Catalyst and adsorbent replacement in Plant-205 (HGU) and 206 (NHT-CCRU) reactors / PSA adsorbers during Refinery-III M and I Shutdown 2021 at CPCL Manali

Amount

Part-A Catalyst Replacement - SOR

Plant-205 Adsorbent Replacement

Carryout Complete Adsorbent replacement in PSA adsorbers ( 205-C-24A,B,C ,D,E,F,G,H,I,J,K&L(12 vessels) ) at normal atmosphere condition as per the enclosed scope of work, detailed work pacakge,UOP unloding / loading procedures and scope of supply and all other attachments.

Mobilisation and Demobilisation charges for Equipments, Tools & Tackles for Plant -205 adosrbent replacement in 12 vessels.

Plant-206 Reactor Catalyst Replacement Carryout complete replacement of catalyst in Plant-206 (CCRU) Reactors as per the enclosed scope of work, detailed work pacakge and scope of supply, catalyst unloading / loading procedures and all annexures.

Carryout Complete replacement of catalyst in 206-R-01 as per the enclsoed scope of work and other attachments including video graphy requirement.

Carryout Complete replacement of catalyst in 206-R-02 as per the enclsoed scope of work and other attachments including video graphy requirement.

Carryout Complete replacement of catalyst in 206-R-03 as per the enclsoed scope of work and other attachments including video graphy requirement.

Carryout Complete replacement of catalyst in 206-R-04 as per the enclsoed scope of work and other attachments including video graphy requirement.

Carryout Complete replacement of catalyst in 206-R-05 as per the enclsoed scope of work and other attachments including video graphy requirement.

Carryout Complete replacement of catalyst in 206-R-110 as per the enclsoed scope of work and other attachments including video graphy requirement.

Carryout Complete replacement of catalyst in 206-R-201 as per the enclsoed scope of work and other attachments including video graphy requirement.

Carryout Complete replacement of adsorbent in 206-X-201-AD-101A & 101B as per the enclsoed scope of work and other attachments.

Carryout Complete replacement of adsorbent in 206-X-202-AD-101A &101B as per the enclsoed scope of work and other attachments.

Carryout Complete replacement of adsorbent in 206-C-14A & 14B as per the enclsoed scope of work and other attachments.

Carryout Complete replacement of adsorbent in 206-C-142A & 142B as per the enclsoed scope of work and other attachments.

Carryout Complete replacement of adsorbent in 206-C-06B as per the enclsoed scope of work and other attachments.

Mobilisation and Demobilisation charges for Equipments, Tools & Tackles for Plant -206 Reacctors Catalyst / adosrbent replacement.

Part-B Unit Rate SOR

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 and removal 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.

Blinding and deblinding for 150# & 300# ratings:

Blinding & Deblinding - Size Upto 1-1/2 inch dia.

Blinding & Deblinding - Size 2 inch dia. to 5 inch dia.

Blinding & Deblinding - Size 6 inch dia. to 10 inch dia.

Blinding & Deblinding - Size 12 inch dia. to 16 inch dia.

Blinding & Deblinding - Size 18 inch dia. to 24 inch dia.

Blinding and deblinding for 600# & 900# ratings:

Blinding & Deblinding - Size Upto 1-1/2 inch dia.

Blinding & Deblinding - Size 2 inch dia. to 5 inch dia.

Blinding & Deblinding - Size 6 inch dia. to 10 inch dia.

Blinding & Deblinding - Size 12 inch dia. to 16 inch dia.

Blinding & Deblinding - Size 18 inch dia. to 24 inch dia.

SUPPLY, ERECTION & DISMANTLING OF STEEL SCAFFOLDING- For External purpose - Insulation removal, thickness gauging, NDT jobs The job includes transportaiton of scaffolding materials 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 the wooden / steel planks / FRP gratings on top for making sufficient area. Dismantling scaffolding after completion of job and returning the scaffolding material to specified place including all tools, tackles, consumables, labours and contractor's supervision as directed by the Engineer-in-charge. 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.

Supply, Scaffolding Erection & Dismantling (External)

Up to 6m height

Above 6 m up to 10 m height

Above 10 m up to 20 m height

Above 20 m up to 30 m height

Buffing of weld Joints Job involves buffing and cleaning of total weld area of the Reactor / vessel / column etc, using power brush, thejob has to be completed in all respect to the entire satisfaction of the Engineer-in-charge ( each length of buffing will be up to width of 150 mm). Necessaty buffing tools/ machineries and consumables are in contractor's scope. NOTE: (1) For weld seam buffing the width of buffing shall be 150mm (i.e) 75mm on both sides of the weld seam.

Power tool cleaning / Buffing to SSPC - SP-2 / St3 standards - 150 mm width of Weld seams / HAZ.

Dye Penetration test for weld joints Carryout DP test of the Critical weld joints, New / Old RTJ Gakets / RTJ Gasket seating surface areas as per CPCL Inspection advice. Performance of dye penetration test including supply of all necessary materials, penetrant, developer etc, along with all equipments, labour for carrying out the work as per specification and direction of engineer-in-charge at all elevations. Test has to be carried out in all metallurgy the test has to carry out on all schedule.

DP test of weld joints (One Unit EA = One Inch Length)

OPENING & BOXING UP OF MANWAYS / COVERS (Only for the Hoppers, lift pot, Drum) The job involves opening of manways, covers by de-bolting (cold / gas cutting if required), cleaning the manways / covers, servicing of bolts, replacing defective bolts / nuts and finally boxing up with proper gasket / packing to ensure zero leak of joints including hot bolting. The job also involves to & fro transporatation of gaskets, studbolts, packings, etc., between the work site and the owner's storage point. 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 material from owner's storage point to the work site & unused materials back to the storage point and dumping the generated scrap material to the designated place as per EIC instructions.

Opening & boxing up of Manways / covers - Flanges

Rating - 150 # and 300 #

Rating - 600 # and 900 #

INSIDE CLEANING. (Only for the Hoppers, lift pot, Drum) The Job involves thorough cleaning of column / vessel / tank / Drum / Hopper surfaces internally by water, air, scrapper, wire brush etc., from top to bottom including all the internals like trays, downcomers, distributors, steam coil, nozzles, etc., The job also involves provision of ladder wherever necessary to facilitate cleaning / inspection, spot cleaning by emery, removal of sludges, debris, etc. & transportation to the earmarked location. NOTE: (1) Cleaned inner surface area of the column / vessel / tank / drum shall be considered for measurement.,, (2) No additional payment for cleaning of internals like distributors, steam coil, nozzles, etc.,

Inside surface cleaning

Inside cleaning of Lower/Upper Hopper, Lift pot , Surge drum, Reduction chamber.

OPENING OF FLANGE JOINT AND REPLACEMENT OF GASKETS (Other than Blinding / Deblinding flanges) Job involves opening of all types of flanged joints, valve bonent etc., at all elevations by debolting , cold or gas cutting of fasteners, cleaning of flange face revisiting of fasteners, providing proper rating of gaskets including cutting of new gaskets, and boxing up of flange joint. This also includes necessary capping / decamping of threaded joints, area cleaning, hot bolting etc. The size of the flange is mentioned in nominal bore ( DN ).

Size up to 25 MM

Above 25 mm to 80 mm

Above 80 mm to 200 mm

Above 200 mm to 350 mm

Above 450 mm to 600 mm

Above 600 mm to 800 mm

Hiring of Crane, Tractor Trailer, Fork lifts The contractor shall mobilise the following equipments for completion of the entrire job in all respects. The contractor shall de mobilise the equipment on completion of the job with approval from EIC. If there is any extension of days the contractor shall obtain prior approval from EIC for retaining the equipements. For the extended days the rate will be paid on pro rata basis.Entry and exist Gate passes including the operators time sheet (duly signed by CPCL in charge on daily basis ) for all the below mentioned equipments to be enclosed along with bill for processing.

Hiring of 10 Ton 20 Feet Capacity Tractor Trailer with valid operator for transportaion of New catalysts/ Adsorbent stored in drums / jumbo bags from CPCL-Manali ware hosue to Refinery-3 Plant-205,206 Site area & Shifting of the removed old Catalysts / Adsorbent from Plant area to the place as identifed by EIC with in CPCL permises. Necessary Diesel is in Contractor scope. Minimum Capacity : 10 Ton, 20 Feet on round the clock basis. No of Tractor / Trailer required : 2 nos x 30 Days =60 Days Rate is inclusive of mobilisation and demobilisation.

Hiring of 5 Ton Capacity Fork lift with valid operator for transportaion of New catalysts/ Adsorbent stored in drums / jumbo bags from CPCL-Manali ware hosue to Refinery-3 Plant-205, 206 Site area & Shifting of the removed old Catalysts / Adsorbent from Plant area to the place as identified by EIC with in CPCL Permises. Necessary diesel is in contractor scope Minimum capacity : 5 Ton No of Fork lift requried : 2 nos x 30 Days : 60 Days on round the clock basis Rate is inclusive of mobilisation and demobilisation.

Hiring of 70 Ton capacity Crane with valid operator for Fresh catalyst loading , removal / Refixing of top manway / elbow piece and other allied maintenance jobs for Catalyst Replacement in plant-205 &206. Necessary diesel is in contractor scope Minimum capacity : 70 Ton, on round the clock basis No of Crane requried : 3 nos x 20 Days : 60 Days Rate is inclusive of mobilisation and demobilisation.

KOINS INDUSTRIAL SERVICES PVT LTD

Baluram and Bros Co

Plant-Tech Industrial Services Ltd.

Jyotsna Enterprises