Chennai Petroleum Corporation Limited Tender

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 80 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

NOTE: (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). For Fuel Gas lines root TIG welding & E 7018 for filler welding. 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 req uired 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

29-C-009, Refinery-I Flare Water Seal Drum internals repair / replacement jobs (SS & CS) Anticipated Replacement of damaged / corroded vessel internals such as SS perforated cone, support channels & brackets, SS stiffeners & 3" overflow / bottom outlet pipe etc., as per Reference Drawing No.FSH0228-DR-29C-09 Rev 1 (4 sheets). The job includes transporation of all free issue materials from owner's storage point to work site, handling at site, cutting, bevelling, fabrication, erection,welding and testing of SS internals of the vessel as per the Site requirement and instruction of Engineer-in-charge. 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 for CS, E 308 electrodes for SS to SS welding and E 309 for SS to CS welding, DPT wherever required, testing as per codes, specificatio & drawings 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, erection and dismantling of scaffolding inside the vessel The rates shall be inclusive of area preparation for hot work, fabrication, erection and welding and testing of SS internals of the vessel as per the Site requirement and instruction of Engineer-in-charge.

Overflow pipe welding jobs (CS)

Overflow pipe dismantling jobs (CS)

Inside SS Fillet welding jobs

Inside SS Butt welding jobs

SS Plate cutting jobs

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.

Removal of valves - Size 2 ID. to 3 ID.

Removal of valves - Size 4 ID. to 6 ID

Removal of valves - Size 8 ID. to 10 ID

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 ID. to 3 ID.

Installation of valves - Size 4 ID to 6 ID.

Installation of valves - Size 8 ID. to 10 ID

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

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 10 mm thickness using E 6013 electrodes

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.

29-C-08 Refinery-I / LEB Flare KOD (Dia. 3600 x Length 12707mm) 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 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.

29-C-011A Refinery-I / LEB Flare Acid Gas KOD (Dia. 1800mm x Length 4000mm)

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 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. New insulation provision, if required, will be done by CPCL

29-C-009 Refinery-I / LEF Flare Water Seal Drum (Dia. 3900mm x Height. 10100mm) 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 5.25 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.

29X-006, 30" x 3655mm height, Approximate Weight: 2100 Kgs. Flare Tip at the elevation of around 80M - 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 (29C-08/09/11A), 29X-05 (Flare Stack, height approximate 72M) / 29X-06 (Flare Tip) 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 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, (29C-05/06/11A), 29X-05, Flare Stack) and Structurals 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

Carbon Steel Flare header Piping Work - Above ground Replacement of portion of 32” Refinery-I flare header at different locations (Main header) For this replacement work, Supply of power is under contractor's scope. The contractor shall mobilize required number of power generators and welding machines with fuel, consumable and operator etc., The job includes transportation 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 sleepers, existing flare trestles, pipe racks, 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 radiography, stress relieving, erection & dismantling of scaffolding and paninting works, which can be claimed as per respective SOR. The rates for the following items shall be exclusive of pad plate welding, removal of old piping for replacement, Radiography and removal & re-fixing of flanged valves. The rates shall be inclusive of area preparation for hot work, blinding and deblinding, new line fabrication, laying, erection, welding, flushing of piping system, offering stagewise inspection The rates for the following items shall be inclusive of pipeline fabrication, laying, erection, welding, providing shoe supports at support locations, flushing of the piping system, offering stage wise inspection, flushing of piping before pneumatic testing, pneumatic testing of piping systems and draining / drying of the piping system. Replacement of portion of CS 32” flare header at different locations (Main header). 32" dia. minimum 200M, 20" dia.minimum 30M and 16" dia. minimum 6M (Location: from Refinery-I unit flare gas KOD (29C-03) upto hexane B/L) Pipe Material : API 5L, Gr.B PSL 1, including blinding & deblinding jobs, and pneumatic testing of replaced portion at 5.0 Ksc. Old line shall be cold cut using hydraulic / pneumatic cold cutting machine only during dismantling of piping.

BUTT WELDING PIPING AT ALL ELEVATIONS UPTO 15 METRES FROM GROUND LEVEL - USING ELECTRODES E6010 (for root pass) & E7018 (for filler pass)

Carbon Steel - Above ground Piping - Butt welding Joint – Up to 12 mm thickness - (Root E-6010 / Filling E-7018)

Reinforcement pad Fabrication, welding including pneumatic testing of pad plates at all elevations upto 15 Meters from ground level. RF pad pneumatic test pressure : 1.05 KSC.

Pad plate welding for 32" pipe

Pad plate welding for 20" pipe

Pad plate welding for 16" pipe

NOTES (1) Thickness of piping for measurement shall be based on the relevant ANSI or equivalent standards (2) The rates for socket & fillet welding in piping shall remain same for all thickness and elevations as per SOR. (3) Rate for weld joints of vents & drains shall be paid on actual measurement using the applicable SOR (4) For radiography of weld joints, rates shall be as per the SOR. (5) In case of replacement of existing piping, rates for removal of old pipelines shall be paid separately as per applicable SOR and there is no separate payment for welded valves.