Chennai Petroleum Corporation Limited Tender

Carryout Maintenance jobs in 1F-01A Furnace

Carryout Maintenance jobs in 1F-01B Furnace

Carryout Maintenance jobs in 1F-2 Furnace

Carryout Maintenance jobs in 1F-3 Furnace

AIR PRE HEATERS (APH)

Carryout Maintenance jobs in 1-APH-001

Carryout Maintenance jobs in 1E-201

Carryout Maintenance jobs in 1E-202

Part-B Lumpsum job (Equipment Hiring)

Part-B Lumpsum job (Equipment Hiring) The contractor shall mobilise the following equipments for completion of the entrire job in all respects. The contractor shall de mobilise the equipment on completion of the job with approval from EIC. If there is any extension of days the contractor shall obtain prior approval from EIC for retaining the equipements. For the extended days the rate will be paid on pro rata basis.Entry and exist Gate passes for all the below mentioned equipments to be enclosed along with bill for processing.

Provide 300 Ton capcity Crane with operator on hire basis for carrying out replacement of 1F-01A Stacks top 2 meter for a period of 10 days( 24 hrs / Day) Necessary Diesel is in Contractor scope.

Provide 80 Ton capacity Crane with operator on hire basis for Furnace maintenance jobs for a period of 20 days (24 hrs / Day) Necessary Diesel is in Contractor scope.

Provide One Crane (hydra-12 Ton) on hire basis (24Hrs/Day for 45 days ).Diesel is in Contractor scope.

Provide Mobile air compressor 400CFM capacity on hire basis for 10 days period ( 24hrs/Day) for Furnace Decoking jobs. Diesel is in Contractor scope.

Provide Tractor Trailer for material shifting,etc. (24Hrs/Day for 45 Days period ) 10 Ton , 20 Feet length.Diesel is in Contractor scope.

Unit Rate jobs

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. 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 in lumpsum.

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.

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. (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. (8) For blinding & deblinding wherever involved, rates shall be paid separately as per SOR. (9) For stress relieving of weld joints, rates shall be paid separately as per SOR. (10) In case of replacement of existing piping, rates for removal of old pipelines shall be paid separately as per SOR. (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. (13) For removal and refixing of Flanged valves, rates shall be paid separately as per SOR. (14) Wrapping & coating of pipelines is not included in SOR.

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

Patch plate welding - Carbon steel for APH Ducts ( 1-APH-001,1E-201 &1E-202)

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 thickness using E 6013 electrodes

Cutting of Stainless steel Plates - Plasma Cutting 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 Above 2 mm & upto 4 mm

Cutting of Plate-Stainless steel-Thickness Above4 mm & upto 6 mm

OPENING & BOXING OF CONVECTION PANELS ( for 1F-01A) The job involves opening of furnace covection panels by de-bolting (cold / gas cutting if required), cleaning, and finally boxing up with proper gasket, packing, servicing of bolts & nuts, replacing defective bolts / 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, 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 area as per EIC instructions.

Opening and boxing up

Opening and boxing up of Convection panels

FILLET WELDING

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 - Upto 4mm thickness using electrodes of grades - E - 308, 308H, 308L, 347

Fillet welding - Stainless steel - 5 mm to 6 mm thickness using electrodes of grades - E - 308, 308H, 308L, 347

REPLACEMENT OF FURNACE TUBES / RETURN BENDS Job involves removal of old tubes / returnbends / elbows as marked by Inspection, transportation of the required quantity of tubes / return bends / elbows from owners storage point, cutting, grinding, edge preparation of tubes / fittings to match with the mating edges, erection of tubes / fittings in position, preheating (using coil), welding, radiography, Stress relieving, DPT, etc., as per codes / specifications / Inspection procedures. (For cutting of SS tubes, if necessary, plasma cutting machine shall be arranged by the contractor as per the instructions of the EIC). 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., on the tubes / fittings prior to furnace hydrotesting. For alloy steel tubes / return bends / elbows welding, the rates shall be inclusive of 100% Stress relieving of weld joints and exclusive of radiography (BSR & ASR) NOTE: (1) Nominal bore of the tube shall be used for measurement purposes. (2) For radiography of weld joints, rates shall be as per SOR. (3) All scaffolding rearrangement to carryout the job is included in the schedule of rates and no extra payment shall be paid.

Replacement of Furnace tubes / return bends - Alloy steel

Alloy steel (Upto P5 grades) - Tubes / Return bends / Elbows

Alloy steel ( P9 grades) - Tubes / Return bends / Elbows

SHELL CASING WELDING JOBS

Casing plate replacement / Insert plate on Shell casing / duct - Carbon steel Job involves cutting & removal of old casing plate / duct as marked by Inspection, cutting the new plate to the required size, edge preparation, bending it to the desired curvature, providing stiffeners / supports, fitting the insert plate in position, welding on all four sides, DP testing if required. 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 materials from owner's storage point / unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions. Refer the detailed scope of work given in the furnace scope of work. Notes: (i) CPCL will provide necessary CS Plates and structural materials. (ii) contracto shall transport the material from CPCL ware house / ETP yard to site. (iv) Rates of Bending/ Rolling of plate for suit at Cylindrical furnace is included in SOR.

Carbon steel Casing plate replacement in 1F-01A Furnace - Radiant section by Fillet welding

Carbon steel Casing Plate replacement in 1F-01B Furnace Radiant section top shell coarse by Fillet welding

Carbon steel Arch Roof Plate Replacement in 1F-01B, 1F-02 & 1F-03 furnaces by Fillet welding

Carbon steel Floor Plate Replacement in 1F-2 furnaces by Fillet welding

Carbon steel insert plate welding in 1F-03 furnaces

Replacement of 1F-01A Stack top 2 meter portion as per drawing no : 01-B-41087

Fabrication of 1F-01A Stack top 2 meter portion as per drawing no : 01-B-41087

SKIN POINT THERMOCOUPLE

Replacement / providing Skin point The job involves replacement / providing new skin point thermocouples including pad fabrication, surface preparation fit up, welding & DP testing. 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 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 area as per EIC instructions. NOTE: (1) Actual weld length shall be taken for measurement.

Providing new skin point thermocouples including pad fabrication, surface preparation, fit up, welding

TUBE HANGERS / TUBE SUPPORTS / TUBE GUIDES

Replacement of Tube hangers and Tube supports in 1F-01A,1B,1F-02 & 1F-03 Job involves debolting / cutting and removal of existing wall / roof tube hangers / locking bars and fix back the repaired / new hangers in position as per the TS-Inspection / EIC. Minor repair of parts / alignment and replacement of locking pin and removal of refractory to facilitate removal / replacement of tube guide / locking bar shall be treated as part of the job. 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 materials from owner's storage point / unused materials to owner's storage point and dumping the generated scrap material to designated area as per EIC instructions. NOTE:(1) The rate is inclusive of tag wleding of bolts for fixing and grinding of tag welds for removal. (2) The rate is Exclusive of full wleding of supports to the casing . Rate for full welding shall be paid additionally.

Tube hanger / Tube support - Replacement

HTube guide / tube pad welding (up to 12 mm thk.):/ Job involves removal of old bottom return bend tube guides / pads, if required, as marked by Inspection, transportation of all materials from owners storage point, cutting, grinding, edge preparation of tube guides / fittings like half coupling, etc., to match with the mating edges, erection of tube guides in position, welding, DPT, etc., as per codes / specifications / Inspection procedures. Job involves grinding the cracks as marked by Inspection, welding, DPT, 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.

Radiant tube bottom return bend guide (Spigot) welding (Using SS-308 / 309 / 316 / 316L / 309 Mo / 347 ElectrodeS)

Radiant tube bottom return bend guide (Spigot) weld cracks - grinding and reweld (Using SS-308 / 309 / 316 / 316L / 309 Mo / 347 ElectrodeS)

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

RADIOGRAPHY (conventional method) 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 - Upto 2" nominal dia (One Unit EA = One Joint)

Pipe weld joints - 3" nominal dia (One Unit EA = One Joint)

Pipe weld joints - 4" nominal dia (One Unit EA = One Joint)

Pipe weld joints - 6" nominal dia (One Unit EA = One Joint)

Weld joint size - above 6" nominal dia and weld seams of storage tanks, pressure vessels and plate welds (Unit: Inch length of Film)

Close Proximity Radiography The contractor shall carryout Close Proximity Radiography jobs at the location as instructed by the EIC in Plants- 1 & 2 during Refienry-1 M &I Shutdown-2019.

Radiography Se-75 CPR with equivalent shielding and accessories.(One Unit EA = 24 hours per day)

Upto 2inch Dia. Elliptical shot. (One Unit EA = Per Exposure)

4inch Film Width (One Unit EA = Per inch length of film)