Replacement of Damaged Penstock pipe line by Supply, Fabrication, Erection of 220 meter Penstock pipe line, reconditioning of Butterfly valve at valve house, Overhauling of expansion joint, rectification of defective joints, painting at Suruliyar PH

Amount

Activities at Fabrication Works

Cost of 100% UT tested new ASTM A285 Gr.C plates and Charges for plate cutting, edge preparation, surface cleaning, rolling & re-rolling. 1. Pipe shells - ID. ɸ1.3 meter & minimum wall thickness of 10 mm – 200 meter (Length of each pipe shell is 2.5 meter & Total Nos. of pipe shell is 80 Nos.) 2. Bend as per site condition of length 15 meter long (various sections)–1 no with provision for fabrication and erection allowance of 5 meter for cutting, edge preparation during fabrication at shop and erection works at site. (including Transportation Charges)

charges for procurement of 1. New Expansion joints (No.21 &22) as per attached drawing 2.New Manhole (No.21 & 22 ) with dummies as per site conditions. ( including surface preparation and inner & outer painting)

Charges for longitudinal weld joint of the rolled pipe shells & bend segments using Electric Fusion Welding by engaging IBR certified welders (80 Nos. of longitudinal weld joint for 80 Nos. of pipe shell of length 2.5 meter and 6 Nos. of longitudinal weld joint approx. as per site condition for 1 No. of Bend segments of length 2.5 meter)

Charges for circumferential weld joint by joining 2 nos. of fabricated pipe shells of length 2.5 meter having indicative standard length of 5 meter each and 3 nos Bend segments having length of 5 meter each as per site conditions respectively by using Electric Fusion Welding by engaging IBR certified welders (40 Nos. of circumferential weld joint for 40 Nos. of pipe shells of length 5 meter and 3 Nos. of circumferential weld joint for 3 Nos. Bend segments of 5 meter length as per site conditions)

Charges for conducting 100% Non-Destructive tests like DPT, UT and Radiography in each longitudinal and circumferential weldments at fabrication workshop (Total no of longitudinal weldments – 86 Nos. & Total no of longitudinal weldments – 43 Nos.)

Charges for Hydro pressure testing of the fabricated pipe of 5 Metres long by putting dummy plates on both sides (40 Nos. of pipe shells of 5 m length and 1 no. Bend as per required of site condition)

Charges for surface preparation using copper slag before painting at inner and outer surfaces of steel pipe of 5 meter length and 1 No. Bend to remove the mill dust and other particles to white metal surface finish of 220 meters.

Charges for Painting, 1 coat of weather resistant Zinc Rich Primer inner and outer surface of the steel pipe shells of 5m length and 1 no. Bend at fabrication shop including material cost.

Transportation Charges for newly fabricated pipe shells, bend segments, expansion joints, man holes from fabrication shop to erection site and local transportation including lead and lift, loading, stacking and unloading & necessary tool and plants like crane arrangements, cable, winch, support structures, machineries, testing equipments, lead & lift equipments, pipe alignment supports and etc.

Activities at Erection site

Charges for dismantling of damaged old penstock pipes for a slopping length of 220 meters approxi. including bends, expansion joints and man holes using suitable cutting gas including lead and lift of dismantled scrap materials from erection site & stacking at Suruliyar valve house.

Cost for new saddle steel plates and graphite pads in 14 piers starting from Anchor 22 after dismantling of old saddle plates and graphite pads.

Charges for lead, lift, maneuvering of Newly fabricated pipe shells, bend segments, Expansion joints, Manholes & mobilizing all newly fabricated materials from suruliyar valve house 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 works at erection site.

Charges for circumferential welding the newly fabricated & aligned penstock pipe segments using suitable special welding Electrode after preparing the welding Edges by 'V' Butt chamfering. The welding will be performed using special Arc Welding machine by engaging IBR qualified welders. (5m length - 40 Nos and 1 No. Bend as per required of site condition).

Charges for Positioning, aligning & erecting 2 Nos. Expansion Joint and 2 Nos of man hole.

Charges for conducting welding test after welding and aligning the penstock pipe segments deploying DPT, UT and Radiographic tests.

Charges for Painting 1 coat of weather resistant Zinc Rich Primer inner and outer surface of the pipe at erection site including material cost.

Charges for Painting 3 coats of Hi-Grade weather resistant coal tar epoxy paint at inner and outer surface of the pipe at erection site including material cost.

Cutting and clearing the Heavy jungle disposing off from the site as directed by the Engineer at site including charges for T&P, labour,lead, lift, etc, complete.

Dismantling the existing RCC Anchor 21 and 14 Nos of Piers (betweenAnchor 22 and bursted portion) with reinforcement and clearing away the debris from site as directed by the Engineer in charge and scrap rods to be stacked with main scrap materials including all cost of labour, lead , lift, T&P, etc., complete.

Providing R.C.C 1:1.5:3 using 12mm to 20mm HBG machine crushed metal for Anchor 21 and 14 Nos of Piers (between Anchor 22 and bursted portion), embedding the penstock pipes and supporting saddle Piers up to the required level, based on the NDT test, including cost of conducting NDT test, 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.

Butterfly valve - Reconditioning works

Charges for dismantling of the butterfly valve, lead, lifting and scaffolding arrangements from valve house to work shop.

Charges for reconditioning of worn out seating area in valve body through Stainless steel welding having a dia1500 mm.

Charges for reconditioning of worn out seating area in butterfly valve disc through aluminium bronze welding.

Charges for post weld Heat Treatment for Normalising / Stress Reliving, DPT, ultrasonic test in welded area before and after machining.

Charges for precision machining in welded areas and fine grinding, maintaining surface roughness average 0.2 to 0.8 µm or newly installed seating ring in valve body.

Charges for trail assembling and blue matching to ensure the perfect closing.

Cost for new rubber seal (15 mm thickness) suitable for high pressure application along with protective stainless steel seal ring.

Charges for hydro test and its necessary dummy, valves and pressure gauge etc.

Charges for Replacement of Hydraulic pressure device and its motor (1.5 KW) including its accessories like inlet / outlet pipe line (1/2 inch –carbon steel seamless pipe) necessary pressure control valves, pressure gauges, limit switches, NRV, Solenoid valve and its panel etc.

Charges for Servicing / Overhauling the Hydraulic Piston engaged in the counter weight mechanism and automatic air inlet / air release valve device.

At Workshop Charges for painting 2 coats of weather resistant Zinc Rich Primer on inner and outer surface followed by 3 coats of Hi-Grade weather resistant coal tar epoxy paint on inner and 1 coat of Hi-Grade weather resistant coal tar epoxy paint on outer surface including material cost. At Erection site ( valve house) Charges for painting remaining 2 coats of Hi-Grade weather resistant coal tar epoxy paint on outer surface including material cost.

Charges for Reassembling, Commissioning and Testing of Reconditioned Butterfly valve.

Charges for transportation of necessary tools and plant like crane arrangments, support structures, machineraries, testing equipments, lead & lift equipments, material for scaffolding arrangment for dismantling of butterfly valve from Suruliyar valve house and To & fro transportation of the butterfly valve from Surilyar valve house for carrying out the reconditioning works.

Expansion joints - Inspection and Overhauling works

Charges for forming scaffolding arrangements for inspection of existing Gland rope & Rubber chord of 20 Nos. Expansion Joint including materials and transportation.

Charges for cleaning, removing of gland ropes and rubber cords from expansion joints from Expansion joint No. 01 to Expansion joint No. 20, reinsertion of New 26 mm square Graphite Gland rope & 25 mm rubber cord and greasing of 20 Nos. expansion Joints including material cost.

Charges for cleaning and replacing the worn out stud and bolts of 20 Nos. Expansion Joint design as per site requirement. (1set = 1 stud + 3 Nuts) including material cost. Size 1. Length of stud -280mm, Dia – 11/2” = 50 sets 2. Length of stud -280mm, Dia – 11/4” = 50 sets

Charges for Reassembling, Commissioning and Testing of 20 Nos. Expansion Joint.

Charges for cleaning and lubricating the piers saddle plates including materials and forming scaffolding arrangements.

Painting of Penstock pipe and Steel pipe liner & UT

Charges for surface preparation for removal of metal dust in inner and outer surface of penstock pipe line for the length of 77.5 meters from Anchor - 20 towards valve house, pipeline between Anchor 20 to Spherical valve and inner surface of steel pipe liner between surge tank to butterfly valve including materials transport and forming scaffolding arrangements in blasting and painting works.

Rectification of defective weld joints identified through 100% Ultrasonic test and Ultrasonic thickness measurement, through surface preparation, EFW welding using suitable welding electrode and grinding, as per site requirements, to the extent of satisfactory Ultrasonic test result in each weld joint.

a) Cost of rectification of longitudinal weld (each longitudinal weld / 2.5M of Penstock pipe line)

b) Cost of rectification of circumferential weld (each circumferential weld/ 4.1M of Penstock pipe line approx.)

Charges for conducting 100% Ultrasonic Test with defect identification and Ultrasonic thickness measurement in each longitudinal and circumferential weldments for a length of 77.5 meters from Anchor-20 towards valve house & 2,587.66 meters between Anchor-20 and Anchor-TA for the above rectification works

a) Cost of 100% Ultrasonic Test and Ultrasonic thickness measurement for each longitudinal weld (each longitudinal weld / 2.5M of Penstock pipe line)(1690 joints X 2.5 meters = 4225 meters)

b) Cost of 100% Ultrasonic Test and Ultrasonic thickness measurement for each circumferential weld (1086 joints X 4.15 = 4507 meters)

Charges for Painting 2 coat of weather resistant Zinc Rich Primer inner surface of the penstock pipe line for the length of 77.5 meters from Anchor - 20 towards valve house, pipeline between Anchor 20 to Spherical valve and inner surface of steel pipe liner between surge tank to butterfly valve followed by 3 coats of Hi-Grade weather resistant coal tar epoxy paint at inner surface of penstock pipe line 77.5 meters from Anchor - 20 towards valve house, pipeline between Anchor 20 to Spherical valve and inner surface of steel pipe liner between surge tank to butterfly valve including material & transportation cost. 1) 1.0 m dia of penstock length – 1120m 2) 1.15 m dia of penstock length – 877.9m 3)1.3 m dia of penstock length – 683m 4)1.5 m dia of steel liner length – 30m Painting.specification 1. Weather resistant Zinc Rich Primer – 25 to 50 micron per coat. 2. Hi-Grade weather resistant coal tar epoxy paint – 100 to 125 microns per coat. (Total thickness of the paint coating per surface 400 to 475 micron to be maintained)

Charges for Painting 2 coat of weather resistant Zinc Rich Primer outer surface of the penstock pipe line for the length of 77.5 meters from Anchor - 20 towards valve house, pipeline between Anchor 20 to Spherical valve followed by 3 coats of Hi-Grade weather resistant coal tar epoxy paint at outer surface of penstock pipe line for the length of 77.5 meters from Anchor - 20 towards valve house, pipeline between Anchor 20 to Spherical valve including material & transportation cost. Painting.specification 1. Weather resistant Zinc Rich Primer – 25 to 50 micron per coat. 2. Hi-Grade weather resistant coal tar epoxy paint – 100 to 125 microns per Coat. (Total thickness of the paint coating per surface 400 to 475 micron to be maintained)

Charges for dismantling and reassembling of man hole dummies during blasting, painting and charges for replacement of rubber cord in manhole dummies including material cost.

Charges for cleaning and replacing the worn out bolts with nuts of 20 Nos. Man hole dummies as per site condition including material cost.

Charges for measurement of coating thickness before blasting, painting and after each coat of painting in every 50 meters.

CGST in % (For Bidders inside TamilNadu)

SGST in % (For Bidders inside TamilNadu)

IGST in % (For Bidders outside TamilNadu)

TRUTECH INDUSTRIES

CLASSIC ENGINEERING ENTERPRISES

SAMY CONSTRUCTION

RAVI ASSOCIATES