Chennai Petroleum Corporation Limited Tender

PART -B UNIT RATE JOBS

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.

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.

OPENING & BOXING UP OF MANWAYS / COVERS The job involves opening of manways, covers by de-bolting (cold / gas cutting if required), cleaning the manways / covers, servicing of bolts, replacing defective bolts / nuts and finally boxing up with proper gasket / packing to ensure zero leak of joints including hot bolting. The job also involves to & fro transporatation of gaskets, studbolts, packings, etc., between the work site and the owner's storage point. 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 material from owner's storage point to the work site & unused materials back to the storage point and dumping the generated scrap material to the designated place as per EIC instructions.

Opening & boxing up of Plate flanged cov

Plate flanged covers of all ratings - Size Upto 20 inch dia.

Plate flanged covers of all ratings - Size Above 20 inch dia.

SUPPLY, ERECTION & DISMANTLING OF STEEL SCAFFOLDING- For External purpose - Insulation removal, thickness gauging, NDT jobs & Painting / Patch repair The job includes supply, transportaiton of scaffolding materials is in contractors scope of supply , erection of scaffolding at site covering the areas specified including providing vertical posts of pipes at inter distance of 1.5m and horizontal numbers at a inter distance of 0.5 to 0.75 meter, providing rods at corners to give sufficient strength to the structure, placing the steel planks / FRP gratings on top for making sufficient area. Dismantling scaffolding after completion of job. Necessary quantity of scaffolding pipes at various lengths, rolling / fixed clamps, metal jolley including all tools, tackles, consumables, labours and contractor's supervision to be mobilised for completion of the jobs scope. "NOTE : i) For measurement in SQM : 2( Length + Width) x height area covered by the scaffolding is to be taken ii) Scaffolding measurement to be done by breaking the height into parts as per height slab mentioned below and adopting respective rates against mentioned height slabs."

Supply,Scaffolding Erection & Dismantling (External)

Up to 6m height

Above 6 m up to 10 m height

Remarks : (i) Mode of measurement for the above items shall be in meter square. Measurement shall be taken as 2 times length + bredth multiplied by height. This shall be applicable for outside of the confined space (ii) For scaffolding erected from any platform,height of the scaffolding shall be taken from the platform i.e platform shall be taken as zero meter level (iii) In addition to above for any other locations the measurement of EIC shall be final and binding to contractor (iv) Erection of scaffolding and removal / dismantling of the same scaffolding after completion of job shall be considered as completed job. No separate payment for removal of scaffolding shall be made (iv) Erection of scaffolding and removal / dismantling of the same scaffolding after completion of job shall be considered as completed job. No separate payment for removal of scaffolding shall be made

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, m achineries, 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.

Power tool cleaning / Buffing to SSPC - SP-2 / St3 standards - Bulk area

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

NOTE: (1) For weld seam buffing the width of buffing shall be 150mm (i.e) 75mm on both sides of the weld seam.

Replacement of Anchor chair bolt as per procedure: The job involves Cutting and removal of the anchor chair bolt /repair/Replacement of the anchor chair bolt of the tank as per procedure The job also includes supplying of all types of tools & tackles, machineries, all consumables, labour & supervision to complete the job in all respects including transportation of all the required materials to the work site.

Replacement of Anchor chair bolt

MECHANICAL LEVEL INDICATOR REPAIR/REPLACEMENT: The job involves repair/Replacement of the Mechanical Levl Indicator of the tank " The job also includes supplying of all types of tools & tackles, machineries, all consumables, labour & supervision to complete the job in all respects including transportation of all the required materials to the work site.

Mechanical Level Indicator Repair/Replacement

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.

Patch plate welding - Carbon steel - Upto 6 mm thickness using E 6013 electrodes

Patch plate welding - Carbon steel - 8mm mm thickness using E 6013 electrodes

HGas Cutting of Plates - Carbon Steel / Alloy steel /( For Drip Plate provision) 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

HFILLET WELDING / ( For Drip Plate provision)

HFillet 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

BUTT WELDING (For Drip Plate provision)

Butt welding - Carbon Steel (Using E-6013 Electrode). The job includes flushing, preparing work area for executing hot work, cutting, grinding, bevelling, bending to suit the contours wherever required, fit ups, butt welding of 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.

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

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.

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.

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.

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

Fabrication and 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.

Anticorrosive layer applicaton: Carryout repair job on the top layer of the damaged portions in the external asphalt pad as indicated by inspection & as per CPCL civil maintenance instruction. To faciliate rain water draining chip off the existing concrete ring wall foundation and provide proper taper on the ring wall Providing and laying 50mm thick compacted thickness, anticorrosive layer around the tank The job also includes removal of the damaged layer as marked by inspection. and transport to the place as identified by EIC

Providing and laying 50mm thick compacted thickness, anticorrosive layer around the tank

TANK BOTTOM PLATE REPLACEMENT AS PER SCOPE OF WORK

"Cutting and dismantling of existing bottom plate and transporting to designated scrapyard, Preparing of fabrication drawing, fabrication, erection, welding and testing as per the direction of Inspection. For payment, theoritical weight given in the fabrication drawing will be considered. Contractor shall also provide sufficient hydraulic jack for lifting of the tank to facilitate botttom plate replacement job "

TANK ANULAR PLATE REPLACEMENT

"Cutting and dismantling of existing bottom plate and transporting to designated scrapyard, Preparing of fabrication drawing, fabrication, erection, welding and testing as per the direction of Inspection. For payment, theoritical weight given in the fabrication drawing will be considered. "

TANK SHELL PLATE REPLACEMENT AS PER SCOPE OF WORK

"Cutting and dismantling of shell plate as marked by inspection andtransporting to designated scrapyard. Payment will be based on thetheoritical weight of the area dismantled."

Fabrication, rolling, erection, welding and testing as per inspectionrequirement. Payment will be based on the theoritical weight of thearitical weight of the area erected

TANK ROOF PLATE REPLACEMENT AS PER SCOPE OF WORK

"Cutting and removal of exiting roof plate and transporting it toscrapyard, preparing fabrication drawing, fabrication, erection andtesting as per inspection direction. Conducting pneumatic test at 50 mmof water colum is also part of roof plate replacement.Payment will bebased on theoritical weight based on fabrication drawing."

Earthing point replacement as per Inspection

Removal of sludge

Removing the sludge, muck etc if any from inside the tank manually or through mechanical means and stacking the same outside in the pits made inside the syke area for tank cleaning and disposal of same to the place identified by EIC/ sludge pit or in disposal ground any where with in the CPCL permises all all lift complete including all loading and unloading transportation and removing any oil spillage during trasnporation and by spreding sand scrapping the area all as directed with all labour, tools and tackles transport etc as directed by EIC

Manual Cleaning with wire brush of shell / bottom plates after hydrotesting

VACCUM BOX TESTING: The job includes supply of vacumm box facility including vacuum pump, etc., testing the tank roof & bottom plate weld seams & HAZ areas using vacuum box / soap solution at all grades & elevations. The job also includes supplying of all types of tools & tackles, machineries, all consumables, labour & supervision to complete the job in all respects including transportation of all the required materials to the work site.

Vacuum box testing of welds / HAZ

NOTE: (1) For surface preparation of weld seams / HAZ by buffing, rates are additionally paid as per SOR 2) Job includes supply of necessar vacuum box testing kit with sufficient qty of glass

DIESEL CHALK TESTING: The job also includes supplying of all types of tools & tackles, machineries, all consumables, labour & supervision to complete the job in all respects including transportation of all the required materials to the work site.

Diesel chalk test of weld seams including buffing

PNEUMATIC TESTING OF NOZZLE PADS:Clean the shell nozzles & pad welds and carry out pneumatic testing as per the scope The job also includes supplying of all types of tools & tackles, machineries, all consumables, labour & supervision to complete the job in all respects including transportation of all the required materials to the work site.

Pneumatic testing of nozzle pads

PNEUMATIC TESTING OF Tank ROOF WELD SEAMS: Carry out the pneumatic testing of all roof weld seams at 50mm of water column. The job also includes supplying of all types of tools & tackles, machineries, all consumables, labour & supervision to complete the job in all respects including transportation of all the required materials to the work site. Offer the pneumatic test to CPCL inspection and get final clearance

PNEUMATIC TEST OF TANK BOTTOM / ROOF

Supply and application of paint CPCL System-X: The Contractor shall carryout external painting of the Column, Condensate pot and drums and other static equipments external surface by applying Painting system ( refer attachment for spec details) After cleaning the surfaces as per EIC / Inspection requirement.

Hand tool cleaning to the requirement of St-2 / SSPC-SP-2 for painting jobs

Supply and application of painting as per CPCL Painting system-X

Concrete dismantling (PLAIN and REINFORCED): Demolishing plain cement concrete in foundation and super structure including disposal of unserviceable material upto 3KM lead as directed and serviceable materials to stores including scaffolding, all labour, tools supervision, safety permits, safety precaution etc. complete 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.

Dismantling Plain cement concrete (PCC): The job involves dismantling of reinforced cement concrete pavements including cutting of reinforcement bars, returning of scrap steels to designated area, breaking the RCC work into pieces and disposal of unserviceable material upto 3.0km lead as directed , etc. as per the direction of the Engineer-in-charge.

Dismantling Reinforced cement concrete (RCC)

Earth work excavation & back filling: The job involves earth work excavation below ground level upto 2 metres depth & to a required width for laying underground piping in all types of soils including removal of vegetation, if required, dressing of sides, levelling, grading, ramming of bottom, back filling on completion of laying of pipes with available excavated soil, watering, rolling, ramming of by manual methods / mechanical compactors, dressing, trimming, etc. 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.

Earth work excavation & back filling - Upto 2 metres depth

Carbon Steel Piping Work - Above ground / Under 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 and draining / drying of the piping system. WITH CPCL SUPPLY OF FREE POWER & CONTRACTOR'S WELDING MACHINE

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 - UPTO 5 METRES FROM 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 (Root E-6010 / Filling E-6013 / E-7018)

Carbon Steel - Above ground Piping - Butt welding Joint - Upto 8.8 mm thickness - Without hydrotest (Root E-6010 / Filling E-6013 / E-7018)

Carbon Steel - Above ground Piping - Butt welding Joint - Above 8.8 mm and upto 12.7 mm thickness - With hydrotest (Root E-6010 / Filling E-6013 / E-7018)

Carbon Steel - Above ground Piping - Butt welding Joint - Above 8.8 mm and upto 12.7 mm thickness - Without hydrotest (Root E-6010 / Filling E-6013 / E-7018)

Hiring of Equipments

"Provide 25 Tonnes capacity New Generation Crane on hire basis for tank maintenance jobs with operator. Necessary Diesel for running crane is in contractor scope. Unit Ea = 12 hrs shift "

"Provide Tractor Trailer 20 feet , 10 Ton on hire basis along with operator for material shifting ,etc. Necessary Diesel is in contractor scope Unit Ea = 12 hrs shift "