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Rate Contract For Insulation Works In Bgr , Iocl, BGR, Dhaligaon-Assam

Indian Oil Corporation Limited-IOCL has published Rate Contract For Insulation Works In Bgr , Iocl. Submission Date for this Tender is 21-07-2020. Insulation work Tenders in BGR, Dhaligaon Assam. Bidders can get complete Tender details and download the document.




Tender Notice

24810186
Rate Contract For Insulation Works In Bgr , Iocl
Open Tender
Indian
Assam
BGR, Dhaligaon
21-07-2020

Tender Details

Rate Contract For Insulation Works In Bgr , Iocl

Key Value

Document Fees
Refer document
EMD
INR 377500.0 /-
Tender Value
INR 3.77 Crore /-

BOQ Items

Name of Work: RATE CONTRACT FOR INSULATION WORKS IN BGR, IOCL
Sl. No. Item Description Item Code / Make Quantity Units
1 10 ARC Insulation, Revenue Part
2 10.01 Taking out old worn out damaged insulation materials of any thickness including wool mattress, performed sections or any other insulating materials including sheet cladding etc. complete and transporting the serviceable materials to owner's storage point and damaged materials within 2.00 km lead inside Refinery .The job includes cleaning the site, transporting the materials to directed place at any height, complete with all labour and materials, etc.as per specification and direction of Engineer-In-Charge but excluding the cost of scaffolding. Scaffolding will be paid seperately as per scaffolding item available in M&I -Mechanical SOR. Item 10.10 20000 M2
3 10.02 Fixing cladding with new/old aluminium/GI plain/corrugated sheets. The job includes cutting, bending & grooving to proper shape and size and fixing with self-tapping screws, providing water proofing tar felt between the sheet overlap/joint securing with mettalic bands wherever required at any height with all labour, materials (except cladding sheets which will be supplied by owner) etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding. Scaffolding will be paid seperately as per scaffolding item available in M&I -Mechanical SOR. (Payment of above shall be made on the area of the finished surface). Item 10.20 2000 M2
4 10.03 Providing and Fixing cladding with new Aluminum plan /corrugated sheets of the following gauges. The job includes cutting, bending and grooving to proper shape and size and fixing with self-tapping screws, providing water proofing tar felt between the sheet overlap/joint, securing with mettalic bands wherever required at any height with all labour , all materials including cladding sheets, etc. complete as per specification and direction of Engineer-In-Charge but excluding the cost of scaffolding ( Payment shall be made on the area of the finished surface). Scaffolding will be paid seperately as per scaffolding item available in M&I-Mechanical SOR.
5 10.04 Plain aluminum sheet - 24 SWG Item 10.40 12000 M2
6 10.05 Plain aluminum sheet - 22 SWG Item 10.50 7000 M2
7 10.06 Corrugated Al. sheet - 24 SWG Item 10.60 500 M2
8 10.07 Corrugated Al. sheet - 22 SWG Item 10.70 500 M2
9 10.08 Providing and fixing spacer rings made out of 30x4mm MS Flats, angle of specified shape over pipelines, heat exchangers, vessels, chillers at required intervals including cutting, welding or bolting with nuts & bolts as directed at any heights with all labour, materials complete as per specifications and direction of Engineer , -In-Charge but excluding the cost of scaffolding. Cost of scaffolding will be paid as per scaffolding item available in M&I Mechanical SOR. Item 10.80 100 KG
10 10.09 Taking out old worn out damaged cladding of any thickness ( plain or corrugated. GI or Aluminium) and transporting the serviceable materials to owner's storage point and damaged materials to the directed place within refinery premises. The job includes, cleaning the site, transporting the materials to directed place, complete with all labor and materials etc.as per direction of Engineer-In-Charge. (Payment shall be made on the previously finished surface). Item 10.90 1000 M2
11 10.1 Providing and fixing single/multiple layer of machine stitched preformed LRB mineral wool mattresses of density 100 kg/cum conforming to IS:8183 in required thickness over the technological equipments like columns, vessels, ducts, horton spheres, storage tanks etc., finishing the surface with approved protective coating like cement sand plaster / aluminum or GI sheet cladding including cleaning of the surface with wire brush, fixing the insulation mattresses in position and securing the same properly, etc. all complete with tools, tackles, materials such as self tapping screws, lacing, binding, stitching wire, labour etc. complete in accordance with the specifications laid down in the contract and in the latest IS standards as per the directions of Engineer-in-Charge; but excluding the cost of scaffolding. Scaffolding will be paid as per scaffolding item available in M&I Mechanical SOR. Note: 1. Contractor has to make his own arrangement for procurement and storage of all the materials. 2. Payment for protective layer of cement sand plaster and / or cladding including Aluminium / GI sheets shall be made under a separate item. 3. The item includes disposal of the debris to the directed place within 2km. lead as per the direction of Engineer-in-Charge. 4. Contractor has to produce manufacturer's certificate in support of characteristics of insulation materials i.e. 'K' value, density etc.
12 10.11 Thickness of insulation - 25mm Item 10.110 1000 M2
13 10.12 Thickness of insulation - 40mm Item 10.120 2500 M2
14 10.13 Thickness of insulation - 50mm Item 10.130 7000 M2
15 10.14 Thickness of insulation - 75mm Item 10.140 500 M2
16 10.15 Providing and fixing single/multiple layer of machine stitched preformed LRB mineral wool mattresses of density 150 kg/cum conforming to IS:8183 in required thickness over the technological equipments like columns, vessels, ducts, horton spheres, storage tanks etc., finishing the surface with approved protective coating like cement sand plaster / aluminum or GI sheet cladding including cleaning of the surface with wire brush, fixing the insulation mattresses in position and securing the same properly, etc. all complete with tools, tackles, materials such as self tapping screws, lacing, binding, stitching wire, labour etc. complete in accordance with the specifications laid down in the contract and in the latest IS standards as per the directions of Engineer-in-Charge, but excluding the cost of scaffolding. Cost of Scaffolding will be paid as per scaffolding item available in M&I Mechanical SOR. Note: 1. Contractor has to make his own arrangement for procurement and storage of all the materials. 2. Payment for protective layer of cement sand plaster and / or cladding including Aluminium / GI sheets shall be made under a separate item. 3. The item includes disposal of the debris to the directed place within 2km. lead as per the direction of Engineer-in-Charge. 4. Contractor has to produce manufacturer's certificate in support of characteristics of insulation materials i.e. 'K' value, density etc.
17 10.16 Thickness of insulation - 25mm Item 10.160 1000 M2
18 10.17 Thickness of insulation - 40mm Item 10.170 2500 M2
19 10.18 Thickness of insulation - 50mm Item 10.180 7000 M2
20 10.19 Thickness of insulation - 75mm Item 10.190 500 M2
21 10.2 Providing and fixing dual insulation for temperature exceeding 5500 C comprising of 1st layer of 25mm thick supercera ceramic fibre blanket of M/s Lloyds Insulation India Ltd. or Cerlane of M/s Unifrax or any other approved equivalent conforming to ASTM C-892 in density of 128 kg/m3 (Grade RTZ) ensuring interface surface temperature over ceramic blanket is below 5500 C and followed by second / multiple layers with Resin Bonded Rockwool machine stitched mattress of density 120 kg/m3 conforming to IS : 8183 in required thickness over the technological equipments, vessells, ducts, finishing the surface with approved protective coating like cement sand plaster / aluminum or GI sheet cladding including cleaning of the pipes with wire brush, fixing the insulation pipe sections & mattresses in position and securing the sample property with aluminium bands on each layer of insulation etc. all complete with tools, tackles, materials such as binding and lacing wire etc. complete in accordance with the specifications laid down in the contract and in the latest IS standards as per the directions of the Engineer-in-Charge, but excluding the cost of scaffolding. Cost scaffolding will be paid as per scaffolding item available in M&I Mechanical SOR. Note: 1.Contractor has to make his own arrangement for procurement and storage of all the materials. 2. Payment for protective layer of cement sand plaster and / or cladding including Aluminium / GI sheets shall be made under a separate item. 3.The item includes disposal of the debris to the directed place within 2km. lead as per the direction of Engineer-in-Charge. 4.The measurements shall be done as per the IS 14164: 1994. 5.Insulation shall be bound securedly by using SS binding wire of 18 SWG at pitch not more than 450mm. For long lasting securement, 20mm wide alluminium band of 24 SWG shall be provided at a pitch of max. 600mm. At each end of pipe insulation, the distance between the end of pipe insulation and the band/wire should not be less than 50mm. The wire should be tightened by twisting and the ends of wire to be pressed on to the insulation material. 6. Contractor has to produce manufacturer's certificate in support of characteristics of insulation materials i.e. 'K' value, density etc.
22 10.21 Thickness of insulation - 50mm Item 10.210 100 M2
23 10.22 Thickness of insulation - 65mm Item 10.220 100 M2
24 10.23 Thickness of insulation - 75mm Item 10.230 100 M2
25 10.24 Thickness of insulation - 90mm Item 10.240 100 M2
26 10.25 Providing and filling loose mineral wool (density 120 kg/cum) with wire net, if required, in boxes and packing it properly complete with all labour and materials (measurement shall be based on finished volume of box). Item 10.250 750 M3
27 10.26 Providing and applying ceramic fibre braided rope of approved make, such as Supercera of M/s Lloyds Insulation India Ltd. or Cerlane of M/s Unifrax or any other approved equivalent, made from ceramic fibre strip braided with SS 304 wire (An additional wire is provided at center for reinforcement) for hot insulation of pipes, valves, flanges, tubes, instruments, gauge glasses etc. including taking out worn out insulation, if necessary etc. complete with all labour and materials but excluding the cost of scaffolding . The rope is applied spirally over small dia pipelines. (Payment shall be made on the basis of length of the rope wrapped). Cost of scaffolding will be paid seperately as per scaffolding item available in M&I Mechanical SOR.
28 10.27 Rope size - 6mm to 10mm Item 10.270 200 M
29 10.28 Rope size -12mm Item 10.280 200 M
30 10.29 Rope size -19mm Item 10.290 100 M
31 10.3 Rope size -25mm Item 10.300 50 M
32 10.31 Supply and fixing in position of 25mm thick ceramic rope of approved make such as Supercera of M/s Lloyds Insulation India Ltd. or Cerlane of M/s Unifrax or any other approved equivalent suitable upto 14250 C for insulation of instrument impuse piping including cleaning and removal of dust, rust, grease etc. from the piping surface, wrapping the ceramic fibre rope around the piping so as to cover the piping completely without leaving any gap and final application of two layers of insulcoat with reinforcement of fibre glass cloth for water proofing as per the direction of the Engineer-in-Charge including all material, tools, tackles and labour etc. complete. (The payment shall be made per metre length of instrument impuse piping covered with insulation). Item 10.310 50 M
33 10.32 Providing all necessary materials and carrying out cold insulation works as per the following specifications on equipments like columns, vessels, exchagers, ducts etc., at any height including the cost of all materials, tools and tackles, labour etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding. Cost of scaffolding will be paid seperately as per scaffolding item available in M&I Mechanical SOR. 1) A coat of approved bituminous paint (IS:158/69) shall be applied on the metal surface after through cleaning. 2) A coat of hot bitumen of 85/25 grade conforming to IS:702 to be applied on the painted surface for fixing Polyurathene foam (PUF) blocks and preformed pipe section of density 36 kg/cum without gaps in between the required size and shape, tightening them by tying each layer with 16 SWG wire at the rate of 500mm centre to centre. 3) A coat of hot bitumen of 85/25 grade conforming to IS:702 to be applied on each layer, surface and joint of blocks and sections. 4) Encircle the last layer of insulation with bitumen impregnated kraft paper with a minimum overlapping of 75mm and wire netting with 12mm size, 18 SWG GI wire net. 5) Encasement of the kraft paper and GI wire netting to be provided for cement plaster / cladding. 6) Payment for protective layer of cement sand plaster and / or cladding including Aluminium / GI sheets shall be made under a separate item.
34 10.33 25mm thick Item 10.330 100 M2
35 10.34 50mm thick Item 10.340 100 M2
36 10.35 Providing and fixing wire net protection around insulation of tanks, columns, vessels etc. with 3"x3" size PVC coated corrosion proof chain link wire net of 10 SWG including cutting to size, tightening and stitching the vertical and horizontal joints with PVC coated corrosion proof wire of 10 SWG etc. with all labour materials, tools, tackles complete as per direction of the Engineer-in-Charge but . excluding the cost of scaffolding. Cost of scaffolding will be paid as per scaffolding itme available in M&I Mechanical SOR. Item 10.350 100 M2
37 10.36 Providing and laying plastering two layers with 1:4:1 (1 cement: 4 medium sand: 1asbestos fluff) including finishing, curing etc. over insulation surface as per the direction of Engineer-in-Charge. 3mm thick coat of approved weather proofing compound like Shalicoat' of M/S STP Ltd / Insulcoat of M/s Lloyd Insulation India Ltd. shall be applied on the plastered surface. The plaster shall be reinforced with 3/4 inches 24 SWG GI wire netting.
38 10.37 Plastering two layers - 20mm thick Item 10.370 100 M2
39 10.38 Cleaning the surface thoroughly, providing all materials such as calcium silicate slabs/ curved segments/bevelled legs, wire mesh (3/4" x 24 swg), binding wires, aluminium bends, weather proofing compound and tying wire etc. and carrying out insulation works as per the following specifications on pipelines at any height including the cost of all materials, tools, tackles, labour etc. complete as per direction of the Engineer-in-Charge but excluding the cost of scaffolding. Cost of scaffolding will be paid as per scaffolding item available in M&I Mechanical SOR. a) The surface shall be cleaned thoroughly using wire brush etc. and wiping it clean so that the surface is dry, free from dust, rust, grease and scales. b) Calcium silicate insulation in the form of half round pipesections/curved segments/bevelled legs shall be fixed on the clean surface. For insulation thicknesses upto 75mm, only half round pipesections shall be used for pipes of diameter upto 300mm. For insulation thicknesses greater than 75mm, insulation shall be provided in two layers and for diameters upto 300mm, first layer shall be of half round pipesections. For diameters more than 300mm curved segments / bevelled legs shall be used. c) Insulation shall be bound securedly by using SS binding wire of 18 SWG at pitch not more than 450mm. For long lasting securement, 20mm wide alluminium band of 24 SWG shall be provided at a pitch of max. 600mm. At each end of pipe insulation, the distance between the end of pipe insulation and the band/wire should not be less than 50mm. The wire should be tightened by twisting and the ends of wire to be pressed on to the insulation material. d) Any unavoidable installation gaps shall be filled up with clacium silicate powder paste. e) For single layer of insulation, circumferential joints shall be staggered. f) Insulation over 50mm thick may be applied in multilayers. g) Insulation of flanges, valves and bends etc. shall be done using performed insulation as far as practicable. h) For bends, pipe-coverings shall be cut as per the bend radius at site. any unavoidable gaps shall be sealed by calcium silicate powder paste. Chicken wire-mesh shall be used as additional securement for insulation over bends, in place of aluminium bands. i) Expansion joints of 25mm shall be provided at suitable intervals as per the following guidelines:- Temp. (Deg. C.) Spacing Interval (mtr) Upto 300 5 300-400 4 400 2.7 j) Expansion joints shall be tightly packed with fibrous insulation. k) Applying 3mm thick Shalicoat / Insulcoat or equivalent weather proofing compound over the insulated surface. l) Approved protective finish like cement, sand plaster / sheet metal clading shall be provided over the insulated surface for which payment shall be made under a separate item. Note: 1. Contractor has to make his own arrangement for procurement and storage of all the material. 2. Payment for protective layer of cement sand plaster and / or cladding including Aluminium / GI sheets shall be made under a separate item. 3. The item includes disposal of the debris to the directed place within 3 km. lead as per the direction of the Engineer-in-Charge. 4. The measurements shall be done as per the IS 14164: 1994.
40 10.39 Thickness of insulation - 25mm Item 10.390 100 M2
41 10.4 Thickness of insulation - 50mm Item 10.400 100 M2
42 10.41 Supplying & Applying various epoxy and other protective finish paints of approved make and brand over steel structures, pipelines, tanks and equipments, concrete floors etc. with all materials, labours, tools-tackles and consumables etc. complete as per manufacturers specification & directions of Engineer-in-charge.
43 10.42 Two or more coats of Phenolic Epoxy Paint such as Epilux 9 Phenolic coating of M/s. Berger paints or equivalent prepared and applied as per manufacturer's specification to achieve a finish coat DFT up to 250 micron min. by brush or spray application. Item 10.420 3000 M2
44 10.43 Two or more coats of HEAT RESISTANT COATING of temparature resistance upto 250 degree centigrade i.e. Ferrotol HR Aluminium paint of M/s Berger Paints or equivalent to achieve a minimum DFT of 15-20microns in each coat and total 30 to 40 microns in two coats by brush or spray application. Item 10.430 8000 M2
45 10.44 Two or more coats of Heat resisting aluminium paint temparature resistance upto 250 deg to 400 deg centigrade such as Lustrotherm HT 400 of M/s. Shalimar paints or Intertherm 972 of M/s. Akzo nobel or equivalent of other IOCL approved manufacturer to achieve the DFT of 50 microns (25 microns in each coat) by brush or spray application. Item 10.440 3500 M2
46 10.45 Two or more coats of Heat resisting aluminium paint 400 deg to 600 deg centigrade such as Lustrotherm HT 600 of M/s. Shalimar paints or Intertherm 972 of M/s. Akzo nobel or equivalent of other IOCL approved manufacturer to achieve the DFT of 50 microns (25 microns in each coat) by brush or spray application at site Item 10.450 1000 M2
47 10.46 Providing and fixing Ceramic Fibre anchor Modules of 160 kg/m3 density of approved make and manufacture like Fiberfrax Cerlock of M/s Unifrax / Supercera of M/s Lloyd Insulation India Ltd. or any other equivalent make as approved by engineer-in-charge (made by compressing ceramic fibres double needled blankets of 128 kg/m3) over the 25mm thick back up lining of ceramic fibre blankets of density 128 kg/m3. The module shall be provided with SS Anchor of requisite grade complete with bolts and sliding arangements. The specially designed anchors shall be provided for corner modules. On the surface of the module a suitable Zirconia based low temperature setting coating shall be provided to enhance velocity resistance and to protect the fibre from chemical attack. Item is excluding the cost of scaffolding.
48 10.47 125 mm thick ceramic fibre modular lining with 100 mm thick anchor modules (Grade 1260 deg. C) and 25 mm thick blanket backing. Item 10.470 5 M2
49 10.48 175 mm thick ceramic fibre modular lining with 150 mm thick anchor modules (Grade 1260 deg. C) and 25 mm thick blanket backing Item 10.480 5 M2
50 10.49 225 mm thick ceramic fibre modular lining with 200 mm thick anchor modules (Grade 1260 deg. C) and 25 mm thick blanket backing Item 10.490 5 M2
51 10.5 150 mm thick ceramic fibre modular lining with 100 mm thick anchor modules (Grade 1260 deg. C) and 50 mm thick blanket backing. Item 10.500 5 M2
52 10.51 200 mm thick ceramic fibre modular lining with 150 mm thick anchor modules (Grade 1260 deg. C) and 50 mm thick blanket backing. Item 10.510 5 M2
53 10.52 250 mm thick ceramic fibre modular lining with 200 mm thick anchor modules (Grade 1260 deg. C) and 50 mm thick blanket backing. Item 10.520 5 M2
54 10.53 Steel work welded in built up section/framed work including cutting hoisting, fixing in position and applying a priming coat of approved steel primer using structural steel etc. as required.
55 10.54 In gratings, frames, guard bar, ladders, railings, brackets, gates & similar works. Item 10.540 300 KG
56 10.55 FIXING OF LUGS Fabrication of CS / SS lugs by cutting, bending etc. from CS / SS annealed wire etc. (supplied by owner free of cost) and fixing the same by welding on the fabricated panel segments for holding the castable refractories including supply of labour, tools, tackles as per direction of the Engineer-in-Charge.
57 10.56 CS Lugs Item 10.560 500 EA
58 10.57 SS Lugs Item 10.570 500 EA
59 10.58 Non-SOR items
60 10.59 CERAMIC FIBRE BLANKET LAYING
61 10.6 Laying of Ceramic fiber blanket. (Upto 50 mm thick layer of Ceramic fibre blanket.) Removal of the old and damaged ceramic fibre from furnace roof, end side wall, duct etc. and do the new lining of cyramic fibre blanket on those area of radiation and convection zone of Furnace; insert twist stud, ceramic caps etc., as per instruction and guidance of EIC for the 50 mm thick layer with the help of blanket of 25 mm thick supplied by BGR. Item 10.600 50 M2
62 10.61 Laying of Ceramic fiber blanket with wire net.(Upto 50 mm thick layer of Ceramic fibre blanket.) Removal of the old and damaged ceramic fibre from furnace stack and chimney (upto 10 mtr. from the bottom of the chimney), Duct, roof, end and side wall etc. Fix wire insert twist stud, ceramic caps etc., Fix wirenet above the ceramic fibre blanket in order to hold it rigidly on the surface, complete all jobs as per instruction and guidance of EIC for the 50 mm thick layer with the help of blanket of 25 mm thick. Item 10.610 50 M2
63 10.62 Ceramic fibre blanket insret in expansion gaps between the bridge wall, brick lining and tube sleeves of radiation zone and convection including supply of tools & tackles complete. Item 10.620 50 M
64 10.63 Supply of refractory castable Insulyte-11 LI or equivalent of Type 4, for application in the furnace floor,header box cover, manhole, peepholes, explosion doors,chimney area etc and other areas as per instruction of Engineer-in-charge. product specifications are as follows:- Service temperature : 1350 Deg C dry density- 1100-1250 kg/m3 Minimum Alumina content : 85 percent Maximum Fe2O3 : 1.5 percent typical Minimum CCS after heating at 1350 Deg C / 3 Hrs - Typical value 50-60 Kg/cm2 Item 10.630 5 TO
65 10.64 Supply of refractory castable Whytheat A or Whytheat super for application in the burner blocks, muffle blocks,and other areas as per instruction of Engineer-in-charge, product specifications are as follows:- Service temperature : 1700 Deg C Minimum Alumina content : 85 percent Maximum Fe2O3 : 1.6 percent typical Minimum CCS after heating at 1550 Deg C / 3 Hrs - Typical value 750 Kg/cm2 Item 10.640 5 TO
66 10.65 Supply of CERAMIC fIBRE BALNKET for application in the furnace area and other areas as per instruction of Engineer-in-charge. BLANKET,CERAMIC FIBRE,128 KG/M3, 25 mm Temperature-1425 DEG celcius, SIZE : 7620 X 610 X 25 mm Item 10.650 200 EA
67 10.66 Providing and fixing 0.1mm thick aluminium foil over the pipelines having single or multiple tracers prior to application of LRB mattress for insulation.Overlap of the foils shall not be less than 25mm on any side and the foil should be bound securedly using SS binding wire of 22SWG at pitch not more than 450mm c/c. The item includes the cost of all materials, labour, tools and tackles, consumables etc complete.(Payment shall be made on the area of the finished surface) Item 10.660 15000 SQM
68 10.67 Providing and fixing 0.1mm to 0.15mm thick SS-304 foils over the SS or AS pipe lines or equipments prior to application of the LRB mattress/ceramic fibre mattress for insulation. Overlap of the foils shall not be less than 50mm on any side and the foil should be bound securedly using SS-304 binding wire of 25 SWG at pitch not more than 450 c/c and the lap joints shall be interposed with barrium chromate primer. The item includes the cost of all materials, labour, tools and tackles, consumables, scaffolding etc. complete. (Payment shall be made on the area of the finished surface) Item 10.670 1500 SQM
69 10.68 TACK WELDING (Length of 1 tack is 10 mm)
70 10.69 CS to CS Tack Welding Item 10.690 500 EA
71 10.7 SS to SS Tack Welding Item 10.700 500 EA
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