Bids Are Invited For Custom Bid for Services - IRC for Mechanical Maintenance Works at GAIL DT Vizag - A PART-A Deploy Highly Skilled, Skilled Service Providing High Skilled Service Providing High Skilled Services as per directions of EIC either in General or shift duties. (1 Activity Unit = 8 Man Hours) 10 Qualification & Experience of deployed resources to be as mentioned in the scope of work This estimated rate is inclusive of Basic wages, PF, ESI(or Employee Compensation Policy with Medical Floater Policy), Bonus, Leave with Wages and Overheads of Vendor as per SCC. Providing Skilled Services Providing Skilled Services as per directions of EIC either in General or shift duties (1 Activity Unit = 8 Man Hours). 20 Qualification & Experience of deployed resources to be as mentioned in the scope of work This estimated rate is inclusive of Basic wages, PF, ESI(or Employee Compensation Policy with Medical Floater Policy), Bonus, Leave with Wages and Overheads of Vendor as per SCC. - part-b - special services - Alignment of Pump with Drive machine ALIGNMENT OF PUMP WITH DRIVE MACHINE: The bidder shall arrange qualified alignment fitter for LPG pumps & other centrifugal pumps installed at DT Vizag. Level the Base: Ensure that the pumps base is level. This ensures proper Horizontal alignment of the pump shaft. Horizontal Mounting: The suction side of the pump should be mounted Horizontally, while the discharge flanges are horizontally aligned. Motor and Pump Shaft Alignment: With the motor and pump shaft flanges close to each other but disconnected, follow these steps: Mark a Spot: Mark a spot on each shaft. Measure Separation: Use afeeler gauge or taper gauge to measure the separation between the marked spots. Rotate Shafts: Rotate both shafts by approximately 90 degrees, keeping the marks close to each other. Measure Again: Measure the separation distance again. Repeat: Repeat the process for 180 and 270 degrees 1. Pre-Alignment Checks: Before final alignment, perform the following checks: Coupling Faces: Ensure there is enough spacing between the coupling halves faces to prevent striking against each other Laser Alignment of Pumps The bidder shall arrange laser alignment Equipment Setup along with equipment operator for LPG pumps & other centrifugal pumps installed at DT Vizag. Correcting misalignment with laser alignment Alignment: Alignment is the process of positioning two or more machines that are coupled, so that the centrelines of rotating machines will form a single straight line when the machines are working at normal operating temperature. Offset: In case of pure Offset misalignment the centrelines of both the machines will be displaced from one another. Angularity: Centrelines of two shafts will meet at coupling centre. But they will neither parallel nor form a single straight line. Sign Conversion: Vertical Alignment: During the vertical alignment Negative (-) Sign before reading indicates machine is down and Positive (+) sign before reading indicates machine is up. Horizontal Alignment: During the horizontal alignment Negative (-) sign before reading indicates the movable machine is in left side and Positive (+) readings indicate right side. (You should always stand behind the motor to interpret horizontal signs). Tolerances Table: Alignment tolerances depend on large extent on the speed of rotation of shafts. Machine alignment should be carried out to within the manufacturers tolerances. The tolerances are the maximum allowable deviation from the desired values, whether zero or targeted offset for thermal growth. Once the alignment checks are done to figure out exactly how far out of alignment the shaft couplings are, the assigned engineer will proceed to use laser alignment as the solution. The lasers to be mounted on the shafts of the Pumps to be aligned. Then while the shafts are being rotated, the lasers will measure the deflection of the shafts and determine the number of shims to add in order to achieve the correct alignment. The Engineer shall submit a report indicating deflections & also guide Maintenance Personnel in Correct Alignment of Pump-Motor Couplings. PROVIDING FORK LIFT OPERATOR SERVICES PROVIDING FORK LIFT OPERATOR SERVICES: Assistance of Skilled operator for Fork Lift for Material Handling(Loading/Unloading) as per directions of EIC, Operators to be provided as on call basis. These operators ensure timely movement of goods, Safety and Risk Reduction: Forklift operators follow strict safety protocols to prevent workplace injuries. Proper handling of machinery reduces accidents and minimizes damage to goods. Skills and Expertise: Forklift operators need excellent hand-eye coordination, depth perception, and control precision., Stn. Piping works for AG Piping STATION PIPING WORKS - For Above ground (Carbon Steel Pipe 12 & Below (FABRICATION: Fabrication/Welding (for TIG Welding-SOR 70 & Arc Welding-SOR 80) including cutting, edge preparation, inclusive of grinding the edges of pipes, fittings, flanges etc., to match with the matching edges of uneven/different thickness wherever required, welding, attachment of all pipe fittings like elbows, tees, reducers. ERECTION: Erection including prior cleaning, lifting, placing on pipe sleepers and supports, overhead on racks, skids and at all elevations including installation and carrying out connected activities for all types of valves including fixing of gaskets, studs/bolts, nuts wherever required for all sizes, levelling, aligning, joining of flanges, blind flanges, connecting with equipment, tapping for inline instruments like pressure gauges, thermowells, sample connections etc. supply of studs and gaskets in GAIL scope Getting ready for hook-up with the existing piping requiring purging, blinding, de-blinding of certain pipelines and equipment. Hook-up with the existing piping, nozzles, elbows, reducers, tees, spectacle blinds etc. Compressed air flushing/cleaning of the piping fabricated. Carrying out the NDT like DP test, Radiography by gamma ray or X-ray as suitable (Payment shall be made for radiography or X- ray work as SOR item No: 90), carrying out hydrotesting of fabricated assemblies including dewatering and drying as per standard specification and (payment shall be paid as per SOR Item No.100) as per instructions of EIC. All materials, equipment, instruments, consumables are in the scope of contractor except pipes, flanges, fittings and valves. Hook-up works with existing piping within terminal premises and mainline. Preparation of final bill of material based on piping GADs. Preparation of isometric and fabrication drawings. Jobs of above ground conforming high pressure piping for API 5L, Gr. B. Seamless/A333/A106 Gr. B. Seamless BE) Stn. Piping works - TIG Welding on job c Station Piping works for Above Ground Piping: Piping fabrication works with TIG/ARGON welding with qualified welder, cutting, edge preparation, (inclusive of grinding the edges of pipes, fittings, flanges, etc., to match with the matching edges of uneven / different thickness wherever required, fit-up, preheating wherever required welding, threading etc. The Job includes supply of all materials and resources including consumable materials like defined electrodes, filler wires, tools and tackles for carrying out the job, labour and other incidental works,. Fittings shall be supplied by GAIL. Payment shall be made only after acceptance of Radiography/testing. Fire water nw rep - C.S. pipe Arc Weldin Fire water Network repair/replacement C.S. pipe Arc Welding upto 10 mm wall thick for Fire Water network replacement for Carbon Steel conforming to (CS) IS: 3589 / IS: 1239 / IS: 1978. (In case of underground firewater network replacement excavation shall be operated by SOR 120) (1/2 Dia to 14 Dia Performing all above ground piping fabrication works with ARC welding with qualified welder, scope is included cutting, edge preparation, (inclusive of grinding the edges of pipes, fittings, flanges, etc., to match with the matching edges of uneven/different thickness wherever required, fit-up, preheating wherever required welding, threading etc., hook up with the equipment nozzles; of pipings, installation of fitting of all sizes i.e., elbows, reducers, tees, spectacle blinds etc., as per the instructions of EIC. (This requirement is for maintenance, repair of new / modification jobs of Fire water pipeline in the plant area (Scope shall include supply of all material, consumables, tools and tackles). Pipes for replacement shall be provided by GAIL. Radiography Test RADIOGRAPHY TEST: MOBILIZATION OF RADIOGRAPHY UNIT AND COORDINATION WITH THE RADIOGRAPHY PARTY Radiography of piping of all types, sizes, thickness including providing or hiring of all necessary equipments, supply of all consumables including radiographic films and radiation source (X-ray or gamma-ray) and whatever else even though not expressly mentioned but required to perform the work as per specifications and as per instruction of EIC. Mobilization and Demobilzation, Transportation with all radiography m/cs and appliances including required radiography source for radiography through radiography agency are in vendor scope. As per instructions of EIC, Contractor has to deploy radiography/X-Ray Vendor having requisite statutory permits and the radiographer shall have valid ASNT Level -I Certificate. Later on the review shall be carried out by ASNT Level-II Interpreter as per API 1104 standard. In case of reshoots/retakes no separate payment shall be made. Secondly in case of weldrepairs the contractors shall have to attend to repairs and carry out Radiography re-takes after repairs. No separate payment shall be made for welding as well as re-shoot in this regard. Hydrotest work for the Fabricated assemb HYDROTEST WORK FOR THE PIPELINE SIZE 1 TO 12 DIA: The fabricated assemblies shall be hydrotested as per directions of EIC and as per Pressure testing requirement. Later on dewatering and drying shall be carried out prior to installation Hydrotest of modified and newly installed piping as per specifications, standards and as per the instructions of EIC. Scope incudes, required blinding and deblinding of equipment prior to hydrotesting and after hydrotesting. (Scope shall include supply of all material, hydrotesting pumps, consumables, tools and tackles) HIRING OF HYDRA/JCB HIRING OF HYDRA/JCB: The supplied hydra/crane of 15 MT for works shall be fit/load tested along with Slings/D-shackles etc. which are duly tested and certified by competent Authority. The period of hiring of Hydra(SOR 120) or JCB (SOR 130) will start after the equipment reaches at site and ends when Equipment leaves the site. Breakdown of the equipment will not be paid. Normal working time per day will be 8 Hrs. Rate for idle time shall be 50%. Estimated rates is inclusive of diesel, operators, maintenance cost etc. Hydra of lifting capcty upto 15MT deploy Hydra Deployment: Hydra of minimum capacity 15 MT deployment along with Slings, D Shackles, Belts having valid fitness certificates as per Instruction of EIC. The Hydra shall have valid operators License, Driving License, PUC, RC, Fitness Certificate etc. JCB Deployment JCB Deployment: JCB deployment as per Instruction of EIC. The JCB shall have valid operators License, Driving License, PUC, RC, Fitness Certificate etc. PAINTING OF ABOVE GROUND PIPING PAINTING OF ALL ABOVE GROUND PIPING & MISC. STRUC: Supply and Application of Two Coats (DFT 30-40 Micron per coat) of PU finish paint of Acrylic polyurethane finish paint. The painting is for steel structures and above ground pipes. DFT measurement is in the scope of contractor. Scaffolding to be arranged by contractor at all heights and it is in the scope of contractor. Structural fabr. on 100% completion of SUPPLY, FABRICATION & ERECTION OF STRUCTURAL WORKS: Fabrication of structures as per instructions from EIC. Complete work of fabrication of structural requirements such as platforms, walkovers, handrailings, ladder provision, clamps, saddles, guide stops, cradle, turn buckles, an hors, T-posts, stockade/trestle and pipe bridge etc. The job is inclusive of materials supply, Fabrication, erection inclusive of tagging etc. The materials requirement is enclosed in scope of work. All materials, equipment, instruments, consumables are in the scope of the contractor. Painting of all fabricated and erected instruments, consumables are in the scope of the contractor as per the specifications written in the tender as per instructions of EIC. The job is all inclusive i.e., Supply, fabrication, erection, 4 Layer PU painting etc. along with all necessary tools, tackles, equipment, machinery. NITROGEN SUPPLY WITH PORTABLE CYLINDERS NITROGEN SUPPLY WITH PORTABLE CYLINDERS: Supply of Nitrogen cylinders as per instruction of EIC: Contractor shall supply the Nitrogen gas cylinders having capacity of 7 M3 with a purity of 99.9% or better, as and when required basis. The cylinder should have gauge (with valid calibration certificate) with regulator. The rate of N2 cylinder shall be as per the SOR item rate only.N2 Gas weight shall be arrived by the weight difference between filled cylinder and empty cylinder or derived from Nitrogen pressure calculations. Total Quantity :
