Chennai Petroleum Corporation Limited - Tamil Nadu
36884264 refractory repair works, insulation, concrete repairs and painting of cogen boiler chimney 121 x 001 during refinery ii m and i shutdown, 2023 at cpcl manali , refractory repair works, insulation , lumpsum charges: a ) for scaffolding providing and erecting of scaffolding system for any / all elevations on the interior side of cogen boiler 1 / 2 / 3 rcc chimney, the scaffolding shall be erected between two corbels which are 10 m apart in elevation repairs are called for and sufficient material to cover 50% height of the chimney ( ~1520 m2 ) shall be available at any point of time. b ) for fabrication, erection and operation of ms cage arrangement of dia ~750 mm hoisted with electrical operated winch arrangement to move through the ventilation opening within the chimney structure upto height of 97 metres ( any holes required in the top rcc platform for fixing the guide ropes shall be made by the contractor ) c ) for fabrication, erection and operation of 3 nos of ms cage arrangement of dia ~750 mm hoisted with electrical operated winch arrangement to move through the individual boiler flue gas stack within the chimney structure upto height of 100 metres ( cpcl shall arrange for provision ofopenings in the bottom metal duct of each stack to allow the cage / platform to move through ) to enable parallel working in all 3 stacks. additional 1 no. of similar ms cage hoisted with electric operated winch arrangement to be kept ready as standby arrangmement. d ) for erection and operation of exterior cradle system ( with 2 nos supspension jib system ) of capacity ~800 kg and lift height 100 metres, capable of manouvering up and down and along the circumference of the chimney structure. , refractory lining replacement in double skewed 115 mm thick refractory fire brick / acid proof bricks job involves removal of old / damaged refractory for all elevations as marked by inspection, transportation of the required quantity of refractory materials from storage point, surface preparation andapplication of refractory material as per codes / specifications / inspection procedures / scope of work and work details including welding / fixing of anchors / plates ( as per attached sketch ) . job also includes transportation of unused serviceable materials to owners storage point / warehouse / scrap yard as directed by eic andincluding collecting, stacking the generated unserviceable materials / debris at designated place at ground level upto a lead of 100m as directed by eic. repairs to refractory lining could be in any or all of the 3 boiler stacks at different elevations.in case of extensive damages, entire lining shall be replaced betwen two adjacent corbels. however, partial repair of the lining shall be undertaken at any elevation as per inspection recommendation in case damages are limited.the contractor should be prepared with manpower and tools / machinery to take up works parallely in all 3 stacks. ( all refractory materials will be supplied by cpcl at free of cost ) reference drawing no 10 cnt0290 c 009 , renewal of 25 mm dia asbestos / ceramic rope sealing at the interface of refractory brick lining between corbels, including removal of the worn out rope segments. ( material will be supplied by cpcl at free of cost ) , insulation lining replacement job involves removal of old / damaged insulation lining as marked by inspection, surface preparation andsupply and application of resin bonded glass / rockwool insulation mattress of density 80 kg / m3 confirming to is 8183 as per codes / specifications / inspection procedures / scope of work and work details including provision of steel straps over the brick work, anchor welding to hold the insulation, fixing25 mm wide ss 304 24 swg ss strips over the insulation to tighten and secure the same. repairs to insulation lining could be in any or all of the 3 boiler stacks at different elevations.job also includes collecting, stacking the generated unserviceable materials / debris at designated place at ground level upto a lead of 100m as directed by eic , same as item 10.04 above, for 100 mm thick liningbetween elevations of +9.5 m and +14.5 m. all materials shall be in contractors scope. , same as item # 10.04 above, for 50 mm thick lining between elevations of +14.5 m and +100 m. all materials shall be in contractors scope. , same as item # 10.04 above, for 100 mm thick liningbetween elevations of +9.5 m and +14.5 m. ( material will be supplied by cpcl at free of cost ) .contractor has to arrange for collection of materials from issue points & transportation and safe storage at site before start of shutdown and return of unused materials to owners storage point as directed by eic. , same as item # 10.04 above, for 50 mm thick lining between elevations of +14.5 m and +100 m. ( material will be supplied by cpcl at free of cost ) .contractor has to arrange for collection of materials from issue points& transportation and safe storage at site before start of shutdown and return of unused materials to owners storage point as directed by eic. , supply and fixing of 20 mm thick ci cap inner diameter ~1570 mm including anti corrosive rag bolt at 300 mm c / c atop the 3 individual boiler flue stacks including removal of the old corroded cap segments. reference drawing no 10 cnt0290 c 009 detail a all materials shall be in contractors scope. , fixing of ms handrails for external platforms at elevations of +48.5 m and +97.0 m using 10 mm dia ss anchor fasteners 2 each for each of the handrail leg support plates ( spaced 1 m apart ) . diameter of the platform is ~13.35 m. fabrication of handrails segments at ground level shall be in cpcl scope. hoisting and fixing shall be in contractors scope. , chipping of unsound / weak concrete material from chimney rcc wall / corbel slabs / external rcc platformsetc., for all elevations with standard power drivenpercussion type of pneumatic chisel of standard make as directed by engineer in charge. includig tapering all edges making square shoulders of cavities, removing concrete all round reinforcement including from behind the reinforcing bars to give an average 50 mm thickness. job also includes collecting, stacking the generated unserviceable materials / debris at designated place at ground level upto a lead of 100m as directed by eic. , providing and fixing special water tight centering including bolting, strutting, propping, etc., so as to with stand a pressure of 0.1mpa including removal of forms for all locations and all elevations , introducing new reinforcement bars in chimney rcc wall / corbel slabs / external rcc platformsetc., including power drilling holes of appropriate diameters in reinforced or plain cement concrete a minimum depth of 150 mm and upto 200mm fixing the reinforcement in position drilling in concrete, epoxy cartridges, plastic nozzle etc., complete including cleaning the drilled holes of loose dust by blowing air. reinforcement bar materials will be supplied by cpcl at free of cost , injecting epoxy grout into crack / honey comb areas of concrete by suitable gun / pump of required pressure including cutting the nipples after curing etc. complete as per directions of the engineer in charge sikadur 53uf of sika make or conbextra ep 10 of fosroc or masterinject 1315 of basf make or equivalent approved by eic ( payment shall be made on the basis of actual weight of approved grout injected ) ( material will be supplied by cpcl at free of cost ) , application of alkaline passivating & anticorrosive coat of approved epoxy zinc anti corrosive primer for reinforcements rust removal chemical rustoff 100 of sika make or reebaklens rr of fosroc or rustkleen of basf or equivalent approved by eic followed by one coat of zinc rich coating of frianzinc r of sika make or nitozinc primer of fosroc or concressive zri of basf or equivalent approved by eic payment shall be qty of resin plus hardener in manufacturer specified proportion ( material will be supplied by cpcl at free of cost ) , application of approved epoxy ( total weight of resin & hardener in proportion specified by manufacturer ) bonding material for prepared non metallic surface sikadur 32lp of sika make or nitobond ar of fosroc or masteremaco sbr 2 of basf or equivalent make approved by eic ( material will be supplied by cpcl at free of cost ) , placing in position microconcrete of grade m50, which shall be cement based prepacked single component , chloride free, non shrink, free flow, self compacting ready to use after mixing water in specified proportion obtained from approved manufacturer as per specification and direction of engineer in charge sikarep microcrete 4 of sika / rendroc rg of fosroc / master emaco s 346 of basf make or equivalent approved by eic with necessary water required as per manufacturer’s specification ( material will be supplied by cpcl at free of cost ) , application of approved protective coating for the exterior concrete surfaces of penetratingsilane / silaxone primer as a base coat with 2 ( two ) coats of single component aliphatic acrylate of dft not less than 175microns / coat and shall be capable of providing carbon dioxide diffusion resistance and of make fosroc / sika / basf in alternate bands of red and white ( top most band be red colour ) .the exterior cradle system ( with supspension jib system ) shall be used for painting. water jet cleaning has to be done before application of paint. ( material will be supplied by cpcl at free of cost ) , application of approved protective coating for the interior concrete surfaces of 2 ( two ) coats of penetrating sodium silicate solution ( acid, alkali and heat resistant ) paint of make fosroc / sika / basf. interior scaffolding shall be used for painting. water jet cleaning has to be done before application of paint. ( material will be supplied by cpcl at free of cost ) , dismantling of acid proof brick lining 230mm thick in wall and floor including the bed mortar and cleaning the wall surface for all depth and height. job involves removal of old / damaged lining at elevation +97m top platform as marked by inspection including collecting, stacking the generated unserviceable materials / debris at designated place at ground level upto a lead of 100m as directed by eic , supply and application of acid resistant tile lining using 230 x 115 x 38 mm thick a.r. tiles to bedded in potassium silicate cement mortar 6 mm thick, joints will be racked and filled with phenolic resin to full depth of tile as per eil standard specification 6 65 0062 complete in top platform at +97m elevation. job involves surface preparation andapplication of tiles material as per codes / specifications / inspection procedures / scope of work and work details. all materials shall be in contractors scope....