Fabrication and Erection of SS304L Piping Subassemblies and associated structural works for Overhead Trench Piping Systems in FRP, FRFCF Kalpakkam.

SS Pipe Erection involves Collection of Free Issue Material (FIM), handling at all stages, transportation, storage, pickling & passivation, physical/dimensional measurement, preparation of fabrication and isometric drawings, checking interferences, installation & alignment on supports of SS304L pipelines & fittings at various elevations. This also includes supply of consumables, instruments, setting up of fabrication shop, providing as built drawings, documentation, FIM accounting etc. Rates shall be inclusive of arranging Scaffolding, temporary support, proper ventilation and lighting as per site requirement. (Pipe sizes up to 25NB are considered as 1")

Fabrication of pipe sub-assemblies involving preparation of drawings at site, cutting, grinding, edge preparation, fit up, butt / nozzle / mitre welding of Sch 40 SS 304L pipes, fittings and specialities using GTAW process (using ER 308L filler material and Argon for purging and shielding), including LP Examination at first and final passes and weld passivation. (Pipe sizes upto 25NB are considered as 1").

Fabrication of stainless steel pipe-in-pipe bends (90 to 150-degree bends) by filling with fresh river sand (or any suitable material as approved by EIC) in annular space between two pipes, closing of annular space and pipe inside separately by using machined SS washer and SS dummy or wooden plug. Fabrication of bend by hydraulic bending machine or any other means as per approved drawing and procedure. Bending procedure shall be dully approved by department in advance. The rate shall include liquid penetrant examination, thickness measurement of pipes before and after bending at bend portion using ultrasonic thickness measurement gauge and local passivation as per approved procedure. As per specification Bend radius shall be 5D of pipe size (NB). For payment size of outside pipe will be considered. Please see the relevant clause Section-V of tender document. Sizes of pipe involved are 20 NB to 50 NB.

Fabrication of stainless steel pipe bends upto 50 NPS size using hydraulic bending machine or any other means as per approved drawing. Bending procedure and bending die shall be duly approved by department in advance. The rate shall include liquid penetrant examination, thickness measurement at bend portion using ultrasonic thickness measurement guage and local passivation as per specification. Bend radius (R) = 5D mm of pipe NPS. (Bend sizes upto 25NB are considered as 1").

Handling, transportation, surface treatment, fabrication and erection of end closure / dummy plate for pipe / annular pipe made from free issue material (FIM) of 3 to 6mm thick SS304L plate / sheet and fillet / Groove fillet welding with the SS304L pipe ends. Welding shall be carried out using GTAW process with argon gas for shielding & purging followed by LPE and local passivation of weld joints as per tech specifications

Fabrication & installation of SS spacer wire includes Supply, handling, transportation, surface treatment, fabrication and erection of spacer wires made from AISI 304L / 308L IGC practice A & C tested (average of 18mpy corrosion rate) as per Drawing and tech specification. The item rate includes Supply of 3mm dia Stainless Steel 304L / 308L spacer wire, Fabrication and Tack / stitch welding of spacer wire using GTAW process with argon gas for shielding & purging using ER 308L filler wire, followed by site installation as per approved procedure, drawing and tech specification. All the weld joints shall be subjected to surface treatment and local passivation as per approved procedure prior to erection at site.

Pneumatic leak testing of erected spools or sub - assemblies by providing temporary blinds as per technical specifications. Arranging testing setup, temporary hose connections, blinds, pressure gauges, compressed air, soap solution etc. are in the scope of contractor. (Each Line from start to end is considered as one number).

X-ray examination of butt welded pipe joints as per the technical specifications of the tender using conventional X-ray machine as per approved procedure. The supply of X-ray machine, film, dark room facility, consumables for film washing, skilled & unskilled personnel, digitization of the films are under the scope of the contractor. 3% audit radiography shall be performed at no extra cost.

Handling, Transportation, acid cleaning, preparation of drawings, obtaining approval, fabrication of 6mm thick SS 304L saddle support plates (FIM) including drilling/trepanning to match pipe OD, cutting into two halves, grinding, edge finishing, positioning first half below pipe, placing pipe in sector, fixing the matching half from opposite side, alignment and complete welding as per approved drawings, procedures and technical specifications. This work includes supply of consumables, and all incidental works like cutting, installation & welding of 3mm half clamps made out of 50 NB SS 304L pipes (FIM) for pipe in pipe joints.

Handling, transportation, surface treatment, preparation of drawings, fabrication, forming, and erection of supports/structural members/top cover plates made from AISI 304L stainless steel plates supplied by the Department as Free Issue Material (FIM), in accordance with approved drawings and technical specifications. The item rate includes Collection of Stainless Steel 304L quality 3 mm to 6mm thick plates/sheets from stores, Forming/Fabrication/Drilling of holes of stainless steel plates/angles of various sizes as required, Fabrication and erection of plates and angles as per approved drawings and welding using GTAW process with argon gas for shielding using ER 308L filler wire, followed by site installation for closing of trench as per approved procedure and drawing. All the weld joints shall be subjected to LPE on roots & final pass as per approved procedure, all the plates and angles shall be subjected to surface treatment and local passivation as per approved procedure prior to erection at site.