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| 1 | Part-A1.1 Column Lumpsum jobs |
| 2 | PART-A1.1 COLUMN LUMPSUM JOBS:Lumpsum rate for carrying out maintenance activities of the followingjobs as per the enclosed Attachments. Referwork package for the list of jobs excluded from lumpsum scope. |
| 3 | 121-C-01 : DEARATOR. |
| 4 | 121-C-02 : DEARATOR. |
| 5 | Part-A1.2 Column Unit rate jobs |
| 6 | PART-A1.2 COLUMN UNIT RATE JOBS: |
| 7 | TRAY REMOVAL, COLD REPAIR & RE-FIXING:The job involves opening of tray manways / trays with proper marking by opening of bolts / nuts, cutting of corroded bolts ( cold / hot cutting if required), straightening of trays / downcomer segments, providing all the missing valves, bubble caps, clamps, bolts, re-fixing of trays / downcomers & boxing up of tray manways.The job also involves transportation of new trays from owner\"s storage point to work site for replacement if replacement to the trays are warranted.The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, suitable slings / belts, etc., 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 the designated place as per EIC instructions. |
| 8 | Removal, cold repair & refixing of Trays. |
| 9 | TRAY / DOWNCOMER REPAIR:Job involves grinding the cracks / damaged portion as marked by Inspection, as welding with suitable filler wire / electrode as per the recommendations, DPT, etc as per Inspection procedures.Job also includes supplying of all types of tools & tackles, 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.Job also includes cleaning of all foreign materials like weld spatters, clamps, fixtures, etc., on parent metal surface. |
| 10 | Tray / downcomer cracks grinding & welding upto 3 mm -Using E-6013 / E-7018 (Inside columns). |
| 11 | Tray / downcomer cracks grinding & welding upto 3 mm -Using E-6013 / E-7018 (Outside columns). |
| 12 | SURFACE PREPARATION - POWER TOOL CLEANING / BUFFING for WFMPT job:The job includes mechanical cleaning of metal surfacesto SSPC - SP-2 / St3 Power tool cleaning standards using power tools like buffing wheels / grinding machine / rotating steel wire brush, etc., to make the surface free of rust, scales, dirt, grease / oil, etc., for the purpose of painting / conducting Wet flourescent magnetic particle testing or dye penetrant inspection or diesel chalk testing on welds / HAZ\"s.The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects including assistance during Wet flourescent magnetic particle testing inspection or dye penetrant inspection or diesel chalk testing on welds / HAZ\"s, if required.NOTE: (1) For weld seam buffing the width of buffing shall be 150mm (i.e) 75mm on both sides of the weld seam. |
| 13 | Power tool cleaning / Buffing to SSPC - SP-2 / St3 standards - 150 mm width of Weld seams / HAZ. |
| 14 | REMOVAL & REFIXING OF FLANGED SAFETY VALVES:The job includes removal of flanged safety valves at all grades & elevations by de-bolting / cold cutting / gas cutting, providing a temporary blind flange at the inlet & outlet of safety valve, providing identification mark on the safety valve with a tag and transportation of the valve to the maintenance valve shop for servicing / testing.The job also includes transportation of safety valves from maintenance valve shop after servicing & testing, servicing of all the fasteners using oil, replacing with new fasteners wherever required, installation of the safety valve at all heights & grades using proper gaskets & studs.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 required materials like gaskets & fasteners from owner\"s storage point, transportation of unused materials to owner\"s storage point and dumping the generated scrap material to designated area as per EIC instructions. |
| 15 | Upto 15 metres elevation from ground level: |
| 16 | Valve rating - 150# &300# - Upto 15 metres elevation from ground level: |
| 17 | Removal & re-fixing of Safety / relief vavles - Size Upto 3 inch dia. |
| 18 | Removal & re-fixing of Safety / relief vavles - Size Above 3 inch dia. & upto 6 inch dia. |
| 19 | Removal & re-fixing of Safety / relief vavles - Size Above 6 inch dia. & upto 10 inch dia. |
| 20 | Above 15 metres elevation from ground level: |
| 21 | Valve rating - 150# &300# - Above 15 metres elevation from ground level: |
| 22 | Removal & re-fixing of Safety / relief vavles - Size Upto 3 inch dia. |
| 23 | Removal & re-fixing of Safety / relief vavles - Size Above 3 inch dia. & upto 6 inch dia. |
| 24 | Removal & re-fixing of Safety / relief vavles - Size Above 6 inch dia. & upto 10 inch dia. |
| 25 | Patch plate welding - Carbon steel - using E 7018 electrodes:The job includes collection & transportation of required materials from owner\"s storage point, marking to the required size, cutting, bending to the desired curvature wherever required, edge preparation, fit up & fillet welding on all four sides using E 7018 electrodes, flushing the finished weld surface by grinding and offering DPT at all grades & elevations.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.NOTE: (1) The above rates are applicable for all external welding jobs and internal welding jobs using E 6013 / E 7018 electrodes as applicable. |
| 26 | Patch plate welding - Carbon steel - Upto 6 mm thickness using E 7018 electrodes. |
| 27 | Patch plate welding - Carbon steel - 8mm thickness using E 7018 electrodes. |
| 28 | Dye Penetration test:Performance of dye penetration test including supply of all necessary materials, penetrant, developer etc.along with all equipment’s, labour ,for carrying out the work as pe rspecification and direction of engineer-in-charge at all elevations.Test has to becarried out in all metallurgy the test has to carry out on all schedules of pipes.NOTE: (1) For weld seamthe width of DPT shall be 150mm (i.e) 75mm on both sides of the weld seam. (2) for the gasket seating surface, width of the DPT shall be 150 mm. |
| 29 | For Vessels/ Tanks/Other locaations. (One Unit EA = One Inch length) |
| 30 | Part-A2 Piping and Hot Works Jobs - Unit |
| 31 | PART-A2 PIPING AND HOT WORKS JOBS - UNIT RATE JOBS: |
| 32 | SUPPLY, ERECTION & DISMANTLING OF STEEL SCAFFOLDING- For External purpose -thickness gauging, Pipe line replacement, NDTjobs :The job includes supply, transportaiton of scaffolding materials is 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 thesteel planks / FRP gratings on top for making sufficient area. Dismantling scaffolding after completion of job.Necessary quantity of scaffolding pipes at various lengths, rolling / fixed clamps, metal jolleyincluding all tools, tackles, consumables, labours and contractor\"s supervision to be mobilised for completion of the jobs scope.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.Remarks: (i) Mode of measurement for the above items shall be in meter square. Measurement shall be taken as 2 times length + bredth multiplied by height. This shall be applicable for outside of the confined space. (ii) For scaffolding erected from any platform,height of the scaffolding shall be taken from the platform i.e platform shall be taken as zero meter level. (iii) In addition to above for any other locations the measurement of EIC shall be final and binding to contractor. (iv) Erection of scaffolding and removal / dismantling of the same scaffolding after completion of job shall be considered as completed job. No separate payment for removal of scaffolding shall be made. (iv) Erection of scaffolding and removal / dismantling of the same scaffolding after completion of job shall be considered as completed job. No separate payment for removal of scaffolding shall be made. |
| 33 | Supply, Scaffolding Erection & Dismantling (External): |
| 34 | Up to 6m height. |
| 35 | Above 6 m up to 10 m height. |
| 36 | Above 10 m up to 20 m height. |
| 37 | Above 20 m up to 30 m height. |
| 38 | Intermediate platform. |
| 39 | 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.NOTE: (1) Nominal diameter of the flanges shall be taken for all measurements. (2) In case of either one of the activity like Blinding or de-blinding arise, 50% of the applicable rate shall be paid for the single activity. (3)This rate will be applicable only for the pipeline replcement job / modification jobs only. For all other jobs bliding & deblinding is included inlumpsum. |
| 40 | Blinding and deblinding for 150# & 300# ratings: |
| 41 | Blinding & Deblinding - Size Upto1-1/2 inch dia. |
| 42 | Blinding & Deblinding - Size 2 inch dia. to 5 inch dia. |
| 43 | Blinding & Deblinding - Size 6 inch dia. to 10 inch dia. |
| 44 | Blinding & Deblinding - Size 12 inch dia. to 16 inch dia. |
| 45 | Blinding & Deblinding - Size 18 inch dia. to 24 inch dia. |
| 46 | Blinding & Deblinding - Size 24 inch dia. to48 inch dia. |
| 47 | Blinding and deblinding for 600# & 900# ratings: |
| 48 | Blinding & Deblinding - Size Upto1-1/2 inch dia. |
| 49 | Blinding & Deblinding - Size 2 inch dia. to 5 inch dia. |
| 50 | Blinding & Deblinding - Size 6 inch dia. to 10 inch dia. |
| 51 | Blinding & Deblinding - Size 12 inch dia. to 16 inch dia. |
| 52 | Blinding & Deblinding - Size 18 inch dia. to 24 inch dia. |
| 53 | Blinding & Deblinding - Size 24 inch dia. to48 inch dia. |
| 54 | Blinding and deblinding for 1500# & 2500# ratings withoutTorque wrench: |
| 55 | Blinding & Deblinding - Size Upto1-1/2 inch dia. |
| 56 | Blinding & Deblinding - Size 2 inch dia. to 5 inch dia. |
| 57 | Blinding & Deblinding - Size 6 inch dia. to 10 inch dia. |
| 58 | Blinding & Deblinding - Size 12 inch dia. to 16 inch dia. |
| 59 | Blinding & Deblinding - Size 18 inch dia. to 24 inch dia. |
| 60 | REMOVAL / INSTALLATION / REFIXING OF FLANGED VALVES: |
| 61 | Removal of Flanged valves (Other than safety valves):The job includes removal of flanged valves at all grades & elevations by de-bolting / cold cutting / gas cutting and transportation of the valve to the maintenance valve shop or any other designated place inside the refinery premises for repair / disposal.The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, dumping the generated scrap material to the designated area, all consumables and labour to complete the job in all respects. |
| 62 | Valve rating - 150# & 300#: |
| 63 | Removal of valves - Size 2 inch dia. to 3 inch dia. |
| 64 | Removal of valves - Size 4 inch dia. to 6 inch dia. |
| 65 | Removal of valves - Size 8 inch dia. to 10 inch dia. |
| 66 | Removal of valves - Size 12 inch dia. to 14 inch dia. |
| 67 | Removal of valves - Size 16 inch dia. to 18 inch dia. |
| 68 | Removal of valves - Size 20 inch dia. to 24 inch dia. |
| 69 | Removal of valves - Size 26 inch dia. to 28 inch dia. |
| 70 | Removal of valves - Size 30inch dia. to 32 inch dia. |
| 71 | Removal of valves - Size 34inch dia. to 36 inch dia. |
| 72 | Installation of Flanged valves (Other than safety valves):The job includes transportation of valves, gaskets, fasteners, etc., from the owner\"s storage point or valve maintenance shop, cleaning, checking, tightening the gland, greasing & freeing up etc., servicing of all the fasteners using oil, replacing with new fasteners wherever required, hydrotesting the valve if required, at the specified pressure at valve maintenance shop,installation of flanged valve at all heights & grades using proper gaskets & studs.The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, dumping the generated scrap material to the designated area, all consumables and labour to complete the job in all respects. |
| 73 | Valve rating - 150# & 300#: |
| 74 | Installation of valves - Size 2 inch dia. to 3 inch dia. |
| 75 | Installation of valves - Size 4 inch dia. to 6 inch dia. |
| 76 | Installation of valves - Size 8 inch dia. to 10 inch dia. |
| 77 | Installation of valves - Size 12 inch dia. to 14 inch dia. |
| 78 | Installation of valves - Size 16 inch dia. to 18 inch dia. |
| 79 | Installation of valves - Size 20 inch dia. to 24 inch dia. |
| 80 | Installation of valves - Size 26 inch dia. to 28 inch dia. |
| 81 | Installation of valves - Size 30 inch dia. to 32 inch dia. |
| 82 | Installation of valves - Size 34 inch dia. to 36 inch dia. |
| 83 | CHANGING / REPLACEMENT OF FLANGE GASKETS:The job includes collection & transporatation of required quantity of materials like gaskets, fasteners, etc., from owner\"s storage point, changing / replacement of flange gaskets in pipelines, valves, all types of equipments at all elevations including loosening & tightening of studs (cold / gas cutting if required), wedge opening, cleaning of flanges, 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. |
| 84 | Flange gaskets - 150# & 300# ratings: |
| 85 | Replacement of Gaskets - Size Upto 1-1/2 inch dia. |
| 86 | Replacement of Gaskets - Size 2 inch dia. to 5 inch dia. |
| 87 | Replacement of Gaskets -Size 6 inch dia. to 10 inch dia. |
| 88 | Replacement of Gaskets -Size 12 inch dia. to 16 inch dia. |
| 89 | Replacement of Gaskets - Size 18 inch dia. to 24 inch dia. |
| 90 | Replacement of Gaskets - Size 26 inch dia. to 28 inch dia. |
| 91 | Replacement of Gaskets - Size 30 inch dia. to 32 inch dia. |
| 92 | Replacement of Gaskets - Size 34 inch dia. to 36 inch dia. |
| 93 | Flange gaskets - 600# & 900# ratings: |
| 94 | Replacement of Gaskets - Size Upto 1-1/2 inch dia. |
| 95 | Replacement of Gaskets - Size 2 inch dia. to 5 inch dia. |
| 96 | Replacement of Gaskets -Size 6 inch dia. to 10 inch dia. |
| 97 | Replacement of Gaskets -Size 12 inch dia. to 16 inch dia. |
| 98 | Replacement of Gaskets - Size 18 inch dia. to 24 inch dia. |
| 99 | Replacement of Gaskets - Size 26 inch dia. to 28 inch dia. |
| 100 | Replacement of Gaskets - Size 30 inch dia. to 32 inch dia. |
| 101 | Replacement of Gaskets - Size 34 inch dia. to 36 inch dia. |
| 102 | Dismantling & Removal of Piping:The job involves removal of existing above ground, under ground, overhead insulated or uninsulated or steam traced piping including all types of fittings like elbows / tees / reducers, etc., flanges, valves, all types of instruments, supports by coldcutting / gas cutting / grinding, etc., at all locations at all grades & elevations without damaging any other portion of the existing unit, lowering down the same to ground level, transportation of the same to the designated area as per the instructions of Engineer-in-charge. The insulation materials to be removed from the pipesand transported to their respective designated locations as per EIC.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. |
| 103 | Dismantling & removal of Piping - Carbon steel / Alloy steel. |
| 104 | Concrete dismantling (PLAIN and REINFORCED):Demolishing plain cement concrete in foundation and super structure including disposal of unserviceable material upto 3KM lead as directedand serviceable materials to stores including scaffolding, all labour, tools supervision, safety permits, safety precaution etc. complete.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.The job involves dismantling of reinforced cement concrete pavements includingcuttingofreinforcement bars, returning of scrapsteelsto designated area, breaking the RCC work into piecesand disposal of unserviceable material upto 3.0km lead as directed , etc. as per the direction of the Engineer-in-charge. |
| 105 | Dismantling Plain cement concrete (PCC). |
| 106 | Dismantling Reinforced cement concrete (RCC). |
| 107 | Earth work excavation & back filling:The job involves earth work excavation below ground level upto 2 metres depth & to a required width for laying underground piping in all types of soils including removal of vegetation, if required, dressing of sides, levelling, grading, ramming of bottom, back filling on completion of laying of pipes with available excavated soil, watering, rolling, ramming of by manual methods / mechanical compactors, dressing, trimming, etc.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. |
| 108 | Earth work excavation & back filling - Upto 2 metres depth. |
| 109 | Dewatering - with Contractor\"s pump:The job involves pumping out of water including dewatering oily water mixed with muck / sludge etc. from trenches, pits etc. by contractor\"s own pump as per the direction of the Engineer-in-charge.The job also includes supplying of all types of pumps, tools & tackles, hoses, fuel, all consumables and labour to complete the job in all respects as per EIC instructions. |
| 110 | Hire charges for 5 HP Diesel driven dewatering pump with all accessories including hoses along with one operator - For 8 Hrs. (One Unit EA = One Shift (8 Hrs)) |
| 111 | Carbon Steel Piping Work - Above ground/ Below 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, draining / drying of the piping system and removal of insulation wherever required.WITH CPCL SUPPLY OF FREE POWER & CONTRACTOR\"S WELDING MACHINE. NOTES FOR SOR SL. NOS. (1) Thickness of piping for measurement shall be based on the relevant ANSI or equivalent standards. (2) The finished weld joint elevation at site shall be taken as reference for measurement, wherever applicable. (3) The rates for socket & fillet welding in piping shall remain same for all thickness and elevations as per SOR. (4) Rate for weld joints of vents & drains shall be paid on actual measurement using the applicable SOR. (5) For reinforcement pad welding, the rates shall be paid separately as per SOR. (6) Fabrication & welding of pipe shoe supports & pad at support locations are included in SOR and will not be considered for measurement. (7) For scaffolding work wherever required, rates shall be paid separately as per SOR. (8) For blinding & deblinding wherever involved, rates shall be paid separately as per SOR. (9) For stress relieving of weld joints, rates shall be paid separately as per SOR. (10) In case of replacement of existing piping, rates for removal of old pipelines shall be paid separately as per SOR. (11) During hydrotesting of the above piping jobs, some portions of the existing piping in the circuit required to be hydrotested depending on the blinding and the same is included in the applicable welding SOR. (12) Radiography of weld joints is not included in SOR and rate shall be as per SOR. (13) For removal and refixing of Flanged valves, rates shall be paid separately as per SOR. (14) Wrapping & coating of pipelines is not included in SOR. (15) for the underground piping, above ground piping rates shall be applicable. |
| 112 | SOCKET WELDING - ALL ELEVATIONS: |
| 113 | Carbon Steel - Above ground Piping - Socket / fillet welding Joint - With Hydrotest. |
| 114 | Carbon Steel - Above ground Piping - Socket / fillet welding Joint - Without Hydrotest. |
| 115 | BUTT WELDING - UPTO 5 METRES FROM GROUND LEVEL - USING E-6010/E-6013 / E-7018 ELECTRODES: |
| 116 | Carbon Steel - Above ground Piping - Butt welding Joint - Upto 8.8 mm thickness - With hydrotest. |
| 117 | Carbon Steel - Above ground Piping - Butt welding Joint - Upto 8.8 mm thickness - Without hydrotest. |
| 118 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 8.8 mm and upto 12.7 mm thickness-With hydrotest. |
| 119 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 8.8 mm and upto 12.7 mm thickness-Without hydrotest. |
| 120 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 12.7 mm and upto 26 mmthickness-With hydrotest. |
| 121 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 12.7 mm and upto 26 mmthickness-Withouthydrotest. |
| 122 | BUTT WELDING PIPING AT ELEVATIONS -ABOVE 5 METRES FROM GROUND LEVEL- USING E-6010/E-6013/E-7018 ELECTRODES: |
| 123 | Carbon Steel - Above ground Piping - Butt welding Joint - Upto 8.8 mm thickness - With hydrotest. |
| 124 | Carbon Steel - Above ground Piping - Butt welding Joint - Upto 8.8 mm thickness - Without hydrotest. |
| 125 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 8.8 mm and upto 12.7 mm thickness - With hydrotest. |
| 126 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 8.8 mm and upto 12.7 mm thickness - Without hydrotest. |
| 127 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 12.7 mm and upto 26 mmthickness-With hydrotest. |
| 128 | Carbon Steel - Above ground Piping - Butt welding Joint - Above 12.7 mm and upto 26 mmthickness-Without hydrotest. |
| 129 | Alloy Steel Piping Work - Aboveground: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 alloy steel piping above ground level at all locations, 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 TIG welding process for root run followed by manual arc welding process for the filling passes with relevant filler wires / electrodes as required with necessary pre-heating prior to welding, DPT wherever required, Post weld heat treatment (PWHT - stress relieving) after welding, 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 designated area as per EIC instructions.The rates for the following items shall be exclusive of blinding & deblinding, reinforcement pad welding,radiography , removal of old piping for replacement and erection & removal of scaffolding.The rates for the following items shall be inclusive of fabrication, laying, erection, preheating, welding,100% stress relieving of joints,providing shoe supports, pads at support locations, flushing of the piping system, offering stagewise inspection, hydrotesting and draining / drying of the piping system.WITH CPCL SUPPLY OF FREE POWER & CONTRACTOR\"S WELDING MACHINE. Notes: (1) Thickness of piping for measurement shall be based on the relevant ANSI or equivalent standards. (2) The finished weld joint elevation at site shall be taken as reference for measurement, wherever applicable. (3) The rates for socket & fillet welding in piping shall remain same for all thickness and elevations as per SOR. (4) Rate for weld joints of vents & drains shall be paid on actual measurement using the applicable SOR. (5) For reinforcement pad welding, the rates shall be paid separately as in General category jobs under SOR Sl. Nos.1.10. (6) Fabrication & welding of pipe shoe supports & pad at support locations are included in SOR and will not be considered for measurement. (7) For scaffolding work wherever required, rates shall be paid separately as per General category jobs under SOR. (8) For blinding & deblinding wherever involved, rates shall be paid separately as per General category jobs under SOR. (9) Radiography of weld joints is not included in SOR and rate shall be as per General category jobs under SOR. (10) Preheating (Using coil ) and 100% Post weld heat treatment (stress relieving) of weld joints is included in SOR for both socket & butt welding. (11) In case of replacement of existing piping, rates for the removal of old pipelines shall be paid separately as per SOR. (12) During hydrotesting of the above piping jobs, some portions of the existing piping in the circuit required to be hydrotested depending on the blinding and the same is included in the applicable welding SOR. (13) For steam tracing piping work, hydraulic testing of piping is not required and applicable SOR (Without hydrotest) shall be paid on account of this.For bending tracer pipelines, the rates shall be paid separately as per SOR. |
| 130 | SOCKET WELDING - ALL ELEVATIONS - ALLOY STEEL: |
| 131 | Alloy Steel - Above ground Piping - Socket / fillet welding Joint usingalloy welding filler wire / electrode upto P5 grades - With hydrotest. |
| 132 | Alloy Steel - Above ground Piping - Socket / fillet welding Joint using low alloy welding filler wire / electrode upto P5 grades - Without hydrotest. |
| 133 | BUTT WELDING - UPTO 5 METRES FROM GROUND LEVEL - ALLOY STEEL: |
| 134 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - Upto 8.8 mm piping thickness - with hydrotest. |
| 135 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - Upto 8.8 mm piping thickness - without hydrotest. |
| 136 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - above 8.8 mm and upto 12.7 mm piping thickness - with hydrotest. |
| 137 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - above 8.8 mm and upto 12.7 mm piping thickness - without hydrotest. |
| 138 | BUTT WELDING PIPING AT ELEVATIONS -ABOVE 5 METRESFROM GROUND LEVEL- ALLOY STEEL: |
| 139 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - Upto 8.8 mm piping thickness - with hydrotest. |
| 140 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - Upto 8.8 mm piping thickness - without hydrotest. |
| 141 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - above 8.8 mm and upto 12.7 mm piping thickness - with hydrotest. |
| 142 | Alloy Steel -Above ground Piping - Butt welding Joint using alloy welding filler wire / electrode upto P5 grades - above 8.8 mm and upto 12.7 mm piping thickness - without hydrotest. |
| 143 | Carbon steel Piping Specials like Mitre cut bend, reducers:The job includes transporation of all free issue materials from owner\"s storage point to work site, handling at site, cutting, bevelling, fabrication & welding of carbon steel piping specials (of any thickness) like 4 element - 3 weld type 90° mitre cut bend,3 element - 2 weld type 45° mitre cut bend / reducers, etc., at all locations above ground level, overhead, over sleepers, piperacks, crossovers, pipe sleeves, trenches, stand posts, connecting with equipments & nozzles at all grades & elevations including under road culverts of different schedules, pressure ratings and for various temperature applications.The job includes flushing, preparing work area for executing hot work, bending to suit the contours wherever required, welding using E 6010 / E 6013 / E 7018 electrodes as 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 designated area as per EIC instructions.The rates for the following items shall be exclusive of radiography, stress relieving,welding of vents & drainsand erection & removal of scaffolding.The rates for the following items shall be inclusive of fabrication, welding,offering stagewise inspection.NOTE: (1) Rate for weld joints of vents & drains shall be paid on actual measurement using the applicable SOR. (2) For radiography of weld joints, rates shall be as per General category jobs under SOR. (3) For stress relieving of weld joints, rates shall be paid separately as per General category jobs under SOR. |
| 144 | Mitre Bends - Butt weld Joint - Carbon steel: |
| 145 | Mitre Bends - Butt weld Joint - Upto 8.8 mm thickness. |
| 146 | Mitre Bends - Butt weld Joint - Above 8.8 mm and upto 12.7 mm thickness. |
| 147 | Reducers - Butt weld Joint - Carbon steel: |
| 148 | Reducers - Butt weld Joint - Upto 8.8 mm thickness. |
| 149 | Reducers - Butt weld Joint - Above 8.8 mm and upto 12.7 mm thickness. |
| 150 | Fabrication & erection of structural: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.NOTE: (1) For scaffolding work wherever required, rates shall be paid separately as per SOR. |
| 151 | Fabrication and erection of structurals. |
| 152 | Dismantling & Removal of Structurals / Gratings:The job involves removal of existing above ground, overhead structurals including platforms, ladders, GI & steel gratings by unfastening / coldcutting / gas cutting / grinding, etc., from various locations at all grades & elevations without damaging any other portion of the existing unit, lowering down the same to ground level, transportation of the same to the designated area or scrap yard as per the instructions of Engineer-in-charge including weighment of the material at the appropriate place within the refinery premises, if required.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.NOTE: (1) For scaffolding work wherever required, rates shall be paid separately as per SOR. |
| 153 | Dismantling & Removal of Structurals / Gratings. |
| 154 | Erection and welding of Platform / ladder gratings:The job includes erection & welding of gratings in position under the support structure in columns, vessels, tanks, staircase, platforms, step ladders, etc., at all grades & elevations with necessary corrections at work site on the supplied grating to fit to the site requirements.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. |
| 155 | Erection and welding of Gratings upto 15 m elevation. |
| 156 | Erection and welding of Gratings above 15 m elevation. |
| 157 | RADIOGRAPHY:The job includes performing radiography examination of welds on piping & all type of equipments as per relevant ASME / ASTM standards & as per CPCL specification CPCL-INSP-RAD-01 at all grades & elevations with film width not less than 4 inches.The job also includes supplying of radiation source camera, other machineries required, all consumables required for filming & developing, transportation of camera, etc., area preparation before starting the job, labour, supervision to complete the job in all respects including preparation of developing chemicals, developing the films & submission of films for inspection review.Note: (1) For pipe weld joints, nominal diameter of the pipe shall be taken for measurement. (2)Payment shall not be permissible for repeated radiography for the same joints on repair work & poor radiography quality. |
| 158 | Pipe weld joints - Upto 2\" nominal dia. (One Unit EA = One Joint) |
| 159 | Pipe weld joints - 3\" nominal dia. (One Unit EA = One Joint) |
| 160 | Pipe weld joints - 4\" nominal dia. (One Unit EA = One Joint) |
| 161 | Pipe weld joints - 6\" nominal dia. (One Unit EA = One Joint) |
| 162 | Weld joint size - above 6\" nominal dia and weld seams of storage tanks, pressure vessels and plate welds. (One Unit EA = One Inch length of film) |
| 163 | Weld overlay / reinforcement / build up - Carbon steel - using E 7018 electrodes:The job includes flushing, preparing work area for executing hot work, preparing the metal surface by grinding, weld deposition / overlay / reinforcement to a depth of 3 mm on the pitted metal surfaces / weldments as required using E 7018 (for carbon steel) , flushing the finished overlaid surface by grinding and offering DPT at all grades & elevations.The job also includes supplying of all types of tools & tackles, machineries, all consumables and labour to complete the job in all respects. |
| 164 | Weld overlay / reinforcement / build up - Carbon steel - Upto 3 mm thickness using E 7018 electrodes. |
| 165 | Weld overlay / reinforcement / build up - Carbon steel - 4 mm to 6 mm thickness using E 7018 electrodes. |
| 166 | Weld overlay / reinforcement / build up - Carbon steel - 7 mm to 9 mm thickness using E 6013 electrodes. |
| 167 | Weld overlay / reinforcement / build up - Carbon steel - 10 mm to 12 mm thickness usingE 6013 electrodes. |
| 168 | Gas Cutting of Plates- Carbon Steel / Alloy steel:The job includes gas cutting of carbon steel / Alloy steel plates at all heights & grades including area preparation for hot work.The job also includes supplying of all types of tools & tackles, machineries, gas, all consumables and labour to complete the job in all respects and dumping the generated scrap material to designated area as per EIC instructions. |
| 169 | Gas Cutting of Plates - Carbon Steel / Alloy steel - Thickness upto 6 mm. |
| 170 | Gas Cutting of Plates-Carbon Steel / Alloy steel-Thickness 8 mm. |
| 171 | Plate Rolling:The job includes spreading the required plate for marking,cutting,marking of plates, edge preparation, chipping, shifting of plate to rolling machine, rolling of plates including transportation and shifting of rolled plates to work site.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 unused materials to owner\"s storage point and dumping the generated scrap material to designated area as per EIC instructions. |
| 172 | Plate rolling CS/AS - upto 1500 mm dia.: |
| 173 | Plate Rolling - Carbon steel / Alloy Steel - 6 to 10 mm thickness. |
| 174 | Plate Rolling - Carbon steel / Alloy Steel - 12 to 14 mm thickness. |
| 175 | Gas Cutting of bolts:The job includes gas cutting of carbon steel & B7 studs at all heights & grades including area preparation for hot work.The job also includes supplying of all types of tools & tackles, machineries, gas, all consumables and labour to complete the job in all respects and dumping the generated scrap material to designated area as per EIC instructions. |
| 176 | Gas Cutting of Studs size - Carbon Steel & B7 material - Upto Size M 20. |
| 177 | Gas Cutting of Studs size - Carbon Steel & B7 material - Above Size M 20. |
| 178 | Fillet welding - Carbon Steel (Using E-6013 Electrode):The job includes flushing, preparing work area for executing hot work, grinding, fillet welding on plate surfaces using E 6013 electrodes at all grades & elevations.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. |
| 179 | Fillet welding - Carbon Steel - upto4 mm thickness using E 6013 electrodes. |
| 180 | Fillet welding - Carbon Steel - 5 to 6 mm thickness using E 6013 electrodes. |
| 181 | Fillet welding - Carbon Steel - 8 mm thickness using E 6013 electrodes. |
| 182 | Dismantling / Erection ofDuct:The job involves removal of connected piping as necessary and removal of old duct including cutting of corroded bolts ( cold / hot cutting if required).The job also involves transportation of new vessel from owner\"s storage point to work site , erection of new duct in position and reconnect the removed pipe lines.The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, suitable slings / belts, etc., machineries, all consumables and labour to complete the job in all respects, transportation of unused materials to owner\"s storage point and dumping the old duct/ generated scrap material to the designated place as per EIC instructions. |
| 183 | Dismantling of Duct. |
| 184 | Erection of Duct. |
| 185 | Pipe line hydro testing:The job involves hydrotesting of pipelines to the specified test pressure at all elevations by providing necessary hose connections from the source of water supply to the work location for preparing the test, flushing, filling up water on the piping circuit, vent entrapped air, pressurize to the required hydro test pressure with necessary test pumps, and offer for inspection including access & assistance to CPCL Inspection team during the checking, draining & drying of the piping circuit.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. |
| 186 | Upto 2\" dia. |
| 187 | 2.5\" dia - 6\" dia. |
| 188 | 8\" dia & 10\" dia. |
| 189 | 12\" dia - 16\". |
| 190 | STRESS RELIEVING -For Carbon steel piping job:The job involves Post weld heat treatment (PWHT) / Stress relieving of carbon steel / alloy steel metal surfaces, weld seams or HAZ, etc., shop fabricated or site fabricated or existing piping / static equipment at all grades & elevation.The job also includes cleaning the adjoining surfaces, welding of required thermocouples, insulating the portion using super fine glass wool / asbestos tape, heating the metal surface using a induction heating equipment as per the requirement, ensuring uniform temperature attainment at all points, recording the temperatures by means of thermocouples / pyrometer / automatic temperature recorders suitably calibrated, removal of insulation, providing assitance for hardness testing, submitting recorded charts for approval, removal & dressing of thermocouple leads, etc., as per the instructions of EIC.The job also includes supplying of all types of tools & tackles, machineries, all consumables, labour & supervision to complete the job in all respects including transportation of all the required materials to the work site. |
| 191 | Stress Relieving - Pipe weld joints. |
| 192 | Part-A3 Exchangers Maintenance Jobs - Un |
| 193 | PART-A3 EXCHANGERS MAINTENANCE JOBS - UNIT RATE JOBS: |
| 194 | MAINTENANCE OF HEAT EXCHANGERS / COOLERS / CONDENSERS- ALL TYPES - ALL SIZES:The job includes collection & transporatation of required quantity of materials like blinds, gaskets, fasteners, etc., from owner\"s storage point, providing necessary flushing / steaming arrangement for draining the shell & tube fluids, blinding the exchanger as per the Operations list,erecting scaffolding wherever required for the jobs like, blinding, cover dropping, channel head removal, insulation removal in the shell, removing insulation over flanges, if required to facilitate removal of bolts, connecting hoses & assisting static passivation wherever required, opening all the covers after de-bolting and dropping all the components like channel cover, shell cover, channel section and floating head cover, etc., and servicing of all the fasteners for re-use.The job also includes pulling the tube bundle wherever applicable with proper rigging arrangement, shifting the tube bundle & components to Bundle cleaning yard or to the desired locations within the refinery premises as per EIC, cleaning the tube bundle externally by scrapping / wire brushing / hydroblasting& internally by rodding / hydrolancing / air blowing as required, cleaning the shell and all the exchanger components by scrapping, wire brushing, chiseling & hydroblasting, shifting the bundle & components back to the work site, re-installing the tube bundle in position after obtaining Inspection / Operations clearance and boxing up the covers in stages to conduct hydrotesting with suitable gaskets.The job also includes preparing the test flanges, arranging & offering shell test, tube test & back shell test to Inspection, plugging the leaky tubes as marked during the test, box up the equipment in all respects including de-blinding, removal of scaffolding, etc., providing start up coverage for hot bolting, etc., till the equipment is commissioned.The job also includes transportation of tube bundle to the owners work shop for retubing / repairs, if recommended during any stages of the work, and back to the work site on completion of retubing / repairs.The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, suitable slings / belts, etc., 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.The job also includes, i. Operator assistance for shutting down the exchanger. ii. Connecting steam hoses to make oil free. iii. Blinding / deblinding as per work package. iv. Servicing of test rings. v. Removal of all shell and tube bundles, channel head and shell cover, vi. Removal of floating heads or plugs of fin fan coolers. vii. Removal of end covers for fixed tube bundles. viii. Cleaning of all the above parts and offer to inspection. ix. After clearance from inspection, insert tube bundle and other parts of exchanger with proper gasket. x. Replacement of sacrificial anodes. xi. Torque tool tightening kit. xii. Perform shell test, tube test and back shell test as mentioned in the work package & get inspection clearance. xiii. Plug the leaky tubes. xiv. Erection and dismantling of scaffolding. xv. Area cleaning and hot bolting and provide startup coverage. xvi. Except Part B SOR all other items mentioned in the contractor scope of supply is covered under various unit rate SOR.NOTE: (1) Nominal diameter of the tube as per drawings shall be taken for all measurements. (2) For measurement, number of tubes for any exchanger shall be as per the relevant drawings. In case of non-availability of drawings, actual no. of tubes on the equipment shall be taken for measurements. (3) Though the rate is based on no. of tubes with free supply of crane by CPCL, cranes will be supplied by CPCL as per EIC instructions only at the locations where there is no monorail arrangement or no provision for removing the covers & tube bundle using chain pulley block.Additional increase in basic rate for removing covers & tube bundle using chain pulley block/ monorail arrangement shall be paid as applicable. (4) In case of U-tube bundles,the number of U-tubes are to be doubled for measurement purpose. (5) For equipment with less than 50 nos. of tubes, number of tubes shall be considered as 50 for measurement. (6) For single equipment having tubes upto 100 nos. of tubes , the rates shall be paid as per SOR. (7) For single equipment having tubes more than 100 nos. of tubes - ,,a) for 100 nos. of tubes, the rates shall be paid as per SOR & ,,b) for the balance tubes, the rates shall be paid as per SOR. (8) In general, Hydrotest pressures as in the relevant drawings shall be taken for measurement.However, hydrotesting pressures shall be varied in specific cases based on the requirement as per EIC instructions and the same shall be considered for measurement. (9) Rate for shell side & tube side hydrotesting once upto 60 Kg/sq.cm. is included in the basic rate and no additional rate shall be payable. (10) In case of tube / gasket leak during hydrotesting, the system may have to be depressurised for plugging leaky tubes or replacing gaskets and payment for hydrotesting can be claimed only once as a whole. (11) For Ground level bottom exchanger in the stacked condition, no additional rate shall be payable. (12) For exchangers, reboilers, coolers & condensers under SOR rate for shell side & tube side hydrotesting once is included in the basic rate and no additional rate shall be payable.However, any waiver of shell or tube tests arise as per CPCL requirements, rate for each test as per additional rate shall be deducted. (13) If any hot work warrented during during dismantling & erection (Excluding bolts cutting), rates shall be paid as per Piping Category jobs. I) Carrying out Hydro testing and offer to CPCL Inspection charges of the above equipment were already covered in individual equipment SOR. |
| 195 | Exchangers, reboilers, coolers, condensers - Maintenance work - Upto 100 tubes of an equipment: |
| 196 | Exchangers, reboilers, coolers, condensers Maintenance work - Fixed tube bundle / Inposition cleaning / Bundle sent to retubing before thoruogh cleaning - (Tube size < 2\" , All length (Straight tubes), Test pressure - upto 60 KSC, Ground level exchanger). (One Unit EA = Per tube) |
| 197 | Extra rate - Elevation / Position/ bundle pulling & reinstallation using chain block / passivation/ Size of tubes: |
| 198 | Ground level - top exchanger in the stacked condition. (One Unit EA = Per tube) |
| 199 | Exchangers at elevation ( Base - Above 5 Mtr elevation)& bottom exchanger in the stacked condition. (One Unit EA = Per tube) |
| 200 | Exchangers at elevation( Base - Above 5 Mtr elevation)& top exchanger in the stacked condition. (One Unit EA = Per tube) |
| 201 | Bundle pulling out / reinstallation using chain pulley block. (One Unit EA = Per tube) |
| 202 | Extra rate - Dismantling & erection of exchanger: |
| 203 | Disconnect / removal of connected pipelines, removal of exchanger completely , shell along with bundle (including cold / hot cutting of bolts, if required) from the foundation / supports, bring it to Ground level, lifting, erection of exchanger in position and reconnect / reerect the connected pipe linesand servicing of fasteners - Upto 5 Mtr elevation. (One Unit EA = Per tube) |
| 204 | Disconnect / removal of connected pipelines, removal of exchanger completely , shell along with bundle (including cold / hot cutting of bolts, if required) from the foundation / supports, bring it to Ground level, lifting, erection of exchanger in position and reconnect / reerect the connected pipe linesand servicing of fasteners - Above 5 Mtr & upto 10 Mtr elevation. (One Unit EA = Per tube) |
| 205 | Exchangers, reboilers, coolers, condensers - Maintenance work - Beyond 100 tubes of an equipment: |
| 206 | Exchangers, reboilers, coolers, condensers Maintenance work - Fixed tube bundle / Inposition cleaning / Bundle sent to retubing before thoruogh cleaning - (Tube size < 2\" , All length (Straight tubes), Test pressure - upto 60 KSC, Ground level exchanger). (One Unit EA = Per tube) |
| 207 | Extra rate - Elevation / Position/ bundle pulling & reinstallation using chain block / passivation/ Size of tubes: |
| 208 | Ground level - top exchanger in the stacked condition. (One Unit EA = Per tube) |
| 209 | Exchangers at elevation ( Base - Above 5 Mtr elevation) & bottom exchanger in the stacked condition. (One Unit EA = Per tube) |
| 210 | Exchangers at elevation ( Base - Above 5 Mtr elevation) & top exchanger in the stacked condition. (One Unit EA = Per tube) |
| 211 | Bundle pulling out / reinstallation using chain pulley block. (One Unit EA = Per tube) |
| 212 | Extra rate - Dismantling & erection of exchanger: |
| 213 | Disconnect / removal of connected pipelines, removal of exchanger completely , shell along with bundle (including cold / hot cutting of bolts, if required) from the foundation / supports, bring it to Ground level, lifting, erection of exchanger in position and reconnect / reerect the connected pipe linesand servicing of fasteners - Upto 5 Mtr elevation. (One Unit EA = Per tube) |
| 214 | Disconnect / removal of connected pipelines, removal of exchanger completely , shell along with bundle (including cold / hot cutting of bolts, if required) from the foundation / supports, bring it to Ground level, lifting, erection of exchanger in position and reconnect / reerect the connected pipe linesand servicing of fasteners - Above 5 Mtr & upto 10 Mtr elevation. (One Unit EA = Per tube) |
| 215 | MAINTENANCE OF GENERATOR AIR COOLER:The job includes collection & transporatation of required quantity of materials like blinds, gaskets, fasteners, etc., from owner\"s storage point, providing necessary flushing / steaming arrangement for draining the tube fluids, blinding the coolers as per the Operations list,erecting scaffolding wherever required, connecting hoses & assisting static passivation wherever required, opening all the covers / plugs after de-bolting and dropping all the covers and servicing of all the fasteners for re-use.The job also includes cleaning the tube externally by air blowing& internally by rodding / hydroblasting / air blowing as required, cleaning the end covers & nozzles by scrapping, wire brushing, chiseling & hydroblasting and boxing up the covers to conduct hydrotesting with suitable gaskets.The job also includes preparing & boxing up the covers / refixing the plugs with proper gaskets, offering tube test, cold cutting the leaky tubes & providing stubs at both ends, plugging the leaky tubes wherever required, and box up the equipment in all respects including de-blinding, removal of scaffolding, etc., providing start up coverage for hot bolting, etc., till the equipment is commissioned.The job also includes transportation of Generator Air Cooler to the owners work shop for retubing / repairs, if recommended during any stages of the work, and back to the work site on completion of retubing / repairs.The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, suitable slings / belts, etc., 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. |
| 216 | Generator air cooler - Maintenance work - Upto 200 tubes of an equipment: |
| 217 | Generator air cooler Maintenance work - (All length , Test pressure - upto 60 KSC, All elevation, all tube sizes). (One Unit EA = Per tube) |
| 218 | Generator air cooler - Maintenance work - Beyond 200 tubes of an equipment: |
| 219 | Generator air coolerMaintenance work - (All length , Test pressure - upto 60 KSC, All elevation, all tube sizes). (One Unit EA = Per tube) |
| 220 | Supply and application ofinternalPaintingofExchanger components as perCPCL Painting system - XXVII:For certain heat Exchangers,components ( interior surfaces of channel head, channel cover, channel part partition plate & floating head)are to be painted as mentioned in the work package. After obtaining clearance, these components to be shifted to the designated place for Grit blasting and painting as per the system indicated.The job also includes supply of Necessary grits and grid blasting machines are in contractors scope. Safety precautions to be taken before grit blasting. Mobile Air Compressor shall be provided by CPCL.Supply of necessary painting material from CPCL approved vendors. |
| 221 | Supply and application of internal painting as per enclosed CPCL Painting specification XXVII with surface prepation by metal grit blasting for Exchanger componentsinternal surface. Paint application by air less spray. Necessary hopper and accesories to carryout the jobs is in contractor scope. |
| 222 | CERAMIC COATING ON TUBE SHEET SURFACES OF EXCHANGERS: |
| 223 | The Scope includes Supply and Application of Ceramic coating ( Loctite Nordbak Brushable Ceramic Gray or Titanium Putty / Equivalent Grade) of 500 Microns Minimum (Including preparation of tube sheet surfaces by Grit blasting confriming to Sa 2.5 quality) ontube sheets of the Coolers , as per the enclosed scope of work and other Attachments.Note: The rate quoted shall inclusive of carrying outGrit blast machine with mobile air compressors and accessories to carryout the job. Necessary Mobile Air Compressor shall be provided by CPCL.List of Ceramic Coating Brands : Shailnick, Loctite, Duromar & Belzona make. |
| 224 | Dismantling , Shiffting & erection of New generator Air cooler: The job includes collection & transporatation of required quantity of materials like gaskets, fasteners, etc., from owner\"s storage point, rearranging scaffolding wherever required, dismantle the connected pipelines (including hot / cold cutting of bolts wherever required), remove the cooler from the support, transport to garage / retubing yard / cleaning yard, shifting back to site after completion of work, erection of cooler in its position , re-erect / connect the dismantled / disconnected pipelines and servicing of all the fasteners for re-use.The job also includes supplying of all types of tools & tackles, lifting arrangements like chain pulley blocks, suitable slings / belts, etc., 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. |
| 225 | Dismantling & Shifting of Generator Air coolers to garage / retubing yard for retubing / cleaning yard / scrap yard and bring back Old New Generator Air Cooler from Warehouse / Retubing yard to site after completion of work and erection in position- Coolers having no. of tubes upto 240. (One Unit EA = Per cooler) |
| 226 | Part-A4 Valve Servicing |
| 227 | PART-A4 VALVE SERVICING: |
| 228 | INSITU SERVICING AND OVERHAULING OF HIGH PRESSURE GATE / GLOBE / CHECK VALVES:The scope of work includes shiting of valves to their workshop or insitu servicng, dismantling of valves completely, cleaning of valve and their internals, Inspection of valve internals etc.Lapping of Plug & Seat Ring for removal of scoring / cut marks, blue matching, Specialized Work of Trim parts for Plug valves Special Welding / weld repair, Stelliting, annealing, Machining, Grinding, Mirror Image finishing, buffing, suiting with body etc., replacement of pressure seal gaskets, gland retainer ring, gaskets, and other allied spares, Reassembling of valve, greasing, testing of valves as per standard and painting as per scope of attached and EIC instructions:All consumables and all the spare parts excepts stem, bonnet & valve boby will be in Contractor’s scope and same shall be included in the quoted rate.SPARES: Supply of spares such as Gland Packing, Pressure seal gasket, Gland Retainer Ring, Bonnet gaskets for Gate & Globe valves of 1500# are in contractors scope. (Valve Makes are L&T / BHEL / KSB). |
| 229 | Complete refurbishment of size upto2\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 230 | Complete refurbishment of 3\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 231 | Complete refurbishment of 4\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 232 | Complete refurbishment of 6\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 233 | Complete refurbishment of 8\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 234 | Complete refurbishment of 10\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 235 | Complete refurbishment of 12\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 236 | Complete refurbishment of 16\" 1500# Gate / Globe Valve including servicing, welding machining and all spare parts such as gland packings, pressure seal gasket, bolts, gland retainer ring etc - Except stem, bonnet and body. |
| 237 | Re-Packing of GATE & GLOBE Valves of 1500# Class - Gate / Globe / Check Valve - Class 150 , 300, 600 & 900#:Job involves removing existing gland packing completely from gate and globe valves of various sizes in-situ and re-packing the valves with new gland (supplied by CPCL) 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. |
| 238 | Valve - Class 150 , 300 and 600#: |
| 239 | Size - Upto 1.5 Inch. |
| 240 | Size - 2\" to 3\". |
| 241 | Size - 4\" to 6\". |
| 242 | Size - 8\" to 10\". |
| 243 | Size - 12\" to 14\". |
| 244 | Size - 16\" to 20\". |
| 245 | Valve - Class 900 and Above: |
| 246 | Size - Upto 1.5 Inch. |
| 247 | Size - 2\" to 3\". |
| 248 | Size - 4\" to 6\". |
| 249 | Size - 8\" to 10\". |
| 250 | Size - 12\" to 14\". |
| 251 | Size - 16\" to 20\". |
| 252 | Supply of Spares: |
| 253 | 1EA means supply of high pressure gland packing, upto 2 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 254 | 1EA means supply of high pressure gland packing,Of 3 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 255 | 1EA means supply of high pressure gland packing, Of 4 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\"\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 256 | 1EA means supply of high pressure gland packing,Of 6 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 257 | 1EA means supply of high pressure gland packing,of 8 inch NB 900#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 258 | 1EA means supply of high pressure gland packing,Of 10 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 259 | 1EA means supply of high pressure gland packing,Of 12 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 260 | 1EA means supply of high pressure gland packing,Of 14 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 261 | 1EA means supply of high pressure gland packing,Of 16 inch NB 150, 300, 600,900 & 1500#. For ball valves along with gland packing, retainer packing & body seat of MOC \"reinforced PTFE with secondary metal to metal\" shall also to be supplied. Dimensions and MOC shall be taken as per site conditions. |
| 262 | Reconditioning / Servicing of Gear Operated Butterfly Valves:The job includes Opening and dismantling of valves including the gear box assembly thorough cleaning of all parts using Rustolene or kerosene, further inspection of internal parts in the presence of EIC, repair / reconditioning of valves by hand facing, and lapping with all tools and tackles, replacement of defective missing spares including studs, glands, hand wheel, bush and any other parts recommended by EIC, (Weld deposit on pitted area wherever required grinding / smoothening the same will be carried out by CPCL), reassembling the valves.Necessary rubber sealing for the valve disc shall be contractor. However If EIC requires any spares parts to be supplied by the contractor, the contractor shall carry out and the rate of those items shall be finalized before taking furthur action.The job also includes supplying of all types of tools & tackles and dumping the generated debristo the designated place, all consumables and labour to complete the job in all respects.Necessary crane for lifitng the valve and transportation to the designated placeis in contractor scope of work.The valve after service shall be operated in presence of EIC and obtain his certification. If body test and seat test of the valve is not carried out,10% for each test shall be deducted from the above mentioned rates.Any sprares required for reconditioning of the valve shall be paid extra. |
| 263 | Size - 20\"Butterfly vave including gear box. |
| 264 | Size - 24\"Butterfly vave including gear box. |
| 265 | Size - 28\"Butterfly vave including gear box. |
| 266 | Size - 30\"Butterfly vave including gear box. |
| 267 | Part-A5 Miscellaneous jobs |
| 268 | PART-A5 MISCELLANEOUS JOBS: |
| 269 | Hire charges for Hydraulic torque wrench bolt size up to 2 1/4 inch nominal dia.: |
| 270 | Fasteners for all flanges( includign valves) should necessarily be tightened using torque wrenches only where ever possible. Arrangement of wrenches with operator & supervisor for the same is in contractor scope. payment for blinding / deblinding / replacement of gaskets / orifice plates shall be as per respective SOR. This job shall be executed for the exclusive flanges which were not opened duringthis shutdown. (One Unit EA = 12 hrs shift). |
| 271 | In Situ machining of Flanges of pipe line, Column, Vessel Nozzle:Provide necessary skilled man power, tools and tackles & equipment, full time expert supervison, materials ( both consumable and non consumable), transportation etc., to carryout in situ machining of gasket seating surfaces of existing pipe flanges. column / vesselnozzles, exchanger nozzle flanges.Contractor to fabricate & mobilize necessary jigs & fixtures required for carrying out the jobs. No extra payment for the same shall be made by CPCL.Machining will include in situ serrations on the gasket face of the pipe flange / column / vessel nozzle flanges.Maintain all necessary documents and records as required by CPCL EIC.After completion of the job contractor shall obtain approval from EIC.All other jobs associated with in situ machining but not specifically mentioned in the scope of job and required to be done will have to be carried out bythe vendor at no extra cost to CPCL.Payment will be made on per inch dia of the average of ID and OD of the machining done. |
| 272 | In situ Machining up to12 inch OD of machined surface. |
| 273 | In situ Machining above 12 inch OD of machined surface. |
| 274 | Hiring ofDG ( Diesel Generator ) set125 KVA capacityon round the clock basis:Supply of DG Set along with all consumables ( Fuel ), cables accessories, operator etc. operate them at site to carryout necessary jobs. Agency must depute an operator all the time at the site for operating the DG set. The DG setshall be mobilzed only on advice of CPCL EIC. Rate is inclusive of mob & demob & operator charges.Necessary diesel for running the unit is in contractor scope. How ever CPCL will proivde diesel on chargeable basis. |
| 275 | Provide DG Set 125 KVA on hire basis round the clock basis. Unit of Measurement Day = 24 hrs. |
| 276 | Supply of Carbon steel / low alloy steel / SS 410 / SS 410S Hardware: |
| 277 | Contractor to supply carbon steel / low alloy steel / stainless steel hardware itesm likebolts, studs,screws with or without nut as per sample.contractor has to take apporval from CPCL Planning Engineer prior to supply of these items. Contractor has to submit the gate pass and test certificate details to CPCL for payment. Payment will be made as under supply of CS / Low alloy steel/ SS 410/410s Hardware per kg basis. |
| 278 | Supply of SS304/SS304H/SS316/SS316L Hardware: |
| 279 | Contractor to supplystainless steel hardware itesm likebolts, studs ,screws with or without nut as per sample.contractor has to take apporval from CPCL Planning Engineer prior to supply of these items. Contractor has to submit the gate pass and test certificate details to CPCL for payment. Payment will be made as under supply of stainless steel Grade SS304 /SS304H /SS316 / SS316LHardware per kg basis. |
| 280 | Supply of Semi-Skilled Manpower for Miscallenneuous jobs: |
| 281 | For Normal Working day. Rate per 12 Hrs. shift for One person (07.30 Am to 7.30 Pm) & (07.30 pm to 7.30 Am). Unit EA = 12 hrs shift. |
| 282 | For Sunday / Company Declared Holiday. Rate per 12 Hrs. shift for One person (07.30 Am to 7.30 Pm)& (07.30 pm to 7.30 Am). Unit EA = 12 hrs shift. |
| 283 | Part-B Equipment Hiring |
| 284 | PART-B EQUIPMENT HIRING: |
| 285 | Provide Tractor Trailer 10 Ton , 20 Feet length on hire basis along with the operator formaterial shifting,etc. (24Hrs/Day for 25 Days period) Necessary Diesel is in Contractor scope. |
| 286 | ProvideHydra Crane along with valid operator on hire basis. Minimum capacity : 12 Tons. for a period of 25 Days ( 24 hrs / Day). New Generation Hydra to be mobilised. Necessary Diesel for running crane is in contractor scope. |
