Mechanical Maintenance Work And Statutory Internal Inspection Assistance Jobs In Mounded Bullets At Cpcl , Manali Refinery, CPCL, Manali - Chennai.-Tamil Nadu

Mechanical Maintenance Work And Statutory Internal Inspection Assistance Jobs In Mounded Bullets At Cpcl , Manali Refinery , Rate Cont@Mounded Bulet-Mech Maint/Inspn: , Rate Contract For Mechanical Maintenance Work & Statutory Internal Inspection Assistance Jobs In Mounded Bullets At Cpcl - Manali Refinery , Chennai - 600068 , Scaffolding Erection At Bullet Inside Area: , Transportation Of All Required Scaffolding Materials ( Contractors Own Material ) From Contractors Storage Point To Work Site , Erection Of Scaffolding With Steel Jolly Platform At Bullet Inside Area To Carryout All Ndt Tests That Needs To Be Carried Out For The Completion Of Bullet Inside Statutory Inspection Requirement , Dismantling Of Scaffolding Materials After Completion Of All Jobs And Transportation Of The Same To Contractors Storage Point Including All Labour , Tools & Tackles , Necessary Equipments , Consumables Etc . To Complete The Job As Per Instructions Of Eic . , For Lpg Bullet , For Propylene Bullet , For Propane Bullet , For Butylene Bullet , Degassing Of Bullet: , Degassing Of Bullets With Cpcl Supplied Water After Making Necessary Connections For In And Out Flow With Suitable Pipelines / Hose Arrangements As Directed On Site . The Water Used For Degassing Should Be Disposed Off Safely In The Drainage And The Sludge If Any Coming Along With Water Should Be Carefully Removed And Disposed / Kept In Safe Place As Directed At Site . The Sludge Should Be Buried If Necessary As Per Directions Of Engineer-In-Charge Or His Representative . A Sample Of All Sludge Collected Should Be Handed Over To The Engineer-In-Charge . Deboxing / Boxing , Dismantling / Pitting Back All Gadgets On Bullet , Also All Jobs Related To Blind Flanging Up To First Block/Isolation Valve . , For Lpg Bullet , For Propylene Bullet , For Propane Bullet , For Butylene Bullet , Ndt Test Arrangements ( Buffing ) At Bullet Inside Area: , Thoroughly Prepare All The Weld Seam Surfaces By Buffing To Carryout 100% Wet Flourescent Magnetic Particle Testing As Per Astm E-709 ( Buffed Area Shall Be Made Available For 6 Inches Width On Either Side Of The Weld Seam Including The Weld ) , Offer Dye Penetrant Inspection ( As Per Astm E-165/Is-3658 ) Of Weld Joints , Hardness Testing ( Astm E-110 ) Of Weld Joints And Radiographic Examination Of Bullet Weld Joints , Haz And Any Left Out Cleat Weld Areas Wherever Necessary As Per Inspection And Offer For Inspection For Ndt Tests Including All Labour , Tools & Tackles , Necessary Equipments , Consumables Etc . To Complete The Job As Per Instructions Of Eic . Ndt Tests Will Be Carried Out By Cpcl . , Scaffolding Erection At Bullet Outside For Piping: , Transportation Of All Required Scaffolding Materials ( Contractors Own Material ) From Contractors Storage Point Work To Site , Erection Of Scaffolding With Steel Jolly Platform At Bullet Outside Area For Piping To Carryout All Ndt Tests / Painting That Needs To Be Carried Out For The Completion Of Bullet Statutory Inspection Requirement , Dismantling Of Scaffolding Materials After Completion Of All Jobs Including Painting Portion And Transportation Of All Materials To Contractors Storage Point Including All Labour , Tools & Tackles , Necessary Equipments , Consumables , Safety Appliance Etc . To Complete The Job As Per Instructions Of Eic . , Bullet Inside Cleaning: , Thoroughly Clean The Entire Area Inside The Bullet With Water ( General Cleaning ) , Remove Sludge As Directed By Eic For Visulal Inspection . Contractors Scope Includes All Labour , Tools & Tackles , Necessary Equipments , Consumables Etc . , For Lpg Bullet , For Propylene Bullet , For Propane Bullet , For Butylene Bullet , Nozzle / Nozzle Flange Replacements With Stress Relieving ( Nozzle Joints Upto First Break Off Flanges ) : , Carry Out Nozzle/ Nozzle Flange Replacements After Preparing Necessary Drawings And Procedures And Getting The Same Approved By Cpcl Inspection / Third Party Agency Before Presenting To Ccoe , Nagpur For Final Approval , Job Including Transportation Free Issue Of Material From Cpcl Storage Point To Work Site , Cutting Of Existing Nozzles By Cold Cutting Procedure , Fabrication , Erection , Welding , Radiography Before And After Pwht ( 100% ) , Necessary Stress Relieving After Welding Including All Labour , Tools & Tackles , Necessary Equipments , Consumables Etc . To Complete The Job As Per Instructions Of Eic . Returning All The Un-Used Material / Scrap To The Designated Location As Per Eic Instruction And Providing Material Re-Conciliation Statement . ( This Rate Includes Radiography & Stress Relieving , Which Are Under Contractors Scope Of Work ) . Ccoe Approval Is In Cpcl Scope . , Repair Of Weld Joints / Haz: , Carry Out Weld Reinforcement / Repair Of Shell Weld Joints , Which Will Be Decided Based On The Detailed Ndt Inspection , Use Er 70S-2 For Root Welding And Use E7018-1 ( Use Only Baked ) Electrodes For Filling Passes Welding And Follow Cpcl Standard Pwht ( Radiography Before And After Pwht: 100% ) Procedure On Completion Of Welding Including Supply Of Electrodes , Including All Labour , Tools & Tackles , Necessary Equipments , Consumables Etc . To Complete The Job As Per Instructions Of Eic . , Replacement Of Thinned Out Process Pipe Lines: , Transportation Of Cpcl Free Issue Of Materials From Owners Storage Point To Work Site , Cut And Remove The Existing Thinned Out Lines , ( Material A 333 Gr . 6 ) As Marked By Inspection , Fabricate , Grinding , Cutting , Dismantling , Erection , Welding , Providing Necessary Supports , Radiograpy Before And After Pwht ( 100% ) , Hydro Test Of Lines Including All Labour , Tools & Tackles , Necessary Equipments , Consumables Etc . To Complete The Job As Per Instructions Of Eic . Returning All The Un-Used Materials / Generated Scrap To The Designated Location And Clean-Up The Area As Per Eic Instruction And Providing Material Re-Concillation Statement . ( This Rate Includes Radiography & Stress Relieving , Which Is Under Contractors Scope Of Work ) , Hydrotesting Of Fire Water Sprinkler System: , Dechoking The Entire Fire Water Sprinkler System , Removal Of Spray Nozzles And Fixng Of Plugs For Hydrotesting , Cleaning And Refixing Of Spray Nozzles , Removal Of Plugs After Hydrotesting . Contractors Scope Includes All Necessary Labour , Consumables , Tools & Tackles Etc . , For Lpg Bullet , For Propylene Bullet , For Propane Bullet , For Butylene Bullet , Bullet Hydrotest: , Offer The Bullet For Hydrotest At A Pressure Specified By Eic , After Cleaning Of All Weld Joints & Painting As Per The Requirements Of Inspection Including Necessary Blinding And Deblinding Of Lines , Flanges Etc . , Including All Labour , Tools & Tackles , Necessary Equipments , Consumables Etc . To Complete The Job As Per Instructions Of Eic . , For Lpg Bullet , For Propylene Bullet , For Propane Bullet , For Butylene Bullet , Painting Jobs: , Surface Preparation As Specified For Each Item In Scope Of Work And Supply & Application Of Paints As Per Cpcl Painting System , Offering Stage Wise Inspection To Cpcl Inspection / Third Party Agency , Using The Existing Scaffolding Structure With All Paint Materials Including Primer , Intermediate , Finish And All Labour , All Kind Of Consumables , Tools & Tackles / Equipments To Complete The Work As Per Instruction Of Eic . , Surface Preparation , By Power Tool Cleaning To Sspc-Sp-3/St3 Surface Finish , By Hand Tool Cleaning To Sspc-Sp-2/St2 Surface Finish , By Grid Blast Cleaning To Sa 2-1/2 Surface Finish , External Painting: Paint The External Surface Of The Bullet Connected Nozzles , Support Legs , And Process Pipelines Up To First Block Valve , Structural Members , Top Platform , Handrails And Firewater Sprinkler Lines As Per Cpcl Painting System No . : X And Surface Preparation To The Requirement Of Power

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INR 143000.0 /-

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Name of Work: Mechanical Maintenance Work & Statutory Internal Inspection Assistance Jobs in Mounded Bullets at CPCL, Manali Refinery
	Sl. No.	Item Description	Item Code / Make	Quantity	Units
1	10	RATE CONT@MOUNDED BULET-MECH MAINT/INSPN:
2	10.01	RATE CONTRACT FOR MECHANICAL MAINTENANCE WORK & STATUTORY INTERNAL INSPECTION ASSISTANCE JOBS IN MOUNDED BULLETS AT CPCL - MANALI REFINERY, CHENNAI - 600068
3	10.02	SCAFFOLDING ERECTION AT BULLET INSIDE AREA:
4	10.03	Transportation of all required scaffolding materials (Contractor's own Material) from contractor's storage point to work site, erection of scaffolding with steel jolly platform at Bullet inside area to carryout all NDT tests that needs to be carried out for the completion of Bullet inside statutory inspection requirement, dismantling of scaffolding materials after completion of all jobs and transportation of the same to contractor's storage point including all labour, tools & tackles, necessary equipments, consumables etc. to complete the job as per instructions of EIC.
5	10.04	For LPG Bullet		5	LS
6	10.05	For Propylene Bullet		1	LS
7	10.06	For Propane Bullet		1	LS
8	10.07	For Butylene Bullet		1	LS
9	10.08	DEGASSING OF BULLET:
10	10.09	Degassing of bullets with CPCL supplied water after making necessary connections for in and out flow with suitable pipelines / hose arrangements as directed on site. The water used for degassing should be disposed off safely in the drainage and the sludge if any coming along with water should be carefully removed and disposed / kept in safe place as directed at site. The sludge should be buried if necessary as per directions of Engineer-in-charge or his representative. A sample of all sludge collected should be handed over to the Engineer-in-charge. Deboxing / Boxing, dismantling / Pitting back all gadgets on bullet, also all jobs related to blind Flanging up to first block/isolation Valve.
11	10.1	For LPG Bullet		5	LS
12	10.11	For Propylene Bullet		1	LS
13	10.12	For Propane Bullet		1	LS
14	10.13	For Butylene Bullet		1	LS
15	10.14	NDT TEST ARRANGEMENTS (BUFFING) AT BULLET INSIDE AREA:
16	10.15	Thoroughly prepare all the weld seam surfaces by buffing to carryout 100% Wet Flourescent Magnetic Particle Testing as per ASTM E-709 (Buffed area shall be made available for 6 inches width on either side of the weld seam including the weld), Offer Dye Penetrant Inspection (As per ASTM E-165/IS-3658) of weld joints, Hardness Testing (ASTM E-110) of weld joints and Radiographic Examination of Bullet weld joints, HAZ and any left out cleat weld areas wherever necessary as per Inspection and offer for Inspection for NDT Tests including all labour, tools & tackles, necessary equipments, consumables etc. to complete the job as per instructions of EIC. NDT tests will be carried out by CPCL.		1950	SQM
17	10.16	SCAFFOLDING ERECTION AT BULLET OUTSIDE FOR PIPING:
18	10.17	Transportation of all required scaffolding materials (Contractor's Own Material) from contractor's storage point work to site, erection of scaffolding with steel jolly platform at Bullet outside area for piping to carryout all NDT tests / painting that needs to be carried out for the completion of Bullet statutory inspection requirement, dismantling of scaffolding materials after completion of all jobs including painting portion and transportation of all materials to Contractor's storage point including all labour, tools & tackles, necessary equipments, consumables, safety appliance etc. to complete the job as per instructions of EIC.		600	CUM
19	10.18	BULLET INSIDE CLEANING:
20	10.19	Thoroughly clean the entire area inside the Bullet with water (general cleaning), remove sludge as directed by EIC for visulal inspection. Contractor's scope includes all labour, tools & tackles, necessary equipments, consumables etc.
21	10.2	For LPG Bullet		5	LS
22	10.21	For Propylene Bullet		1	LS
23	10.22	For Propane Bullet		1	LS
24	10.23	For Butylene Bullet		1	LS
25	10.24	NOZZLE / NOZZLE FLANGE REPLACEMENTS WITH STRESS RELIEVING (NOZZLE JOINTS UPTO FIRST BREAK OFF FLANGES):
26	10.25	Carry out nozzle/ nozzle flange replacements after preparing necessary drawings and procedures and getting the same approved by CPCL Inspection / Third Party agency before presenting to CCOE, Nagpur for final approval, job including transportation free issue of material from CPCL storage point to work site, cutting of existing nozzles by cold cutting procedure, fabrication, erection, welding, radiography before and after PWHT (100%), necessary stress relieving after welding including all labour, tools & tackles, necessary equipments, consumables etc. to complete the job as per instructions of EIC. Returning all the un-used material / Scrap to the designated location as per EIC instruction and providing material re-conciliation statement. (This rate includes Radiography & Stress relieving, which are under contractor's scope of work). CCOE approval is in CPCL scope.		200	ID
27	10.26	REPAIR OF WELD JOINTS / HAZ:
28	10.27	Carry out weld reinforcement / repair of Shell weld joints, which will be decided based on the detailed NDT Inspection, Use ER 70S-2 for root welding and use E7018-1 (use only baked) electrodes for filling passes welding and follow CPCL standard PWHT (Radiography before and after PWHT: 100%) procedure on completion of welding including supply of electrodes, including all labour, tools & tackles, necessary equipments, consumables etc. to complete the job as per instructions of EIC.		40	M
29	10.28	REPLACEMENT OF THINNED OUT PROCESS PIPE LINES:
30	10.29	Transportation of CPCL free issue of materials from owner's storage point to work site, cut and remove the existing thinned out lines, (Material A 333 Gr.6) as marked by Inspection, fabricate, grinding, cutting, dismantling, erection, welding, providing necessary supports, Radiograpy before and after PWHT (100%), hydro test of lines including all labour, tools & tackles, necessary equipments, consumables etc. to complete the job as per instructions of EIC. Returning all the un-used materials / generated Scrap to the designated location and clean-up the area as per EIC instruction and providing material re-concillation statement. (This rate includes Radiography & Stress Relieving, which is under contractor's scope of work)		200	ID
31	10.3	HYDROTESTING OF FIRE WATER SPRINKLER SYSTEM:
32	10.31	Dechoking the entire Fire Water Sprinkler system, removal of Spray Nozzles and fixng of Plugs for hydrotesting, cleaning and refixing of Spray Nozzles, removal of Plugs after hydrotesting. Contractor's scope includes all necessary labour, consumables, tools & tackles etc.
33	10.32	For LPG Bullet		5	LS
34	10.33	For Propylene Bullet		1	LS
35	10.34	For Propane Bullet		1	LS
36	10.35	For Butylene Bullet		1	LS
37	10.36	BULLET HYDROTEST:
38	10.37	Offer the Bullet for hydrotest at a pressure specified by EIC, after cleaning of all weld joints & painting as per the requirements of Inspection including necessary blinding and deblinding of lines, flanges etc., including all labour, tools & tackles, necessary equipments, consumables etc. to complete the job as per instructions of EIC.
39	10.38	For LPG Bullet		5	LS
40	10.39	For Propylene Bullet		1	LS
41	10.4	For Propane Bullet		1	LS
42	10.41	For Butylene Bullet		1	LS
43	10.42	PAINTING JOBS:
44	10.43	Surface preparation as specified for each item in scope of work and supply & application of paints as per CPCL painting system, offering stage wise Inspection to CPCL Inspection / Third Party agency, using the existing scaffolding structure with all paint materials including Primer, Intermediate, Finish and all labour, all kind of consumables, tools & tackles / equipments to complete the work as per instruction of EIC.
45	10.44	Surface preparation
46	10.45	By Power tool cleaning to SSPC-SP-3/St3 surface finish		1025	SQM
47	10.46	By Hand tool cleaning to SSPC-SP-2/St2 surface finish		400	SQM
48	10.47	By Grid blast cleaning to Sa 2-1/2 surface finish		4900	SQM
49	10.48	EXTERNAL PAINTING: Paint the external surface of the bullet connected nozzles, support legs, and process pipelines up to first block valve, structural members, top platform, handrails and firewater sprinkler lines as per CPCL Painting System No.: X and surface preparation to the requirement of power tool cleaning to SSPC-SP-3/St-3 and application by Brush / Airless Spray.
50	10.49	Primer : One coat of Self Priming Epoxy Paint (100 microns / coat)		1025	SQM
51	10.5	Intermediate : One coat of Polyamide cured HB Epoxy MIO paint (75 microns / coat)		1025	SQM
52	10.51	Finish : Two coats of Acrylic Polyurethane Paint (35 microns / coat)		1025	SQM
53	10.52	INTERNAL PAINTING: Painting (before hydro testing of bullet) on the weld joint area (paint removed area) and if any paint damaged on the shell other than weld joints area. Note: The bottom 90 Deg. internal portion (painted portion) of the bullet Shell, stiffeners, pipes, ETC. shall be coated with anticorrosive solvent-Less air dried Epoxy coating suitable for LPG immersion services after hydro test of the bullet before box up.
54	10.53	Supply & Application of One Coat of Two component high build solvent less phenolic cured with polyamine hardener paint to a DFT of 250 - 300 microns.		4900	SQM
55	10.54	Paint the Safety Valves (2 Nos.) Discharge lines connected to Flare as per CPCL Painting System No.: I and Surface preparation to the requirement of hand tool cleaning to SSPC-SP-2 / St-2 and application by brush.
56	10.55	Two Coats of Heat Resistant Aluminium Paint (upto 250 deg C) of Min. DFT / Coat is 20 microns		400	SQM
57	10.56	STENCILLING:
58	10.57	The Bullet No., Explosive License No., License Validity Date, Statutory Inspection Done On, Next Statutory Inspection Due On, etc., have to be stenciled as per standards on support column of the Bullet and at two locations on the Bullet Shell which should be visible from the road side. Two yellow bands of 2000mm x 1500mm width at the center of the Bullet have to be made. CPCL Logo and statutory instructions have to be painted in two places on the Bullet as directed by EIC.		2	LS
59	10.58	GENERAL NOTE-1: This SOR includes dismantling of nozzles, manways, valves, shifting the valves to CPCL Valve Section for servicing and refixing all items in its' original place as directed by Inspection/EIC. Servicing of valves is in CPCL scope.