Contract For Replacement Of Radiant Tube Cast Supports In Furnaces 86-F-01A Dcu Plant At Cpcl Manali , Replacement Of Radiant Tube Cast Support , Erection & Dismantling Of Steel Scaffolding (With Contractors Own Materials),,,, Job Involves Erection Of Sc, CPCL, Manali - Chennai.-Tamil Nadu

Contract For Replacement Of Radiant Tube Cast Supports In Furnaces 86-F-01A Dcu Plant At Cpcl Manali , Replacement Of Radiant Tube Cast Support , Erection & Dismantling Of Steel Scaffolding (With Contractors Own Materials),,,, Job Involves Erection Of Scaffolding At The Required Locations Using 1-1/2 Inch Dia Steel Tubular Pipes With Suitable Clamping Arrangement, Providing Steel Planks / Steel Gratings At The Required Locations Firmly Tied On To The Scaffolding Pipes, Removal Of Theplanks / Steel Gratings & Scaffolding Materials On Completion Of The Job.,, ,,The Job Also Includes Mobilising Required Scaffolding Materials Like Steel Pipes, Clamps And Steel Planks, Supplying Of All Types Of Tools & Tackles, Lifting Arrangements Like Chain Pulley Blocks, All Consumables And Labour To Complete The Job In All Respects. ,,,, , Erection & Dismantling - Base Reference 10 & 20 Mtr Elevation From Ground Level. (Internal) , Erection & Dismantling - Base Reference Upto 10 Mtr From Ground Level, Upto 10.0Mtr Height Of Scaffolding As Per Site Requirement Using Contractors Own Materials. , Erection & Dismantling - Base Reference Above 10 Mtr And Upto 20 Mtr, Upto 10.0Mtr Height Of Scaffoldingas Per Site Requirement Using Contractors Own Materials. , 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 Andremoval 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 150# & 300# Ratings:,,,, , Blinding & Deblinding - Size Upto1-1/2 Inch Dia. , Blinding & Deblinding - Size 2 Inch Dia. To 5 Inch Dia. , Blinding & Deblinding - Size 6 Inch Dia. To 10 Inch Dia. , Opening & Boxing Of Manways The Job Involves Opening Of Furnace Manways, Covection Panels, Header Box Covers, Header Plugs, Etc., 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 Owners 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 Manways (3 X 7 , Checking Of Existing Skin Point Thermocouples The Job Involves Condition Checking The Existing Skin Point Thermocouples Using Heating Torch And Offering To Maintenance Instruments As Per The Instructions Of Eic . 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. , Condition Checking The Existing Skin Point Thermocouples Using Heating Torch For The Inspection Of Maintenance - Instruments , 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 Owners 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. , Providing New Clamp By Welding On Radiant Tubes Fit Up, Welding & Dp Test , Radiant Tube Cast Tubular Ladder Supports 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 Owners Storage Point / Unused Materials To Owners Storage Point And Dumping The Generated Scrap Material To Designated Area As Per Eic Instructions. , Removal And Replacement Of Cast Support Pipe Along With Tube Support Bracket (Cast Support Pipe As Per Part No : 601.1)(Tube Support As Per Part No : 601.2) , Note: 1. For Providing Lifting Lug For The Damagedsupport Pipe, Rates Shall Be As Per Sor Sl No:5.1.1 2. For Blinding & Deblinding Wherever Involved, Rates Shall Be As Per General Category Jobs Under Sor Sl. Nos.2.0 3. For Scaffolding Work In The The Columns / Vessels, Rates Are Applicable As Per Sor Sl. No.1.0 4.Free Supply Of Cranes, Fork Lift, Tractors & Trailers Shall Be Arranged By Cpcl For Shifting Material From / To -Ware House & Work Site Wherever Required As Per The Discretion Of Eic.However, The Contractor Shall Arrange His Own Tractors & Trailers For Shifting The Scrap Material To The Owners Designated Area , Hydrotesting The Job Includes Hydrotesting Of Heatertubes (Radiant / Convection / Superheater Steam Coil) As Per The Specified Test Pressure. The Job Also Includes Fabrication Of Suitable Manifolds, If Required, Filling Connections Etc., Blowing With Compressed Air / Nitrogen To Displace And Drain Out All The Entrapped Water In The Tubes After Hydrotesting.(Mobile Air Compressor / Nitrogen Cylinder Required For The Job Shall Be Provided By Cpcl). The Job Also Includes Supplying Of All Types Of Tools & Tackles, Suitable Test Pumps, Pressure Gauges, Machineries, All Consumables And Labour To Complete The Job In All Respects. , Hydrotesting Quantity - Upto 3000 Inch Mtr Tube Length Of An Equipment , Hydrotesting Quantity - Upto 1000 Inch Mtr Tube Length Of An Equipment - Test Pressure Upto 167.0 Ksc , Hydrotesting Quantity - Above 1000 Inch Meter & Upto 3000 Inch Mtr Tube Length Of An Equipment - Test Pressure Upto 167.0 Ksc , Hydrotesting Quantity - Above 3000 Inch Mtr Tube Length Of An Equipment , Hydrotesting Quantity - Above 3000 Inch Mtr - Test Pressure Upto 167 Ksc , Carbon Steel Piping Work - Above Ground The Job Includes Transporation Of All Free Issue Materials From Owners 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 Owners 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 And Draining / Drying Of The Piping System. , Lifting Lug Provision In The Damaged Radiant Tube Support By Fillet Welding , Lifting Lug Fillet Welding Using E-309 Electrode , Dismantling & Removal Of Structurals / Gratings , Dismantling & Removal Of Structurals / Gratings , 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 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 Owners Storage Point And Dumping The Generated Scrap Material To Designated Area As Per Eic Instructions. , Refixing Of Removedstructurals/Bracing Erection , Refixing Of Removedstructurals/Bracing Erection Upto 15 M Elevation

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Name of Work:Contract for replacement of Radiant tube cast supports in Furnaces 86-F-01A DCU Plant at CPCL Manali.

Sl. No.	Item Description
1	REPLACEMENT OF RADIANT TUBE CAST SUPPORT
2	ERECTION & DISMANTLING OF STEEL SCAFFOLDING (WITH CONTRACTORS" OWN MATERIALS),,,, Job involves erection of scaffolding at the required locations using 1-1/2 inch dia steel tubular pipes with suitable clamping arrangement, providing steel planks / steel gratings at the required locations firmly tied on to the scaffolding pipes, removal of theplanks / steel gratings & scaffolding materials on completion of the job.,, ,,The job also includes mobilising required scaffolding materials like steel pipes, clamps and steel planks, supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, all consumables and labour to complete the job in all respects. ,,,,
3	Erection & dismantling - Base reference 10 & 20 Mtr elevation from Ground level. (Internal)
4	Erection & dismantling - Base reference Upto 10 mtr from ground level, upto 10.0mtr height of scaffolding as per site requirement using contractors OWN MATERIALS.
5	Erection & dismantling - Base reference above 10 Mtr and upto 20 mtr, upto 10.0Mtr height of scaffoldingas per site requirement using contractors OWN MATERIALS.
6	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 andremoval 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. ,,,,
7	Blinding and deblinding for 150# & 300# ratings:,,,,
8	Blinding & Deblinding - Size Upto1-1/2 inch dia.
9	Blinding & Deblinding - Size 2 inch dia. to 5 inch dia.
10	Blinding & Deblinding - Size 6 inch dia. to 10 inch dia.
11	OPENING & BOXING OF MANWAYS The job involves opening of furnace manways, covection panels, header box covers, header plugs, etc., 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.
12	Opening and boxing up
13	Opening and boxing up of Manways (3" X 7
14	Checking of Existing Skin point thermocouples The job involves condition checking the existing skin point thermocouples using heating torch and offering to Maintenance Instruments as per the instructions of EIC . 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.
15	Condition checking the existing skin point thermocouples using heating torch for the inspection of Maintenance - Instruments
16	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.
17	Providing new clamp by welding on radiant tubes fit up, welding & DP test
18	RADIANT TUBE CAST TUBULAR LADDER SUPPORTS 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.
19	Removal and replacement of cast support pipe along with tube support bracket (cast support pipe as per part no : 601.1)(Tube support as per part no : 601.2)
20	Note: 1. For providing Lifting lug for the damagedsupport pipe, rates shall be as per SOR sl no:5.1.1 2. For blinding & deblinding wherever involved, rates shall be as per General category jobs under SOR Sl. Nos.2.0 3. For scaffolding work in the the columns / vessels, rates are applicable as per SOR Sl. No.1.0 4.Free supply of cranes, fork lift, tractors & trailers shall be arranged by CPCL for shifting material from / to -ware house & work site wherever required as per the discretion of EIC.However, the contractor shall arrange his own tractors & trailers for shifting the scrap material to the owner"s designated area
21	HYDROTESTING The job includes hydrotesting of HeaterTubes (Radiant / Convection / Superheater Steam Coil) as per the specified test pressure. The job also includes fabrication of suitable manifolds, if required, filling connections etc., blowing with compressed air / nitrogen to displace and drain out all the entrapped water in the tubes after hydrotesting.(Mobile air compressor / Nitrogen cylinder required for the job shall be provided by CPCL). The job also includes supplying of all types of tools & tackles, suitable test pumps, pressure gauges, machineries, all consumables and labour to complete the job in all respects.
22	Hydrotesting quantity - Upto 3000 inch mtr tube length of an equipment
23	Hydrotesting quantity - Upto 1000 inch mtr tube length of an equipment - Test pressure upto 167.0 KSC
24	Hydrotesting quantity - Above 1000 inch meter & upto 3000 inch mtr tube length of an equipment - Test pressure upto 167.0 KSC
25	Hydrotesting quantity - Above 3000 inch mtr tube length of an equipment
26	Hydrotesting quantity - Above 3000 inch mtr - Test pressure upto 167 KSC
27	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 and draining / drying of the piping system.
28	LIFTING LUG PROVISION IN THE DAMAGED RADIANT TUBE SUPPORT BY FILLET WELDING
29	Lifting Lug fillet welding using E-309 electrode
30	Dismantling & Removal of Structurals / Gratings
31	Dismantling & Removal of Structurals / Gratings
32	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.
33	Refixing of removedstructurals/Bracing erection
34	Refixing of removedstructurals/Bracing erection upto 15 m elevation