Catalyst Replacement In Plant-207 Ohcu Reactors 207-R-01 , 207-R-02 And 207-R-201 During Refinery-Iii M And I Shutdown-2021 At Cpcl-Manali, CPCL, Manali - Chennai.-Tamil Nadu

Catalyst Replacement In Plant-207 Ohcu Reactors 207-R-01 , 207-R-02 And 207-R-201 During Refinery-Iii M And I Shutdown-2021 At Cpcl-Manali , Part - A Sor Items , Part - A Sor Items , Plant-207 Reactors Catalyst Replacement The Rate Quoted For Unit Cum Includes The Following Jobs , I ) Unloading Of Complete Catalyst By Inert Atmosphere By Vacuum Machine / Dump Nozzle . Ii ) Loading Of Fresh Catalyst By Sock / Dense At Normal Atmospheric Condition . Iii ) Collection & Transportaion Of Empty Drums / Fresh Catalyst From Cpcl Stores To Site . Iv ) Collection And Transporation Of Old Removed Catalyst From Site To The Place As Identified By Eic With In Cpcl Permises . V ) Necessary Torque Tool Tightening Kit & Video Recording Facility . Vi ) Manway Opening , Inside Lighting , Internal Scaffolding , Thorough Cleaning , Removal And Refixing Of Internals/ Cold Repair . Vii ) Shutting Down/ Start Up Assistance To Manufacturing . Viii ) Area Cleaning . , Carryout Complete Catalyst Replacement In 207-R-01 As Per Enclosed Scope Of Work And Detailed Loading Diagram . , Carryout Complete Catalyst Replacement In 207-R-02 As Per Enclosed Scope Of Work And Detailed Loading Diagram . , Carryout Complete Catalyst Replacement In 207-R-201 As Per Enclosed Scope Of Work And Detailed Loading Diagram . , Mobilisation And Demobilisation Charges For Equipments , Tools & Tackles For Plant -207 Reacctors Catalyst Replacement . , Part - B Sor Items , Part - B Sor Items , Blinding And De-Blinding The Job Includes Collection & Transportation Of Required Quantity Of Materials Like Blinds , Gaskets , Fasteners , Etc . , From Owners 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 Owners Storage Point And Dumping The Generated Scrap Material To Designated Area As Per Eic Instructions . , Blinding And Deblinding For 1500# & 2500# 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 . , Supply , Erection & Dismantling Of Steel Scaffolding- For External Purpose - Insulation Removal , Thickness Gauging , Ndt Jobs The Job Includes Transportaiton Of Scaffolding Materials In Contractors Scope Of Supply , Erection Of Scaffolding At Site Covering The Areas Specified Including Providing Vertical Posts Of Pipes At Inter Distance Of 1 . 5M And Horizontal Numbers At A Inter Distance Of 0 . 5 To 0 . 75 Meter , Providing Rods At Corners To Give Sufficient Strength To The Structure , Placing The Wooden / Steel Planks / Frp Gratings On Top For Making Sufficient Area . Dismantling Scaffolding After Completion Of Job And Returning The Scaffolding Material To Specified Place Including All Tools , Tackles , Consumables , Labours And Contractors Supervision As Directed By The Engineer-In-Charge . Note: I ) For Measurement In Sqm : 2 ( Length + Width ) X Height Area Covered By The Scaffolding Is To Be Taken . Ii ) Scaffolding Measurement To Be Done By Breaking The Height Into Parts As Per Height Slab Mentioned Below And Adopting Respective Rates Against Mentioned Height Slabs . , Supply , Scaffolding Erection & Dismantling ( External ) , Up To 6M Height . , Above 6 M Up To 10 M Height . , Above 10 M Up To 20 M Height . , Above 20 M Up To 30 M Height . , Above 30 M Up To 40 M Height . , Buffing Of Weld Joints Job Involves Buffing And Cleaning Of Total Weld Area Of The Reactor / Vessel / Column Etc , Using Power Brush , Thejob Has To Be Completed In All Respect To The Entire Satisfaction Of The Engineer-In-Charge ( Each Length Of Buffing Will Be Up To Width Of 150 Mm ) . Necessaty Buffing Tools/ Machineries And Consumables Are In Contractors Scope Note: ( 1 ) For Weld Seam Buffing The Width Of Buffing Shall Be 150Mm ( I . E ) 75Mm On Both Sides Of The Weld Seam . , Power Tool Cleaning / Buffing To Sspc - Sp-2 / St3 Standards - 150 Mm Width Of Weld Seams / Haz . , Dye Penetration Test For Weld Joints Carryout Dp Test Of The Critical Weld Joints , New / Old Rtj Gakets / Rtj Gasket Seating Surface Areas As Per Cpcl Inspection Advice . Performance Of Dye Penetration Test Including Supply Of All Necessary Materials , Penetrant , Developer Etc , Along With All Equipments , Labour For Carrying Out The Work As Per Specification And Direction Of Engineer-In-Charge At All Elevations . Test Has To Be Carried Out In All Metallurgy The Test Has To Carry Out On All Schedule . , Dp Test Of Weld Joints ( One Unit Ea = One Inch Length ) , Hiring Of Crane , Tractor Trailer , Fork Lifts 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 Including The Operators Time Sheet ( Duly Signed By Cpcl In Charge On Daily Basis ) For All The Below Mentioned Equipments To Be Enclosed Along With Bill For Processing . , Hiring Of 5 Ton Capacity Fork Lift With Valid Operator For Transportaion Of New Catalysts/ Adsorbent Stored In Drums / Jumbo Bags From Cpcl-Manali Ware Hosue To Refinery-3 Plant-207 Site Area & Shifting Of The Removed Old Catalysts / Adsorbent From Plant Area To The Place As Identified By Eic With In Cpcl Permises . Necessary Diesel Is In Contractor Scope . Minimum Capacity : 5 Ton No Of Fork Lift Requried : 3 Nos X 30 Days : 90 Days On Round The Clock Basis Rate Is Inclusive Of Mobilisation And Demobilisation . , Hiring Of 10 Ton 20 Feet Capacity Tractor Trailer With Valid Operator For Transportaion Of New Catalysts/ Adsorbent Stored In Drums / Jumbo Bags From Cpcl-Manali Ware Hosue To Refinery-3 Plant-205 , 206 Site Area & Shifting Of The Removed Old Catalysts / Adsorbent From Plant Area To The Place As Identifed By Eic With In Cpcl Permises . Necessary Diesel Is In Contractor Scope . Minimum Capacity : 10 Ton , 20 Feet On Round The Clock Basis No Of Tractor / Trailer Required : 3 Nos X 30 Days =90 Days Rate Is Inclusive Of Mobilisation And Demobilisation . , Hiring Of 5 Ton Capacity Fork Lift With Valid Operator For Transportaion Of New Catalysts/ Adsorbent Stored In Drums / Jumbo Bags From Cpcl-Manali Ware Hosue To Refinery-3 Plant-207 Site Area & Shifting Of The Removed Old Catalysts / Adsorbent From Plant Area To The Place As Identified By Eic With In Cpcl Permises . Necessary Diesel Is In Contractor Scope . Minimum Capacity : 5 Ton No Of Fork Lift Requried : 3 Nos X 30 Days : 90 Days On Round The Clock Basis Rate Is Inclusive Of Mobilisation And Demobilisation . , Hiring Of 200 Ton Capacity Crane ( For 207R-01/02 ) With Required Boom Height For Executing The Job With Valid Operator For Fresh Catalyst Loading , Removal / Refixing Of Top Manway / Elbow Piece And Other Allied Maintenance Jobs For Catalyst Replacement In Plant-207 . Necessary Diesel Is In Contractor Scope . Minimum Capacity : 200 Ton , On Round The Clock Basis . No Of Crane Requried : 1No X 20 Days : 20 Days . Rate Is Inclusive Of Mobilisation And De

Sr No	CorrigendumDate	Corrignedum	CorrigendumType	NewSubmissionDate
1	11-Feb-2021	Corrigendum No 1 - Catalyst Replacement in Plant-207 OHCU Reactors 207-R-01, 207-R-02 and 207-R-201 during Refinery-III M and I shutdown-2021 at CPCL-Manali	Date	18-02-2021
2	17-Feb-2021	Corrigendum No.2 for Catalyst Replacement in Plant-207 OHCU Reactors 207-R-01, 207-R-02 and 207-R-201 during Refinery-III M and I shutdown-2021 at CPCL-Manali	Date	19-02-2021

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Name of Work: Catalyst Replacement in Plant-207 OHCU Reactors 207-R-01, 207-R-02 & 207-R-201 during Refinery-III M&I shutdown-2021 at CPCL-Manali
	Sl. No.	Item Description	Item Code / Make	Quantity	Units
1	10	PART - A SOR ITEMS	Item 00010
2	10.1	PART - A SOR ITEMS	Item 10.10
3	10.2	Plant-207 Reactors Catalyst Replacement The Rate quoted for Unit CUM includes the following jobs, i) Unloading of complete catalyst by Inert Atmosphere by vacuum machine / dump nozzle. ii) Loading of fresh catalyst by sock / dense at normal atmospheric condition. iii) Collection & Transportaion of empty drums / Fresh catalyst from CPCL stores to site. iv) Collection and Transporation of old removed catalyst from site to the place as identified by EIC with in CPCL permises. v) Necessary torque tool tightening kit & video recording facility. vi) Manway opening , inside lighting, internal scaffolding, thorough cleaning, Removal and refixing of internals/ cold repair. vii) Shutting down/ start up assistance to manufacturing. viii) Area cleaning.	Item 10.20
4	10.3	Carryout Complete Catalyst replacement in 207-R-01 as per enclosed scope of work and detailed loading diagram.	Item 10.30	160	M3
5	10.4	Carryout Complete Catalyst replacement in 207-R-02 as per enclosed scope of work and detailed loading diagram.	Item 10.40	180	M3
6	10.5	Carryout Complete Catalyst replacement in 207-R-201 as per enclosed scope of work and detailed loading diagram.	Item 10.50	85	M3
7	10.6	Mobilisation and Demobilisation charges for Equipments, Tools & Tackles for Plant -207 Reacctors Catalyst replacement.	Item 10.60	1	LS
8	20	PART - B SOR ITEMS	Item 00020
9	20.01	PART - B SOR ITEMS	Item 20.10
10	20.02	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.	Item 20.20
11	20.03	Blinding and deblinding for 1500# & 2500# ratings:	Item 20.30
12	20.04	Blinding & Deblinding - Size Upto 1-1/2 inch dia.	Item 20.40	50	EA
13	20.05	Blinding & Deblinding - Size 2 inch dia. to 5 inch dia.	Item 20.50	50	EA
14	20.06	Blinding & Deblinding - Size 6 inch dia. to 10 inch dia.	Item 20.60	25	EA
15	20.07	Blinding & Deblinding - Size 12 inch dia. to 16 inch dia.	Item 20.70	20	EA
16	20.08	Blinding & Deblinding - Size 18 inch dia. to 24 inch dia.	Item 20.80	5	EA
17	20.09	SUPPLY, ERECTION & DISMANTLING OF STEEL SCAFFOLDING- For External purpose - Insulation removal, thickness gauging, NDT jobs The job includes transportaiton of scaffolding materials in contractors scope of supply , erection of scaffolding at site covering the areas specified including providing vertical posts of pipes at inter distance of 1.5m and horizontal numbers at a inter distance of 0.5 to 0.75 meter, providing rods at corners to give sufficient strength to the structure, placing the wooden / steel planks / FRP gratings on top for making sufficient area. Dismantling scaffolding after completion of job and returning the scaffolding material to specified place including all tools, tackles, consumables, labours and contractor's supervision as directed by the Engineer-in-charge. NOTE: i) For measurement in SQM : 2( Length + Width) x height area covered by the scaffolding is to be taken. ii) Scaffolding measurement to be done by breaking the height into parts as per height slab mentioned below and adopting respective rates against mentioned height slabs.	Item 20.90
18	20.1	Supply,Scaffolding Erection & Dismantling (External)	Item 20.100
19	20.11	Up to 6m height.	Item 20.110	500	M2
20	20.12	Above 6 m up to 10 m height.	Item 20.120	500	M2
21	20.13	Above 10 m up to 20 m height.	Item 20.130	500	M2
22	20.14	Above 20 m up to 30 m height.	Item 20.140	500	M2
23	20.15	Above 30 m up to 40 m height.	Item 20.150	500	M2
24	20.16	Buffing of weld Joints Job involves buffing and cleaning of total weld area of the Reactor / vessel / column etc, using power brush, thejob has to be completed in all respect to the entire satisfaction of the Engineer-in-charge ( each length of buffing will be up to width of 150 mm). Necessaty buffing tools/ machineries and consumables are in contractor's scope NOTE: (1) For weld seam buffing the width of buffing shall be 150mm (i.e) 75mm on both sides of the weld seam.	Item 20.160
25	20.17	Power tool cleaning / Buffing to SSPC - SP-2 / St3 standards - 150 mm width of Weld seams / HAZ.	Item 20.170	200	M
26	20.18	Dye Penetration test for weld joints Carryout DP test of the Critical weld joints, New / Old RTJ Gakets / RTJ Gasket seating surface areas as per CPCL Inspection advice. Performance of dye penetration test including supply of all necessary materials, penetrant, developer etc, along with all equipments, labour for carrying out the work as per specification and direction of engineer-in-charge at all elevations. Test has to be carried out in all metallurgy the test has to carry out on all schedule.	Item 20.180
27	20.19	DP test of weld joints (One Unit EA = One Inch Length)	Item 20.190	500	EA
28	20.2	Hiring of Crane, Tractor Trailer, Fork lifts 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 including the operators time sheet (duly signed by CPCL in charge on daily basis ) for all the below mentioned equipments to be enclosed along with bill for processing.	Item 20.200
29	20.21	Hiring of 5 Ton Capacity Fork lift with valid operator for transportaion of New catalysts/ Adsorbent stored in drums / jumbo bags from CPCL-Manali ware hosue to Refinery-3 Plant-207 Site area & Shifting of the removed old Catalysts / Adsorbent from Plant area to the place as identified by EIC with in CPCL Permises. Necessary diesel is in contractor scope. Minimum capacity : 5 Ton No of Fork lift requried : 3 nos x 30 Days : 90 Days on round the clock basis Rate is inclusive of mobilisation and demobilisation.	Item 20.210	90	DAY
30	20.22	Hiring of 10 Ton 20 Feet Capacity Tractor Trailer with valid operator for transportaion of New catalysts/ Adsorbent stored in drums / jumbo bags from CPCL-Manali ware hosue to Refinery-3 Plant-205 ,206 Site area & Shifting of the removed old Catalysts / Adsorbent from Plant area to the place as identifed by EIC with in CPCL permises. Necessary Diesel is in Contractor scope. Minimum Capacity : 10 Ton, 20 Feet on round the clock basis No of Tractor / Trailer required : 3 nos x 30 Days =90 Days Rate is inclusive of mobilisation and demobilisation.	Item 20.220	90	DAY
31	20.23	Hiring of 5 Ton Capacity Fork lift with valid operator for transportaion of New catalysts/ Adsorbent stored in drums / jumbo bags from CPCL-Manali ware hosue to Refinery-3 Plant-207 Site area & Shifting of the removed old Catalysts / Adsorbent from Plant area to the place as identified by EIC with in CPCL Permises. Necessary diesel is in contractor scope. Minimum capacity : 5 Ton No of Fork lift requried : 3 nos x 30 Days : 90 Days on round the clock basis Rate is inclusive of mobilisation and demobilisation.	Item 20.230	90	DAY
32	20.24	Hiring of 200 Ton capacity Crane (for 207R-01/02) with required boom height for executing the job with valid operator for Fresh catalyst loading , removal / Refixing of top manway / elbow piece and other allied maintenance jobs for Catalyst Replacement in plant-207. Necessary diesel is in contractor scope. Minimum capacity : 200 Ton, on round the clock basis. No of Crane requried : 1no x 20 Days : 20 Days. Rate is inclusive of mobilisation and demobilisation.	Item 20.240	20	DAY
33	20.25	Hiring of 300 Ton capacity Crane (For 207R-201) with required boom height for executing the job with valid operator for Fresh catalyst loading , removal / Refixing of top manway / elbow piece and other allied maintenance jobs for Catalyst Replacement in plant-207. Necessary diesel is in contractor scope. Minimum capacity : 300 Ton, on round the clock basis. No of Crane requried : 1 nos x 20 Days : 20 Days. Rate is inclusive of mobilisation and demobilisation.	Item 20.250	20	DAY