Replacement and Refurbishment of entire stretch of 3Nos High Pressure penstocks in Moyar Power House

Amount

REVERSE ENGINEERING WORK, Design , Drawing &CFD Analysis (any one unit)

DISMANTLING OF THE EXISTING HIGH PRESSURE PENSTOCK

Charges for dismantling of damaged old penstock pipes in between flanges after and before anchor C to MIV for a slopping length of 700 meters approximately including expansion joints and man holes using suitable cutting gas including suitable winch arrangements, lead and lift of dismantled scrap materials from erection site, weighing of the dismantled materials & devolution to central stores/Singara.

MATERIAL PROCUREMENT

Charges for Procurement of 100% UT tested new ASTM A537 CLASS 1 plates as per ASTM A578 standard acceptance level for pipes, bends.

ANCHOR C-D : 14 mm Thickness

ANCHOR D-E : 16 mm Thickness

ANCHOR E-F: 20 mm Thickness

ANCHOR F-G: 22 mm Thickness

ANCHOR G-I: 26 mm Thickness

ANCHOR I-L :36 mm Thickness

ANCHOR L-MIV :38 mm Thickness

Charges for Procurement of New Expansion joint and New Man hole dummies as per Site conditions.

Charges for New Expansion joints as per site requirement and new manhole dummies as per site conditions. Workshop testing must be done as per relavant standard. (Including stud, bolts, glands, SS cladding and other consumables etc.)

Charges for Procurement of 7018 welding electrode or electrode recommended by plate supplier length 3.15X350mm

Charges for Procurement of 7018 welding electrode or electrode recommended by plate supplier length 4X450mm

Charges for Procurement of Paint Zinc ethyl silicate primer/ Zinc phosphate epoxy primer for 5506 Sq.Mtr with 50 Micron DFT

Charges for Procurement of two component coal tar paint conforming to IS 290/1961 Type B for 11012 Sq.Mtr with 2 coats of 125 Micron DFT each.

Charges for Procurement of thinner

Charges for Procurement of consumables for NDT Tests DPT, UT AND RT (DPT kit, UT probe, x ray flim,) at erection site.

Charges for Procurement of copper slag for surface preparation/Blasting

Charges for Procurement of saddle plate including lubrication oil/grease

MOBILIZATION AND DEMOBILIZATION OF SPECIAL TOOLS AND PLANTS, EQUIPMENTS, MACHINERIES TO AND FROM SITE

TRANSPORTATION OF PIPE SHELLS FROM MANUFACTURING PLANT TO FABRICATION SITE

Transportation Charges of plates from manufacturing plant to fabrication site for fabrication of pipe shell segment, expansion joints, man holes, flanges etc including transit insurance.

FABRICATION ACTIVITIES at SITE

Fabrication of Bulk heads for field Hydro static pressure testing purpose.

Charges for cutting, Butt weld preparation, Pipe rolling and re-rolling for the required profile and checking using a sample profile template.

Charges for longitudinal weld joint of the rolled pipe shells segments using Manual metal arc/Submerged metal arc Welding by engaging welders qualified as per ASME SECTION IX certified by Type A inspection body accredited to ISO 17020 Standard. Preheating and post weld heat treatment and normalizing included.

Charges for circumferential weld joint by joining 2 nos. of fabricated pipe shells of length 2.5 meter using Manual metal arc/Submerged metal arc welding by engaging welders qualified as per ASME SECTION IX certified by Type A inspection body accredited to ISO 17020 Standard. Preheating and post weld heat treatment and normalizing included.

Charges for conducting 100% Non-Destructive tests like DPT, UT and Radiography in each longitudinal, circumferential weldment in Areas where circumferential and longitudinal welds joints at workshop/ Fabrication site.

Fabrication of test rig facility for hydraulic testing of standard pipes as per standard design and fabrication site requirement. (1 Set)

Charges for Hydro pressure testing of the fabricated pipe at fabrication site with 1.5 times the operating pressure including marking of the location of erection.

REFURBUISHMENT OF PENSTOCK PIPES EMBEDDED INSIDE ANCHORS (PIPES BETWEEN FLANGES AT ENTRY AND EXIT OF EACH ANCHORS)

Charges for checking the Structural stability of Anchors

Refurbishment of penstock pipes embedded inside anchors (pipes between flanges at entry and exit of each anchors) including inspection, measurement of thickness and refurbishment using suitable metal building to the required ID or any other better Strengthening methodology for all 11 Anchors including material and labour cost.

ERECTION ACTIVITIES AT SITE

Charges for lead, lift, maneuvering of Newly fabricated pipe shells segments, Expansion joints, Manholes & mobilizing all newly fabricated materials from fabrication site area to erection site including charges for making arrangement for scaffolding, lifting equipments and aligning of pipe shells one by one for carrying out the erection and welding works.

Charges for positioning, aligning and circumferential welding the newly fabricated aligned penstock pipe segments using suitable special welding Electrode/Electrode recommended by plate supplier for ASTM A 537 CLASS 1 by preparing the standard "V" Butt weld preparations maintaining the root gap between pipe shells as per given standard. The welding will be performed using Manual metal arc/Submerged metal arc welding by engaging welders qualified as per ASME SECTION IX certified by Type A inspection body accredited to ISO 17020 Standard.

Charges for replacement of saddle plates including cleaning and lubrication.

Charges for conducting 100% complete NDT test after aligning and welding the penstock pipe segments deploying DPT for root joints, UT and Radiographic tests for fill and capping.

Charges for position, aligning, welding and erection of new expansion joint in the newly erected High pressure penstock according to the design.

Charges for positioning, welding and erection of new man hole dummies in the newly erected High pressure penstock according to the design. (Including stud, bolts, glands, SS cladding and other consumables etc)

Charges for erection of new platforms near manhole dummies to create access while carrying out inspection activities. MS angles, chakar plates five pattern etc.)

PAINTING (OUTER)

Charges for Sand/copper slag blasting of outer surfaces of the penstock considering all the conditions and including materials transport, Tools and equipments for blasting and forming scaffolding arrangements in blasting and painting works.

Charges for Painting 1 coat of Zinc Rich Primer/ Zinc phosphate epoxy primer coat of thickness 25-50 Micron to be applied on the outer surface of the pipe at erection site including materials transport, Tools and equipments for painting and forming scaffolding arrangements in painting works.

Charges for Painting 2 coats two component coal tar epoxy paint coat of thickness 100-125 Micron (Each coat) to be applied on the outer surface of the pipe at erection site. Combined Micron 250 Micron including materials transport, Tools and equipments for painting and forming scaffolding arrangements in painting works.

Charges for Inspection of Dry Flim Thickness for the entire length of penstock for every two metre interval and Tabulation of the same. (Including scaffolding and labour)

PAINTING (INNER)

Charges for Wire brush cleaning/Power Tool of both inner surfaces of the penstock considering all the conditions and including materials transport, Tools and equipments for blasting and forming scaffolding arrangements in blasting and painting works.

Charges for Painting 1 coat of Zinc Rich Primer/ Zinc phosphate epoxy primer coat of thickness 25-50 Micron to be applied on the inner surface of the pipe at fabrication/erection site including materials transport, Tools and equipments for painting and forming scaffolding arrangements in painting works.

Charges for Painting 2 coats two component coal tar epoxy paint coat of thickness 100-125 Micron (Each coat) to be applied on the inner surface of the pipe at fabrication/erection site including materials transport, Tools and equipments for painting and forming scaffolding arrangements in painting works.

Charges for Inspection of Dry Flim Thickness for the entire length of penstock for every two metre interval and Tabulation of the same. (Including scaffolding and labour dismantling and reassembling of man hole dummies)

CIVIL WORKS

Clearing of Scrub Jungle (TOTAL LENGTH OF PENSTOCK FROM C TO MIV = 675 WIDTH = 10 MTRS)

Providing R.C.C 1:1.5:3 using 12mm to 20mm HBG machine crushed metal for Anchor, embedding the penstock pipes and supporting saddle Piers up to the required level, based on the NDT test, including cost of conducting NDT test charges, cost of all materials, scaffolding, shuttering, strutting charges, cost of MS/RTS steel, Fabrication reinforcement, admixtures of Epoxy coating, Grip rod vibrating charges, Curing, lead, lift, T&P etc complete as directed by the Engineer at Site

Grouting the voids in the concrete around the steel liner using suitable special grout with cibex-100 (Ordinary and low heat Portland cement) or equivalent in anchors, including hire charges for grouting machinery, drums, hoses, grouting pump, suitable pressure gauge. etc., all accessories, including cost of all materials, labour, lead, lift charges and transporting charges along with personal protection equipments.

CGST in % (For Bidders inside TamilNadu) (MATERIAL and LABOUR)

SGST in % (For Bidders inside TamilNadu) (MATERIAL and LABOUR)

IGST in % (For Bidders outside TamilNadu) (MATERIAL and LABOUR)

SHRI SARAVANA INDUSTRIES PRIVATE LIMITED

KSK Fabricators and Erectors Private Limited