Works Contract for Carrying out Mechanical Works Package-XIII in connection with Composite Works comprising of Piping, Mechanical, Electrical and Instrumentation Jobs for Interconnecting Piperack and Allied Areas of Lupech (J-18) Project,IOCL Gujarat

SP-1: PART-A : PIPING, INSULATION AND PAINTING WORKS

PIPING WORKS FOR OFFSITES & UTILITIES (INTERCONNECTING PIPEWAYS)

PIPING (ABOVE GROUND) : - Receipt of free issued Materials, transportation of all piping item(s) from Owner's storage point to worksite/work shop; fabrication including cutting, edge preparation, (inclusive of grinding the edges of pipe, fittings, flanges,etc. to match with the mating edges of uneven/different thickness wherever required); Locking arrangement for valves: fitup, bending, preheating wherever required, welding, threading, and laying of pipes of all types and thickness over sleepers, overhead on racks and at all elevations, connecting with equipment nozzles, strainers, sight glass, steam traps, expansion bellows, orifice assemblies, spray nozzles, rotameters, tappings for pressure gauges, thermowells, sample connections, springs, sample coolers, pressure relief valves, desuperheater etc. and fixing of gaskets, bolts, nuts including application of torque wherever required & all other inline instruments and fittings , like elbows, reducers, tees, vents, drains, SW/threaded valves upto 1.5 NB, Steam Supply/ Condensate Recovery stations (Cast/ Fabricated), alignment, Fixing and welding of RF pad, cleaning & flushing loop wise and system wise by water/Chemical/compressed air, hydrostatic, pneumatic, vacuum, spark testing , reinstatement, card board blasting, leak test, inertization, hot bolting if required and any other type of testing as specified, draining, drying by compressed air, completing all such works in all respects as per the specifications, drawings and instructions of Engineer- In-Charge. Contractor's scope of work includes transportation of fabricated / spooled piping from workshop to wok site . Scope of work Includes Instrument piping hook up items like impulse pipes, fittings etc., from piping isolation valve to instrument shall be fabricated, erected/installed based on the instrument hook drawing and other applicable standards (Instrument Impulse piping and fitting are free issue to contractor)

FABRICATION

CARBON STEEL / LTCS PIPING (NON IBR), THK. <= 10 MM

BELOW 2 INCH (FILLET WELD)

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL / LTCS PIPING (NON IBR), THK. > 10MM AND <= 20MM

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL / LTCS PIPING (NON IBR), THK. > 20MM

ABOVE 24 INCH

STAINLESS STEEL PIPING (NON IBR), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ALLOY STEEL PIPING (NON IBR), THK. <= 10 MM

2 TO 6 INCH

CARBON STEEL PIPING (JACKETED), THK. <= 10 MM

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL PIPING (NACE,HIC,H2), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

CARBON STEEL PIPING (NACE,HIC,H2), THK. > 10MM AND <= 20MM

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

ALLOY STEEL PIPING (NACE,H2), THK. <= 10MM

2 TO 6 INCH

CARBON STEEL PIPING (IBR), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL PIPING (IBR), THK. > 10MM AND <= 20MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

ALLOY STEEL PIPING (IBR), THK. <= 10MM

2 TO 6 INCH

ALLOY STEEL PIPING (IBR), THK. > 10MM AND <= 20MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ALLOY STEEL PIPING (IBR), THK. > 20MM

ABOVE 24 INCH

CARBON STEEL PIPING (GALVANIZED), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

ERECTION

CARBON STEEL / LTCS PIPING (NON IBR), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL / LTCS PIPING (NON IBR), THK. > 10MM AND <= 20MM

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL / LTCS PIPING (NON IBR), THK. > 20MM

ABOVE 24 INCH

STAINLESS STEEL PIPING (NON IBR), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ALLOY STEEL PIPING (NON IBR), THK. <= 10 MM

2 TO 6 INCH

CARBON STEEL PIPING (JACKETED), THK. <= 10 MM

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL PIPING (NACE,HIC,H2), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

CARBON STEEL PIPING (NACE,HIC,H2), THK. > 10MM AND <= 20MM

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

ALLOY STEEL PIPING (NACE,H2), THK. <= 10 MM

2 TO 6 INCH

CARBON STEEL PIPING (IBR), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL PIPING (IBR), THK. > 10MM AND <= 20MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

ALLOY STEEL PIPING (IBR), THK. <= 10 MM

2 TO 6 INCH

ALLOY STEEL PIPING (IBR), THK. > 10MM AND <= 20MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ALLOY STEEL PIPING (IBR), THK. > 20MM

ABOVE 24 INCH

CARBON STEEL PIPING (GALVANIZED), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

FIRE WATER /COOLING WATER PIPING (ABOVE GROUND & UNDER GROUND)

Receipt of Materials, Transportation of all piping items from Owner's storage point to worksite /work shop, fabrication including cutting, edge preparation (including the grinding of edges of pipe, fittings, flanges etc. to match with the mating edges of uneven / different thickness wherever required); fit up, bending, preheating, wherever required, welding, threading and laying of pipes of all types and thicknesses over sleepers, overhead on racks and at all elevations and fixing of gaskets, bolts, nuts including application of torque where ever required & all other inline instruments and fittings like elbows, reducers, tees, piping specials such as mitres and fabricated fittings, vents, drains , SW valves up to 1.5 NB, alignment, cleaning & flushing by water/compressed air, hydrostatic, pneumatic, vacuum, spark testing and any other type of testing as specified, draining, during by compressed air. Contractor will follow Technical specification(077154C-000-JSS-1300-001-3LPE COATING and 077154C-000-JSS-1300-002 Internal Glass flake Epoxy Coating) for "Coating of Fire Water / Cooling Water Line". For coated pipes, item rates shall be inclusive of application of coating of Weld joints/Modified joints (internal & external) as per Technical specification. Erection of Low Friction Pads (Teflon/Graphite/ SS 304 mirror finish) is inclusive in the quoted Price. PAD materials shall be supplied free issue to CONTRACTOR.

FABRICATION

CARBON STEEL PIPING (COATED), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL PIPING (COATED), THK. > 10MM AND <= 20MM

14 TO 24 INCH

ABOVE 24 INCH

ERECTION

CARBON STEEL PIPING (COATED), THK. <= 10 MM

2 TO 6 INCH

8 TO 12 INCH

14 TO 24 INCH

ABOVE 24 INCH

CARBON STEEL PIPING (COATED), THK. > 10MM AND <= 20MM

14 TO 24 INCH

ABOVE 24 INCH

VALVES: - Transportation of all types of valves (including special valves) from Owner's Storage point to contractor's stores /worksite and installation of valves for all rating including assembly of valves accessories, if any, fixing of gaskets bolts/nuts wherever required as per specification, drawings and directions of Engineer-In-charge.

All Types of Piping Bulk Valves (Gate, Globe, Check, Butterfly, Ball, Plug, Bellows & Other Flanged components) -150#

NB. 0.75 INCH

NB. 1 INCH

NB. 2 INCH

NB. 3 INCH

NB. 4 INCH

NB. 6 INCH

NB. 8 INCH

NB. 10 INCH

NB. 12 INCH

All Types of Piping Bulk Valves (Gate, Globe, Check, Butterfly, Ball, Plug,Bellows & Other Flanged components) -300#

NB. 0.75 INCH

NB. 1 INCH

NB. 2 INCH

NB. 3 INCH

NB. 4 INCH

NB. 6 INCH

NB. 8 INCH

NB. 10 INCH

NB. 12 INCH

All Types of Piping Bulk Valves (Gate, Globe, Check, Butterfly, Ball, Plug,Bellows & Other Flanged components) -600#

NB. 0.75 INCH

NB. 2 INCH

NB. 3 INCH

NB. 8 INCH

NB. 10 INCH

All Types of CONTROL VALVES, ON-OFF VALVES, MOTOR OPERATED VALVES: Erection of Flanged /welded/Sandwiched Control valves, On off Valves, MOVs of all ratings with actuators and volume bottles. Valves once erected for mechanical clearance, needs to be dropped for hydro testing and flushing of lines and kept in safe location for reinstallation after hydro test and flushing of lines. Valves to be reinstalled.

NB. 4 INCH

NB. 6 INCH

NB. 8 INCH

NB. 10 INCH

Flow Instruments: Erection as per mechanical and commisioning requirements of Flanged /welded/Sandwiched flow instruments of all ratings

NB. 2 INCH

NB. 3 INCH

NB. 4 INCH

NB. 6 INCH

NB. 8 INCH

NB. 10 INCH

PIPE SUPPORTS

PIPE SUPPORTS (FROM MATERIALS SUPPLIED BY OWNER) : Receipt of Materials, Transportation of all piping items from Owner's Storage point to Contractor Storage/worksite/work shop, Fabrication, welding,erection (at all elevations) of Itemized pipe supports (a. Hangers, b. Spring Supports c. Tie Rods d. Rigid Struts e.sliding plates f.expansion joints/bellows) , Pads, Trunnion supports, Paint touchup for Owner supplied items, all necessary equipments, consumables, labour, returning surplus materials etc. to OWNER's storage point and completing work as per drawings, specifications and instructions of Engineer-in-charge. Modifications/rectifications, if required; and adjustments/ alignment during precommissioning, commissioning as per the instructions of Engineer-in-charge. Installation of Spring hangers shall be in contractor's scope .Also unlocking of the Spring / hangers / and /or adjusting of turn buckles etc. during commissioning shall be in the scope of Contractor within the quoted price. Scope also includes : Providing all the tools & tackles, machineries, Man lift, consumables, steel scaffolding at all location and all elevation, manpower, PPE, supervision, etc.

Itemized Pipe Supports

PIPE SUPPORTS (FROM MATERIALS SUPPLIED BY CONTRACTOR) : Fabrication, erection (at all elevations) of pipe supports like shoes, cradles, hangers, clamps, U-Bolts, turn buckles, saddles, guides, special supports, T post, brackets etc. of all types including supply and application, shot blasting, one coat of primer, intermediate & final paint, all necessary equipments, consumables, labour, and completing work as per drawings, specifications and instructions of Engineer-in-charge. Modifications/rectifications, if required; and adjustments/alignment during precommissioning, commissioning as per the instructions of Engineer-in-charge. The scope of Works also includes grouting of supports, if required as part of Pipe Supports Works within the quoted price which includes supply of grouting materials also and nothing extra shall be payable in this regard. While fabricating the supporting elements the Contractor will ensure that dimensions shown in the drawings match with the site conditions. Pad and Trunnion welding in Contractor scope. Additional supports as necessary with the site condition shall be fabricated and erected in accordance with the Standard. The measurement shall be done in MT of finished support. Wastage shall not be considered. Scope also includes : Providing all the tools & tackles, machineries, Man lift, consumables, steel scaffolding at all location and all elevation, manpower, PPE, supervision, etc.

Pipe Supports for Carbon steel piping

Pipe Supports for Alloy steel piping

Pipe Supports for Stainless steel piping

Misc. Works (Related to Piping Fabrication and Erection)

Flame Cutting C.S. Piping IBR/Non IBR

Hacksaw cutting C.S. Piping IBR/Non IBR

Bevelling C.S. Piping IBR/Non IBR

Fitup & Welding C.S. Piping IBR/Non IBR

Hydrotesting, flushing loop wise and system wise by water/Chemical/compressed air,drying etc. of existing lines C.S. Piping IBR/Non IBR including Blinding and Deblinding of existing lines

Flame Cutting S.S. Piping IBR/Non IBR

Hacksaw cutting S.S. Piping IBR/Non IBR

Bevelling S.S. Piping IBR/Non IBR

Fitup & Welding S.S. Piping IBR/Non IBR

Hydrotesting, flushing loop wise and system wise by water/Chemical/compressed air,drying etc. of existing lines S.S. Piping IBR/Non IBR including Blinding and Deblinding of existing lines

Flame cutting A.S. Piping IBR/Non IBR

Hacksaw cutting A.S. Piping IBR/Non IBR

Bevelling A.S. Piping IBR/Non IBR

Fitup & Welding A.S. Piping IBR/Non IBR

Hydrotesting, flushing loop wise and system wise by water/Chemical/compressed air,drying etc. of existing lines A.S. Piping IBR/Non IBR including Blinding and Deblinding of existing lines

Dismantling and removal of under ground (upto 5 M depth) carbon steel pipe by gas cutting or by grinder (after removing coating and wrapping) from various locations including removal material, fittings, flanges, valves, vents, drains, branching etc.; pulling up the same to ground level with due care so that no other piping, equipments, machinerys etc. is damaged and cutting into pieces, if required; segregating for reclaiming useful fittings such as bends, flanges, valves, by unbolting, gas cutting, cold cutting etc.; transporting and stacking the salvageable useful materials to workshop / store or as per the direction of the Engineer-in-Charge and shifting the scrap pipes etc. to scrap yard or any other location within refinery premises and completing the job as per the instructions of Engineer-in-Charge. Job also includes supplying of all types of tools & tackles, lifting arrangements, equipment, machineries, all consumables & labour etc. to complete the work in all respects in a workman like manner including area preparation, taking clearance for hot/cold jobs, blinding and de-blinding, area cleaning after completion of work, flushing wherever required as directed by the Engineer-in-Charge. Note : 1. Carrying out the job is under contractor's scope and the same has to be complied with as per the directions of the Engineer- in-Charge. 2. Civil works (excavation and back filling) for underground dismantling shall be paid under separate item from Civil SOR. 3. Contracor shall get necessary work permit from the refinery authorities prior to the above works

MISCELLANEOUS CUTTING/WELDING WORKS (Applicable for specific works as per issued drawings , modification works / Miscellaneous works as per directions of E-i-C)

Gas cutting in Structural beams,plates etc

Grinding in Structural beams, plates at cutting locations etc

Welding in Structural beams,plates etc

Making holes in Structural beams,plates etc

Upto 30mm dia.

Upto Above 30mm dia.

Gas cutting in Pipes etc

Grinding & fitups in Piping etc

Welding in pipes etc

Making welded joints in reinforcement bar of any dia. to satisfaction of Engineer in charge.

Reinforcement bar cutting as directed by Engineer in Charge

Upto 16mm dia.

Above 16mm dia.

MISCELLANEOUS ACTIVITIES DURING REFINERY SHUTDOWN AND COMMISSIONING:

Contractor shall be responsible for carrying out pre-commissioning / commissioning (PCC) activities until plant handover, including but not limited to : preparation of PCC procedures, preparation of schedule of PCC activities, preparation of PCC manual, preparation of PCC team organogram, carry our PCC checks on equipment and machinery, equipment/machinery/ hardware preservation, test run of machinery in accordance with vendor requirements, charging/ loading of catalysts and chemicals, flushing/ blowing/ cleaning of systems, handling and safe disposal of PCC effluents in accordance with local regulations, prepare PCC checklists for various PCC activities, carry out PSSR, carry out JSA for PCC activities, arrange all equipment/ tools & tackles (including preparartion of temporary spools) and utilities required for PCC activities, operational tightness test, system leak checks, arrange skilled manpower (with Hand Tools, Equipment / Machinery, Consumables) and for PCC activities, refractory dry out, trouble shooting, maintain records/ data, arrange on-site lab analysis.

Foreman Supervisor

Skilled Manpower

Semi Skilled Manpower

Helper / Unskilled Manpower

"NOTE:- THE ABOVE RATE SHALL BE INCLUSIVE OF ALL TAXES & DUTIES, ROYALTIES, CESS, FEE, ENVIORMENTAL & POLLUTION, FITNESS & SAFETY CLEARANCE CHARGES (IF ANY), OR ANY OTHER INCIDENTAL CHARGES ETC BUT EXCLUDING GST."

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