Bids Are Invited For Custom Bid for Services - RATE CONTRACT FOR VALVE REVISIONING TESTING JOBS AT IOCL BONGAIGAON REFINERY - REVISIONING & TESTING OF VALVES, RECONDITIONING OF GATE, GLOBE, CHECK, BUTTERFLY, PLUG VALVES OF ANY CLASS Job involves transportation of valves (any class) from owners storage location to contractors store, identifying the repairable valves by visual inspection, opening and dismantling of valves, cleaning by rustoline or kerosene of all the components thoroughly, further inspection of internal parts in the presence of the Engineer-in-Charge, repair / reconditioning of valves by hand facing, machining, grinding, lapping etc. with all tools, tackles, replacement of missing or defective parts such as studs and nuts of gland, body hand wheel, nut bonnet, back seat bush, gland chaser and any other parts recommended by Engineer-in-Charge and finally reassembling the valves, gland packing and testing as per API 598 / BS 5146. In case valves fail during testing, the above sequence will be repeated at no extra cost. Note: Supply of spares/ Gland packing shall be under IOCL scope., REVISIONING VALVES WITHOUT OPENING BONNETS Job involves opening of gland chaser, cleaning of parts, renewal of gland packing, replacement of missing Nuts/Bolts/ Wheel Nut and revisioning of parts without opening of bonnet, HYDROTESTING OF GATE/GLOBE/ CHECK/ BUTTERFLY/ PLUG VALVES Job involves collection of valves from stores, go-down etc. transportation to testing bay or contractors own premises, test the val ves for seat, body and backseat at recommended pressure including cleaning and greasing, transport back as per instruction and satisfaction of the Engineerin-Charge. Requirement of heavy equipment to be envisaged by Engineer in Charge and to be arranged separately, if required, as the same in not included in the item rate., RE-PACKING VALVES Job involves removing existing gland packing completely from gate, globe, check valves of various sizes in situ and re-packing the valves, with new gland (supplied by IOCL) including supply of tools, tackles and equipment if any. Valves should be tested for free rotation. Hand wheels to be fitted back along with the spindle, if required. , INSITU OVERHAULING / REVISIONING OF GATE, GLOBE, CHECK, BUTTERFLY, PLUG VALVES OF (UPTO #300 CLASS) Revisioning and overhauling job of valves up to #300 rating. Dismantling of valve bonnet from the body by removing studs, bolts, dismantling all the parts, cleaning of all parts of the valves, repair of the components, replacement of damaged / worn out spare parts wherever necessary, depositing the welded material, machining, blue matching for the in-situ / manual lapping, greasing and assembly, pressure testing per applicable standard. For welded valve, blue match will be the criteria. Repair will include machining (if required) grinding and or lapping before blue match polishing etc. wherever required. All the consumables except grease, rustoline, nuts, bolts will be in the scope of contractor. Contractor will deploy technically qualified, experienced, skilled manpower in sufficient quantity, to carry out the necessary jobs in well organised way so that the job can be completed within scheduled time. Requirement of heavy equipment to be envisaged by Engineer in Charge and to be arranged separately, if required, as the same in not included in the item rate. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters INSITU OVERHAULING / REVISIONING OF GATE, GLOBE, CHECK, BUTTERFLY, PLUG VALVES (ABOVE #300 CLASS AND UPTO #900 CLASS), Revisioning and overhauling job of valves above #300 and up to #900 rating. Dismantling of valve bonnet from the body by removing studs, bolts, dismantling all the parts, cleaning of all parts of the valves, repair of the components, replacement of damaged / worn out spare parts wherever necessary, depositing the welded material, machining, blue matching for the in-situ / manual lapping, greasing and assembly, pressure testing per applicable standard. For welded valve, blue match will be the criteria. Repair will include machining (if required) grinding and or lapping before blue match polishing etc. wherever required. All the consumables except grease, rustoline, nuts, bolts will be in the scope of contractor. Contractor will deploy technically qualified, experienced, skilled manpower in sufficient quantity, to carry out the necessary jobs in well organised way so that the job can be completed within scheduled time. Requirement of heavy equipment to be envisaged by Engineer in Charge and to be arranged separately, if required, as the same in not included in the item rate. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. , INSITU OVERHAULING / REVISIONING OF GATE, GLOBE, CHECK, BUTTERFLY, PLUG VALVES (ABOVE #900 CLASS) Revisioning and overhauling job of valves above #900 rating. Dismantling of valve bonnet from the body by removing studs, bolts, dismantling all the parts, cleaning of all parts of the valves, repair of the components, replacement of damaged/ worn out spare parts wherever necessary, depositing the welded material, machining, blue matching for the in-situ/ manual lapping, greasing and assembly, pressure testing per applicable standard. For welded valve, blue match will be the criteria. Repair will include machining (if required) grinding and or lapping before blue match polishing etc. wherever required. All the consumables except grease, rustoline, nuts, bolts will be in the scope of contractor. Contractor will deploy technically qualified, experienced, skilled manpower in sufficient quantity, to carry out the necessary jobs in well organised way so that the job can be completed within scheduled time. Requirement of heavy equipment to be envisaged by Engineer in Charge and to be arranged separately, if required, as the same in not included in the item rate. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. INSTALLATION OF FLANGED / RTJ VALVES/ LEVEL TROLL/ FIRE HYDRANT/ MONITORS/ SAFETY VALVES ETC. Transportation of all types of flanged / RTJ valves, level troll, fire hydrant, monitor, gaskets, nut bolts etc. either from owners storage point to workshop and/ or worksite. Installation at ground level i.e. up to a height of 5 meters on sleepers, pipe racks etc. or up to 5 meters depth in trenches including assembly of valve accessories, cleaning of flanged faces, lapping of RTJ rings, providing new gasket (IOCL supplied) or cutting of new gaskets to proper size if required, placing the gaskets / RTJ ring properly, installation in position with correct direction, tightening of studs, providing earthing protection by way of fixing strips, complete the job in all respect as per drawings and direction of the Engineerin-Charge, including all labour, tools, tackles, consumables and supervision etc. and tightening of the gland to ensure zero leak including hot bolting wherever applicable. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. Requirement of heavy equipment (other than transportation) to be envisaged by Engineer in Charge and to be arranged separately, if r equired, as the same in not included in the item rate. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately. REMOVAL OF FLANGED / RTJ VALVES/ LEVEL TROLL/ FIRE HYDRANT/ MONITORS/ SAFETY VALVES ETC. Dismantling and removal of all types of flanged including RTJ valves, level troll, fire hydrant, monitor by debolting/ cold/ hot cutting of fasteners wherever required from pipelines at ground level i.e. up to a height of 5 meters on sleepers, pipe racks etc. or up to 5 meters depth in trenches including removal of gaskets, nut bolts etc. and transportation either to owners storage point / workshop and / or scrapyard including loosening of studs, disconnecting earthing protection all complete as per direction of the Engineerin-Charge including all labour, tools, tackles, consumables and supervision etc. For job execution beyond 5 Mtr. elevation above or below ground level, rates are to be escalated by 10% for every 5 meters. Requirement of scaffolding to be envisaged and decided by Engineer in Charge as per site requirement and scaffolding item to be paid separately REMOVAL OF FLANGED / RTJ VALVES/ LEVEL TROLL/ FIRE HYDRANT/ MONITORS/ SAFETY VALVES ETC. REVISIONING OF SAFETY VALVES (PSV/TSV etc.): CDSP test, Seat tightness test and adjustment of safety valves as per ASME & API requirements including supply of manpower, tools/tackles, consumables (lapping paste/ powder, flange sealants, emery/polishing paper, soap solution etc.), Painting with one coat of red oxide and two coat of heat resistant aluminium paint (special varnish medium with aluminium flakes) & Stenciling as per the direction of Engineer-In-Charge. In case Safety Valve fail during testing, the procedure shall be repeated at no extra cost. REVISIONING OF SAFETY RELIEF VALVES (PVRV, PRV etc.): Revisioning of SRVs by dismantling, cleaning, lapping of seat surfaces and testing including supply of manpower, tools/ tackles, consumables (Lapping paste/powder, Flange sealants, Emery/Polishing paper, Rustolene etc.) as per direction of Engineer-In-Charge. Painting with one coat of red oxide and two coat of heat resistant aluminium paint(special varnish medium with aluminium flakes) & Stenciling as per the direction of Engineer-In-Charge. In case Safety Relief Valve fails during testing, the procedure shall be repeated at no extra cost. REVISIONING OF PILOT OPERATED SAFETY VALVE: CDSP test and seat tightness test and adjustment of pilot operated safety valves as per ASME & API requirements including supply of manpower, tools/tackles & consumables (lapping paste/powder, flange sealants, emery/polishing paper, soap solution etc), Painting with one coat of red oxide and two coats of heat resistant aluminium paint (special varnish medium with aluminium flakes) & Stenciling as per the direction of Engineer-In-Charge. In case Safety Valve fails during testing, the procedure shall be repeated at no extra cost as per direction of Engineer-In-Charge Shutdown Factor (25% of IOCL common SOR rate items) This is shutdown factor which shall be paid @ 25% of executed value of IOCL Common SOR items Total Quantity :
