plate including cutting, hoisting, fixing in position and applying a priming coat of approved steel primer all complete.

Cutting road and making good the same including supply of extra quantities of materials I.e. aggregate, moorum screening, red bajri and labour required.

Bituminous portion

Water bound macadam

Structural steel work riveted, bolted or welded in built up sections, trusses and framed work, including cutting, hoisting, fixing in position and applying a priming coat of approved steel primer all complete: