The Fertilisers And Chemicals Travancore Limited Tender

Fabrication of SS pipelines in NP Plant and Offsite area. Work involves the fabrication of pipelines and nozzles with necessary fittings to suit site conditions for the replacement of damaged pipelines, installation of new pipelines, and modification or rerouting of existing pipelines. The pipelines and nozzles shall be fabricated using Stainless Steel (SS) material for handling acid, slurry, water, ammonia, fire hydrant, air, and other utility services. Upon receiving clearance to commence work, the contractor shall collect and transport the required materials, tools, and tackles from the FACT-CD Stores or Main Workshop to the work site. Accurate site measurements must be taken by the contractor to ensure proper fitment during erection. Fabrication work shall be carried out with maximum utilization of straight pipe lengths to minimize wastage. Pipe fittings such as elbows, tees, reducers, and other components shall be installed as per site requirements. In the event of a shortage or if special fittings are required, the contractor shall fabricate the necessary items using the materials provided. All fabrication and erection activities shall be carried out in compliance with applicable safety standards, company guidelines, and industry best practices, ensuring proper alignment, support, and secure installation. Standard welding procedures shall be followed for all weld joints. All welding shall be carried out using Tungsten Inert Gas (TIG) welding, and all joints shall be prepared properly, including cleaning, marking out, cutting, profiling, bevelling, grinding, aligning, fitting up, tack welding, chipping, and final full TIG welding. The accessories necessary for TIG welding, including the welding gun, filler rod, Argon gas, plasma cutting set, etc. will be within the contractor's scope. Cutting of SS material shall be done using plasma cutting only. Dye Penetrant (DP) testing shall be conducted for each weld joint, and the contractor shall be responsible for supplying all materials and consumables required for the DP test. If any weld joint is found defective, it shall be rectified by the contractor at no additional cost. Pipe sizes involved in this work range from 15 NB to 300 NB.

Erection / Replacement of MS /CS / SS pipelines, Flexible Hoses and Fittings in NP Plant and Offsite area. Work involves the transportation and erection or replacement of prefabricated pipelines/flexible hoses, including the support clamps, padplates, valves, flow meters, pressure gauges, and related fittings, at various locations, elevations, and pipe bridges. Upon receiving clearance to commence work, the contractor shall collect and transport the required materials, tools, and tackles from the FACT-CD Stores or Main Workshop to the work site. The contractor shall also transport the prefabricated pipelines/flexible hoses from the storage area to the erection site. The scope includes dismantling the damaged pipeline/flexible hose, removing old gaskets, cleaning the flange faces, erecting the new pipeline/flexible hose with new gaskets, positioning and aligning it without strain, securely fastening all bolts, and performing a leak test. If any joint is found defective during leak testing, it shall be rectified by the contractor at no additional cost. The dismantling and refixing of valves, flow meters, pressure gauges, and control valves associated with pipeline/flexible hose replacement are included in the scope of this contract. The provision and installation of blind dummies or slip plates to isolate the line during replacement or erection are also within the contractor’s scope. The contractor shall ensure that the pipeline/flexible hose is properly aligned and securely placed on the supports provided. The contractor shall fabricate and provide suitable pads and holding clamps as per the site requirements. Pipe sizes range from 15 NB to 300 NB. The damaged MSRL pipelines shall be transported to the PA Plant for rubber removal. Upon completion of rubber removal, the pipelines shall be transported back to the designated area. It is to be noted that rubber removal is not included in the scope of this contract.

Repair of Damaged MSRL/SS Pipelines in NP Plant and Offsite area. Work involves the repair of Carbon Steel (CS), Mild Steel (MS), and Stainless Steel (SS) pipelines, including bends, tees, reducers, and associated fittings. Upon receiving clearance to commence work, the contractor shall collect and transport the required materials, tools, and tackles from the FACT-CD Stores or Main Workshop to the work site. Damaged or thinned-out sections of the pipeline shall be cut and removed, followed by proper edge preparation. The replacement of the damaged portion shall be carried out by butt welding, in accordance with standard welding procedures. In the case of repairs to MSRL pipelines, once the patchwork is completed, the items shall be transported to the rubber lining area for rubber lining. After rubber lining is completed, the repaired items shall be transported to the NP Plant or Off-site area and stacked as per the instructions of the Engineer-in-Charge. It is to be noted that rubber lining is not included in the scope of this contract.

Fabrication & Erection of Pipe Supports in NP Plant and Offsite area. Work involves the fabrication of pipe supports to suit site conditions during the replacement of damaged pipelines, installation of new pipelines, and modification or rerouting of existing pipelines. Upon receiving clearance to start the work, the contractor shall collect and transport the required materials, tools & tackles from the FACT - CD Stores or Main Workshop to the work site. Accurate site measurements must be taken by the contractor to ensure proper fitment during erection and fabrication work shall be carried out by the contractor with maximum utilization of material to reduce wastage.