Chennai Petroleum Corporation Limited Tender

General jobs

ERECTION & DISMANTLING OF STEEL SCAFFOLDING - External (Base reference from ground level): 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, steel scaffolding materials ,clamps, steel gratings, all consumables and labour to complete the job in all respects. Scaffolding shall be adequately safe for welding and inspection activities.

Erection & dismantling - Upto 10 mtr height of scaffolding (External).

Erection & dismantling - Above 10 mtrs and upto 20 mts height of scaffolding (External).

Erection & dismantling - Above 20 mtrs and upto 104 mts height of scaffolding (External).

ERECTION & DISMANTLING OF STEEL SCAFFOLDING - Internal (Base reference upto 5 Mtr elevation from ground level - inside the vessels)

Erection & dismantling - Upto 10 mtr height of scaffolding (Internal) - inside the vessels

(1) For measurement, the scaffolding height shall be measured from the erected base level upto the top plank reference or the top horizontal poles. (2) Supply of all scaffolding materials are under contractor's scope.

Carbon Steel Piping Work - Flare Stack / Flare Area Piping Jobs Replacement of flare stack / flare area piping including all utility , process pipelines from bottom of flare stack upto flare tip as per CPCL inspection requirement. 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 and below the ground levels as per the requirement, overhead, flare stack, over sleepers, piperacks, crossovers, pipe sleeves, trenches, stand posts, connecting with equipments & nozzles, providing tappings from the existing pipelines at all grades & elevations 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 as 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, equipment like suitable crane, tractor trailer, winches for lifting, 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. Scraps shall be disposed after segragation and sizing as required by Scrap Yard personnel The job also include erection and dismantling of scaffolding wherever required. Supply of required scaffolding materials is under contractor's scope. The rates for the following items shall be exclusive of blinding & deblinding, radiography, stress relieving, reinforcement pad welding, removal of old piping for replacement, erection & dismantling of scaffolding. The rates shall be inclusive of area preparation for hot work, new line fabrication, laying, erection, welding, providing shoe supports, pads at support locations, flushing of piping system, offering stagewise inspection , hydrotesting and draining / drying of the piping system after hydrotesting. Note: If hydrotesting is not done / not required for the piping service, 10% of the SOR will be deducted.

SOCKET WELDING - (All thickness and All Elevation)

Carbon Steel Piping - Socket / Fillet welding Joints

BUTT WELDING CS - (All thickness and All Elevation)

Carbon Steel Piping - Butt welding Joints for all piping works Note : (A) Electrode E 6010 (for root pass) / E 7018 (for filler pass). Radiography : 100% for Fuel gas / 20% for MP steam / 10% for other lines. Hydrotest : 22.0 Ksc for MP steam and 15.0 Ksc for other lines. Offer for stagewise Inspection. Pipe line Insulation jobs will be done by CPCL. Note: (B) If hydrotesting is not done / not required for the piping service, 10% of the SOR will be deducted.

BUTT WELDING CS (TIG welding) using ER 70S2 filler wire / E-7018 Electrode - (All thickness and All Elevation)

Carbon Steel Piping - Butt welding Joints (TIG) for all piping works Note: If hydrotesting is not done / not required for the piping service, 10% of the SOR will be deducted.

BUTT WELDING SS (TIG welding) using ER-316L / E-316L-15/16 (All thickness and All Elevation)

Stainless Steel Piping - Butt welding (TIG) Joints for all piping works Note: If hydrotesting is not done / not required for the piping service, 10% of the SOR will be deducted.

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, all types of instruments, supports by cold 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. Removal insulation from the pipes before dismantling is under contractor's scope without any additional cost. Removed Valves shall be shifted to designated locations as per EIC without any additional cost. Segragation / sizing of scraps for scrap dispoal shall be under contractor's scope. While dismantling of piping, the cutting of Flare header / any hydro carbon piping shall be using cold cutting machines only - pneumatic / hydraulic operated cold cutting machine shall only be deployed. In case of power operated cold cutting machine, the electrical motor of the cutting machine shall be flame proof machines and the same shall be approved by CPCL. The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, machineries, cranes, tractor and trailer all consumables and labour to complete the job in all respects.

Dismantling & removal of Piping - Carbon steel / Alloy steel teel (by hot or cold cutting as per site requirement / as per instruction of EIC) NOTE: (1) For erection and dismantling of scaffolding wherever required, rates shall be paid separately as per available SOR (2) Cold cutting of old piping shall only be permitted due to safety reasons. (3) The job includes hot cutting after first cold cuts of the old piping as per the insturction of EIC / cold cutting of carbon steel pipes, etc., at all heights & grades using power hacksaw / gas cutting etc., (4) The job also includes supplying of all types of tools & tackles, all consumables and labour to complete the job in all respects and dumping the generated scrap material to designated area as per EIC instructions. (5) The job includes cold cutting of carbon steel pipes, etc., at all heights & grades using power hacksaw / grinding / cold cutting machines etc., (6) The job also includes supplying of all types of tools & tackles, all consumables and labour to complete the job in all respects and dumping the generated scrap material to designated area as per EIC instructions.

Dismantling & Removal of Structurals / Gratings (All Elevation) 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, segragation / sizing of scraps as per the instruction of EIC, 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 specified place within the refinery premises. 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 NOTE: (1) Weighment procedure stipulated by CPCL is required to be followed for shifting the removed materials to scrap yard.

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.

Fabrication and erection of structurals upto 15m elevation

Fabrication and erection of structurals above 15m elevation NOTE: (1) For erection and dismantling of scaffolding wherever required, rates shall be paid separately as per available SOR

Erection and welding of gratings for platforms, Staircase & 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 grating materials from owners' 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 upto 15m elevation

Erection and welding of Gratings above 15m elevation

BLINDING AND DE-BLINDING (Only for flare area piping jobs) 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 / grinding if required), wedge opening, cleaning of flanges, insertions / removal of blind, 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 (All ratings)

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

Blinding & Deblinding - Size 2 inch dia. to 4 inch dia.

Blinding & Deblinding - Size 6 inch dia. to 10 inch dia. NOTE: (1) Nominal diameter of the pipes 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

REMOVAL / INSTALLATION / REFIXING OF FLANGED VALVES

Removal of Flanged valves The job includes removal of flanged valves at all grades & elevations by de-bolting / cold cutting / gas cutting / grinding 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 (All ratings)

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. NOTE: 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.

Installation of Flanged valves Valve (All ratings)

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.

PLATE WELDING

Fillet welding - Carbon Steel for RF pads (All elevation) 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 and inspection as per requirement.

Fillet welding - Carbon Steel - Upto 8 mm thickness using E 6013 electrodes Unit "M" represents "Running Meter"

Patch plate welding - Carbon steel 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 12 mm thickness using E 6013 electrodes Unit "M" represents "Running Meter"

Radiography 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.

Pipe weld joints NOTE: (1) Retaking radiography due to poor density or lack of clarity or poor developing or any other fault on account of contractor shall be borne by the contactor at his own cost (2) For pipe weld joints, nominal diameter of the pipe shall be taken for measurement

Stress Relieving The job involves Post weld heat treatment (PWHT) / Stress relieving of carbon steel / alloy steel metal surfaces, weld seams or HAZ, etc., shop fabricated or site fabricated or existing piping / static equipment at all grades & elevation. The job also includes cleaning the adjoining surfaces, welding of required thermocouples, insulating the portion using super fine glass wool / asbestos tape, heating the metal surface using a induction heating equipment as per the requirement, ensuring uniform temperature attainment at all points, recording the temperatures by means of thermocouples / pyrometer / automatic temperature recorders suitably calibrated, removal of insulation, providing assitance for hardness testing, submitting recorded charts for approval, removal & dressing of thermocouple leads, etc., as per the instructions of EIC. 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.

Stress Relieving - Pipe weld joints NOTE: (1) For pipe weld joints, nominal diameter of the pipe shall be taken for measurement.. (2) Re-stress relieving arised due to improper heating / cooling or any other fault on account of contractor shall be borne by the contractor at his own cost.

229-C-01 Main Flare KOD (Dia. 4500mm x Length 15830mm)

Blinding, opening the manways/nozzleways & providing eductors. Providing internal and external scaffolding, thorough cleaning of inside as per CPCL Inspection requirement, assisting for internal inspection & thickness gauging,cleaning of all gasket seating areas, shell external patch work, boxing up the vessel, offering hydrotest at 4.6 Kg/Sq cms, deblinding and all related jobs as per enclosed work package. Note: The rate is exclusive of painting, patch welding and scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package.

229-C-02 Sour Flare KOD (Dia. 1800mm x Length 4900mm)

Blinding, opening the manways/nozzleways & providing eductors. Removal of external insulation as per CPCL Inspection. Providing internal and external scaffolding, thorough cleaning of inside as per CPCL Inspection requirement, assisting for internal inspection & thickness gauging ,cleaning of all gasket seating areas, shell external patch work, internal repair works as per Inspection, boxing up the vessel, offering hydrotest at 4.6 Kg/Sq cms, deblinding and all related jobs as per enclosed work package. Note: The rate is exclusive of painting, patch welding and scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package. Reinsulation will be done by CPCL

229-C-03 Water seal drum (Dia. 4000mm x Height 8500mm)

Blinding, opening the manways/nozzleways & providing eductors. Providing internal and external scaffolding, thorough cleaning of inside as per CPCL Inspection requirement, assisting for internal inspection & thickness gauging,cleaning of all gasket seating areas, shell external patch work, internal repair works as per Inspection, boxing up the vessel, offering hydrotest at 5.4 Kg/Sq cms, deblinding and all related jobs as per enclosed work package. Note: The rate is exclusive of painting, patch welding and scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package.

229-C-04 Fuel Gas KOD (Dia. 900mm x Height 2800mm)

Blinding, opening the manways/nozzleways & providing eductors. Thorough cleaning of inside as per CPCL Inspection requirement, assisting for internal inspection & thickness gauging,cleaning of all gasket seating areas, shell external patch work, internal repair works as per Inspection, boxing up the vessel, hydrotesting of steam coil at 9.1 Kg per Sq.Cm and then vessel with 9.1 Kg per Sq.Cm, deblinding and all related jobs as per enclosed work package. Note: The rate is exclusive of painting, patch welding, internal piping modifcation jobs and scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package.

229C-05 Closed Blow Down Drum (Dia. 2000mm x Length 5900mm)

Blinding, opening the manways/nozzleways & providing eductors. Providing internal and external scaffolding, thorough cleaning of inside as per CPCL Inspection requirement, assisting for internal inspection & thickness gauging,cleaning of all gasket seating areas, shell external patch work, internal repair works as per Inspection, boxing up the vessel, offering hydrotest at 4.6 Kg/Sq cms, deblinding and all related jobs as per enclosed work package. Note:The rate is exclusive of painting, patch welding and scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package.

229-X-01 Refinery-III Flare Stack (Stack Pipe Height: 73M Approx) : Partial Replacement of Standpipe (Ref.Drg.No - 4648\90\62\43\0722 Rev.2, of EIL) using suitable capacity cranes

"Blinding, thorough cleaning of flare stack stand pipe and made hydrocarbon free, Cold cutting using hydraulic / pneumatic cold cutting machine, dismantle the old stand pipe and partially replace the flare stack pipe of 52"" dia. stack pipe below the molecular seal drum for about 30.0 metres height by using 52"" pipe as per the following specification Pipe, 52"" NB Material: API 5L Gr.B (SAW) or A 672 EFSW Thickness: 14.3 mm Use E 6010 / E 7018 electrodes for welding. Offer for fit up, verticality using plumb and root DPT. Radiography: 100%"

229X-02 Molecular Seal (HC) (Dia. 2430mm x Height 6750mm)

Blinding, opening the manways/nozzleways & providing eductors. Providing internal and external scaffolding, thorough cleaning of inside as per CPCL Inspection requirement, assisting for internal inspection & thickness gauging,cleaning of all gasket seating areas, shell patch work, internal repair works as per Inspection, boxing up the vessel, (if required) offering hydrotest at 5.25 Kg/Sq cms, deblinding and all related jobs as per enclosed work package. Note:The rate is exclusive of painting, patch welding and scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package.

229X-03, 44" Hydro Carbon Flare Tip Replacement - Using suitable capacity crane

The existing flare tip shall be dismantled and replaced with new flare tip assembly as directed by EIC. The old flare tip assembly to be carefully dismantled and handed over to EIC. The contractor shall make necessary arrangements for dismantling and erection of new tip which includes supply of all labour, necessary tools and tackles, crane etc., providing transporting arranagement and shifting of the new flare tip from CPCL ware house and erection of new flare tip, shifting the old flare tip assembly to the designated place as directed by EIC. The rate includes steam purge / dechoking of all pilot fuel gas lines and utility lines to the flare tip as per inspection. Power will be provided by CPCL at free of cost. All the jobs at higher elevations shall only be done with fall arrestors. Supply of required no. of fall arrestors under contractor's scope. Note: The rate is exclusive of scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package.

229X-06, 24" Sour Flare Tip Replacement - Using suitable capacity crane

The existing flare tip shall be dismantled and replaced with new flare tip assembly as directed by EIC. The old flare tip assembly to be carefully dismantled and handed over to EIC. The contractor shall make necessary arrangements for dismantling and erection of new tip which includes supply of all labour, necessary tools and tackles, crane etc., providing transporting arranagement and shifting of the new flare tip from CPCL ware house and erection of new flare tip, shifting the old flare tip assembly to the designated place as directed by EIC. The rate includes steam purge / dechoking of all pilot fuel gas lines and utility lines to the flare tip as per inspection. Power will be provided by CPCL at free of cost. All the jobs at higher elevations shall only be done with fall arrestors. Supply of required no. of fall arrestors under contractor's scope. Note: The rate is exclusive of scaffolding which will be paid seperately. The rate includes all blinding and deblinding works. The rate is inclusive of all other works as detailed in the work package.

PAINTING WORKS

Surface preparation works for Flare Equipments (229C-01/02/03/04/05, 229X-01 (Flare Stack) / 229X-02 and Structurals

By Hand tool cleaning to SSPC-SP-2 / St 2

CPCL Painting System-I (Application : brush / conventional spray)

Two Coats of Heat Resistant Aluminium Paint (to withstand upto 250 deg C), Min DFT 20 microns / coat

CPCL Painting System II (Application brush / conventional spray) (for painting of molecular seal 229X-02 and other locations as per Inspection)

Two coats of Heat resistant Aluminium paint ( to withstand upto 400 deg C) , Min DFT 20 microns /coat

CPCL Painting System-X for Flare Equipment, (229C-01/02/03/04/05, 229X-01(Flare Stack ), 229X02 (moleucular seal) 229-X-04/06/07 (Flare tips) structural, derrick structurals and all flare equipment structural, platforms, ladders and all connected uninsulated pipelines upto the length instructed by Engineer-in.charge (Application brush / conventional spray). The complete painting of the Flare Stack Structruals, Flare tip area, and Molecular Seal pot shall be done within the shutdown period using the latest, very safe and proven Rope Access System with the approval of CPCL Fire and Safety Department and Operations.

Provision of Rope Access System for Painting Works

Primer : One Coat of Self Priming Epoxy Paint, Min DFT 100 microns / coat

Inter : One coat of Polyamide cured HB Epoxy MIO Paint, Min. DFT of 75 microns / coat

Finish : Two Coats of Acrylic Polyeurethene Finish Paint, Min. DFT of 35 microns / coat

Stainless Steel to Inconel Welding - Socket / Butt welding (using suitable electrodes) Joints for all Flare equipments (All thichness, All elevation) (Unit "M" represents "Running Meter") 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 and below the ground levels as per the requirement, overhead, flare stack at all grades & elevations The job includes all modification and replacement jobs involving pipes, plates & 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 job includes preparing work area for executing hot work, cutting & bending to suit the contours wherever required, socket, fillet, butt welding using suitable electrodes as required, DPT wherever required, as per codes, specification, drawings. The job also includes supplying of all types of tools & tackles, machineries, equipment, 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. Scraps shall be disposed after segragation and sizing as required by Scrap Yard personnel. The job also include erection and dismantling of scaffolding wherever required. Supply of required scaffolding materials is under contractor's scope. The rates for the following items shall be exclusive of blinding & deblinding, radiography, stress relieving, erection & dismantling of scaffolding. The rates shall be inclusive of area preparation for hot work, Cutting of plate materials into required sizes, fabrication, laying, erection, welding, offering stagewise inspection.