Chennai Petroleum Corporation Limited Tender

Carryout Maintenance jobs in Plant-72 Columns, Vessels & Drums (Total No of Equipments : 7 Nos)

Carryout Maintenance jobs in Plant-73 Columns, Vessels & Drums (Total No of Equipments : 24 Nos)

Carryout Maintenance jobs in Plant-71 Exchangers, Coolers /Condensers and Fin Fan Coolers (Total No of Equipments :20 Nos)

Carryout Maintenance jobs in Plant- 72 Exchangers, Coolers (Total No of Equipments : 7 Nos)

Carryout Maintenance jobs in Plant-73 Exchangers, Coolers/Condensers and Fin Fan Coolers (Total No of Equipments : 31 Nos)

Carryout Unit Isolation blinding and Deblinding in Plant-71, 72 & 73 Plants as per the enclosed attachment. (Total no of blinds : 88 nos)

Carryout removal and refixing of the PSV/TSV in Plant-71, 72 & 73 Plants as per the enclosed attachment. (Total no of PSV's : 103 nos)

Provide service assistance for Shutting Down and start up activities to Manufacturing. 18 mens / 12 hrs shift basis for 12 days on round the clock basis (Total man power = 18x2x12=432 Nos)

Provide One Primavera planner along with primavera software loaded laptop for 2 month period

Unit Rate jobs

Unit Rate jobs

SUPPLY, ERECTION & DISMANTLING OF STEEL SCAFFOLDING- Job Includes supply of necessary scaffolding pipes various lengths, scaffolding clamps ( fixed , rolling ) and metal jolleys, ladders to complete the job as per the scope of work and work package. Job involves erection of scaffolding at the required locations using 1-1/2 inch dia steel tubular pipes with suitable clamping arrangement, providing steel gratings at the required locations firmly tied on to the scaffolding pipes, removal of the steel gratings & scaffolding materials on completion of the job. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, all consumables and labour to complete the job in all respects, collection & transportation of steel scaffolding materials & steel gratings from the owner's storage point to the work site and back to owner's storage point. NOTE: (1) The above rates shall be paid in a telescopic manner within the Category. (2) For measurement, the scaffolding height shall be measured from the erected base level upto the top plank reference or the top horizontal poles. (3) The Scaffolding materials under contractor scope of supply.Required scaffolding material to be mobilised well in advance. (4) In case of either one of the activity like erection or dismantling arise, 60% of the applicable rate shall be paid for erection of scaffolding work & 40% of the applicable rate shall be paid for dismantling work.

Supply, Scaffolding Erection & Dismantling (External)

Supply , Erection & dismantling - Upto 10 mtr height of scaffolding

Supply , Erection & dismantling- Above 10 Mtr and upto 20 mtr height of scaffolding

Supply , Erection & dismantling- Above 10 Mtr and upto 20 mtr height of scaffolding

BLINDING AND DE-BLINDING - The job includes collection & transportation of required quantity of materials like blinds, gaskets, fasteners, etc., from owner's storage point, loosening & tightening of studs (cold / gas cutting if required), wedge opening, cleaning of flanges, insertions and removal of blind & gaskets, providing new gaskets after removal of blinds, overhauling of fasteners using oil, replacing the defective studs / nuts to ensure zero leak of joints including hot bolting. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects, transportation of unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions. NOTE: (1) Nominal diameter of the flanges shall be taken for all measurements. (2) In case of either one of the activity like Blinding or de-blinding arise, 50% of the applicable rate shall be paid for the single activity. (3)This rate will be applicable only for the pipeline replcement job / modification jobs only. For all other jobs bliding & deblinding is included inlumpsum.

Blinding and deblinding for 150# & 300# ratings:

Blinding & Deblinding - Size Upto 1-1/2 inch dia.

Blinding & Deblinding - Size 2 inch dia. to 5 inch dia.

Blinding & Deblinding - Size 6 inch dia. to 10 inch dia.

Blinding & Deblinding - Size 12 inch dia. to 16 inch dia.

Blinding & Deblinding - Size 18 inch dia. to 24 inch dia.

REMOVAL / INSTALLATION / REFIXING OF FLANGED VALVES

Removal of Flanged valves (Other than safety valves) The job includes removal of flanged valves at all grades & elevations by de-bolting / cold cutting / gas cutting and transportation of the valve to the maintenance valve shop or any other designated place inside the refinery premises for repair / disposal. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, dumping the generated scrap material to the designated area, all consumables and labour to complete the job in all respects.

Valve rating - 150# & 300#

Removal of valves - Size 2 inch dia. to 3 inch dia.

Removal of valves - Size 4 inch dia. to 6 inch dia.

Removal of valves - Size 8 inch dia. to 10 inch dia.

Removal of valves - Size 12 inch dia. to 14 inch dia.

Installation of Flanged valves (Other than safety valves) The job includes transportation of valves, gaskets, fasteners, etc., from the owner's storage point or valve maintenance shop, cleaning, checking, tightening the gland, greasing & freeing up etc., servicing of all the fasteners using oil, replacing with new fasteners wherever required, hydrotesting the valve if required, at the specified pressure at valve maintenance shop, installation of flanged valve at all heights & grades using proper gaskets & studs. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, dumping the generated scrap material to the designated area, all consumables and labour to complete the job in all respects.

Valve rating - 150# & 300#

Installation of valves - Size 2 inch dia. to 3 inch dia.

Installation of valves - Size 4 inch dia. to 6 inch dia.

Installation of valves - Size 8 inch dia. to 10 inch dia.

Installation of valves - Size 12 inch dia. to 14 inch dia.

TRAY REMOVAL, COLD REPAIR & RE-FIXING The job involves opening of tray manways / trays with proper marking by opening of bolts / nuts, cutting of corroded bolts ( cold / hot cutting if required), straightening of trays / downcomer segments, providing all the missing valves, bubble caps, clamps, bolts, re-fixing of trays / downcomers & boxing up of tray manways. The job also involves transportation of new trays from owner's storage point to work site for replacement if replacement to the trays are warranted. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, suitable slings / belts, etc., machineries, all consumables and labour to complete the job in all respects, transportation of unused materials to owner's storage point and dumping the generated scrap material to the designated place as per EIC instructions. The rate is applicable if the contractor remvoes the full tray assembly from the column TSR. For Tray manway opening rate is included in the Column Lumpsum.

Tray Removal, cold repair & refixing of Trays

Removal, cold repair & refixing of Trays

HYDROTESTING The job involves hydrotesting of columns / vessels / drums, etc., & steam coil as per the specified test pressure. The job also involves fabrication of suitable manifolds, if required, filling connections etc., and drain out all the entrapped water from the equipment. The job also includes supplying of all types of tools & tackles, suitable test pumps, pressure gauges, machineries, all consumables and labour to complete the job in all respects.

Hydrotesting of column / vessel / drum, etc.,

Hydrotesting of column / vessel / drum, etc., (Upto 10 Cu.mtr of an equipment)

Hydrotesting of column / vessel / drum, etc., (Beyond 10 Cu.mtr of an equipment)

SURFACE PREPARATION - POWER TOOL CLEANING / BUFFING The job includes mechanical cleaning of metal surfaces to SSPC - SP-2 / St3 Power tool cleaning standards using power tools like buffing wheels / grinding machine / rotating steel wire brush, etc., to make the surface free of rust, scales, dirt, grease / oil, etc., for the purpose of painting / conducting Wet flourescent magnetic particle testing or dye penetrant inspection or diesel chalk testing on welds / HAZ's. The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects including assistance during Wet flourescent magnetic particle testing inspection or dye penetrant inspection or diesel chalk testing on welds / HAZ's, if required. NOTE: (1) For weld seam buffing the width of buffing shall be 150mm (i.e) 75mm on both sides of the weld seam.

Power tool cleaning / Buffing to SSPC - SP-2 / St3 standards - 150 mm width of Weld seams / HAZ

Carbon Steel Piping Work - Above ground The job includes transporation of all free issue materials from owner's storage point to work site, handling at site, cutting, bevelling, fabrication, laying, welding & erection of carbon steel piping at all locations above ground level, overhead, over sleepers, piperacks, crossovers, pipe sleeves, trenches, stand posts, connecting with equipments & nozzles, providing tappings from the existing pipelines at all grades & elevations including under road culverts. The piping job includes all modification and replacement jobs involving pipes & all types of fittings like elbows / tees / reducers / half coupling / full coupling, etc., all types of flanges like slip on / raised face, etc., all types of inline instruments like rotameter / pressure gauges / thermowells, etc., valves, expansion joints, steam traps, orifice assemblies, strainers, vents, drains, funnels, etc., of different schedules, pressure ratings and for various temperature applications. The piping job includes providing shoe supports, pads at support locations, reinforcement pads, etc., wherever required. The job includes flushing, preparing work area for executing hot work, bending to suit the contours wherever required, socket, fillet, butt welding using E 6010 / E 6013 / E 7018 electrodes / ER 70S2 filler wire as required, Post weld heat treatment (PWHT - stress relieving) after welding wherever required, DPT wherever required, hydraulic / pneumatic test as per codes, specification, drawings and draining of water & drying with compressor air after hydrotest. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects, returning back the unused materials to owner's storage point and dumping the generated scrap material to the designated area as per EIC instructions. The rates for the following items shall be exclusive of blinding & deblinding, radiography, stress relieving, reinforcement pad welding, removal of old piping for replacement and erection & removal of scaffolding. The rates for the following items shall be inclusive of fabrication, laying, erection, welding, providing shoe supports, pads at support locations, flushing of the piping system, offering stagewise inspection, hydrotesting, draining / drying of the piping system and removal of insulation wherever required. WITH CPCL SUPPLY OF FREE POWER & CONTRACTOR'S WELDING MACHINE. NOTES FOR SOR SL. NOS. (1) Thickness of piping for measurement shall be based on the relevant ANSI or equivalent standards. (2) The finished weld joint elevation at site shall be taken as reference for measurement, wherever applicable. (3) The rates for socket & fillet welding in piping shall remain same for all thickness and elevations as per SOR. (4) Rate for weld joints of vents & drains shall be paid on actual measurement using the applicable SOR. (5) For reinforcement pad welding, the rates shall be paid separately as per SOR 9. (6) Fabrication & welding of pipe shoe supports & pad at support locations are included in SOR and will not be considered for measurement. (7) For scaffolding work wherever required, rates shall be paid separately as per SOR 1. (8) For blinding & deblinding wherever involved, rates shall be paid separately as per SOR 2. (10) In case of replacement of existing piping, rates for removal of old pipelines shall be paid separately as per SOR 12. (11) During hydrotesting of the above piping jobs, some portions of the existing piping in the circuit required to be hydrotested depending on the blinding and the same is included in the applicable welding SOR. (12) Radiography of weld joints is not included in SOR and rate shall be as per SOR 20. (13) For removal and refixing of Flanged valves, rates shall be paid separately as per SOR 3.

SOCKET WELDING - ALL ELEVATIONS

Carbon Steel - Above ground Piping - Socket / fillet welding Joint - With Hydrotest

Carbon Steel - Above ground Piping - Socket / fillet welding Joint - Without Hydrotest

BUTT WELDING - ABOVE GROUND LEVEL - USING E-6010/E-6013 / E-7018 ELECTRODES

Carbon Steel - Above ground Piping - Butt welding Joint - Upto 8.8 mm thickness - With hydrotest

Carbon Steel - Above ground Piping - Butt welding Joint - Upto 8.8 mm thickness - Without hydrotest

Seal welding of Exchanger Bull Plugs

Seal welding of exchanger bull plugs using E 7018 electrodes

Patch plate welding - Carbon steel

Patch plate welding - Carbon steel - using E 6013 electrodes The job includes collection & transportation of required materials from owner's storage point, marking to the required size, cutting, bending to the desired curvature wherever required, edge preparation, fit up & fillet welding on all four sides using E 6013 electrodes, flushing the finished weld surface by grinding and offering DPT at all grades & elevations. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects, transportation of unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions. NOTE: (1) The above rates are applicable for all external welding jobs.

Patch plate welding - Carbon steel - Upto 6 mm thickness

Patch plate welding - Carbon steel - Upto 8 mm thick

Gas Cutting of Plates - Carbon Steel / Alloy steel The job includes gas cutting of carbon steel / Alloy steel plates at all heights & grades including area preparation for hot work. The job also includes supplying of all types of tools & tackles, machineries, gas, all consumables and labour to complete the job in all respects and dumping the generated scrap material to designated area as per EIC instructions.

Gas Cutting of Plates - Carbon Steel / Alloy steel - Thickness upto 6 mm

Gas Cutting of Plates-Carbon Steel / Alloy steel-Thickness 8 mm

Cutting of Stainless steel Plates - By grinding The job includes cutting of SS plates by grinding wheel at all heights & grades including area preparation for hot work. The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects and dumping the generated scrap material to designated area as per EIC instructions.

Cutting of Plate - Stainless steel - Thickness - 8 mm

Dismantling & Removal of Piping The job involves removal of existing above ground, under ground, overhead insulated or uninsulated or steam traced piping including all types of fittings like elbows / tees / reducers, etc., flanges, valves, all types of instruments, supports by cold cutting / gas cutting / grinding, etc., at all locations at all grades & elevations without damaging any other portion of the existing unit, lowering down the same to ground level, transportation of the same to the designated area as per the instructions of Engineer-in-charge. The insulation materials to be removed from the pipes and transported to their respective designated locations as per EIC. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects. NOTE: (1) For scaffolding work wherever required, rates shall be paid separately as per General category jobs under SOR Sl. Nos.1.1

Dismantling & removal of Piping - Carbon steel / Alloy steel

Dismantling & removal of Piping - Carbon steel / Alloy steel

Dismantling & removal of Piping - Stainless steel

Dismantling & removal of Piping - Stainless steel

FILLET WELDING

Fillet welding - Carbon Steel (Using E-6013 Electrode) The job includes flushing, preparing work area for executing hot work, grinding, fillet welding on plate surfaces using E 6013 electrodes at all grades & elevations. The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects as per EIC instructions.

Fillet welding - Carbon Steel - 5 to 6 mm thickness using E 6013 electrodes

Fillet welding - Carbon Steel - 8 mm thickness using E 6013 electrodes

Fillet welding - Carbon Steel - 10 mm thickness using E 6013 electrodes

Fillet welding - Carbon Steel (Using E-6013 Electrode)- Inside Columns/ Vessels The job includes flushing, preparing work area for executing hot work, grinding, fillet welding on plate surfaces using E 6013 electrodes at all grades & elevations. The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects as per EIC instructions.

Fillet welding - Carbon Steel - 5 to 6 mm thickness using E 6013 electrodes (Inside columns / Vessels)

Fillet welding - Carbon Steel - 8 mm thickness using E 6013 electrodes (Inside columns / Vessels)

Fillet welding - Stainless steel - using electrodes of grades - E - 308, 308H, 308L, 347 The job includes flushing, preparing work area for executing hot work, grinding, fillet welding on plate surfaces using suitable stainless steel electrodes at all grades & elevations. The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects as per EIC instructions.

Fillet welding - Stainless steel - 10 mm thickness using electrodes of grades - E - 308, 308H, 308L, 347

Fillet welding - Stainless steel - 12 mm thickness using electrodes of grades - E - 308, 308H, 308L, 347

NOZZLES REPLACEMENT Job involves removal of old / worn out nozzles as marked by Inspection, transportation of the required quantity of pipes, fittings, plates from owners storage point, cutting, grinding, edge preparation of pipes, etc to match with the mating edges, erection of nozzles, reinforcement pad in position, welding (Root - E-6010 Electrode & Filling E-6013/E-7018 Electrodes), radiography, Stress relieving, DPT, pad pneumatic testing, nozzle testing etc., as per codes / specifications / Inspection procedures. Job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects, transportation of unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions. Job also includes cleaning of all foreign materials like weld spatters, clamps, fixtures, etc., prior to testing. NOTE: (1) Thickness of piping for measurement shall be based on the relevant ANSI or equivalent standards.

Nozzle replacement with reinforcement pad including Nozzle & reinforcement testing - Pipe thickness upto 8.8 mm thick (One Unit EA = One Inch dia of nozzle)

Nozzle replacement with reinforcement pad including Nozzle & reinforcement testing - Pipe thickness above 8.8 & upto 12.7 mm thick (One Unit EA = One Inch dia of nozzle)

TRAY / DOWNCOMER REPAIR Job involves grinding the cracks / damaged portion as marked by Inspection, as welding with suitable filler wire / electrode as per the recommendations, DPT, etc as per Inspection procedures. Job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects, transportation of unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions. Job also includes cleaning of all foreign materials like weld spatters, clamps, fixtures, etc., on parent metal surface. NOTE: (1) DPT will be done by CPCL. (2) Rate is applicable for carrying out trays repair work inside the columns. (3) If trays repair work carried out outside the columns / Ground level, rates shall be paid as per SOR. (4) For other welding related jobs like patch plate, insert plate or weld reinforcement, etc., the rates are applicable SOR.

Tray / downcomer welding upto 3 mm - (Repair work - inside the columns)

Tray / downcomer cracks grinding & welding upto 3 mm - Using E-6013 / E-7018 (Inside columns)

Tray / downcomer cracks grinding & welding upto 3 mm - Using E / ER - 309 / 309 Mo / 316 / 316 L (Inside columns)

Tray / downcomer welding upto 3 mm - (Repair work - Outside the columns)

Tray / downcomer cracks grinding & welding upto 3 mm - Using E-6013 / E-7018 (Outside columns)

Tray / downcomer cracks grinding & welding upto 3 mm - Using E / ER - 309 / 309 Mo / 316 / 316 L (Outside columns)

Fabrication & erection of structurals: The job includes fabrication and erection of carbon steel structurals in position such as platforms, ladders, stairs, brackets, pipe supports, pipe shoe, using the structural materials like angles, flats, channels, beams, rounds, plates etc. at all grades & elevations. The job also includes transportation of the required structural materials from owner's storage point to worksite, cutting to the required size, bolting and / or welding of joints etc. as per drawings, specifications & instructions of EIC and preparing the area for hot work. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects, returning back the unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions. NOTE: (1) For scaffolding work wherever required, rates shall be paid separately as per SOR.

Fabrication and erection of structurals

Fabrication and erection of structurals

Dismantling & Removal of Structurals / Gratings The job involves removal of existing above ground, overhead structurals including platforms, ladders, GI & steel gratings by unfastening / cold cutting / gas cutting / grinding, etc., from various locations at all grades & elevations without damaging any other portion of the existing unit, lowering down the same to ground level, transportation of the same to the designated area or scrap yard as per the instructions of Engineer-in-charge including weighment of the material at the appropriate place within the refinery premises, if required. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects. NOTE: (1) For scaffolding work wherever required, rates shall be paid separately as per SOR.

Dismantling & Removal of Structurals / Gratings

Dismantling & Removal of Structurals / Gratings

Erection and welding of Platform / ladder gratings: The job includes erection & welding of gratings in position under the support structure in columns, vessels, tanks, staircase, platforms, step ladders, etc., at all grades & elevations with necessary corrections at work site on the supplied grating to fit to the site requirements. The job also includes transportation of the required structural materials from owner's storage point to worksite, cutting to the required size, bolting and / or welding of joints etc. as per drawings, specifications & instructions of EIC and preparing the area for hot work. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, all consumables and labour to complete the job in all respects, returning back the unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions.

Erection and welding of Gratings

Erection and welding of Gratings upto 15 m elevation

Erection and welding of Gratings above 15 m elevation

Plate Rolling The job includes spreading the required plate for marking, cutting, marking of plates, edge preparation, chipping, shifting of plate to rolling machine, rolling of plates including transportation and shifting of rolled plates to work site. The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects, transportation of unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions.

Plate Rolling - Carbon steel / Alloy Steel - 6 to 10 mm thickness

Plate Rolling - Stainless steel - 6 mm to 10 mm thickness

RADIOGRAPHY-Closed Proximity The job includes performing radiography examination of welds on piping & all type of equipments as per relevant ASME / ASTM standards & as per CPCL specification CPCL-INSP-RAD-01 at all grades & elevations with film width not less than 4 inches. The job also includes supplying of radiation source camera, other machineries required, all consumables required for filming & developing, transportation of camera, etc., area preparation before starting the job, labour, supervision to complete the job in all respects including preparation of developing chemicals, developing the films & submission of films for inspection review.

Radiography camera SE-75 CPR with equivalent shielding and acessories and manpower assistance. Unit EA= 24 hrs

Transportation charges. Unit Ea= per day

Upto 2" dia, Elliptical Shot, unit EA= per Exposure

4" Film Width , Unit EA= per inch length of film

SUPPLY OF SEMI SKILLED LABOUR

Provide semi skilled labour assistance for 12 hr shift basis for operator / technician Assistance

Part-B Lumpsum job (Equipment Hire)

Part-B Lumpsum job (Equipment Hire) Quote lumpsum rate for the proposed equipments / machineries under contractor scope of supply. For other consumables and machineries under contractor scope of supply shall be included in the lumpsum scope of above sl no: 1 to 8.

Provide Diesel Driven Hydroblast Machine ( 15000psi Pressure) on hire basis for 15 days period (24Hrs/Day) For Exch. Cleaning Jobs.Diesel is in Contractor scope

Provide Mobile air compressor 400CFM capacity on hire basis for 25 days period ( 24hrs/Day) for Exchanger jobs. Diesel is in Contractor scope

Provide Tractor Trailer for material shifting,etc. (24Hrs/Day for 30 Days period ) 10 Ton , 20 Feet length.Diesel is in Contractor scope

Provide One hydra Crane (12 ton) on hire basis (24Hrs/Day for 30 days period ) . Diesel is in Contractor scope

Provide One 25 ton Crane on hire basis (24Hrs/Day for 25 days period ) . Diesel is in Contractor scope

Provide One 70 ton Crane on hire basis (24Hrs/Day for 25 days period ) . Diesel is in Contractor scope

Provide One 180 Ton Crane on hire basis ( 24 hrs / Day for 25 days) Diesel is in Contractor scope

Provide Steam hose 1inch, 15meter length IS 10655, Type:3 ,BLACK =50 Nos , Air hose 1 inch 25meter length =250 nos All hoses shall have suitable couplings on both ends.( All these items should be handed over to CPCL Tool room after usage)