Tender Notice

Enquiry No. HOC/MECH/43/Prep. Boilers-RLA/ October 13, 2009

Sub : Preparatory Work for RLA study of Main Boilers

Sealed tenders are invited from registered contractors with HOCL, Kochi for the Preparatory Work for RLA study of Main Boilers

Scope of Work

Scope of Work : The scope of work includes but not limited to the following

  1. Supply & Erection of scaffolding (inside & outside).
  1. Removal and re-application of insulations, wherever required
  1. Removal and re-application of refractory, wherever required
  1. Cleaning and surface preparation for non-destructive testing by buffing or grinding process as the case may be.
  1. Gas cutting of boiler shell plates, stiffeners, structural etc. wherever required for removal of insulation / refractory to carry out NDT and re-welding of the shell plates (New plates/ old plates) stiffeners, structural etc. to the original location as per the instruction of the engineer in charge.
  1. Removal of dust, sludge etc. from tube, furnace, economizer etc. and to dispose to a place as instructed by the Engineer-in-Charge.
  1. Supply & Erection of Steel Scaffolding – Inside and Outside

Steel scaffolding is to be made out of tubular structures (standards scaffolding pipes of 40mm dia and clamps) in order to make entire inner surface of Main Boilers (2 Nos) (furnace area, convection tube area, Boiler steam drum, Mud drum and economiser area) safely accessible for cutting and removal / fixing and re-welding of boiler shell plates, removal / application of insulation, removal / application of refractory, visual inspection, non-destructive testing (NDT) work and video Boroscopy. All the scaffolding material including necessary pipes, clamps and steel platforms to be arranged by the Contractor at his own cost. The Engineer-in-Charge may accept better scaffolding material/technique than that given below, in case if Contractor prefers to provide.

Height between two horizontal members (pipe) of tubular structures should be 500mm to 800mm (maximum) to have ease and safety of climbing up or down by the working and inspecting personnel. In special cases the height may have to be reduced if felt necessary by the Engineer-in-Charge of HOCL. Provision must be kept for the same.

Working platform or stages are to be made by Steel grills / Aluminium Perforated Sheets/ grills or similar material and secured firmly. These platforms are to be provided at a vertical distances of about 1200mm below each welding joint of the tube / header / Drum to enable visual inspection and NDT work of these welds and surfaces conveniently while inspecting personnel are standing on the platform/stages. Similar stages are to be made inside (furnace) and outside the boiler furnace, convection tube area, Boiler steam drum area, Mud drum area and economiser area for the inspection and NDT of all the weld joints and plates. Platforms are also required to be built for inspection of all nozzles welds.

A clear gap of 50 – 70mm should be maintained between the edge of scaffolding pipes and side wall of boiler shell outside and from the refractory inside the furnace, convection tube area, Boiler steam drum, Mud drum and economiser area. In no case the pipe edges should touch shell surface except at bottom support points, where pipes should be supported on flat plates of proper size (flat pieces of plates to be welded at the end of the vertical scaffolding pipes) to avoid injury to shell surfaces.

Suitable rigid ladders should be brought by the party and provided for landing into the platforms stage at all locations wherever required by the NDT inspectors as per the instruction of Engineer-in-charge.

All the material required for making scaffolding including scaffolding pipes, clamps, platforms plates/grills, tools, tackles and consumables shall be in the scope of the contractor.

  1. Removal of Scaffolding

Scaffolding is to be removed after completion of cutting and removal / fixing and re-welding of boiler shell plates, removal / application of insulation, removal / application of refractory all inspection/NDT work and repairs, both inside and outside.

Same scaffolding shall be used for necessary replacement of any repairs to be done after NDT. The Contractor shall have to keep scaffolding intact till all any repairs to be done after NDT.

  1. Removal of Insulations

Insulation shall be removed wherever required from releaser tubes, top header, back header, steam drum, mud drum, down comers, connecting pipes to headers and steam pipe and any other areas as deemed necessary by the NDT inspector as per the instructions of the engineer-in-charge.

Number of locations to be exposed may vary depending on actual requirement. Provision must be kept for the same.

  1. Re-application of Insulation

On completion of inspection, thermal insulation shall be re-applied by the Contractor as per IS 7413-1981. Which includes Supply of labour and supervision of work including transportation of materials to work site from store, preparation of mattresses or asbestos ropes to prescribed thickness and densities, applying on surfaces as specified including all preparatory work thereon, all binding, tying, lacing, stitching and or otherwise securing finishing with aluminium sheet cladding (if required), providing bolts, rivets or self tapping screws wherever specified providing necessary scaffolding and completing the works in all respects as per drawings, specifications and instructions of engineer-in-charge to give a joint less surface / seal the joints to prevent ingress of moisture into it.

  1. Removal of Refractory lining

This includes removal of mineral wool, calcium silicate blocks, refractory tiles / bricks and anchor washer / nuts / breaking of insulating castables at the required area without damaging other nearby areas at all elevation and cleaning of shell plates for gas cutting of plates as per instruction of Engineer-in-Charge.

  1. Reapplication of Refractory lining

This includes application of mineral wool, calcium silicate blocks, refractory tiles / bricks and anchor washer / nuts / casting of insulating castables with suitable shutters etc. at the required area with suitable joint preparation (joint to be leak free) with the nearby areas at all elevation as per instruction of Engineer-in-Charge.

  1. Cleaning & Surface Preparation for Non Destructive Testing

All appropriate tools (grinding machines, buffing wheels of different grades, emery wheels of different grades, emery tape, files etc., tackles and any other consumables required for the internal and external surface preparation and cleaning as enumerated in the following paragraphs shall be the responsibility of the Contractor.

Areas as indicated below are to be thoroughly cleaned and prepared as per the procedure given at paragraph (b & c) for magnetic particle inspection.

Visual Inspection

The area for visual inspection to be cleaned thoroughly (loose scale, oil, dirt, sludge etc. shall be removed from surface) as per the requirement of the inspection agency and the Engineer-in-Charge.

UT Flaw Detection, Wet Fluorescent Magnetic Particle Inspection, Dye Penetrant Testing, Ultrasonic Thickness Measurement and OD Measurement, In-situ Metallography (Replilca) and Hardness Measurement

Cleaning of surfaces is to be done by buffing. The surface finish to be of maximum finish (white metal finish) for carrying out the above inspections. The locations to be buffed will be intimated at the time of execution. The quality of buffing should be to the satisfaction of Engineer in charge. Cleaning shall be done by using mechanical striking tools, chipping hammers, emery paper, buffing wheels, grinding wheels or rotating wire brushes or by any other better and safe technique. The detached rust, mill scale etc. shall be removed by clean rags.

  1. The dimension of the spot to be prepared for UT Flaw detection is throughout the length of the weld with 200mm parent metal on either side of the weld.
  2. The dimension of the spot to be prepared for WFMPI and DP Test is throughout the length of the weld with 150mm parent metal on either side of the weld.
  3. The dimension of the spot to be prepared for Thickness Survey is 2” dia size.
  4. The dimension of the spot to be prepared for Metallography and Hardness Test is 2 × 2” size.

Video Boroscope / Fibre Optic Inspection

Inside cleaning of headers to be done as per the instruction of the Engineer in Charge.

Gas Cutting of Boiler Shell Plates Re-Welding of the Shell Plates (with New Plates / Old Plates) Stiffeners, Structural etc.

Cutting and removal of shell plates / stiffeners / structural after removal of insulation or refractory as required. Aligning and rewelding (with old / new plates / stiffeners / structural) of the removed plates after RLA study, insulation and refractory work, cleaning / painting with 2 coats of epoxy paints as per instruction of the Engineer – in –Charge. Welding of damaged stud bolts with new stud bolts to the boiler tube to hold refractory.

NOTE :

RLA study of the main Boilers are planned in two phases. Out of the two Boilers, in the 1st phase, Main Boiler K 480 shall be released for work. After this there will be a gap of five to six months to start the 2nd Phase of the work of similar nature i.e. Main Boiler K479 as mentioned above.

Visual Inspection

The area for visual inspection to be cleaned thoroughly (Loose scale, oil, dirt, sludge etc. shall be removed from surface) as per the requirement of the inspection agency and the Engineer-in-charge and also to provide assistance for carrying out the visual inspection on the following areas.

a)Steam Drum

b)Mud (Bottom) Drum

c)Economiser

d)High temperature Headers (Top headers) (2 Nos.)

e)Economiser header(top & bottom)

f)Boiler Bank Tubes (Convection)

g)Water Wall Tubes Furnace Tubes

h)Steam Pipe

UT Flaw Detection

The area to be inspected is to be buffed with electric buffing machine

a)Steam Drum

Inside

  • 100% of the welds including circumference and longitudinal seams, all butt welded joints and welds of the dish ends are to be checked by angle probe scanning for UT FLAW DETECTION.

b)Mud (Bottom) Drum

Inside

  • 100% of the welds including circumference and longitudinal seams, all butt welded joints and welds of the dish ends are to be checked by angle probe scanning for UT FLAW DETECTION.

c)High temperature Headers (Top headers) (2 Nos.)

Outside

  • 100% of the butt welds joints to be done with suitable probe.

d)Economiser header(top & Bottom)

  • 100% of the butt welds joints to be done with suitable probe.

e)Steam Pipe

  • 100% of the butt welds joints to be done with suitable probe.

Wet Fluorescent Magnetic Particle Inspection

a)Steam Drum

Inside

  • 100% of the welds including circumference and longitudinal seams, nozzle welds, welding spots/areas of temporary attachments i.e. brackets, clamps, cleat etc. 100mm parent metal on either side of the weld.

Outside

  • Fillet welds of supports, reinforcements in the dish ends and legs/stub to reinforcement pads (if any) are to be checked by WFMPI. Nozzle to shell welds and reinforcement pads including manhole welds to be checked from outside by WFMPI. 100mm of parent metal on either side of the weld is to be covered in WFMPI of welds.

b)Mud (Bottom) Drum

Inside

  • 100% of the welds including circumference and longitudinal seams, Downcomer, nozzle welds, welding spots/areas of temporary attachments i.e. brackets, clamps, cleat etc.

Outside

  • Fillet welds of supports, reinforcements in the dish ends and legs/stub to reinforcement pads (if any) are to be checked by WFMPI. Downcomer, Nozzle to shell welds and reinforcement pads including manhole welds to be checked from outside by WFMPI. 100mm of parent metal on either side of the weld is to be covered in WFMPI of welds.

c)High temperature Headers (Top headers) (2 Nos.)

  • 100% of the butt welds joints, welding spots / areas of temporary attachments.

d)Economiser header(top & Bottom)

  • 100% of the butt welds joints to be done.

e)Steam Pipe

  • 100% of the butt welds joints, welding spots / areas of temporary attachments.

Dye Penetrant Testing

a)Steam Drum

Inside

  • 100% of the welds including circumference and longitudinal seams, nozzle welds, welding spots/areas of temporary attachments i.e. brackets, clamps, cleat etc.

Outside

  • Fillet welds of supports, reinforcements in the dish ends and legs/stub to reinforcement pads (if any).
  • Nozzle to shell welds and reinforcement pads including manhole welds.

b)Mud (Bottom) Drum

Inside

  • 100% of the welds including circumference and longitudinal seams, Downcomer, nozzle welds, welding spots/areas of temporary attachments i.e. brackets, clamps, cleat etc.

Outside

  • Fillet welds of supports, reinforcements in the dish ends and legs/stub to reinforcement pads (if any).
  • Downcomer, Nozzle to shell welds and reinforcement pads including manhole welds.

c)Economiser

Butt weld joint where accessible.

d)High temperature Headers (Top headers) (2 Nos.)

Outside

  • 100% of the butt welds joints, welding spots / areas of temporary attachments.

e)Economiser header(top & Bottom)

  • 100% of the butt welds joints to be done.

In-Situ Metallography (Replica)

a)Steam Drum

Inside & Outside

5 Points.

b)Mud (Bottom) Drum

Inside & Outside

5 Points.

c)High temperature Headers (Top headers) (2 Nos.)

2 Points per header (4 Points)..

d)Water Wall Tubes Furnace Tubes

2 Points

e)Steam Pipe

2 Points.

Video Boroscopy/ Fibre Optic Inspection

a)High temperature Headers (Top headers) (2 Nos.)

Required for both the headers of length 5 mts.

Ultrasonic Thickness Measurement and OD Measurement

a)Steam Drum

40 points.

Mud (Bottom) Drum

40 points.

b)Economiser

50 points.

c)High temperature Headers (Top headers) (2 Nos.)

10 points.

d)Economiser header (top & Bottom)

10 points.

b)Boiler Bank Tubes (Convection)

50 points.

c)Water Wall Tubes Furnace Tubes

300 points.

d)Steam Pipe

20 points.

Hardness Measurement

a)Steam Drum

20 points.

b)Mud (Bottom) Drum

20 points.

c)High temperature Headers (Top headers) (2 Nos.)

16 points each header.

d)Water Wall Tubes Furnace Tubes

8 points.

e)Steam Pipe

8 points.

Payment Terms

  • 90% payment will be made on completion of the job in all respect like submission of reports in 6 sets, area cleaning and certification by Engineer-in-Charge.
  • Balance 10% payment will be made after completion of defect liability period of one year or on production of Performance Bank Guarantee.

Taxes & Duties

Rates quoted will be inclusive of all taxes, duties, octroi except Service Tax. Service Tax will be paid extra if the contractor produces the service tax registration number and other details.

Security Deposit

Security deposit shall be collected as per G.C.C.

Completion Period

The work shall be completed within 15 days from the date of clearance to start the work.

ESI, Safety Regulations, Workmen Compensation, Personal Protective Equipments, Labour Laws & Provident Fund, Guidelines to Contractors / Suppliers for Environmental Protection & Confined Space Entry

Refer attached Annexure - A

Note:

This tender aims for already enlisted contractors for this work with HOCL Kochi Unit. Any new contractor who wish to empanel for this type of work may submit the credentials as detailed below so that they will be evaluated and pre-qualified and shall be considered for similar future work.

Credentials to be submitted for the pre-qualification.

  1. Details of the Organization and the works carried out
  2. Work Order copies of the work executed showing the order value for the last 3 years.
  3. Man Power Organogram
  4. Solvency Certificate from a Nationalized Bank
  5. Annual Turn over for the last 3 Years.

Application should reach the office of the Dy. General Manager (Personnel & Administration Dept., Hindustan Organic Chemicals Limited, Ambalamugal, PIN – 682 302, Ernakulam on or before 04/11/’09.

Annexure – A

ESI, PF, Labour Law etc. – Requirements

ESI As per the ESI Act 1948

The Contractor shall enroll all his men deployed for the work in the ESI scheme. Registration for all workmen under ESI scheme is also to be complied with.

Safety Regulations and General Conditions of Contract

The Contractor should be strictly abide all the safety regulation of HOC specified in GCC. Contractor should obtain necessary safety work permit from authorised officer before starting the work every day, in every shift.

Workmen Compensation

It will be your responsibility to meet all claims for compensation under workmen’s Compensation Act 1923. ESI or under any other law in respect of sickness, accidents injury or death suffered by workmen engaged by you for carrying out the work. It shall be the sole responsibility of the contractor to comply with Employee’s State Insurance Act 1948. You will also be responsible and liable in respect of claims for damage to property or persons arising from or in the course of execution of the contract work undertaken by you. You hereby agree that you shall keep HOC fully indemnified in respect of claims under the Workmen Compensation Act and all other claims aforesaid and you shall not under any circumstances raise any dispute with regard to the same.

Personal Protective Equipments (PPE)

You are requested to use personal protective equipment such as

  1. Safety Helmet
  2. Safety belts
  3. Welder’s Personal Protective equipment like goggles, gloves, shoes and face shield

It is the basic responsibility of the Contractor to provide all the safety gadgets (PPE’s) as mentioned above to all their Supervisors/Workers.

And without these PPE’s Contractor will not be allowed to carryout any job, which may please be noted.

Labour Laws & Provident Fund

You are requested to possess:

  1. A Licence from the Labour Dept. under Contract Labour (Regulation and Abolition) Act 1970.
  1. A separate PF Code under the Employee PF Act – 1952 and also furnish details of CPF Contribution payment made with the Regional PF Commissioner.

Schedule of Rates
Sub: Preparatory Works for RLA study of Main Boilers K480 & K479
Sl.No. / Description / Unit / Qty / Rate (Rs.) / Amount (Rs.)
1 / Supply and erection of scaffolding both inside and outside / Lumpsum / per boiler / 2.00
2 / Removal and refixing of insulation (200 mm Thk) / M2 / 400.00
3 / Removal and relining of refractory (100 mm Thk) / M2 / 200.00
4 / Removal / Cutting and refixing by welding of casing plate / MT / 2.00
5 / Surface preparation by scale removal / grinding / buffing etc. for UT/PT/WFMPI / M2 / 30.00
6 / Surface preparation for thickness survey by scale removal / grinding /buffing / Point / 1000.00
7 / Surface preparation of In-situ Metallography and hardness by scale removal / grinding / buffing / Point / per boiler / 180.00
8 / Lumpsum charges for arriving RLA teams for inspection and video borography / Lumpsum / per boiler / 2.00
9 / Cleaning of tubes / headers / drum and soot removal / Lumpsum / per boiler / 2.00
2 / Service tax @
Total
The above rates are inclusive of all taxes, duties, octroi (including KGST on works contract) except Service Tax. Service Tax to be paid extra on production of the service tax registration number and other details.
Name of the contractor :
Signature of the Contractor :
Date :

Annexure – A