Manpower Services along with supply of tools and tackles for Instrumentation maintenance job during predictive, preventive, shutdown and daily routine maintenance for Two (02) years at HURL, Sindri Project

Amount

SOR PART A: INSTRUMENTATION MAINTENANCE WORKS

Installation of Control Valves (up to 300#) The job includes the following: Shifting of control valve with its accessories from store to worksite and if required reshifting of the old control valve with its accessories back to the instrument store yard. Installation of control valve in- the process line at any height &location with its all accessories like positioner, air filter regulator, limit switch, hand wheel etc. Connection/Termination of all existing associated cables/tubes with proper gaskets, nuts & bolts, providing gland packing if required. Removal of existing control valve if required. Glanding, ferruling and termination of the cable wherever required, including supply of ferrule and lugs is in contractor’s scope of supply but cable gland shall be supplied free of cost by owner. Supplied lugs shall be Dowel make only (Applicable for any electrical device like limit switch, SOV etc. mounted on the control valve.) Fabrication; installation and grouting of support, if required. Grouting material (cement, concrete, sand etc.) shall be in contractor’s scope Hot bolting of the flanges after charging of line, if required. Leakage testing, stroke checking and calibration of the control valve will be in contractor’s scope. Painting of all erected structural items with one coat of ready mixed primer and two coats of approved quality synthetic enamel paint inclusive supply of paint and primer. (Paint and Primer make shall be Asian/Berger/Nerolac) The installation shall be as per typical installation diagram as enclosed. Necessary skilled & unskilled manpower, supervision tools & tackles, transporting vehicle, consumables including Teflon tape etc. required for the job will be in contractor’s scope. The job shall be carried out as per specification, direction of Engineer-in- charge. Size of Control valve: up to 2”

Installation of Control Valves (up to and above 600#,900#,1500#,2500#) Size of Control valve: up to 2”

Removal of Control Valves (up to 300#) The job includes the following: Removal of control valve from process line after getting proper clearance. Removal of copper / SS tube connections, cable connections and deglanding, wherever required. All necked wires must be properly taped. Cleaning of the control valve with air/ water/ steam/ solvent etc.as per direction of Engineer-in-charge. Shifting of the control valve to instrument workshop or any other site with in fertilizer plant if required. Shifting of instrument includes shifting from & to any height in the fertilizer area including loading and unloading at both ends. Necessary skilled & unskilled manpower, supervision, tools &tackles, transporting vehicle, supply of all sorts of consumables required for the job will be in contractor’s scope. The job shall be carried out as_ per specification and direction of Engineer- in-charge. Size of Control valve: up to 2”

Removal of Control Valves (up to and above 600#900#,1500#,2500#) Size of Control valve: up to 2”

Gland packing of control valve The job includes the following: Removal of old gland packing from the control valve. Insertion of new gland packing as per requirement. Gland packing shall be supplied by HURL. The job shall be carried out as per specifications and direction of engineer-in-charge.

Size of Control valve: up to 2”

Size of Control valve: above 2” and up to 4”

Size of Control valve: above 4” and up to 6”

Size of Control valve: above 6” and up to 8”

Size of Control valve: above 8”

CLEANING & SERVICING OF CONTROL VALVE The job includes the following: Shifting of valve from valve installation site to contractor’s work site. De-coupling of actuator from valve body. Dismantling of valve body & other components for joint inspection to assess the condition of the control valve. Complete cleaning, overhauling & servicing of control valve, handwheel, and other components, reconditioning, lapping and replacement of defective parts wherever required.Replacement of gland packing in the valve. Diaphragm checking and replacement if required. Offering the valve for inspection on Blue Match basis.Re-assembly of valve and mounting of actuator. Stroke checking and calibration of the control valve. Re- shifting of valve from contractor’s work site to valve installation site. Necessary skilled & unskilled manpower, supervision, tools & tackle’s, including lapping machine & fixtures, consumables like rustolene, Teflon tap e etc. required for the job will be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge. HURL scope of work & supply: -The scope includes the following: Removal of control valve from process line. Supply of all spares including diaphragm, gland packing & gasket sheet etc. Fixing· of control valve in the process line after repair and servicing. Note: HURL will supply gasket sheet, however all gasket cutting required to complete the job will be in vendor’s scope.

Size of Control valve: up to 2”

Size of Control valve: above 2” and up to 4”

Size of Control valve: above 4” and up to 6”

Size of Control valve: above 6” and up to 8”

Size of Control valve: above 8”

Transportation of Actuator to & from Workshop (Check Place) of any Rating & size.

Transportation of Gas Cylinders: Handling, shifting and. stacking of gas cylinders from any site to instrument store/main store/scrap yard or vice versa. It includes shifting of cylinders from site to loading place and from unloading place to instrument site/ instrument store/main store/scrap yard. Lowering of the cylinders from any elevation to ground and from ground to any elevation, if required will be in contractor’s scope. Loading and unloading of the cylinders, supply of labour, tools & tackles, consumables, equipment’s, material carrying vehicle etc. "will be in contractor’s scope. Contractor should ensure that cylinders should be transported vertically at all stages. The job shall be carried out as per specification and direction of Engineer-in-charge

Laying of Inst Air headers lines of 1/2”, ¾” size of SS pipe from Air Header to Consumption Point by Threaded Pipe Fabrication.

Laying of Inst Impulse Pipe lines of 1/2”, ¾” size SS/Other MOC Pipe after Fabrication.

Fabrication, clamping, supporting, painting of inclined sheds on junction boxes and instruments etc. made of MS angle & aluminium sheet.

Size 3 feet x 2 feet

Size 4 feet x 2 feet

Complete installation of RADAR/ displacer type/ capacitance type/ magnetic type / Capillary type / level transmitters, level switches (all sizes and pressure ratings} from various vessels at all elevations in the plant, and to provide new gaskets. The job includes the following: Receiving & shifting of instrument with its accessories from store/any other place inside fertilizer & transport to work site. Fixing of instrument with all accessories on existing support. and manifold at any height. Process connection of instrument to existing manifold/process line etc. Modification of existing support/manifold/process line if required to fix the available instrument in the existing support /manifold/ process line shall also be in the scope of contractor. It includes any type of job like bending/welding of pipe/incorporation of new pipe to complete the job. Servicing and gland packing of all valves. Glanding, ferruling and termination of signal & power cables including Aluminium tagging. Necessary skilled & unskilled manpower, supervision, tools & tackles, transporting vehicle, supply of all sorts of consumables including Teflon tape, insulation tape, ferrule, lugs, aluminium tag etc. shall be in contractor’s scope. Supplied lugs shall be Dowel make only. Hydraulic testing for any leakage from the flange. If any leakage is found rectification of the same will be in contractor’s scope. HURL will provide gasket sheet, however all gasket cutting for completing the job will be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge.

INSTALLATION OF LEVEL GAUGE/ GAUGE GLASS: Shifting of new instrument with its accessories from store to worksite and if required re-shifting of the old instrument with its accessories back to. the instrument store yard. Installation of Gauge Glass with its all accessories like standpipe, illuminators & drain valve etc. at any height in the fertilizer. Cutting and removal of existing manifold with the instrument wherever required. Fabrication and installation of vent & drain pipe with valve and/manifold and/modification of existing installation hardware inclusive of supply of all ·sorts of erection materials, grouting material (cement, concrete, sand etc.) and consumables, excepting supply of all pipe fittings, piping materials, structural, instruments and its calibration. Fabrication, installation and grouting of support wherever required. Cutting and modification of existing supp ort if required. Hydraulic testing of the process impulse line and of the gauge glass, arresting leaks , if any & replacement of gaskets if required{Gaskets will be supplied by HURL).Painting of all erected structural items (excluding impulse line)inclusive supply of paint (Paint make shall be Asian/Berger/Nerolac).The installation shall be as per typical installation diagram as enclosed with a consideration of 10% variation in Bill of Materials .In case of increase in quantity of execution beyond 10% the job shall be considered per joint basis or mutually agreed up on for the extra item. Necessary skilled & unskilled manpower, supervision, tools & tackles, transporting vehicle, supply of all sorts of consumable shall be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge.

In carbon steel

In Stainless steel

In Alloy steel

Complete removal of RADAR/ displacer type/ capacitance type/ magnetic type / Capillary type / level transmitters, level gauges, level switches (all sizes and pressure ratings} from various vessels at all elevations in the plant, and to provide new gaskets.The job includes the following: Removal of instrument from process line /equipment at any height after taking proper clearance. Removal of the instrument includes removal of supply and signal connection and their associated cables from the gland. All naked wires must be properly taped. Proper cleaning of the instrument with water/steam/solvent etc. as per direction of Engineer-in-charge. Shifting of the instrument-to-instrument work shop/ any other place inside fertilizer. Necessary skilled & unskilled manpower, supervision, tools& tackles, transporting vehicle, supply of all sorts of consumables including Rustolene, insulation tape etc. shall be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-chrage.

Removal of power cylinders of dampers

up to and including 3" dia.

above 3" up to and including 6" dia.

Fixing of power cylinders of dampers / control valves etc. The job includes the following: Shifting of power cylinder with its accessories from store to worksite and if required re-shifting of the old power cylinder with its accessories back to the instrument store yard. Installation of power cylinder at the location with its all accessories like positioner, air filter regulator, limit switch, solenoid valve etc. Removal of existing power cylinder, if required. Fabrication, installation and grouting of support as per requirement. Grouting material (cement, concrete, sand etc.) shall be in contractor’s scope. Cutting and modification of existing support, if required. Termination of all pneumatic connections. Glanding, ferruling and termination of the cable wherever required, including supply of ferrule and lugs is in contractor’s scope of supply but cable gland shall be supplied free of cost by owner. Supplied lugs shall be Dowel make only. Stroke checking of the power cylinder will be in contractor’s scope. The installation shall be as per typical installation diagram. Painting of all erected structural items inclusive supply of paints. Necessary skilled & unskilled manpower, supervision, tools & tackles, transporting vehicle, consumables including Teflon tape etc. required for the job will be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge

up to and including 4" dia.

above 4" up to and including 8" dia.

Above 8” dia.

Servicing of Power Cylinder The job includes the following: Removal, dropping and re-fixing of power cylinders from air damper / flue gas damper/ any other equipment at any height with in the fertilizer. Removal and re-fixing of seals and gaskets. Disassembling of the parts for inspection. Cleaning, servicing and over hauling of the power cylinder. Replacement of spares if required. Supply of spares, seals and gaskets shall be in HURL’s scope. Re-fixing back the power cylinder into position. Testing of power cylinder for proper functioning. Necessary skilled & unskilled manpower, supervision, tools &tackles, consumables like Rustolene, Teflon tape etc. required for the job will be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge

up to and including 4" dia.

above 4" up to and including 8" dia.

Above 8” dia.

Laying of cable trays with proper angle iron supports (welding & grouting included). for following sizes of trays: - Shifting of tray from store to wor½ site, fabrication and laying of perforated trays as per specifications & direction of Engineer in charge. Supply of Perforated Trays & structural steel shall be in HURL’s scope. All other material including grouting material (cement, concrete, sand etc.), clamps, bolts, nuts etc. required to complete the job shall be in contractor’s scope. Fabrication, installation and grouting of support wherever required, cutting and modification of existing support if required inclusive of supply of erection consumable materials. Painting of all erected structural items with one coat of ready mixed primer and two coats of approved quality synthetic enamel paint inclusive of supply of paint and primer. (Paint and Primer make shall be Asian/Berger/Nerolac). Necessary skilled & unskilled manpower, supervision, tools & tackles, transporting vehicle, consumables will be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge.

50 mm wide cable tray

100 mm wide cable tray

150 mm wide cable tray

300 mm Wide cable tray

600 mm Wide cable tray

750 mm FRP cable tray

Laying and clamping of armoured, signal, power, conduit pipes or thermocouple extension cables (armoured) with conductor size upto 2.5 mm2 on cable trays/ Angle/ Ducts with proper glanding at both ends of following sizes: -

2/3/4 Pairs/Triads x 0.5/1.5 mm2

12/19/24 Pairs/Triads x 0.5/1.5 mm2

3Cx2.5 SQ mm

3Cx4 SQ mm

Laying and clamping of SS tubes in trays/ducts/angles, making connections at both ends using compression fittings, leakage checking and rectification Tubes in following sizes: - The job includes the following: Shifting of copper / SS tube & fittings from store to work site and if required resifting of the old scrap tubes back to the instrument store yard. Laying & Fabrication of copper / SS tube with any type of fitting on existing support / perforated tray / angle iron as per drawing. Clamping of copper/ SS tube on existing supports. Minimum one Clamp/ meter or as per the requirement clamps are to be provided. Supply of clamps, bolts & nuts ·shall be in contractor’s scope. Supply of all tubes and fittings shall be in HURL’s scope. Necessary skilled & unskilled manpower, supervision, tools& tackles, transporting vehicle, consumables will be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge.

6 mm/ 1/4-inch OD SS tube

8 mm/ 1/3-inch OD SS tube

10 mm/ 3/8-inch OD SS tube

12 mm/ ½-inch OD SS tube

Installation of Junction Box Shifting of new Junction Box with its accessories from store to work site Fabrication and installation of supports and installation of junction box. Screwing, plugging of unused entries of Junction Box. Fabrication, installation and grouting of support. Grouting material (cement, concrete, sand etc.] shall be in contractor’s scope. Cutting and modification of existing support, if required. Glanding of multi core & branch cables, aluminium tagging of the glands, supply of aluminium tag is in contractor’s scope of supply but cable gland shall be supplied free of cost by owner. Supply of all structural, pipefitting, piping materials, and junction box shall be in HURL’s scope. Painting of all erected structural items with one coat of ready mixed primer and two coats of approved quality synthetic enamel paint inclusive supply of paint and primer. (Paint and Primer make shall he Asian/Berger/Nerolac). Necessary skilled & unskilled manpower, supervision, tools &tackles, transporting vehicle, consumables will be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge.

Weatherproof junction box suitable for up to 6 pair cable.

Explosion proof junction box suitable for up to 6 pair cable.

Weatherproof junction box suitable for above 6 pair and up to 12 pair cable

Explosion proof junction box suitable for above 6 pair and up to 12 pair cable

Removal of Junction Box The job includes the following: Removal of junction box from existing location at any height after taking proper clearance. Removal of the junction box includes removal of all· wire terminations and their associated cables from the gland. All naked wires must be properly taped. Proper cleaning of the junction box. Shifting of junction box to instrument work shop / any other place inside fertilizer plant. Necessary skilled & unskilled manpower, supervision, tools &tackles, transporting vehicle, supply of all sorts of consumables including "Rustolene, insulation tape etc. shall be in contractor’s scope. The job shall be carried out as per specification and direction of Engineer-in-charge.

Up to 6 pair cable

Above 6 pair cable

Removal of 1/2" Threaded Isolation of Any Type and rating.

Fabrication of mounting frames and supports for instruments from angle irons / flats / channels or pipes and applying primer & painting to the fabricated frames/supports.

Dismantling of Different Types of Copper / SS Tube/ GI Pipes

Copper I SS Tube (Up to ½”)

GI pipe (Up to ½”)

GI pipe (Above½” and Up to 1”)

CABLE LAYING ON TRAYS:- Horizontal and vertical laying of different instrument cables(Signal / Power/ Control / Alarm / Thermocouple / RTD etc.)of different sizes and types (armoured/ unarmoured) in cable trays/ wall and steel structures up to any height , fixing of "galvanized clamps and screws for fixing cables on to the trays/"structures etc., providing aluminium cable tags at both the ends ""of the cable, testing and transportation from stores to site, ""unpacking, straightening, dressing of cable & returning the empty ""drums with unused cable, if any to stores complete with labour '"'and materials as per the drawings, specification s and directions "of the engineer-in-charge. NOTE: Cables will be supplied by owner free of cost.

Overall diameter up to 20 mm

Overall diameter >20 mm

Overall diameter >35 mm

FABRICATION AND ERECTION OF STRUCTURAL WORKS: Fabrication and erection of structural steel works, pipe supports, ""cross over, platforms, ladder tray, stairways, cable duct, ""instrument yoke support wind girder, hand railings, gratings, ""chequered plates for providing on platform on plates, steel ""structures like channels, beams, angles, flats, etc. including ""derusting, cutting to size, aligning welding with 8 mm continuous ""fillet weld all around, bolting etc.,

CABLE DISMANTLING / PULLOUT: Dismantling/pulling out the LT/HT Control/telephone/ computer, armoured/ unarmoured cables of various voltage grades/types/ sizes/ makes from the trench {up to 1.5 metres deep) /pipes/ structures / racks or trays, rolling it into empty cable drums, returning the filled up cable drums to the store/another site including transportation of empty cable drums from stores to site and filled up cable drums from site to stores/another site, etc. including cutting of cables at joints/termination, dismantling of clamps etc. all complete with labour and materials as per directions of the Engineer-in-Charge.

Overall diameter up to 35 MM

Overall diameter> 35 MM but up to 55 MM

SOR PART B: MANPOWER SERVICES Contractor's Profit per mandays (in Rs./MDY)

MANPOWER ASSISTANCE FOR for routine maintenance in general shift and shift maintenance - Unskilled Worker (USW)

MANPOWER ASSISTANCE FOR for routine maintenance in general shift and shift maintenance - Skilled Worker (SW)

MANPOWER ASSISTANCE FOR for routine maintenance in general shift and shift maintenance -Highly Skilled Worker (HSW)

Bidder Name

Amount in Words

TELECON SYSTEMS

ANI Integrated Services Limited

SMART AUTOMATION

TELECON SYSTEMS

ANI Integrated Services Limited