ESTIMATE

Sub: Minor fabrication works in fired heater overhead pipelines in SGTF – reg.

Sl.
Approx Unit Rate Total cost
Description of work Unit
No Qty (Rs) (Rs)
1. Cutting & dismantling of existing carbon steel
piping.
Measurement shall be taken, as-built drawings
shall be prepared and approval of Engineer in
Charge shall be obtained before dismantling.
Dismantling of existing pipe lines at various
heights by gas cutting, cold cutting including
fittings; elbows, insulation etc along with
structural pipe supports as saddles, shoes, anchors, Inch meter 325 80.00 26,000
clamps, valves etc., and safely transporting to
salvage yard/warehouse. Supply of tools & tackles
and arrangement for transportation etc are in the
scope of contractor.
All essential safety features for workman such as
safety belts, safety shoes, hand gloves, helmets,
height passes, height permit, hot work permit etc.,
are to be provided by the contractor.
2. Fabrication of carbon steel pipe by butt
welding.
Work includes fabrication of CS pipes as per as-
built isometric drawing. Fabricate the
pipeline/spool as per approved drawing.
Conducting the liquid penetrate test, hydro testing
of lines as per specifications/isometric drawing.
Supply of cleaner, penetrate, developer, grinding
wheel, welding rod, welding machine, wire brush
Inch dia 233 550.00 1,28,150
and equipment for hydro test etc., are in the scope
of contractor. In case of failure of joints during
testing same shall be rectified without any
additional cost and re-conduct the test. The entire
inspection tests are in the scope of contractor.
All essential safety features for workman such as
safety belts, safety shoes, hand gloves, helmets,
height passes, height permit, hot work permit etc.,
are to be provided by the contractor.
3. Fabrication of IBR carbon steel pipe by butt Inch dia 150 600.00 90,000
welding.
Work includes fabrication of CS pipes as per as-
built isometric drawing. Fabricate the
pipeline/spool as per approved drawing.
Conducting the liquid penetrate test, hydro testing
of lines as per specifications/isometric drawing.
Supply of cleaner, penetrate, developer, grinding
wheel, welding rod, welding machine, wire brush
and equipment for hydro test etc., are in the scope
of contractor. In case of failure of joints during
testing same shall be rectified without any
additional cost and re-conduct the test. The entire
inspection tests are in the scope of contractor.
Sl.
Approx Unit Rate Total cost
Description of work Unit
No Qty (Rs) (Rs)
Welding shall be done by IBR qualified welder
only and IBR pipes/fitting/valves/flanges etc. only
shall be used wherever IBR requirement exists.
All essential safety features for workman such as
safety belts, safety shoes, hand gloves, helmets,
height passes, height permit, hot work permit etc.,
are to be provided by the contractor.
4. Fabrication of carbon steel pipe by fillet
welding.
Work includes fabrication of CS pipes as per as-
built isometric drawing. Fabricate the
pipeline/spool as per approved drawing.
Conducting the liquid penetrate test, hydro testing
of lines as per specifications/isometric drawing.
Supply of cleaner, penetrate, developer, grinding
wheel, welding rod, welding machine, wire brush
and equipment for hydro test etc., are in the scope Inch dia 120 400.0 48,000.0
of contractor. In case of failure of joints during
testing same shall be rectified without any
additional cost and re-conduct the test. The entire
inspection tests are in the scope of contractor.
All essential safety features for workman such as
safety belts, safety shoes, hand gloves, helmets,
height passes, height permit, hot work permit etc.,
are to be provided by the contractor.

5. Fabrication of IBR carbon steel pipe by fillet

welding.
Work includes fabrication of CS pipes as per as-
built isometric drawing. Fabricate the
pipeline/spool as per approved drawing.
Conducting the liquid penetrate test, hydro testing
of lines as per specifications/isometric drawing.
Supply of cleaner, penetrate, developer, grinding
wheel, welding rod, welding machine, wire brush
and equipment for hydro test etc., are in the scope
of contractor. In case of failure of joints during
testing same shall be rectified without any Inch dia 40 450.0 18,000.0
additional cost and re-conduct the test. The entire
inspection tests are in the scope of contractor.
Welding shall be done by IBR qualified welder
only and IBR pipes/fitting/valves/flanges etc. only
shall be use
All essential safety features for workman such as
safety belts, safety shoes, hand gloves, helmets,
height passes, height permit, hot work permit etc.,
are to be provided by the contractor wherever IBR
requirement exists.

6. Erection of carbon steel pipe with associated Inch meter 325 150 48,750.0
attachments.
Before erection all the pre-fabricated spool pieces,
pipes, fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process
Sl.
Approx Unit Rate Total cost
Description of work Unit
No Qty (Rs) (Rs)
shall include removal of all foreign matter such as
scale, sand, weld spatter chips etc. by wire
brushes, cleaning tools etc. and blowing with
compressed air/or flushing out with water. No
deviations from the piping route indicated in
drawings shall be permitted without the consent of
Engineer-in-Charge. Pipe to pipe, pipe to structure
/ equipments distances / clearances as given in the
drawings shall be strictly followed as these
clearances may be required for the free expansion
of piping / equipment.
All essential safety features for workman such as
safety belts, safety shoes, hand gloves, helmets,
height passes, height permit, hot work permit etc.,
are to be provided by the contractor.
7. Carbon steel structural support fabrication and
replacement.
Replacement of existing piping supports with new
supports and strengthening the existing supports.
kg 200 45.0 9,000.0
If required temporary support should be provided
by the contractor. Crane/hook/hydra/chain pulley
etc if required for execution of the work has to be
arranged by the contractor at his own expense.
8. Painting of Piping and structurals.
Removal/peeling of existing damaged paint of CS
structure and its associate parts like platform,
metal strips, and monkey ladder shall be,
thoroughly cleaning with buffing wheel/wire brush m2 50 113 5,650
to ensure clean metal surface. Painting of the all
the external surface of CS structure with high
epoxy build paint and pipes with high temperature
alumina paint.
9. Scaffolding.
Providing and Fixing double Tubular scaffolding
system using H-Frames / APC system or (cup lock
type) on the exterior side 6 meter with 40mm dia.
M.S. tube 1.5m centre to centre horizontal and
vertical tubes joining with “Cup and lock system”
with M.S tubes, M.S tube challies, M.S clamps
and M.S staircase system in the scaffolding for
working platform etc. and maintaining it in a m2 144 221 31,824
serviceable condition for the required duration as
approved and removing It thereafter. The
scaffolding system shall be stiffened with
bracings, runners, connection with building etc.
wherever required for inspection of work at
required locations with essential ‘safety features
for the workmen etc complete as per directions
and as approved by the Engineer -in-charge.
Total fabrication cost for overhead pipelines inclusive of taxes and GST (12%) 4,05370.0
FREE ISSUE MATERIAL

Sl.No Item description Qty Unit Unit Total

rate
1 ¾”, Sch 80, A106 Grade B, Plain ends 10 m 234 2,340.0
2 1” Sch 80, A106 Grade B , Plain ends 65 m 297 19,305
3 2” Sch40, API 5L Grade B, Bevelled ends 75 m 405 30,375
4 2” Sch40, A106 Grade B, Bevelled ends, IBR 50 m 405 20,250
5 Elbow 90˚,2” Sch40,A234 WPB 26 Nos 120 3,120
6 Elbow 90˚,1”Sch80 A105 Grade B 17 Nos 201 3,417
7 Paints 12 liter 170 2040
8 MS Channel, ISMB 150 200 kg 40 8000
Total cost of free issue material 88,847.0

Total cost for the work (inclusive of all taxes) = Rs.(4,05374 + 88,847.0)

= Rs. 4, 94,221/-
(Rupees Four lakhs ninety four thousand two hundred twenty one only).

(K.G.Radhakrishnan Unni, TO/D)

SGTF OS

(K.G.Radhakrishnan Unni,
TO/D)