4. vendor to quote '+' / '-' / zero % on the schedule of...

4. Vendor to quote '+' / '-' / Zero % on the Schedule of rates (A) mentioned in the following table.

5. Only single % is to be quoted for the complete set of Items/Services and not Item/Service wise.

Specifying more than single percentage (%) or quoting specific unit rates / Lumpsum rates

will make your offer rejected.

6. Prefix the % with, '+' for rates above the scheduled rate, '-' for rates below the scheduled rate.

Put Zero % if the scheduled rate itself are being offered.

7. The % is to be put in the space provided below the following table, both in figures and in words.

Please quote for the following items/service, as per the terms and conditions mentioned below and in

attachments :

DETAILS OF ITEMS / SERVICES

Deliver To : Maintenance-On Site, - . India.

Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

1 1.000 Blinding &

Deblinding

of equip

Inch - Dia 99.00 Inch - Dia

2 2.000 Manway

opening and

head up of

Each 571.00 Each

3 3.000 Safety valve

dropping,

transpo

Each 864.00 Each


dropping &

instal

Each 571.00 Each

5 5.000 Drum manway Each 864.00 Each

Cont on next page . . 12000438 - HD - 46002

ofSign and Seal of the Tenderer 99

Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

opening &

headup

6 6.000 Removal &

re-fixing of

drum in

Lump Sum 2,928.00 Lump Sum

7 7.000 Economiser

tubes

cleaning


8 8.000 Drum & drum

internals

cleaning


9 9.000 Tubes

cleaning


10 10.000 Flue gas

path

cleaning


11 11.000 Cleaning of

burner, oil

gun et


12 12.000 CO inlet /

outlet ducts

inspec

Lump Sum 884.00 Lump Sum

13 13.000 Hydrotesting

of Boiler




Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

14 14.000 Additional

hydrotest


15 15.000 Start up

coverage


16 16.000 Annual

Inspection

of Boilers


17 17.000 General

maintenance

of steam g


18 18.000 Repeat shell

test & tube

test



test & tube

test


20 20.000 Retubing of

exchanger

tube (wi

Tube 246.00 Tube

21 21.000 Reaming of

exchanger

tube

Tube 77.00 Tube

22 22.000 Biennial / Lump Sum 137,562.00 Lump Sum



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

Annua IBR

Inspectio

23 23.000 Boiler tube

replacement

Tube 3,440.00 Tube

24 24.000 Sectional

replacement

of boile

Inch - Dia 1,454.00 Inch - Dia

25 25.000 Window patch

of tubes

Running

Feet

2,083.00 Running

Feet

26 26.000 Re-rolling

of Boiler

tubes

Joints 304.00 Joints

27 27.000 Seal welding

of boiler

tubes


28 28.000 Plug welding

of Boiler

tubes



hydrotest of

econom

Each 2,338.00 Each


of piping

Inch Meter 4.00 Inch Meter



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

31 31.000 Gauge glass

overhauling

Each 864.00 Each

32 32.000 Threaded

fittings

replacement


33 33.000 Gland

packing

replacement


34 34.000 Valve free

up / repair


35 35.000 Valve

replacement


36 36.000 Supply &

operation of

air comp

Hour 652.00 Hour

37 37.000 Supply &

operation of

diesel w

Hour 205.00 Hour

38 38.000 Scaffolding

of 3m x 3m x

3m bl

Each 609.00 Each

39 39.000 Grit

blasting

Square

Meters

766.00 Square

Meters



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

40 40.000 Copper slag

blasting

Square

Meters

334.00 Square

Meters

41 41.000 Solution

annealing of

anchors

Batch 14,727.00 Batch

42 42.000 Repairs to

economiser

tubes -



economiser

tubes -


44 44.000 Butt welding

-IBR X-ray

qualit



- IBR X-ray

quali



- X-ray

quality



- Non-X-ray

quali


48 48.000 Fillet Inch - Dia 448.00 Inch - Dia



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

welding -

IBR

quality(R

49 49.000 Fillet

welding -

IBR quality


50 50.000 Fillet

welding -

Non- IBR

qual


51 51.000 RF pad

replacement

jobs


52 52.000 Replacement

of Corrosion

pads



of SS

anchors

Each 99.00 Each


of CS

anchors

Each 55.00 Each


of

insulation

Each 16.00 Each



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

Anch


of hexmesh

(where

Square

Meters

8,800.00 Square

Meters


of Hex Mesh

(where

Square

Meters

13,200.00 Square

Meters

58 58.000 Fin welding

between

adjacent

Meters 1,395.00 Meters


between

adjacent t

Meters 786.00 Meters

60 60.000 CS Overlay

Patch 6 to

12mm thk

Square

Feet

983.00 Square

Feet

61 61.000 CS Inlay

Patch 6 to

12mm thk f

Square

Feet

1,573.00 Square

Feet

62 62.000 SS Overlay

patch 6 to

12mm thk

Square

Feet

1,945.00 Square

Feet

63 63.000 SS Inlay

patch 6 to

Square

Feet

4,874.00 Square

Feet



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

12mm thk f

64 64.000 Weld repair

to old joint

Running

Feet

108.00 Running

Feet


drum cracks

- Depth

Inches 1,355.00 Inches


drum cracks

- Depth



drum cracks

- Depth


68 68.000 Weld build

up of 5 mm

Thk (fin

Square

Inches

99.00 Square

Inches

69 69.000 Structural

replacements

(Mater

Metric Ton 18,102.00 Metric Ton

70 70.000 WFMPT Inch - Dia 101.00 Inch - Dia

71 71.000 DP test Inch - Dia 73.00 Inch - Dia

72 72.000 Supply of CS

Welder

Shift 602.00 Shift



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

73 73.000 Supply of

gascutter or

grinder

Shift 463.00 Shift

74 74.000 Supply of

fabricator

or fitter

Shift 463.00 Shift

75 75.000 Supply of

rigger

Shift 392.00 Shift

76 76.000 Supply of

Mason

Shift 543.00 Shift

77 77.000 Supply of

Carpentor

Shift 543.00 Shift

78 78.000 Supply of

Gunman

Shift 1,111.00 Shift

79 79.000 Supply of

Nozzleman


80 80.000 Supply of

Helper

Shift 327.00 Shift

81 81.000 Mobilization

&

Demobilizati

on




Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM


&

Demobilizati

on


83 83.000 Chipping &

Removal of

Refracto

Square

Meters

689.00 Square

Meters

84 84.000 Refractory

Casting upto

3"

Square

Meters

3,930.00 Square

Meters


Removal of

Abrasion

Square

Meters

1,867.00 Square

Meters

86 86.000 Application

of abrasion

resist

Square

Meters

2,751.00 Square

Meters

87 87.000 Gunniting of

Refractory

upto 3

Square

Meters

3,243.00 Square

Meters

88 88.000 Painting -

Piping &

Pipe Fitti

Square

Meters

689.00 Square

Meters

89 89.000 Air cleaning

of FD fan

suction




Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

90 90.000 Shifting of

tube bundle

of ste

Each 4,736.00 Each

91 91.000 Stress

Relieving

upto 1.5"

dia


92 92.000 Stress

Relieving

above 1.5"

an


93 93.000 Stress

Relieving

for all

sizes


94 94.000 Radiography

upto 1.5"

dia. (ap



- above 1.5"

dia.



- above 3"

dia. an




Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM


for all

sizes (whe


98 98.000 Re-tubing of

Exchangers/S

ulphu

Tube 1,350.00 Tube

99 99.000 Hydrogen

Diffusion of

Exchange

Square

Feet

6,873.00 Square

Feet

100 100.000 Butt joint

AS/SS -

X-ray quali



AS/SS -

X-ray quali


102 102.000 Fillet joint

AS/SS with

TIG ro



AS/SS with

TIG ro


104 104.000 SS/AS Weld

run jobs-

weld run

Running

Feet

743.00 Running

Feet



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

105 105.000 SS weld

build up

with

electric

Square

Inches

172.00 Square

Inches

106 106.000 SS weld

build up

with diesel

m

Square

Inches

200.00 Square

Inches

107 107.000 Supply of SS

/ AS / TIG

welder


108 108.000 Annual

Inspection

of WHB / Sul


109 109.000 Supply of

Hydra (10 T

capacity

Hour 893.00 Hour

110 110.000 Material

Handling

Trip 884.00 Trip


of Casing

Plates o

Running

Feet

197.00 Running

Feet

Quoted % applicable to the schedule of rates specified in table above for all the Items/Services



XXXXXXXXXXXXX % (in figures) XXXXXXXXXXXXXXXXXXXXXXXX Percent (in words).

QUOTED DELIVERY PERIOD :

EXTRAS (TAXES,DUTIES & OTHERS) :

Details of taxes, duties, levies, etc., if to be paid extra to be filled in the space given below. The values specifically

mentioned below will only be considered for extra payments. The values to be filled below can be in percentage (%)

of unit rate or an add - on amount per unit rate. Vendor to specifically mention % or currency, after the value

(e.g. X% or X Rs/-), else the value having least impact to HPCL on the unit rate will only be considered.

DGS&D Rate Contract ( Y/N ) : __________

NSIC Unit ( Y/N ) : __________

PSE Unit ( Y/N ) : __________

SSI Unit ( Y/N ) : __________

Delivery Terms - Free to Destination location unless specified otherwise ____________________________________

Validity of offer - 120 days from the initial or extended Due Date for submission of Tender whichever is later unless: __________specified otherwise

Liquidated Damages accepted ( Y/N ) : __________

Payment Term ( 30 Days ), unless specified otherwise

NOTES / TERMS / CONDITIONS :

Please refer attached Tender Document.



DETAILED ITEM DESCRIPTION / SPECIFICATIONS :

Tendor Ref Tender Line

Number QuantityItem Description Line No Qty UOM

1.000 Blinding & Deblinding of

equip

Inch -

Dia

Blinding & Deblinding of equipments

The scope of job is as follows :

1. Fabricate and install necessary blinds in position as per operations requirement.

2. Initially blinds are to be installed in spread condition and after the line contents are

emptied, they are to be made up.

3. Remove the blinds after job completion and make up the flanges with new gaskets.

Rate: The rate payable is for Inch dia of blinding and deblinding done (put together), which

includes fabrication of blinds also.

2.000 Manway opening and head

up of

Each

Manway opening and head up of equipments


1. Open all manways including wind box, fire box, super heater, economiser, stack, air inlet duct

and explosion door.

2. Break the refractory wall as per the advise of HPCL.

3. Make up the refractory wall and head up the manways opened after completion of the job.

Rate: The rate payable is lumpsum rate for each manway for the job scope as mentioned above.

3.000 Safety valve dropping,

transpo

Each

Safety valve dropping, transportation & installation




1. Drop all safety valves and install blind flanges in position, from where the safety valves

have been removed.

2. Transport these valves to HPCL valve section for servicing and take them back to the unit

after servicing. Servicing of the valves is excluded from this scope.

3. Remove the blind flanges and reinstall the valves. Make up the flanges with new gaskets and

obtain inspection clearance.

Rate: The rate payable is lumpsum for the entire job scope mentioned above for each safety

valve.

4.000 Safety valve dropping &

instal

Each

Safety valve dropping & installation


1. Drop all safety valves and install blind flanges in position, from where the safety valves

have been removed.

2. Remove the blind flanges and reinstall the valves after job completion.

3. Transportation of the valve to HPCL workshop and back is excluded from this scope.

Rate:The rate payable is lumpsum for the entire job scope mentioned above for each safety valve.

5.000 Drum manway opening &

headup

Each


1. Open all drum manways and head up after inspection clearance.

Rate: The rate payable is lumpsum for the entire job scope mentioned above for each manway.



6.000 Removal & re-fixing of

drum in

Lump Sum

Removal & re-fixing of drum internals


1. Install air eductors as required for better air circulation.

2. Remove all internals and moisture separators.

3. Provide necessary assistance for carrying out vacuum testing.

Note : Towards this, supply and operation of air compressor, shall be paid separately.

4. Refix all internals in position and obtain HPCL clearance.

Rate: The rate payable is lumpsum for the entire job scope mentioned above for each drum.

7.000 Economiser tubes cleaning Lump Sum


1. Clean the economiser tubes thoroughly as per Inspection.

2. Cleaning should done without using water unless it is permitted by HPCL.

Rate: The rate payable is lumpsum for the entire job scope mentioned above, for each economiser.

8.000 Drum & drum internals

cleaning

Lump Sum


1. Clean the internals, moisture separators, steam drum and mud drums thoroughly and offer for

inspection.

Rate: The rate payable is lumpsum for the entire job scope mentioned above for each drum along

with its internals.

9.000 Tubes cleaning Lump Sum




1. Clean all the tubes in fire box manually by wire brushing as per HPCL Inspection.

2. Carry out staging inside the firebox, if required, as per HPCL advise.

Rate:

1. The rate payable is lumpsum for the entire job scope as mentioned above.

2. If cleaning is advised to be carried out by hydrojetting, the same shall be paid, extra,

separately.

10.000 Flue gas path cleaning Lump Sum


1. Clean the flue gas path thoroughly free from soot, from the fire box side as well as from the

transit box/superheater side.

2. Clean the connected ducts free of debris and free up all the dampers.

3. All the soot deposited in fire box, flue gas path and all corners of the boiler shall be

cleaned thoroughly.

4. Use Industrial vaccum cleaner for better cleaning and agency to mobilise the same.

Rate: The rate payable is lumpsum for the entire job scope as mentioned above.

11.000 Cleaning of burner, oil

gun et

Lump Sum

Cleaning of burner, oil gun etc


1. Clean the burner throats, oil guns guides, wind box floor diffuser, peep holes glasses etc.

and offer for inspection.


12.000 CO inlet / outlet ducts

inspec

Lump Sum



CO inlet / outlet ducts inspection


1. Provide approach facility for Inspection of CO inlet and outlet ducts and offer for

inspection.


13.000 Hydrotesting of Boiler Lump Sum


1. Carry out hydrotest of boiler as per the advise of HPCL.

2. For this, clean the manways and box them up and connect the test pumps for pressurising.

3. Fill water in drums and economiser as per the advise of HPCL and pressurise to the designated

pressure and offer for inspection.

4. Provide standby manpower untill the hydrotest is completed and obtain inspection clearance.

Rate: The rate payable is lumpsum for the entire job scope as mentioned above for each hydrotest.

14.000 Additional hydrotest Lump Sum


1. Carry out additional hydrotest, which excludes closing and opening of drum manways.

2. All other actvities required for hydrotest are to be carried out as per the previous item.

Rate: The rate payable is lumpsum for the entire job scope as mentioned above, for each

additional hydrotest.

15.000 Start up coverage Lump Sum


1. Provide start up coverage to attend miscellaneous jobs like removing and refixing of ignitor,

to pull leaks if any, unplugging of lines etc. during start up of the unit.

2. Agency to provide necessary manpower as per the directions of the job engineer upto the



completion of start up.


16.000 Annual Inspection of

Boilers

Lump Sum


1. Carry out necessary blinding as per Operations requirement for obtaining entry permit and for

carrying out hydrotesting.

2. On completion of the job carry out deblinding of the same.

3. Open all manways including wind box, fire box, super heater, economiser, stack, air inlet duct

and explosion door. Break the refractroy wall, if required.

4. Make up the refractory wall and head up the manways opened after completion of the job.

5. Drop all safety valves and install blind flanges at the removed locations.

6. Transport the valves to HPCL valve section for servicing.

7. Transport the valves back and reinstall the same in position, after removing the blind

flanges.

8. Open all drum manways and head up after completion of the job.

9. Install air eductors as required, to maintain fresh air circulation inside the equipment.

10. Remove and refix all the internals and moisture separators.

11. Provide necessary assistance to HPCL inspection for carrying out vacuum testing.

12. Clean the economiser tubes thoroughly as per Inspection. Cleaning shall be done without using

water, unless permitted by HPCL.

13. Clean all internals, moisture separators, steam drum, mud drum etc. thoroughly by wire brush

and buffing.

14. Clean all tubes in fire box manually by wire brushing as per Inspection. If required, carry

out staging inside fire box to facilitate inspection.

15. Clean the flue gas path thoroughly free from soot, from the fire box side as well as from the

transit box/superheater side.

16. Clean the connected duct, transit box, super heater free of debris and free up all dampers.

17. Clean burner throats, oil guns guides, wind box floor diffuser, peep hole glasses etc. and

offer for inspection.

18. Provide approach facility for Inspection of CO inlet and outlet duct.

19. Air clean FD Fan suction silencers after opening manways.



20. Hydrotest the boiler for annual inspection as per Inspection requirement (one preliminary

test for leaks identification, One test for HPCL Inspection (before IBR Inspection) and final

test in presence of IBR Inspector). All these three hydrotests are part of lumpsum scope.

21. Coordinate with Dy.Chief Inspector of Boilers for Inpection and certification.

22. Hydrotesting includes closing of drum manways, water filling in the equipment and economiser,

providing standby manpower and pressurising of boiler to the required pressure, providing

necessary connections for hydrotest pump etc.

23. Provide start up coverage to attend miscellaneous jobs like removing and refixing of ignitor,

to pull leaks if any, unplug lines etc. for a period of 24 hours. Agency to take the signature /

acknowledgement of the job engineer for the above coverage.

24. For any additional manpower supplied beyond the 24 hour period for start up coverage,

additional payment shall be made on manpower rates basis.

Rate:

1. The rate payable is lumpsum for the entire job scope as mentioned above per boiler.

2. In case cleaning is to be done by hydrojetting, as per the advise of HPCL, the same shall be

paid, extra, separately.

Note:

Incase of Heat Recovery Boilers (like HRSGs, DHDS Reformer circut, NHT-CCR circuit, D-SRU

Incinerator Circuit, etc), agency shall carry out necessary jobs as per site condition. (like

cpening of cover plates of coils, casing plate cuttings, staging for access to work, furnace

cleaning, etc).

This item is applicable for following Boilers / Heat Recovery Steam Generators of Refinery.

1. WIL-8 Boiler

2. BHPV Boiler

3. IBH-9 Boiler

4. IBH-10 Boiler

5. HRSG-I / II / III / IV / V / VI

6. D-SRU Tr-I/II Incinerator Steam Generation Circuit (65E002, 65E001 & 65V006 together)

7. D-SRU Tr-IIII Incinerator Steam Generation Circuit (79E002, 79E001 & 79V006 together)

8. New CO Boiler

9. Old CO Boiler

10. DHDS Reformer Steam Generation Cicuit (61D15, 61E12, 61CE11,13, 14 & 17 together)



11. NHT-CCR Steam Generation Cicuit (74F01, 02, 03 & 04 and 74V09 together)

12. 4V63 when taken with Heater (4F01) shutdown and Steam Coils Testing.

(Incase only drum (4V63 tested & inspection due to Heater outage problem, rate will be paid as

per item no.108).

17.000 General maintenance of

steam g

Lump Sum

General maintenance of steam generators


1. Provide necessary flushing, steam connections etc. and install necessary blinds before opening

the equipment, as per Operations requirement.

2. Remove insulation over the flanges, to facilitate removal of bolts.

3. Drop all components viz., channel cover, shell cover, channel section and floating head cover

and erect staging as required, as per the directions of HPCL.

4. Drop all safety valves, and install blind flanges in position and transport these valves to

HPCL valve section.

5. Transport the valves from HPCL valve section and refix them in position after removal of

blind flanges.

6. Make proper arrangements for pulling the bundle out and pull out the bundle.

7. Clean the bundle externally by scraping, wire brushing, water washing etc.

8. Clean the tubes internally by rodding,water washing and air blowing.

9. Offer the equipment for inspection and obtain clearance.

10.Clean the shell and all other components thoroughly by wire brushing / buffing , water washing

and scraping.

11.Offer the shell and components for Inspection and obtain clearance.

12.Prove clear all shell nozzles.

13.Reinstall bundle in the dummy shell, shift & install the test jig in position and carry out

testing. Identify the leaky tubes by way of shell testing, carry out plugging or re-rolling of

tubes as instructed, re-do shell test followed by tube test.

14. Remove the bundle from dummy shell, re-install the same in the steam generator shell and

carryout shell test and obtain inspection clearance.

15. Remove the blinds and make up the flanges.



16. Maintain stand-by crew for hot bolting, pulling leaks etc. for a period of 24 hours (one

fitter + one helper).

17. For any additional manpower supplied beyond the 24 hour period, additional payment shall be

made on manpower rates basis.

Rate:

1. The rate payable is lumpsum for the entire job scope as mentioned above per Steam generator.

2. For any cleaning done by hydrojetting, as per the advise of HPCL, the same shall be paid,

extra, separately.

3. For any retubing or tube rolling done as per the advise of HPCL, the same shall be paid

extra, separately.

4. For any weld repairs to the shell and components, the same shall be paid extra, separately.

18.000 Repeat shell test & tube

test

Lump Sum

Repeat shell test & tube test with bundle pull out


1. If any tube leaks are found while doing shell test inside steam generator shell, agency shall

pull the bundle out again to do the shell test and tube test in dummy shell for plugging or

re-rolling of the leaking tube / tubes.

Rate :

1. The rate payable is lumpsum for the entire job scope as mentioned above per Shell test and

tube test put together.

2. These charges are payable, only if the tube leak is at a new location. In case of leak is

arising from a tube location, which had been plugged by the same ageny previously, agency to

carry out the same at no extra cost.

19.000 Repeat shell test & tube

test

Lump Sum

Repeat shell test & tube test without bundle pull out




1. Incase of tube test failure in the dummy shell, shell test and tube test shall be repeated for

plugging or re-rolling of the leaking tubes.

Rate :

1. The rate payable is lumpsum for the entire job scope as mentioned above per shell test and

tube test put together.

2. These charges are payable, only if the tube leak is at a new location. In case of leak is

arising from a tube location, which had been plugged by the same agency, agency to carry out

repairs to the same at no extra cost.

20.000 Retubing of exchanger

tube (wi

Tube

Retubing of exchanger tube (without Seal Welding)


1. Carry out re-tubing, as per the advsie of HPCL, by mobilisng the required resources including

equipment, tools and tackles and skilled manpower.

2. Obtain HPCL clearance for the job carried out.

Rate :

1. The rate payable is for PER TUBE BASIS for the job scope as mentioned above.

21.000 Reaming of exchanger tube Tube


1. Clean tubes internally by reaming and offer for Inspection and obtain clearance.

Rate :

1. The rate payable is for PER TUBE BASIS for the job scope as mentioned above.



22.000 Biennial / Annua IBR

Inspectio

Lump Sum

Biennial / Annua IBR Inspection of steam generators





3. Drop all components such as channel cover, shell cover, channel section and floating head

cover.

4. Erect staging as required, as per the directions of HPCL.

5. Drop all safety valves and install blind flanges in position and transport these valves to

HPCL valve section.


blind flanges.

7. Make proper arrangements for pulling the bundle out and pull out the bundle.

8. Clean the bundle externally by scraping, wire brushing, water washing etc.


10. Offer the equipment for inspection and obtain clearance.

11. Clean the shell and all other components thoroughly by wire brushing / buffing , water

washing and scraping.

12. Offer the shell and components for Inspection and obtain clearance.

13. Prove clear all shell nozzles.

14. Reinstall bundle in the dummy shell, shift & install the test jig in position and carry out

testing. Identify the leaky tubes by way of shell testing, carry out plugging or re-rolling of

tubes as instructed, re-do shell test followed by tube test.

15. Remove the bundle from dummy shell, re-install the same in the steam generator shell and

carryout shell test and obtain incpection clearance.

16. Remove the blinds and make up the flanges

17. Maintain stand-by crew for hot bolting, pulling leaks, etc, for a period of 24 hours (one




19. Coordinate with Dy.Chief Inspector of Boilers for inspection and certification and related



jobs and obtain clearance from DCIB.

Rate:

1. The rate payable is lumpsum for the entire job scope as mentioned above per Steam generator.

2. For any cleaning done by hydrojetting,or reaming as per the advise of HPCL, the same shall be


3. For any retubing or tube rolling done as per the advise of HPCL, the same shall be paid

extra, separately.


Note:

This item is applicable for following Steam Generators (Heat Exchangers)

1. CDU-I: 2-E-31

2. CDU-2: 12E10, 12E10A, 13E01A, 13E01B, 13E03A & 13E03

3. CDU-3/VBU: 42WHB-01 Circuit, 46E09A, 46E09B, 46E08

4. FCCU-I: 4E55A, 4E55B, 4E57 & 4E56

5. FCCU-2: 14E04B, 14E04C, 14E56, 14E07 & 14E04A

6. DHDS: 61E13A & 61E13B

23.000 Boiler tube replacement Tube

The scope of job for Boiler tube replacement is as follows :

1. Chip out refractory at the ends to facilitate removal of tube.

2. Cut and remove marked tubes.

3. Remove tube stubs from upper and lower drum holes.

4. Clean tube hole, remove burrs and weld build up in any pits that are found, as per Inspection.

5. Clean new tube internally and externally.

6. Install new tube in position and carry out field modification, if required for facilitating

replacement.

7. Roll the tube ends in the drums, offer for inspection and obtain clearance.

Rate :

1. The rate payable shall be for PER TUBE replacement as per the scope mentioned above.

2. Hydrotest if required as per HPCL will be paid extra, separately.



24.000 Sectional replacement of

boile

Inch -

Dia

Sectional replacement of boiler tube

The scope of job for sectional Boiler tube replacement is as follows :

1. Chip out refractory at the ends to facilitate removal of tube.

2. Cut and remove marked section of the tube.

3. Fabricate a new section, carry out fit up and offer for inspection.

4. Weld the tube and obtain inspection clearance.

5. Stage wise DP test is included in the agency's scope.

Rate :

1. The rate payable shall be for PER INCH dia of sectional tube replacement, as per the scope

mentioned above.

2. Hydrotest if required as per HPCL, will be paid extra, separately.

25.000 Window patch of tubes Running

Feet

The scope of job for Window patch of tubes is as follows :

1. Clean tubes by buffing for inspection and marking of the patch area.

2. Cut window as marked, fabricate a new patch, fit up, weld in position, offer for inspection

and obtain clearance.

3.Stagewise DP test is in agency's scope.

Rate :

1. The rate payable shall be for Running foot of welding done for the tube, as per the scope

mentioned above.

2. Hydrotest if required as per HPCL will be paid extra. However, any leak arising out from the

repaired / replaced location, where the same agency worked earlier, shall be rectified with

repeat hydrotest without any extra cost.

3. Obtain inspection clearance.



26.000 Re-rolling of Boiler

tubes

Joints


1.Re-roll the leaking tubes as marked by inspection and obtain inspection clearance.

Rate :

1. The rate payable shall be for PER JOINT of tube rerolling as per the scope mentioned above.

27.000 Seal welding of boiler

tubes

Joints


1. Seal weld the leaking marked roll joints in drums using E-7018 Electrodes or equivalent TIG

wire as advised by Inspection.

2. After welding, roll all the tubes around the seal welded tube and obtain inspection clearance.

3. DP test is inculded in the scope.

Rate :

1. The rate payable shall be for PER JOINT basis for the job scope as mentioned above.

2. No seperate payment shall be made for DP test of the weld joints.

28.000 Plug welding of Boiler

tubes

Joints


1. Plug the leaking marked tubes and seal weld using E-7018 electrodes or equivalent TIG wire as

advised by Inspection.

2. After welding, roll all the tubes around the plugged tube.

3. DP test is included in the job scope.

Rate :

The rate payable shall be per JOINT for the job scope as mentioned above.



29.000 Additional hydrotest of

econom

Each

Additional hydrotest of economiser/ GRE/CPH


1. Carry out hydrotest of economiser as per the advise of HPCL and obtain inspection clearance.

Rate :

The rate payable shall be per hydrotest for each economiser/ GRE of boiler or CPH of HRSGs.

No seperate payment for blinding and deblinsing shall be made.

30.000 Hydrotesting of piping Inch

Meter


1. Carry out hydrotesting of pipelines by filling water and pressurising to the specified test

pressure.

2. Clean the weld joints and offer for Inspection.

3. On clearance, depressurise, drain water and clean the area.

Rate :

1. The rate payable shall be per Inch meter of hydrotest done as per the scope mentioned above.

2. Separate rate shall be paid for blinding and deblinding jobs.

31.000 Gauge glass overhauling Each

The scope of job is as follows:

1. Overhaul the gauge glass including removal of guage glass assembly, installing blinds/ blind

flanges and dismantling of the gauge glass assembly, cleaning and assembly with necessary

replacements.

2. Fix back the assembly in position after removal of blind flanges.

Rate :



1. The rate payable shall be per EACH gauge glass assembly overhauled as per the scope mentioned

above.

32.000 Threaded fittings

replacement

Inch -

Dia


1. Replace the Threaded fittings as per the advise of HPCL, offer for inspection and obtain

clearance.

Rate :

1. The rate payable shall be per Inch dia of threaded fittings replaced as per the scope

mentioned above.

33.000 Gland packing replacement Inch -

Dia


1. Arrest valve gland leaks by add packing/repacking as per Inspection and obtain clearance.

Rate :

1. The rate payable shall be per Inch dia of gland packing replaced/ add packed, as per the

scope mentioned above.

34.000 Valve free up / repair Inch -

Dia


1. Free up the valves by cleaning, servicing the valve components including opening and closing

of bonnet, greasing, etc and ensure trouble free operation.

Rate :

1. The rate payable shall be per Inch dia of valve free up done, as per the scope mentioned

above.



35.000 Valve replacement Inch -

Dia


1. Replace the flanged valves which includes opening flanges, dropping old valves and installing

new valve by collecting them from warehouse or valve section, along with new gasket.

2. Shifting / transportation of valves from any location within the Refinery and returning the

old valves is included in the job scope.

Rate :

1. The rate payable shall be per Inch dia of valve replacement done, as per the scope mentioned

above.

36.000 Supply & operation of air

comp

Hour

Supply & operation of air compressor


1. Supply and operate air compressor along with fuel and operator, for carrying out vacuum test

and other jobs related to boiler, as per the directions of HPCL.

2. Agency shall mobilise the compressor within 24 hrs from the time of notice given to them.

Rate :

1. The rate payable shall be per Hour of operation of air compressor, as per the scope

mentioned above.

2. No idle charges shall be paid.

37.000 Supply & operation of

diesel w

Hour

Supply & operation of diesel welding generators




1. Supply and operate diesel welding generator along with fuel and operator as and when advised

by HPCL.

2. Agency shall mobilise the equipment within 24 hrs from the time of notice given to them.

Rate :

1. The rate payable shall be per Hour of operation of the diesel generator, as per the scope

mentioned above.

2. No idle charges shall be paid.

38.000 Scaffolding of 3m x 3m x

3m bl

Each

Scaffolding of 3m x 3m x 3m block


1. Provide scaffolding as directed by Job engineer at the designated locations.

2. Scaffolding shall be erected with 1-1/2" steel tubular pipe with suitable and safe clamping

arrangement.

3. Proper MS gratings to be laid on horizontal pipes and suitably tied by GI wire of minimum 10

gauge to ensure firm fastening.

4. Supply of all material including scaffolding pipes in standard sizes, clamps, gratings and

other resources is included in the agency's scope.

5. Remove the scaffolding after job completion, after getting clearance from HPCL.

6. Agency shall follow the existing standards followed in the refinery, for scaffolding jobs.

Rate :

1. The rate payable shall be per block of 3 metre x 3 metre x 3 metre of scaffolding done and

removed put together.

39.000 Grit blasting Square

Meters




1. The scope includes supply and mobilisation of all resources required like metallic grit, air

compressor with fuel and operator, copper slag blasting equipment and arrangements, skilled

manpower and everything required to complete the job in its entirety.

2. Carry out grit blasting to SA 2.5 and offer for inspection.

3. After grit blasting, the entire area shall be cleaned and waste material and metallic grit be

removed from the site and obtain clearance from HPCL inspection.

Rate :

1. The rate payable shall be per sq. meter of grit blasting done and approved by HPCL, as per

the scope mentioned above.

40.000 Copper slag blasting Square

Meters


1. The scope includes supply and mobilisation of all resources required like copper slag , air

compressor with fuel and operator, copper slag blasting equipment and arrangements, skilled

manpower and everything required to complete the job in its entirety.

2. Carry out copper slag blasting to SA 2.5 and offer for inspection.

3. After copper slag blasting, the entire area shall be cleaned and waste material and copper

slag be removed from the site and obtain clearance from HPCL inspection.

Rate :

1. The rate payable shall be per sq. meter of copper slag blasting done and approved by HPCL, as

per the scope mentioned above.

41.000 Solution annealing of

anchors

Batch


1. Carry out solution annealing of anchors, as per the directions of HPCL inspection.

2. For this, agency to take out the anchors, to the workshop located at Visakhapatnam - where

solution annealing is to be carried out and bring them back after job completion.

3. Submit the charts for HPCL inspection records and approval.



Rate :

1. The rate payable shall be per batch of anchors solution annealed, as per the scope mentioned

above.

42.000 Repairs to economiser

tubes -

Inch -

Dia

Repairs to economiser tubes - Root TIG and filler by SMAW


1. Cut and remove the marked section of economiser tubes as per inspection.

2. Provide support, if necessary, for other sections.

3. Fabricate new section, carry out fit up and welding in position after HPCL Inspection

approval.

4. Root welding to be done by TIG and Filler runs by SMAW. Electrodes shall be as specified by

Inspection.

Rate :

1. The rate payable shall be per Inch Dia of welding done for the economiser tubes, as per the


43.000 Repairs to economiser

tubes -

Inch -

Dia

Repairs to economiser tubes - Root and filler by SMAW


1. Cut and remove the marked section of economiser tubes.

2. Provide support, if necessary, for other sections.

3. Fabricate new section, carry out fit up and welding in position after HPCL Inspection

approval.

4. Root welding and Filler runs to be done using SMAW. Electrodes shall be as specified by



Inspection.

Rate :

1. The rate payable shall be per Inch Dia of welding done for the tubes including root & final

weld DP test, as per the scope mentioned above.

44.000 Butt welding -IBR X-ray

qualit

Inch -

Dia

Butt welding -IBR X-ray quality (Root TIG + SMAW Filler)


1. Prepare the arae for Hot work and keep the area ready for hot work.

2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of

pipes, fitups, welding, DP test, and / or radiography of weld joints (if required), stress

relieving, Hydrotesting of the entire section etc.

3. Erect scaffolding, wherever required, as per HPCL inspection advise.

4. Removal of existing section also is also inluded in the job scope.

5. Offer the weld joints for HPCL inspection and obtain approval.

Rate :

1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test,

as per the scope mentioned above.

2. Charges for RF pad, Corrosion pads, radiography, Stress relieving, hydrotesting, scaffolding,

threaded fittings & valves replacement shall be paid, extra, separately.

45.000 Butt welding - IBR X-ray

quali

Inch -

Dia

Butt welding - IBR X-ray quality




1. Prepare the arae for Hot work and keep the area ready for hot work.


pipes, fitups, welding, DP test, and / or radiography of weld joints, stress relieving,

Hydrotesting of the entire section etc.

3. Use IBR approved welder and HPCL approved electrodes.


5. Removal of existing section also is also inluded in the jobs cope.


Rate :

1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test, as




46.000 Butt welding - X-ray

quality

Inch -

Dia


1. Prepare the area for Hot work and keep the area ready for hot work.


pipes, fitups, welding, DP test, radiography of weld joints, stress relieving, Hydrotesting of

the entire section etc.

3. Use HPCL approved electrodes.




Rate :







47.000 Butt welding - Non-X-ray

quali

Inch -

Dia

Butt welding - Non-X-ray quality


1. Prepare the araes for Hot work and keep the area ready for hot work.


pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.





Rate :



2. Charges for RF pad, Corrosion pads, hydrotesting, scaffolding, threaded fittings & valves

replacement shall be paid, extra, separately.

48.000 Fillet welding - IBR

quality(R

Inch -

Dia

Fillet welding - IBR quality(Root TIG + SMAW Filler)











Rate :



2. Charges for hydrotesting, scaffolding, threaded fittings & valves replacement shall be paid,

extra, separately.

49.000 Fillet welding - IBR

quality

Inch -

Dia


1. Prepare the ares for Hot work and keep the area ready for hot work.







Rate :




extra,separately.

50.000 Fillet welding - Non- IBR

qual

Inch -

Dia

Fillet welding - Non- IBR quality











Rate :




extra, separately.

51.000 RF pad replacement jobs Inch -

Dia



2. Carry out replacement of RF pads, or laying of new RF pads, which includes cutting, grinding,

beveling, laying of pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.



5. Removal of existing RF pad also is also included in the scope.


Rate :

1. The rate payable shall be per Inch Dia of Branch piping, for jobs done including root & final

weld DP test as per the scope mentioned above.


extra,separately.

52.000 Replacement of Corrosion

pads

Inch -

Dia



2. Carry out replacement of corrosion pads, which includes cutting, grinding, beveling, laying of








Rate :




extra, separately.

53.000 Replacement of SS anchors Each


1. Carry out welding of anchors, of SS material using HPCL approved electrodes and welders, at a

specified pitch.

2. Offer the job for HPCL inspection and approval.

3. Removal of the existing anchors and cleaning the parent material surface also is included

in this scope.

Rate :

1. The rate payable shall be per anchor welding done including DPT.

54.000 Replacement of CS anchors Each


1. Carry out welding of anchors, of CS material using HPCL approved electrodes and welders, at

a specified pitch.


3. Removal of the existing anchors and cleaning the parent material surface also is included

in this scope.

Rate :

1. The rate payable shall be per anchor welding done including DPT.



55.000 Replacement of insulation

Anch

Each

Replacement of insulation Anchors


1. Carry out welding of insulation anchors, of CS material using HPCL approved electrodes and

welders, at a specified pitch.


3. Removal of the existing anchors and cleaning the parent material surface also is included in

this scope.

Rate :

1. The rate payable shall be per anchor welding done.

56.000 Replacement of hexmesh

(where

Square

Meters

Replacement of hexmesh (where mesh is to be welded to studs)


1. Gouge out and remove the existing hexmesh and clean the welding surface free of coke/weld

deposits etc., offer for inspection and obtain clearance.

2. Agency shall collect new Hex mesh panels from HPCL warehouse or any other designated location

inside the refinery as advised by the Engineer-in-charge and transport them to the work spot.

3. Carry out rolling of hex mesh panels to suit to the profile of the equipment, where it is to

be welded.

4. After surface is cleared for fit up, carry out fit up of the hexmesh panels and offer for

inspection.

5. Fabricate edge bars from 6 mm thick SS plate and ensure that edge bars are welded between

joints of every panel and corner tabs are welded at all corner areas.

6. Carry out welding of hex mesh as per EXXON Design welding scheme, or as advised by HPCL.

7. Carryout DP test of weld joints as advised by Inspection.



8. Chip and remove the weld slag completely and offer for Inspection and obtain clearance.

Rate :

1. The rate payable shall be per square meter of hex mesh replaced, for the entire job as per


57.000 Replacement of Hex Mesh

(where

Square

Meters

Replacement of Hex Mesh (where Hex Mesh is to be welded directly to the shell)


1. Gouge out and remove the existing hexmesh and clean the welding surface free of coke/weld

deposits etc., offer for inspection and obtain clearance.

2. Agency shall collect new Hex mesh panels from HPCL warehouse or any other designated location

inside the refinery as advised by the Engineer-in-charge and transport them to the work spot.

3. Carry out rolling of hex mesh panels to suit to the profile of the equipment, where it is to

be welded.

4. After suface is cleared for fit up, carry out fit up of the hexmesh panels and offer for

inspection.

5. Fabricate edge bars from 6 mm thick SS plate and ensure that edge bars are welded between

joints of every panel and corner tabs are welded at all corner areas.

6. Carry out welding of hex mesh as per EXXON Design welding scheme, or as advised by HPCL.

7. Carryout DP test of weld joints as advised by Inspection.

8. Chip and remove the weld slag completely and offer for Inspection and obtain clearance.

Rate :

1. The rate payable shall be per square meter of hex mesh replaced, for the entire job as per


58.000 Fin welding between

adjacent

Meters

Fin welding between adjacent tubes on both sides (Inside & outside the boiler )




1. Cut and remove fins in between tubes as marked by HPCL inspection.

2. Fabricate new fins, fit up and weld fins after carrying out necessary tube replacement, repair

and inspection.

3. Offer the fin repairs and replacement for inspection and obtain clearance.

Rate :

1. The rate payable shall be per meter length of fin welding done on the finished job including

DPT, for the entire job as per the scope mentioned above.

59.000 Fin welding between

adjacent t

Meters

Fin welding between adjacent tubes on one side


1. Cut and remove fins in between tubes as marked by HPCL inspection.

2. Fabricate new fins, fit up and weld fins after carrying out necessary tube replacement /

repair / inspection.

3. Offer the fin repairs and replacement for inspection and obtain clearance.

Rate :

1. The rate payable shall be per meter length of fin welding done on the finished job including


60.000 CS Overlay Patch 6 to

12mm thk

Square

Feet

CS Overlay Patch 6 to 12mm thk for Pressure Parts




1. Remove insulation as required and clean the surface area.

2. Cut and remove marked section of casing plate and fabricate new section using 6mm to 12 mm

thick CS plate.

3. Offer the plate fit up for inspection and carry out welding.

4. Carry out air testing of new welds at 1kg/sq. cm.

5. Carry out necessary repairs on identification of leaks during the test.


Rate :

1. The rate payable shall be per square foot of overlay patch jobs done including root & final


2. This item is applicable only for Pressure parts like Boiler shell,Steam drums etc. but not for

Casing Plates

61.000 CS Inlay Patch 6 to 12mm

thk f

Square

Feet

CS Inlay Patch 6 to 12mm thk for Pressure Parts




thick CS plate.


4. DP test the welds and offer for inspection and obtain clearance.


Rate :

1. The rate payable shall be per square foot of inlay patch jobs done including root & final DPT,

for the entire job as per the scope mentioned above.


Casing Plates



62.000 SS Overlay patch 6 to

12mm thk

Square

Feet

SS Overlay patch 6 to 12mm thk for Pressure Parts




thick SS plate.


4. Carry out air testing of new welds at 1kg/sq. cm.

5. Carry out necessary repairs on identification of leaks during the test.


Rate :

1. The rate payable shall be per square foot of overlay patch jobs done including root & final



Casing Plates

63.000 SS Inlay patch 6 to 12mm

thk f

Square

Feet

SS Inlay patch 6 to 12mm thk for Pressure Parts




thick SS plate.


4. DP test the welds and offer for inspection and obtain clearance.


Rate :



1. The rate payable shall be per square foot of inlay patch jobs done including root & final DPT,

for the entire job as per the scope mentioned above.


Casing Plates

64.000 Weld repair to old joint Running

Feet


1. Carry out air testing of old weld joint, repair old leaking casing weld joints as detected and

marked during air test.

2. After repairs air test again at 1kg/cm sq. and offer for inspection and obtain clearance.


Rate :

1. The rate payable shall be per running foot of weld repairs done for the finished job including

DPT, as per the scope mentioned above.

65.000 Repairs to drum cracks -

Depth

Inches

Repairs to drum cracks - Depth of crack upto 8 mm


1. Identify the crack by means of magnetic particle testing.

2. Remove the tubes etc. for carrying out repairs around the cracked area.

3. Carry out grinding and MPT to find any further cracks on the area as marked by Inspection.

4. Form a V-Groove as advised by Inspection.

5. Carry out welding using E 7018 electrodes by IBR approved welders.

6. Dress up the area and the nearby tube holes etc.

7. Take radiography and submit the films for inspection and obtain approval from Inspection.

8. In case any defects found in the welding, carry out repairs as per Inspection advice.

9. Carry out radiography and obtain Inspection clearance.

10.Carry out the stress relieving of the weld affected zone, using sufficient number of



thermocouples, and as per approved procedure.

11. Carry out hardness test in this area and submit teh reports to Inspection.

12. Carry out re-radiography of the joint after stress relieving and if defects are found, carry

out repairs again.

13. Repeat the radiography and stress relieving after repairs and obtain inspection clearance.

Rate :

1. The rate payable shall be per Inch length of repairs done including DPT as per the scope

mentioned above.


Depth

Inches

Repairs to drum cracks - Depth of crack from 8 mm to 25mm








7. Take radiography and submit the films fro inspection and obtain approval from Inspection.





11. Carry out hardness test in this area and submit the reports to Inspection.

12. Carry out re-radiography of the joint after stress relieving and if defect are found, carry

out repairs again.


Rate :




mentioned above.


Depth

Inches

Repairs to drum cracks - Depth of crack above 25mm








7. Take radiography and submit the films fro inspection and obtain approval from Inspection.





11. Carry out hardness test in this area and submit the reports to Inspection.

12. Carry out re-radiography of the joint after stress relieving and if defect are found, carry

out repairs again.


Rate :


mentioned above.

68.000 Weld build up of 5 mm Thk

(fin

Square

Inches

Weld build up of 5 mm Thk (finish)




1. Clean the surface and prepare the weld buildup area.

2. Carry out weld buildup as marked using E-7018 electrode as advised by Inspection.

3. Flush grind the area and offer for inspection and obtain clearance.

Rate :

1. The rate payable shall be per Square Inch of finish weld build up done for 5 mm thickness

including DPT, as per the scope mentioned above.

2. For any variation in thickness on higher or lower side, the rate shall be proportionately

paid.

69.000 Structural replacements

(Mater

Metric

Ton

Structural replacements (Material supplied by HPCL)


1. Provide additional supports or replace the existing supporting structurals, hand railings,

ladders, etc.

2. Dismantle the existing members is also includes in the job scope.

3. Carry out good housekeeping after job completion.

Rate :

1. The rate payable shall be per Metric tonne of structural steel jobs done and erected in the

field.

2. Material shall be supplied by HPCL free of cost and agency to submit the material

reconciliation sheet.

70.000 WFMPT Inch -

Dia


1. Agency to carry out Wet Magnetic Particle Testing as advised by HPCL.

2. The scope includes mobilisation of all required resources and skilled manpower with



consumables to carry out and complete the job.

3. Obtain HPCL inspection clearance for jobs carried out.

Rate :

1. The rate payable shall be per Inch dia for the testing done, as per the scope mentioned

above.

71.000 DP test Inch -

Dia


1. Agency to carry out Dye Penetrant test as advised by HPCL.

2. The scope includes mobilisation of all resources required like Magna Flux DP Kit along with

skilled manpower required to complete the job in its entirety.

3. The job scope also includes carrying out grinding / buffing required to facilitate DP test

prior to actual testing.

4. Obtain HPCL inspection clearance for jobs carried out.

Rate :

1. The rate payable shall be per Inch dia for the testing done, as per the scope mentioned

above.

72.000 Supply of CS Welder Shift

The scope of job as follows:

1. Supply of CS welder for carrying out miscellaneous jobs not covered under the unit rates.

2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision

and consumables.

Rate:

1.Rate Payable is 8 hours shift.

2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall

be double the rates given under this head on pro-rata basis.



73.000 Supply of gascutter or

grinder

Shift


1. Supply of Gascutter/ Grinder for carrying out miscellaneous jobs not covered under the unit

rates.


and consumables.

Rate:

1.Rate Payable is per 8 hours shift.



74.000 Supply of fabricator or

fitter

Shift


1. Supply of Fitter or fabricator for carrying out miscellaneous jobs not covered under the unit

rates.


and consumables.

Rate:




75.000 Supply of rigger Shift


1. Supply of rigger for carrying out miscellaneous jobs not covered under the unit rates.




and consumables.

Rate:




76.000 Supply of Mason Shift


1. Supply of Mason for carrying out miscellaneous jobs not covered under the unit rates.


and consumables.

Rate:




77.000 Supply of Carpentor Shift


1. Supply of Carpentor for carrying out miscellaneous jobs not covered under the unit rates.


and consumables.

Rate:






78.000 Supply of Gunman Shift


1. Supply of Gunman for carrying out miscellaneous jobs not covered under the unit rates.


and consumables.

Rate:




79.000 Supply of Nozzleman Shift


1. Supply of nozzleman for carrying out miscellaneous jobs not covered under the unit rates.


and consumables.

Rate:




80.000 Supply of Helper Shift


1. Supply of Helper for carrying out miscellaneous jobs not covered under the unit rates.


and consumables.

Rate:






81.000 Mobilization &

Demobilization

Lump Sum

Mobilization & Demobilization Charges for Refractory Jobs - Agency from outside Visakhapatnam

This rate is payable if the agency is asked to mobilize specialised Refractory Contractors

approved by HPCL.

Agency shall engage experienced sub agencies such as M/s. Cape Industrial services, M/s. Rockwool

Insulations, M/s. Kafer Engineering, M/s Ciria India, M/s Furnace Fabrica, M/s Padmaja Systems &

Services or any other HPCL approved agencies.

The refractory agency shall be mobilized within 7 days of advice along with skilled manpower and

tools and tackles.

For the actual refractory jobs to be carried out, rates as applicable will be paid extra.

Agency shall mobilize enough manpower & equipments for carrying out various jobs assigned to the

party. Various types of skilled man power and equipments required for refractory jobs are given

below. The number of personnel and equipment shall be decided based the job requirement and in

consultation with HPCL.

Man Power:

1. Gunman

2. Nozzle man

3. Masons

4. Carpenters

5. Mixer Operators

6. Helpers

Equipment :

1. Paddle Mixers



2. Hobart Mixer

3. Gunniting Equipment with accessories

4. Needle vibrators with accessories

5. Shuttering equipments & and sufficient qty of plywood and other consumables

6. Tools for casting.

7. Rope & pulley arrangement for lifting of materials.

Rate : The rate payable shall be lumpsum for the mobilisation done.

82.000 Mobilization &

Demobilization

Lump Sum

Mobilization & Demobilization Charges for Refractory Jobs - Agency from within Visakhapatnam

This is payable if the agency is asked to mobilize various Refractory application equipments

(Gunniting equipments, Hobart Mixer, etc) if they own them or from local sources. The rate

include demobilization charges as well.

The refractory agency shall be mobilized within 7 days of advice along with skilled manpower and

tools and tackles.

For the actual refractory jobs to be carried out, rates as applicable will be paid extra.

Agency shall mobilize enough manpower & equipments for carrying out various jobs assigned to the

party. Various types of skilled man power and equipments required for refractory jobs are given

below. The number of personnel and equipment shall be decided based the job requirement and in

consultation with HPCL.

Man Power:

1. Gunman

2. Nozzle man

3. Masons

4. Carpenters

5. Mixer Operators



6. Helpers

Equipment :

1. Paddle Mixers

2. Hobart Mixer

3. Gunniting Equipment with accessories

4. Needle vibrators with accessories

5. Shuttering equipments & and sufficient qty of plywood and other consumables

6. Tools for casting.

7. Rope & pulley arrangement for lifting of materials.

Rate : The rate payable shall be lumpsum for the mobilisation done.

83.000 Chipping & Removal of

Refracto

Square

Meters

Chipping & Removal of Refractory upto 3"

The scope of job is given below :

The scope covers chipping and removal of existing refractory, cleaning the shell thoroughly free

of all scales by sand or grit blasting/power tool/manual cleaning as per the instructions of

HPCL.

Rate :

1. The rate payable shall be per sq. meter of refractory chipped and removed as per the scope

mentioned above.

2. For chipping and removal of any thickness other than than 3", (higher or lesser thickness) ,

the rate payable shall be on pro rata basis for each inch of thickness per unit area.

84.000 Refractory Casting upto

3"

Square

Meters




1. The scope of job includes drawing refractory materials from warehouse or any other designated

location inside the refinery premises as advised by the Engineer-in-charge and transportation of

these materials to the work spot.

2. Ensure that refractory material issued from HPCL warehouse is stored in a dry place at the

agency's work shed and covered with tarpaulin. Storage on dry concrete, asphalt or other

impervious surface will prevent moisture from the ground condensing under the plastic pallet

cover and wetting the bags of material which may result in loss of strength.

3. Carryout pre-qualification of masons for executing the job in coordination with HPCL

Inspection group prior to the commencement of job. Pre-qualification job test samples shall be

sent for testing for the required parameters by the agency at its own cost. HPCL's Inspection

department will issue Identity cards for all qualified masons which shall always be carried by

respective personnel while carrying out any refractory job at site. Test for qualification of

Masons shall be carried out prior to commencement of the job.

4. Mobilize all resources including Paddle type mixers required for refractory mixing, shuttering

and application as per the procedure recommended by the manufacturer/ Engineer-in-charge.

5. Agency shall carry out casting of refractory as per the procedure recommended by the

manufacturer/ Engineer-in-charge.

6. The following precautions shall be taken while preparation, mixing & application of refractory

material.

a.Use clean tools and equipment. Contamination can affect setting and strength of castables.

b.Water proof all forms and surfaces. Mold release agents may be used if required.

c.Use only clean water suitable for drinking.

d.A paddle type mechanical mixer shall be used.

e.Mix only as much castable as can be placed immediately. Under ideal conditions 20 minutes is

the maximum placement time. Material left in pails or mortar box may develop a "false" set making

it difficult to properly place.

f.Pre-dampen mixer prior to mixing first batch.

g.Add the dry material to the mixer. Then quickly add the minimum amount of specified water to

the mixer while mixing.



h.Mix for a "Preliminary Mix Time" as per the manufacturer's recommendation, then adjust water to

obtain the desired consistency. Excess water reduces the strength of the castable

proportionately.

i.After placement of refractory, cure either by spraying with a commercial curing compound or

water mist for at least 24 hours after casting. This shall prevent water evaporation required for

proper hydration and maximum properties.

7. Agency to note that welding of anchors is not in agency's scope.

Rate :

1. The rate payable shall be per sq. meter of refractory cast for 3" thickness, as per the scope

mentioned above.

2. For casting of thickness other than than 3", (higher or lesser thickness) , the rate payable

shall be on pro rata basis for each inch of thickness per unit area.

85.000 Chipping & Removal of

Abrasion

Square

Meters

Chipping & Removal of Abrasion resistant lining from Hexmesh


1. The scope of job includes chipping and removal of abrasion resistant lining from hex mesh and

cleaning the surface.

2. Agency to note that this lining shall be approx 1" thick and removal shall expose the

shell surface area.

3. Offer the cleaned / chipped arae for inspection and obtain clearance.

Rate :

1. The rate payable shall be per sq. meter of refractory chipped and removed.

86.000 Application of abrasion

resist

Square

Meters



Application of abrasion resistant refractory of hexmesh


1. The scope of job includes supply of all resources like Hobart mixer, wooden/rubber mallets,

trowels, Ice required for mixing and skilled manpower etc. to complete the job in its entirety.

2. Draw the refractory materials from warehouse or any other designated location inside the

refinery premises as advised by the Engineer-in-charge and transportation of these materials to

the work spot.





3. Carryout pre-qualification of masons for executing the job in coordination with HPCL

Inspection group prior to the commencement of job. Pre-qualification job test samples shall be

sent for testing for the required parameters by the agency at its own cost. HPCL's Inspection

department will issue Identity cards for all qualified masons which shall always be carried by

respective personnel while carrying out any refractory job at site. Test for qualification of

Masons shall be carried out prior to commencement of the job.



5. Agency shall carry out casting of refractory as per the procedure recommended by the



material.

a. Use clean tools and equipment. Contamination can affect setting and strength of castables.

b. Water proof all forms and surfaces. Mold release agents may be used if required.



c. Application surfaces must be clean and free of foreign (loose material, oil rust) matter.

d. Use only clean, cool (2-16deg.c.) Water suitable for drinking.

e. Use planetary, Hobart-type, mixer. The "B" flat agitator and mixing bowl should be made of

stainless steel. The maximum gap between the blade and the bowl at the bottom and sides should

be about 0.25inch (6mm). Mixing efficiency and product quality may be reduced if the clearances

are greater and if the mixing bowl is more than or less than 1/3 full.

f. Material and ambient temperatures should be (16-27deg.c.) during mixing, placing and setting.

g. Mix only as much material at one time as can be applied before material stiffens. Stiff

material becomes crumbly, loses plasticity, and does not knit together. Discard stiff material.

Do not remix.

h. Place the required amount of material into the mixing bowl. Dry blending at lower agitator

speeds, about 70 to 110 RPM. Consult the mixer manual for proper setting.

i. Add water to the dry material, starting at 4% by weight. The percent water used by RESCO or

other third party laboratories for qualification testing is a good guide to determine the amount

needed for mixing during installation. Increase the agitator speed to about 175 to 210 RPM.

Consult the mixer manual for proper setting. Slower or faster agitator speeds may change the

mixing times.

j. Adjust the water content to achieve a dough or putty-like consistency after 3 to 6 minutes of

mixing. Three or four distinct lumps of material will roll around in the bottom of the mixing

bowl. Use that same "final" water content on all batches or until a change in the appearance is

noted, if for example, the ambient temperature gets hotter or colder. If a change should occur,

adjust the water.

k. Add a little more water if the batch does not knit together easily on installation. The batch

will stick to the mixing bowl and blade if too much water is used.

l. Wash the mixing and placing equipment periodically with clean water and dry.

m. Pack the material into the area being lined, working it as needed to fill all holes and

eliminate air bubbles. Wood or rubber mallets, hammers, air rammers and trowels are commonly used

for this step.

n. Trim excess material, Be careful not to cut too deeply into the lining or pull the material

away from the anchor metal. Smooth the surface using a trowel, hardwood, or Teflon block or the

palm of the hand. DO NOT apply water.

o. Do not disturb lining during the first 24hour period after installation.

p. Do not spray water. A curing compound is also not required.



Rate :

1. The rate payable shall be per sq. meter of abrasion resistant refractory applied , as per the


87.000 Gunniting of Refractory

upto 3

Square

Meters

Gunniting of Refractory upto 3"


1. The scope of job includes drawing refractory materials from warehouse or any other designated

location inside the refinery premises as advised by the Engineer-in-charge and transportation of

these materials to the work spot.





3. Carryout pre-qualification of masons and gunmen for executing the job in coordination with

HPCL Inspection group prior to the commencement of job.

4. Pre-qualification job test samples shall be sent for testing for the required parameters by

the agency at its own cost. HPCL's Inspection department will issue Identity cards for all

qualified masons which shall always be carried by respective personnel while carrying out any

refractory job at site. Test for qualification of Masons shall be carried out prior to

commencement of the job.



6. Agency shall carry out gunniting of refractory as per the procedure recommended by the





material.

a. Use clean tools and equipment. Contamination can affect setting and strength of castables.

b. Water proof all forms and surfaces. Mold release agents may be used if required.

c. Use only clean water suitable for drinking.

d. A paddle type mechanical mixer shall be used.

e. Mix only as much castable as can be placed immediately. Under ideal conditions 20 minutes is

the maximum placement time. Material left in pails or mortar box may develop a "false" set making

it difficult to properly place.

f. Pre-dampen mixer prior to mixing first batch.

g. Add the dry material to the mixer. Then quickly add the minimum amount of specified water to

the mixer while mixing.

h. Mix for a "Preliminary Mix Time" as per the manufacturer's recommendation, then adjust water

to obtain the desired consistency. Excess water reduces the strength of the castable

proportionately.

i. After placement of refractory, cure either by spraying with a commercial curing compound or

water mist for at least 24 hours after casting. This shall prevent water evaporation required for

proper hydration and maximum properties.

8. Agency to note that welding of anchors is not in their scope and shall be done separately,

by HPCL.

Rate :

1. The rate payable shall be per sq. meter of refractory gunnited for 3" thickness, as per the


2. For gunniting of thickness other than than 3", (higher or lesser thickness) , the rate

payable shall be on pro rata basis for each inch of thickness per unit area.

88.000 Painting - Piping & Pipe

Fitti

Square

Meters

Painting - Piping & Pipe Fittings & Structurals




1. Carry out surface preparation by copper slag blasting or manual cleaning to SA 2 1/2, as per

the directions of HPCL.

Manual cleaning is permitted only if copper slag blastng cannot be done and the decision of

HPCL shall be final and binding on the agency, in this regard.

2. Carry out Primer application of One Coat of Inorganic Zinc Silicate of DFT 65 Microns OR One

Coat of Zinc Rich Epoxy of DFT 50 Microns.

3. Application shall be done using airless spray or with air spray with bullows. Generally, for

hot lines Inorganic Zinc Silicate shall be applied and for cold lines & stucturals Zinc Rich

Epoxy shall be applied. However Job Engineer's instruction in this regard shall be final &

binding on the agency.

Rate : The rate payable shall be per square meter basis, as per the scope of job given above.

89.000 Air cleaning of FD fan

suction

Lump Sum

Air cleaning of FD fan suction silencer


1.Air clean the FD fan suction silencers after opening the manways.

2.Opening and closing of manways is included in this scope.

Rate: The rate payable is lumpsum for the entire job scope mentioned above.

90.000 Shifting of tube bundle

of ste

Each

Shifting of tube bundle of steam generators- To & Fro

1. Supply of tractor-trailor with operator, other tools & tackles, nylon ropes, manpower

2. Transport the tube bundle from the unit to hydro-jetting yard and back to unit premises after



completion of hydrojetting.

NOTE:

1. Agency shall use only nylon ropes only for removal, loading and unloading the tube bundle.

2. Agency shall use Tractor Trailor only for shifting tube bundle.

91.000 Stress Relieving upto

1.5" dia

Inch -

Dia

Stress Relieving upto 1.5" dia. (applicable when no. of joints less than or equal to 5 nos.)

JOB SCOPE:

1. Supply all necessary tools & tackles, equipment, consumables.

2. Take the advise of Inspection/Job engineer on SR cycle

3. Stress relieve weld joints of shop fabricated / site fabricated / already installed pipe lines

at any elevation

4. Subimit the SR chart of Inspection/Job engineer.

5. Provide Hardness meter and check hardness of the metal near the weld joint after SR.

6. Submit hardness test report to Inspection and obtain clearance.

RATE PAYABLE:

Per Inch Dia. of weld joint of pipe sizes upto 1.5" dia.

NOTES:

1. In case of improper stress relieving, agency has to redo the entire job to the satisfaction of

Job engineer / Inspection engineer at no extra cost.

2. Electricity power shall be supplied by HPCL free of cost

3. This item is applicable only when the number of the weld joints to be stress relieved on a

respective line/loop is less than and upto 5 nos. If the no. of weld joints to be stress relieved

exceeds 5 nos., payment will be made as per Item no.93 and in such case, this item will not be

applicable.

4. This item is not operated inaddition to item no.93 for a particular job.



92.000 Stress Relieving above

1.5" an

Inch -

Dia

Stress Relieving above 1.5" and upto 3" dia. (applicable when no. of joints less than or equal to

5 nos.)

JOB SCOPE:




at any elevation




RATE PAYABLE:

Per Inch Dia. of weld joint of pipe sizes above 1.5" and upto 3" dia.

NOTES:




3. This item is applicable only when the number of the weld joints to be stress relieved on a

respective line/loop is less than and upto 5 nos. If the no. of weld joints exceeds 5 nos.,

payment will be made as per Item no.93 and in such case, this item will not be applicable.

4.This item is not operated inaddition to item no.93 for a particular job.

93.000 Stress Relieving for all

sizes

Inch -

Dia

Stress Relieving for all sizes (when no of joints exceeds 5)

JOB SCOPE:






at any elevation




RATE PAYABLE:

Per Inch Dia. of weld joint of pipe size above 3" dia.

NOTES:




3. In any case item nos. 91& 92 are not applicable for any job, this item is used irrespective of

size of weld joint/pipe including sizes less than 3" dia.

4. This item is not operated inaddition to item nos.91 & 92 for a particular job.

94.000 Radiography upto 1.5"

dia. (ap

Inch -

Dia

Radiography upto 1.5" dia. (applicable when no. of joints less than or equal to 5 nos.)

JOB SCOPE:

1. Supply of radigraphy films, equipment, skilled manpower, tools & tackles and all other

accessories

2. Carrying out radiography of weld joints as per standard procedure for all types and

thicknesses, at any elevation / location

RATE PAYABLE:

Per Inch Dia. of weld joint of pipe sizes less than and upto 1.5" dia.



NOTES:

1. In case of defective film, poor radiographic quality, non-readable film etc. agency shall redo

the radiography at no extra cost and agency will not be paid for any repeat radiography.

2. For any radiographic jobs carried out for straight lengths etc, the length shall be converted

to Inch dia and paid.

3. This item is applicable only when the number of the weld joints to be radiographed on a

respective line/loop is less than and upto 5 nos. If the no. of weld joints to be radiographed


applicable.


95.000 Radiography - above 1.5"

dia.

Inch -

Dia

Radiography - above 1.5" dia. and upto 3" dia. (applicable when no. of joints less than or equal

to 5 nos.)

JOB SCOPE:


accessories



RATE PAYABLE:

Per Inch dia. of weld joint of pipe sizes above 1.5" dia and upto 3" dia.

NOTES:










applicable.


96.000 Radiography - above 3"

dia. an

Inch -

Dia

Radiography - above 3" dia. and upto 6" dia. (applicable when no. of joints less than or equal to

5 nos.)

JOB SCOPE:


accessories



RATE PAYABLE:

Per Inch dia. of weld joint of pipe size above 3" and upto 6" dia.

NOTES:








applicable.


97.000 Radiography for all sizes

(whe

Inch -

Dia

Radiography for all sizes (when no of joints exceeds 5)



JOB SCOPE:


accessories



RATE PAYABLE:

Per Inch dia. of weld joint of pipe size above 6" dia.

NOTES:





3. In any case item nos.94 to 96 are not applicable for any job, this item is used irrespective

of size of weld joint/pipe including sizes less than 6" dia.

4. This item is not operated inaddition to item nos.94, 95 & 96 for a particular job.

98.000 Re-tubing of

Exchangers/Sulphu

Tube

Re-tubing of Exchangers/Sulphur condensers Welded Tubes - Rate per tube of size upto 1" Dia. OD

Job Scope:

1. Remove the existing tubes of Exchanger/Sulphur condenser by grinding existing weld joints.

Make grooves at tube holes as per drawings and carry out DP testing of tube holes.

2. Clean tube sheet hole, remove burrs and weld build up in pits any pits that are found, as per

Inspection. Agency shall record and submit the internal diameters of tube sheet holes using a

calibrated dial gage. The tube shall be identified in the record basis row and tube number.

3. Clean new tube internally and externally.

4. Install new tube in position and carry out field modification, if required for facilitating

the replacement

5. Roll the tube ends as per requirement and obtain clerance from Inspection.



6. Seal weld the tube ends on both sides as per IWL using CS/SS electrode equivalent TIG filler

rod.

7. Offer root and final seal weld DP test to Inspection and obtain clerance.

8. Carryout Stress relieving of joints as advised by Job Engineer.

9. Co-ordinate with IBR in obtaining necessary certification for retubing jobs.

Rate Payable:

1. The rate payable shall be PER TUBE REPLACEMENT OF SIZE UPTO 1" OD as per scope mentioned

above.

2. Incase of variation in tube OD size, rate will be paid on pro-rata basis.

3. Charges for Stress Relieving/PWHT of seal weld joints shall be paid extra as per available

items

4. Carrying out the cutting the 2 to 3 nos. sample tubes into three sections (both ends and

middle) of one-foot length, splitting the tubes axially into two halves and handing over to

Inspection Engineer is part of the scope.

5. In case of requirement for 100% re-tubing of any bundle, cutting and removal the old tubes,

removing the tube stubs from the tube sheets and baffles, cleaning and offering the tube sheets

and cage for Inspection and re-tubing etc are part of the job scope.

99.000 Hydrogen Diffusion of

Exchange

Square

Feet

Hydrogen Diffusion of Exchanger/Sulphur Condenser Tube sheet / PWHT of exchanger tube seal weld

joints

Job Scope:

1. Remove the sulphur/HC deposits over the the tube sheet surface using wire brushes/scrapers.

2. Carry out Hydrogen diffusion of exchanger tube sheet using suitable equipments as per Heating

& Cooling cycle provided by HPCL.

3. Uniform heating/cooling shall be ensured across the tube sheet surface by installing adequate

no. of heating elements.

4. Adequate no. of thermo couples to be installed as per Inspection to record temperature at

various points simultaneously.

5. Take hardness of tube sheet at various location as marked by Inspection before & after



Hydrogen Diffusion/PWHT/SR.

6. After completion of job, submit Time-Temperature record graph and hardness test report to HPCL

Inspection and Obtain clearance.

7. In case above job is done mainly for stress relieving of tube seal weld joints on tube sheet,

ASR and BSR weld joint hardness test report shall be submitted to HPCL Inspection.

Rate Payable: The rate payable shall be PER SQUARE FEET OF TUBE SHEET AREA INCLUDING TUBE SEAL

WELDS Stress Relieved / Hydrogen diffusion done.

100.000 Butt joint AS/SS - X-ray

quali

Inch -

Dia

Butt joint AS/SS - X-ray quality weld joints with TIG weld at root and TIG/Arc weld for Filler

joint using diesel machine

Job Scope:

1. Carry out isolation and preparatory works for obtaining 'Hot work permit' such as isolation,

blinding, flushing, removal of insulation and all other preparatory works.

2. Preparation for welding:

Carry out cold/hot cutting and dismantling of old pipes / pipe fittings, providing

Hook-ups/Tie-in/Additional piping, shifting material from issue points to site, erection,

cutting, grinding, beveling, bending, laying of pipes and preparation of fit-ups

3. Welding:

Carry out welding of pipes, pipe fittings, stubs etc. as per Inspection.

4. Testing and commissioning assistance:

Carry out DP test, WFMPT and/or radiography of welds as required, stress releiving, hydro testing

of pipes of various sizes, thickness etc., capping vent drains, deblinding etc.

Rate:

Per inch dia. of joint for using Diesel welding machine of the agency with TIG filler wire for

root run and subsequent runs with electrodes/TIG filler wire, for all Alloy Steel, SS and IBR-X



ray joints.

NOTES:

1. All non-destructive testing of piping shall be as per EIL Standard specification 3655-6-44-16.

2. Follwing items are paid separately as per applicable items in the tender :

RF pad, corrosion pads, threaded joints, scaffolding, Radiography, WFMPT, UFDT, SR, hydrotesting,

Valves replacement, Painting, Civil and Structural items.

3. No separate payment shall be made for DP TEST as it is included in the job scope.

4. AS/SS X-ray quality weld joints with TIG at root and filler with Arc/TIG welding with agency's

diesel equipment. Consumables and suitable electrodes to be used for AS/SS welding as instructed

by the job engineer/ Inspection.

101.000 Butt joint AS/SS - X-ray

quali

Inch -

Dia

Butt joint AS/SS - X-ray quality weld joints with TIG weld at root and TIG/Arc weld for Filler

joint using electrical machine

Job Scope:







3. Welding:





Carry out DP test, WFMPT and/or radiography of welds as required, stress releiving, hydro testing

of pipes of various sizes, thickness etc., capping vent drains, deblinding etc.

Rate Payable:

Per inch dia. of joint for using Electrical welding machine of the agency with TIG filler wire

for root run and subsequent runs with electrodes/TIG filler wire, for all Alloy Steel, SS and

IBR-X ray joints.

Notes:






4. AS/SS X-ray quality weld joints with TIG at root and filler with Arc/TIG welding with agency's

Electrical welding equipment. Consumables and suitable electrodes to be used for AS/SS welding as

instructed by the job engineer/ Inspection.

102.000 Fillet joint AS/SS with

TIG ro

Inch -

Dia

Fillet joint AS/SS with TIG root using diesel machine

Job Scope:







3. Welding:





Carry out DP test, hydro testing of pipes of various sizes, thickness etc., capping vent drains,

deblinding etc.

Rate:

1.Per inch dia. of joint for using Diesel welding machine of the agency with TIG filler wire,

for for Alloy steel, SS and IBR relevant joints.

Notes:






4. Suitable electrodes shall be used as instructed by the Inspection/Job engineer.

103.000 Fillet joint AS/SS with

TIG ro

Inch -

Dia

Fillet joint AS/SS with TIG root using electrical machine

Job Scope:







3. Welding:



Carry out DP test, hydro testing of pipes of various sizes, thickness etc., capping vent drains,



deblinding etc.

Rate:

1.Per inch dia. of joint for using electrical welding machine of the agency with TIG filler

wire, for for Alloy steel, SS and IBR relevant joints.

NOTES:





3. No separate pyment shall be made for DP TEST as it is included in the job scope.

4. IBR quality welding shall be carried out by IBR approved welders only.

5. Suitable electrodes/filler wire shall be used as instructed by the Inspection/Job engineer.

104.000 SS/AS Weld run jobs- weld

run

Running

Feet

SS/AS Weld run jobs- weld run with SS/AS electrodes per running foot of 6mm thick

JOB SCOPE:

1. Collect the plate from warehouse and fabricate necessary patch plates/box(es) etc. as required

to be installed from plate material

2. Install patch/box on vessels/heaters/any equipment as advised by Job Engineer and carry out

welding as per standard procedure

3. DP test the patch plate welding and offer for inspection and obtain clearance.

RATE PAYABLE: Per Running Feet of welding done using SS/AS electrodes using electrical welding

machine.

NOTES:

1. Blinding, Scaffolding, Hydro testing etc. if carried out shall be payable , extra, seperately

as per respective line items.

2. For any variation in thickness of weld, pro-rata payment shall be made.



3. Incase Diesel welding machine is used, 10% extra rate will be paid and Qty. of item will be

fixed accordingly.

105.000 SS weld build up with

electric

Square

Inches

SS weld build up with electrical machine

Job Scope is as follows

1. Grind the surface where weld build up is to be carried out.

2. Weld build up using Stainlss Steel electrodes (E-308/309/310/309 MO),as advised by Job

engineer upto 5 mm thick.

3. Finish grind after deposition and DP test the weld built up area and offer for inspection.

Rate:

1.Per square inch of deposited area for 5 mm thick deposition with elecrical machine.

2. For any variation in thicknes of weld deposit, payment shall be made in pro-rata basis.

106.000 SS weld build up with

diesel m

Square

Inches

SS weld build up with diesel machine

Job scope is as follows::

1. Grind the surface where weld build up is to be carried out.

2. Weld build up using Stainlss Steel electrodes (E-308/309/310/309 MO),as advised by Job

engineer upto 5 mm thick.

3. Finish grind after deposition and DP test the weld built up area and offer for inspection.

Rate:

1.Per square inch of deposited area for 5 mm thick deposition with diesel machine.

2. For any variation in thicknes of weld deposit, payment shall be made in pro-rata basis.



107.000 Supply of SS / AS / TIG

welder

Shift

JOB SCOPE:

1.Supply a qualified SS / AS / TIG / IBR welder complying with statutory and safety stipulations

along with all tools & tackles, upervision, consumables (suitable electrodes) and safety

equipment to carry out the job at any location.

Rate:

1. Per 8 hour shift

2.Payment for working beyond 8 hrs shift and on sundays and Refinery holidays shall be made at

double the rate on prorata basis.

108.000 Annual Inspection of WHB

/ Sul

Lump Sum

Annual Inspection of WHB / Sulphur Condensers /





3. Open the channel covers and all manways including Thermal Reactor manways opening.

4. Erect staging as required, as per the directions of HPCL.

5. Drop all safety valves and install blind flanges in position and transport these valves to

HPCL valve section.


blind flanges.


8. Clean the demister pads by water washing or using air.

9. Offer the components for Inspection and obtain clearance.

10. Prove clear all shell nozzles.

11. Carryout the shell test at the mentioned pressure and obtain inspection clearance.



12.Refix the demister pads and carry out refractory repair jobs, if any.

13.Fix the channel covers and box up all the manways.

14.Carry out tube test and offer to Inspection.

15. Remove the blinds and make up the flanges

16. Maintain stand-by crew for hot bolting, pulling leaks, etc, for a period of 24 hours (one




18. Coordinate with Dy.Chief Inspector of Boilers for inspection and certification and related

jobs and obtain clearance from DCIB.

Rate:

1. The rate payable is lumpsum for the entire job scope as mentioned above per Sulphur Condensor

/ Waste Heat Recovery Boilers.

2. For any cleaning done by hydrojetting,or reaming as per the advise of HPCL, the same shall be


3. For any refractory chipping and application jobs done as per the advise of HPCL, the same

shall be paid extra, separately.


Note:

This item is applicable for the following condensers / waste heat Boiler / drums.

1. D-SRU Train-1: 65E101, 65E102 & 65E103

2. D-SRU Train-2: 65E201, 65E202 & 65E203

3. D-SRU Train-3: 79E301, 79E302 & 79E303

4. FCCU-I: 4V63 (without Heater S/D & coils testing).

109.000 Supply of Hydra (10 T

capacity

Hour

Supply of Hydra (10 T capacity) - Payment is applicable only for running hours

Job scope is as follows:



1. Supply Hydra along with all consumables (fuel) and accessories, operator and fuels etc

2. Operate them at site to shift material, components etc.

Rate:

Per running hour

110.000 Material Handling Trip

Job Scope is as follows

1. Mobilise necessary tools, tackles, chain pulley blocks, D-shakles, 6" x 6" wooden blocks of

required length, wire ropes etc. for carrying out the job.

2. Shift components like test jig, channel section, channel cover, floating head cover, tube

sheets, shell cover etc. from any location to any other location inside Refinery.

Rate :

1.Per component shifted (One Way) unsing tractor trailer.

Notes:

1. Agency to mobilise trailor/hand trolley, tools etc.

2. This rate is applicable only when using Jeep/Tractor to pull the trailor/trolley for shifting

of components.

2. This item rate is not applicable for shifting within the unit of work and is applicable only

when the components are shifted beyond the battery limits of the unit.

111.000 Replacement of Casing

Plates o

Running

Feet

Replacement of Casing Plates of Boilers/HRSGs/Ducts- applicable 6 mm to 12 mm thick plates

Scope of job is as follows

1.Plate replacement scope covers- Cut, remove and replace the existing casing plate entirely or



Attachment To HPCL Tender Enquiry No. 12000438 - HD - 46002 dated 25/9/2012

Format For Priced Bid

1. Schedule of rates are in INR unless otherwise specified.

2. Vendor to quote '+' / '-' / Zero % on the Schedule of rates (A) mentioned in the following table.

3. Only single % is to be quoted for the complete set of Items/Services and not Item/Service wise.

Specifying more than single percentage (%) or quoting specific unit rates / Lumpsum rates

will make your offer rejected.

4. Prefix the % with, '+' for rates above the scheduled rate, '-' for rates below the scheduled rate.

Put Zero % if the scheduled rate itself are being offered.

5. The % is to be put in the space provided below the following table, both in figures and in words.

Please quote for the following items/service, as per the terms and conditions mentioned below and in

attachments :

DETAILS OF ITEMS / SERVICES

Deliver To : Maintenance-On Site, - . India.

Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

1 1.000 Blinding &

Deblinding

of equip


2 2.000 Manway

opening and

head up of

Each 571.00 Each


dropping,

transpo

Each 864.00 Each



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM


dropping &

instal

Each 571.00 Each

5 5.000 Drum manway

opening &

headup

Each 864.00 Each

6 6.000 Removal &

re-fixing of

drum in


7 7.000 Economiser

tubes

cleaning


8 8.000 Drum & drum

internals

cleaning


9 9.000 Tubes

cleaning


10 10.000 Flue gas

path

cleaning


11 11.000 Cleaning of

burner, oil

gun et


12 12.000 CO inlet / Lump Sum 884.00 Lump Sum



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

outlet ducts

inspec


of Boiler



hydrotest


15 15.000 Start up

coverage


16 16.000 Annual

Inspection

of Boilers


17 17.000 General

maintenance

of steam g



test & tube

test



test & tube

test


20 20.000 Retubing of

exchanger

tube (wi

Tube 246.00 Tube



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

21 21.000 Reaming of

exchanger

tube

Tube 77.00 Tube

22 22.000 Biennial /

Annua IBR

Inspectio


23 23.000 Boiler tube

replacement

Tube 3,440.00 Tube

24 24.000 Sectional

replacement

of boile


25 25.000 Window patch

of tubes

Running

Feet

2,083.00 Running

Feet

26 26.000 Re-rolling

of Boiler

tubes


27 27.000 Seal welding

of boiler

tubes


28 28.000 Plug welding

of Boiler

tubes



hydrotest of

Each 2,338.00 Each



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

econom


of piping

Inch Meter 4.00 Inch Meter

31 31.000 Gauge glass

overhauling

Each 864.00 Each

32 32.000 Threaded

fittings

replacement


33 33.000 Gland

packing

replacement


34 34.000 Valve free

up / repair


35 35.000 Valve

replacement


36 36.000 Supply &

operation of

air comp

Hour 652.00 Hour

37 37.000 Supply &

operation of

diesel w

Hour 205.00 Hour

38 38.000 Scaffolding Each 609.00 Each



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

of 3m x 3m x

3m bl

39 39.000 Grit

blasting

Square

Meters

766.00 Square

Meters

40 40.000 Copper slag

blasting

Square

Meters

334.00 Square

Meters

41 41.000 Solution

annealing of

anchors

Batch 14,727.00 Batch


economiser

tubes -



economiser

tubes -



-IBR X-ray

qualit



- IBR X-ray

quali



- X-ray

quality




Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM


- Non-X-ray

quali


48 48.000 Fillet

welding -

IBR

quality(R


49 49.000 Fillet

welding -

IBR quality


50 50.000 Fillet

welding -

Non- IBR

qual


51 51.000 RF pad

replacement

jobs



of Corrosion

pads



of SS

anchors

Each 99.00 Each

54 54.000 Replacement Each 55.00 Each



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

of CS

anchors


of

insulation

Anch

Each 16.00 Each


of hexmesh

(where

Square

Meters

8,800.00 Square

Meters


of Hex Mesh

(where

Square

Meters

13,200.00 Square

Meters


between

adjacent

Meters 1,395.00 Meters


between

adjacent t

Meters 786.00 Meters

60 60.000 CS Overlay

Patch 6 to

12mm thk

Square

Feet

983.00 Square

Feet

61 61.000 CS Inlay

Patch 6 to

12mm thk f

Square

Feet

1,573.00 Square

Feet



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

62 62.000 SS Overlay

patch 6 to

12mm thk

Square

Feet

1,945.00 Square

Feet

63 63.000 SS Inlay

patch 6 to

12mm thk f

Square

Feet

4,874.00 Square

Feet

64 64.000 Weld repair

to old joint

Running

Feet

108.00 Running

Feet


drum cracks

- Depth



drum cracks

- Depth



drum cracks

- Depth


68 68.000 Weld build

up of 5 mm

Thk (fin

Square

Inches

99.00 Square

Inches

69 69.000 Structural

replacements

(Mater

Metric Ton 18,102.00 Metric Ton

70 70.000 WFMPT Inch - Dia 101.00 Inch - Dia



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

71 71.000 DP test Inch - Dia 73.00 Inch - Dia

72 72.000 Supply of CS

Welder

Shift 602.00 Shift

73 73.000 Supply of

gascutter or

grinder

Shift 463.00 Shift

74 74.000 Supply of

fabricator

or fitter

Shift 463.00 Shift

75 75.000 Supply of

rigger

Shift 392.00 Shift

76 76.000 Supply of

Mason

Shift 543.00 Shift

77 77.000 Supply of

Carpentor

Shift 543.00 Shift

78 78.000 Supply of

Gunman


79 79.000 Supply of

Nozzleman


80 80.000 Supply of

Helper

Shift 327.00 Shift



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM


&

Demobilizati

on



&

Demobilizati

on



Removal of

Refracto

Square

Meters

689.00 Square

Meters

84 84.000 Refractory

Casting upto

3"

Square

Meters

3,930.00 Square

Meters


Removal of

Abrasion

Square

Meters

1,867.00 Square

Meters

86 86.000 Application

of abrasion

resist

Square

Meters

2,751.00 Square

Meters

87 87.000 Gunniting of

Refractory

upto 3

Square

Meters

3,243.00 Square

Meters

88 88.000 Painting - Square 689.00 Square



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

Piping &

Pipe Fitti

Meters Meters

89 89.000 Air cleaning

of FD fan

suction


90 90.000 Shifting of

tube bundle

of ste

Each 4,736.00 Each

91 91.000 Stress

Relieving

upto 1.5"

dia


92 92.000 Stress

Relieving

above 1.5"

an


93 93.000 Stress

Relieving

for all

sizes



upto 1.5"

dia. (ap



- above 1.5"




Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

dia.


- above 3"

dia. an



for all

sizes (whe


98 98.000 Re-tubing of

Exchangers/S

ulphu

Tube 1,350.00 Tube

99 99.000 Hydrogen

Diffusion of

Exchange

Square

Feet

6,873.00 Square

Feet


AS/SS -

X-ray quali



AS/SS -

X-ray quali



AS/SS with

TIG ro



AS/SS with




Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

TIG ro

104 104.000 SS/AS Weld

run jobs-

weld run

Running

Feet

743.00 Running

Feet

105 105.000 SS weld

build up

with

electric

Square

Inches

172.00 Square

Inches

106 106.000 SS weld

build up

with diesel

m

Square

Inches

200.00 Square

Inches

107 107.000 Supply of SS

/ AS / TIG

welder


108 108.000 Annual

Inspection

of WHB / Sul


109 109.000 Supply of

Hydra (10 T

capacity

Hour 893.00 Hour

110 110.000 Material

Handling

Trip 884.00 Trip

111 111.000 Replacement Running 197.00 Running



Sr.

No.

Tender Line

Number

Ref

Line No

Item

Number

Item

Description

Quantity Qty

UOM

Schedule of

Rates (A)

Purchasing

UOM

of Casing

Plates o

Feet Feet



Quoted % applicable to the schedule of rates specified in table above for all the Items/Services

______________ % (in figures) ___________________________________________Percent (in words).

Signature :

Seal :

(Tenderer)

End of Document 12000438 - HD - 46002


VISAKH REFINERY

HINDUSTAN PETROLEUM CORPORATION LIMITED - VISAKH REFINERY

TENDER DOCUMENT

FOR

ANNUAL SERVICE CONTRACT FOR

OVERHAULING OF BOILERS, STEAM

GENERATORS & OTHER IBR JOBS IN

VR

RFQ No.12000438-HD-46002/VNK

OFFICE OF DEUPTY GENERAL MANAGER (I/C) -

MATERIALS

MATERIALS DEPARTMENT – VISAKH REFINERY

ADMINISTRATIVE BLOCK - A, FIRST FLOOR, WEST WING

MALKAPURAM

VISAKHAPATNAM -- 530 011

ANDHRA PRADESH

Tel: 0-891 / 289.4309 & 289.4300

Fax: 0-891 / 257.7139 & 257.7824

RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM

GENERATORS & OTHER IBR JOBS

Seal of the Vendor Page 2 Signature & Name of the Authorised Signatory

with Date

Visakh Refinery

CONTENTS

PAGE NOs.

I. Important Dates & Events and Commercial Details 03 - 04

II. Bidding Procedure 05 - 08

III. Prequalification Criteria 09 - 11

IV. Scope of Job and Important Terms & Conditions 12 - 25

ANNEXURE:

Annexure I : FORMAT FOR BANK GUARANTEE IN LEIU OF EMD. Annexure II : DECLARATION Annexure III : GENERAL TERMS & CONDITIONS OF WORKS CONTRACTS Annexure IV : SAFETY REGULATIONS FOR CONTRACTTORS Annexure V : SWP-01 SPECIFICATION FOR PPE Annexure VI : SWP-02 MINIMUM PPE FOR VARIOUS ACTIVITIES Annexure VII : SWP-06 CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE Annexure VIII : SAFETY, HEALTH & ENVIRONMENT Annexure IX : FORMAT FOR WORKMEN PHYSICAL FITNESS CERTIFICATE Annexure X : PENALIES FOR NON-COMPLIANCE Annexure XI : FORMAT FOR ANTECEDENT VERIFICATION CERTIFICATE Annexure XII : RADIOGRAPHY RULES Annexure XIII : SPECIFICATIONS FOR FIRE RETARDANT CLOTH Annexure XIV : QUALIFICATION & CRITERIA FOR AGENCY’S SAFETY SUPERVISOR’S Annexure XV : MINIMUM RESOURCES TO BE MOBILIZED

* * * * * * * *

RFQ No. 12000438-HD-46002/VNK

ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS

IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS


with Date

Visakh Refinery

IMPORTANT DATES &EVENTS

S.No. TIME & DATE EVENT SUBMISSION MODE REMARKS

1 11:00 a.m. on

02-Nov-2012

Due Date for

Submission of Tender

Fee, EMD, Unpriced &

Priced Offers

Tender Fees, EMD,

Unpriced Bid and Priced

Bid to be submitted in

separate Sealed

Envelopes

In 4 Separate Envelopes:

1. Tender Fees 2. EMD/ Exemption Details

3. UnPriced Bid 4. Priced Bid

All together in one sealed

envelope subscribed with

Tender No., Due Date &

Tender Description,

Tenderer’s Name & Address.

IMPORTANT NOTES:

1.0. This Tender Document can be Downloaded from the following websites: http://www.hindustanpetroleum.com.

1.1. Tenderer have a choice of either obtaining the documents from the office of DGM (I/C) - Materials (address given below at 1.9.) or by downloading the relevant tender documents from website indicated at 1.0. above.

1.2. All the Tenderers who download this Tender Document shall pay the Tender Fees of R5,000/- (Rupees Five Thousand Only) along with the submission Tender in a separate sealed envelope.

* * * * * * * * *

RFQ No. 12000438-HD-46002/VNK


IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS


with Date

Visakh Refinery Visakh Refinery

IMPORTANT COMMERCIAL DETAILS

1.0. TENDER FEES:

1.1. Tenderers shall submit the Tender Fees of R5,000/- (Rupees Five Thousand only) in the form of a Demand Draft issued by a Scheduled Bank (other than Co-Operative Banks) in favour of Hindustan Petroleum Corporation Limited, payable at Visakhapatnam. It is to be noted that Tender Fee is non-refundable.

1.2. Kindly note that all the Tenderers who download this Tender Document (whether interested to participate in the Bidding process or not) shall send us the Tender Fees of R5,000/- (Rupees Five Thousand only) as specified above, to the office of DGM(I/C)-Materials.

1.3. Tenderers registered with National Small Scale Industries Corporation (NSIC) are exempted from Tender Fees. For this purpose, a copy of the valid NSIC registration Certificate should be submitted. 1.4. Tenders received without Tender Fee will be rejected other than those who are exempted. 2.0. EMD (EARNEST MONEY DEPOSIT):

2.1. Tenderers should submit EMD (Earnest Money Deposit) of R1,70,000/- (Rupees One Lakh Seventy Thousand only).

2.2. EMD shall in the form of Demand Draft issued by a Scheduled Bank (other than Co-operative Banks) in favour of Hindustan Petroleum Corporation Limited, payable at Visakhapatnam (OR) in the form of Non-revocable Bank Guarantee on R100/- (Rupees One Hundred only) non-judicial stamp paper (as per format enclosed) issued by a Scheduled Bank (other than Co-Operative Banks).

2.3. Any Bank Guarantee submitted by a tenderer shall be confirmed by the Issuing Bank within 10 days of receipt of HPCL’s letter requesting for confirmation that it is genuine and validly issued in favor of HPCL.

2.4. Public Sector Enterprises and Tenderer registered with National Small Scale Industries Corporation (NSIC) are exempted from EMD. For this purpose, in the event of the tenderer being a Public Sector Enterprise, a declaration to that effect and in case of tenderers registered with NSIC, a copy of the registration Certificate should be submitted. 2.5. Tenders received without Earnest Money Deposit will be rejected other than those who are

exempted. NOTE: HPCL shall not be responsible for any expense incurred by tenderers in connection with the

preparation & acceptance of Bid and any other expenses incurred, for submission of bid.

* * * * * * * * *

RFQ No. 12000438-HD-46002/VNK


BIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDURE


with Date

Visakh Refinery Visakh Refinery Visakh Refinery

1.0. SUBMISSION OF OFFER/ MODE OF BIDDING: ============================================= 1.1. The Tenderer shall submit their offer in FOUR ENVELOPE System as detailed below: 1.2. Tenderer should submit the Tender Fee, EMD, Un-Priced and Priced Bid in separate sealed envelopes. All the envelopes should be superscribed with the RFQ No., RFQ Date, RFQ Due Date and Tenderer's Name & Address. 1.3. In case either (a) the Tenderer submits any two or more of above documents, in the same envelope, or (b) Documents are submitted in differently titled envelopes, or (c) Prices are mentioned in any of these envelopes, or (d) EMD and/ or Tender Fee is not submitted in separate sealed envelope but instead submitted along with Un-Priced Bid or the Priced Bid, such Offers shall be summarily REJECTED, WITHOUT ANY reference to and/ or correspondence with the Vendor.

1.4. TENDER FEE (Envelope No.1): =============================== 1.4.1. The Tender Fee shall be submitted in a separate envelope duly superscribed “Tender Fee” along with HPCL-VR’s RFQ No., RFQ Date, RFQ Due Date and Vendor’s Name & Address. 1.4.2. Please refer clause no.1.0. of Important Commercial Clauses for details of Tender Fees such as Amount as well as mode of payment of the same. 1.5. EARNEST MONEY DEPOSIT (Envelope No.2): ========================================== 1.5.1. The Earnest Money Deposit shall be submitted in a separate envelope duly superscribed “Earnest Money Deposit” along with HPCL-VR’s RFQ No., RFQ Date, RFQ Due Date and Vendor’s Name & Address. 1.5.2. Please refer clause no.2.0. of Important Commercial Clauses for details of Earnest Money Deposit such as Amount as well as mode of payment of the same. 1.6. UNPRICED BID (Envelope No.3): ================================== Please ensure to Submit, in duplicate, the following as Un-Priced Bid:

1) All the Notarised Documents in support of fulfilling their pre-qualification criteria (as specified under PRE-QUALIFICATION CRITERIA, clause no.2.0 to 2.5).

2) A Covering Letter, on Tenderer’s Letter Head, confirming unconditional acceptance to all the terms & conditions contained in HPCL's RFQ and WITHOUT any deviation except deviations if any, given in the deviation list specified at (5) below.

3) All pages of this Tender Document and all its Annexures, duly signed and stamped. 4) Declaration on your Letter Head, confirming that agency have not been banned or

delisted by any Government or Quasi Government agencies or Public Sector Undertakings / Enterprises.

RFQ No. 12000438-HD-46002/VNK




with Date


5) Deviation List: In case of any deviation, the tenderer has to mention the same in this document (titled as “Deviation List”) on their Letter Head. Deviation mentioned in any other place will not be considered. 1.7. PRICED BID (Envelope No.4): ============================= 1.7.1. Tenderer has to quote a SINGLE Percentage (above or below, + / - ) on the schedule of

rates specified by HPCL in this RFQ, in the Priced Bid Format. Please note that the same percentage shall be applicable for all items of this Enquiry, without exception.

1.7.2. The offer of Tenderers quoting separate / different rates and / or separate / different percentages for different items, shall be summarily rejected, without further reference / correspondence to the Tenderer.

1.7.3. The Percentage should be quoted in Figures as well as in Words. 1.7.3.1. If some discrepancies are found between the rate quoted in words and figures in the tender,

the rate as quoted in words shall be adopted. 1.7.4. The Rate(s) quoted shall be towards all cost including Mobilization and Demobilization,

Packing, Forwarding, Freight, Octroi and all Taxes & Duties (viz., Sales Tax, Works Contract Tax, Entry Tax, Excise Duty, Customs Duty, etc.), Cess and any other levies, etc. that are applicable during the execution of contract till completion of work, but EXCLUDING Service Tax and Cess on Service Tax. The rate thus quoted shall be FIRM during the entire period of the contract till completion of the job and no escalation in the rates for any reason whatsoever shall be payable by HPCL.

1.7.5. Please enter the applicable Service Tax and Cess on Service Tax, only in the UNPRICED/ TECHNO COMMERCIAL BID.

1.7.5.1. Any upward variation in Service Tax and Cess on Service Tax shall be reimbursed by HPCL provided any upward variation has come into existence after the opening of un-priced bid. Any downward variation in Service Tax and Cess on Service Tax occurring after opening of Un-Priced Bid shall be passed on to HPCL.

1.7.6. Please note that Service Tax and Cess on Service Tax, shall be payable only if the following conditions are fulfilled:

1.7.6.1. Service Tax shall be paid extra, in accordance with the rate prevailing (before the contractual date of completion) as per the Statutory Provisions and Rules relating to Service Tax.

1.7.6.2. The Tenderer should submit a photocopy of the Certificate from the Service Tax Authorities allocating them their unique 15-digit PAN based STC Number. And this 15-digit PAN based STC Number should be quoted on their Invoice.

1.7.6.3. The Tenderer should submit a photocopy of the Certificate of Registration with the Service Tax Authorities allocating their Registration Number. And this Registration Number should also be quoted on their Invoice.

1.7.6.4. In case of PO, the Tenderer should show the Service Tax component as a separate Item in their Invoice/ Bill/ Challan.

RFQ No. 12000438-HD-46002/VNK




with Date


1.7.6.5. In case of PO, whenever called for by HPCL, the Tenderer shall furnish documentary evidence of having paid the Service Tax payable against the PO, to the Service Tax Authorities.

1.7.6.6. The Tenderer shall provide all necessary documents to enable HPCL to avail the CENVAT credit, as per the prevailing guidelines of Service Tax authorities.

1.8. ESTIMATED FINANCIAL LIMIT: ================================== 1.8.1. The services shall be requisitioned as and when the need arises and the actual quantities shall

be communicated to the Agency, from time to time. 1.8.2. The Total Estimated Financial Limit of this job is R85,00,000/- (Rupees Eighty Five Lakhs),

which is proposed to be distributed between 2 agencies in the ratio of 60:40. The order will be placed on the lowest tenderer with the rate accepted by HPCL for 60% of the total ordered value. This lowest accepted rate will be counter offered to the L2 tenderer for their acceptance based on which the order will be placed for 40% of the total ordered value. However, HPCL reserves the right to allocate the Total Financial Limit to the lowest tenderer.

1.8.3. In case more than 1 tenderer quotes the same lowest (L-1) rate, the total ordered value will be equally apportioned between all such tenderers only.

1.8.4. In case only one tenderer quotes the lowest (L-1) rate and in case more than 1 tenderer quotes the same second lowest (L-2) rate, the remaining 40% of the total ordered value will be equally apportioned between all such tenderers only.

1.8.5. However, HPCL reserves the right to allocate the Total Financial Limit to the lowest tenderer and/or any other ratio.

Tenders received after the stipulated date and time for receipt of the tenders, due to any reasons whatsoever, shall be rejected. 1.9. ADDRESS FOR SUBMISSION OF BIDS: =====================================

The Bid should be submitted at the following address, before the Due Date and Time specified in the RFQ:

OFFICE OF DEPUTY GENERAL MANAGER (I/C) - MATERIALS MATERIALS DEPARTMENT – VISAKH REFINERY ADMINISTRATIVE BLOCK - A, FIRST FLOOR, WEST WING MALKAPURAM VISAKHAPATNAM -- 530 011 ANDHRA PRADESH

RFQ No. 12000438-HD-46002/VNK




with Date


Tel : 0-891 / 2894300 & 2894305 Fax : 0-891 / 257 7139 & 257 7824 E-Mail: [email protected], [email protected], [email protected] & [email protected]

• HPCL shall not be responsible for delay in receipt of the Tenders due to postal delays or any other reason whatsoever.

2.0. SEQUENCE OF OPENING OF ENVELOPES: ========================================= 2.1. The Envelopes shall be opened in the following order, on the due date for submission of

offers, i.e. on 02-Nov-2012 at 11 a.m. 2.1.1. Tender Fee 2.1.2. EMD 2.1.3. Un-Priced Bid

2.2. After the Tender Fee is established and found to be in order, the EMD/Exemption Details shall be opened. After EMD/Exemption Details are established and found to be in order, the Un-Priced Bid Envelope shall be opened.

* * * * * * * * * *

RFQ No.12000162-HD-46002/RD ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM

GENERATORS & OTHER IBR JOBS PREPREPREPRE----QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA


with Date


1.0. Tenderers intending to participate in this tender shall fulfill BOTH the qualification criteria, stipulated at 1.1. & 1.2. below.

1.1. FINANCIAL CRITERIA: Average Annual Financial Turnover during the last 3 years,

ending 31-March-2012, should be at least r25 Lakhs (Rupees Fifteen Lakhs Only). 1.2. TECHNICAL CRITERIA: Tenderers shall have experience of having successfully carried

out and completed similar work during the last 7 years ending 30-Sept-2012 which experience should be any one of the following:

(a) Three similar completed works, each costing not less than the amount equal to R34 Lakhs. OR

(b) Two similar completed works, each costing not less than the amount equal to R42 Lakhs. OR

(c) One similar completed work costing not less than the amount equal to R68 Lakhs.

"Similar Work" shall mean tenderers should have successfully carried out & completed Static Equipment (i.e., Exchanges, Furnaces, Pressure Vessels, Piping etc.) Maintenance Jobs in any Refineries/ Petrochemical/ Fertiliser Industries in India, of the value of work(s) indicated at 1.2 above. Also, for the purpose of experience the tenderer should have carried out and completed at least one job of any value of Boiler Erection/ Maintenance Jobs (repairs, testing, etc.) in any type of Industries in India.

2.0. Tenderer shall furnish the following documentary evidence in support of the above Financial and Technical Criteria for Pre-Qualification, duly attested by a Notary:

2.1. Copy of Purchase Order(s) in support of similar work of value(s) indicated at 1.2 above. 2.2. Copy of Purchase Order as a proof of having experience in Boiler Jobs of any value in any

type of industries in India. 2.3. Copy of valid IBR certificate for from Andhra Pradesh IBR Authorities for repairs or

Overhauling of Boilers/ Steam Generators. 2.4. Details of the IBR Welders whom agency is likely to deploy for this contract and their valid

IBR Certificates and credentials. 2.5. Annual reports containing audited balance sheets and profit & loss accounts statement.

3.0. The tenderers should submit all the documents in the first instance (i.e., along with Unpriced Bid) itself, in support of fulfilling their qualification criteria. Offer of Tenderer’s shall be liable for rejection, if the documents at s.nos.2.0. to 2.5 are not submitted along with the Un-Priced Bid.

3.1. HPCL reserves the right to complete the evaluation based on the details furnished along with the bid, without seeking any additional information.

3.2. HPCL reserves the right to use their in-house information for assessment of Tenderer’s capabilities.




with Date


3.3. HPCL also reserves the right to reject any tender without assigning any reasons whatsoever. 4.0. Parties who are affiliates of one another can decide which Affiliate will make a bid. Only one

affiliate may submit a bid. Two or more affiliates are not permitted to make separate bids directly or indirectly. If 2 or more affiliates submit a bid, then any one or all of them are liable for disqualification. However upto 3 affiliates may make a joint bid as a consortium, and in which case the conditions applicable to a consortium shall apply to them.

4.1. “Affiliate” of a Party shall mean any company or legal entity which: (a) controls either directly or indirectly a Party, or (b) which is controlled directly or indirectly by a Party; or (c) is directly or indirectly controlled by a company, legal entity or partnership which directly or

indirectly controls a Party. “Control” means actual control or ownership of at least a 50% voting or other controlling interest that gives the power to direct, or cause the direction of, the management and material business decisions of the controlled entity.

5.0. Bids may be submitted by: a) a single person/ entity (called sole bidder); b) a newly formed incorporated joint venture (JV) which has not completed 3 financial years

from the date of commencement of business; c) a consortium (including an unincorporated JV) having a maximum of 3 (three) members; d) an Indian arm of a foreign company. 6.0. Fulfillment of Eligibility criteria and certain additional conditions in respect of each of the

above 4 types of bidders is stated below, respectively: a) The sole bidder (including an incorporated JV which has completed 3 financial years after

date of commencement of business) shall fulfill each eligibility criteria. b) In case the bidder is a newly formed and incorporated joint venture and which has not

completed three financial years from the date of commencement of business, then either the said JV shall fulfill each eligibility criteria or any one constituent member/ promoter of such a JV shall fulfill each eligibility criteria. If the bid is received with the proposal that one constituent member/ promoter fulfills each eligibility criteria, then this member/promoter shall be clearly identified and he/it shall assume all obligations under the contract and provide such comfort letter/guarantees as may be required by Owner. The guarantees shall cover inter alia the commitment of the member/ promoter to complete the entire work in all respects and in a timely fashion, being bound by all the obligations under the contract, an undertaking to provide all necessary technical and financial support to the JV to ensure completion of the contract when awarded, an undertaking not to withdraw from the JV till completion of the work, etc.

c) In case the bidder(s) is/are a consortium (including an unincorporated JV), then the following conditions shall apply:

1) Each member in a consortium may only be a legal entity and not an individual person; 2) the Bid shall specifically identify and describe each member of the consortium;




with Date


3) the consortium member descriptions shall indicate what type of legal entity the member is and its jurisdiction of incorporation (or of establishment as a legal entity other than as a corporation) and provide evidence by a copy of the articles of incorporation (or equivalent documents);

4) One participant member of the consortium shall be identified as the “Prime member” and contracting entity for the consortium;

5) this prime member shall be solely responsible for all aspects of the Bid/Proposal including the execution of all tasks and performance of all consortium obligations;

6) the prime member shall fulfill each eligibility criteria; 7) a commitment shall be given from each of the consortium members in the form of a letter

signed by a duly authorized officer clearly identifying the role of the member in the Bid and the member’s commitment to perform all relevant tasks and obligations in support of the Prime/lead member of the Consortium and a commitment not to withdraw from the consortium;

8) No change shall be permitted in the number, nature or share holding pattern of the Consortium members after pre-qualification, without the prior written permission of the Owner.

9) No change in project plans, timetables or pricing will be permitted as a consequence of any withdrawal or failure to perform by a consortium member;

10) No consortium member shall hold less than 25% stake in a consortium; 11) Entities which are affiliates of one another are allowed to bid either as a sole bidder or as a

consortium only; 12) Any person or entity can bid either singly or as a member of only one consortium. d) In case the bidder is an Indian arm (subsidiary, authorized agent, branch office or affiliate) of

a foreign bidder, then the foreign bidder shall have to fulfill each eligibility criteria. If such foreign company desires that the contract be entered into with the Indian arm, then a proper back to back continuing (parent company) guarantee shall be provided by the foreign company clearly stating that in case of any failure of any supply or performance of the equipment, machinery, material or plant or completion of the work in all respects and as per the warranties/ guarantees that may have been given, then the foreign company shall assume all obligations under the contract. Towards this purpose, it shall provide such comfort letter/guarantees as may be required by Owner. The guarantees shall cover inter alia the commitment of the foreign company to complete the entire work in all respects and in a timely fashion, being bound by all the obligations under the contract, an undertaking to provide all necessary technical and financial support to the Indian arm or to render the same themselves so as to ensure completion of the contract when awarded, an undertaking not to withdraw from the contract till completion of the work, etc.

* * * * * * * * *

RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM


SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS

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SPECIAL CONDITIONS OF THE CONTRACT (SCC): ===========================================

This SCC should be read in conjunction with GTCWC (General Terms & Conditions of Works Contract) . In case of any contradiction between the said documents, SCC will be applicable only to the extent of such variance.

1.0. SCOPE OF JOB: ~~~~~~~~~~~~~~~~~~~~~ 1.1. Carrying out overhauling / annual / biennial Inspection of boilers & steam generators in the

Refinery as per scope mentioned against each item. 1.2. Carrying out various IBR piping replacement jobs in the Refinery 1.3. Coordination with IBR authorities for their stage wise approval for completion of the jobs i.e.

agency shall coordinate with IBR authorities for obtaining approvals for the jobs carried out by them inside HPCL. Agency to note that coordination for approval of drawings by IBR authorities for new schemes / modifications etc. is excluded from this scope.

1.4. Co-ordination with Director of Boilers, Hyderabad for obtaining approval / authorization for any repair / replacement job (for example exchanger re-tubing jobs) is excluded from agency’s scope. However, co-ordination for obtaining necessary Certification & Inspection from Inspector of Boilers & DCIB is included in agency’s scope and is part of scope of job. This clause is applicable to all the items of this order.

1.2. OTHER TERMS & CONDITIONS: ===================================== 1.2.1. HPCL's "General Terms & Conditions of Works Contracts" & "Safety Regulations for

Contractors" form an integral part of this order.

1.2.2. Agency to abide by the Refinery's safety rules and regulations without any deviation.

1.2.3. Good housekeeping forms part of the scope and is to be carried out on a daily basis.

1.2.4. The entire job at all stages will be subject to HPCL Inspection and approval.

1.2.5. Agency shall give two telephone nos., preferably of the owner and supervisor for passing on information regarding emergency jobs which may come up beyond normal working hours. On intimation party shall mobilize the resources within 2 hours. Failure to respond to calls from HPCL or failure to mobilize resources within time as informed by the job engineer will be viewed very seriously.

1.2.6. As this is an order to meet regular as well as emergency maintenance requirements of the refinery operations, agency shall be ready for carrying out assigned jobs round the clock.




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Agency shall mobilize the necessary material, manpower, tools, equipment etc., for carrying out the jobs immediately on intimation. Agency shall mobilize material in sufficient quantities in line with the schedule of the work.

1.2.6.1. Outstation agencies/organizations, located outside Visakhapatnam, have to open an office in Visakhapatnam with Two responsible contact persons based at Visakhapatnam for this job. These persons shall have valid mobile telephone numbers and shall be available on round the clock basis, without which the jobs cannot be awarded. They are required to submit an undertaking to that effect - that an office with necessary staffing, tools and tackles shall be opened at Visakhapatnam and will be operational throughout the period of this contract, with responsible persons posted to work on round the clock basis, as required. This undertaking shall be submitted along with the Unpriced Bid, failing which the offer shall be rejected.

1.2.7. In case the agency fails to carry out jobs as per the instructions of the concerned job engineer within the scheduled time, HPCL reserves the right to get the job done by any other agency of its choice and recover the differential expenditure and overheads from the agency.

1.2.8. Agency shall co-ordinate with other agencies working in the same area and working on associated jobs and works in a conducive environment during the course of work execution, towards expeditious and safe completion of jobs.

1.2.9. Agency shall prepare and obtain measurement certification for the jobs completed within 3 days of completion of jobs. Also agency shall prepare and submit schematic diagram of pipeline duly signed by the job engineer. The drawing shall provide minimum information of pipe size, length of pipe, pipe specification, no. of fittings, no. of prefabrication joints & field joints, no. of joints with diesel / electrical welding machine, etc. Both Job completion certificate and certified pipeline schematic diagram to be submitted along with monthly RA bills.

1.2.10. For the jobs completed, as per the duration for submission of bills agreed to, running bills should be numbered and dated, indicating clearly the period of measurement covered should be submitted every month in the Box provided in the Disbursement Section. Agency shall submit the bills to Maint.-Planning within stipulated time given (within first week of every month).

1.2.11. Material shall be brought inside Refinery through valid gate passes. Agency shall submit all these documents, weighment slips, material reconciliation statement duly signed by the Job engineer along with the bill, if requested by job engineer.




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1.2.12. Material under HPCL's scope of supply shall be issued from any location within the refinery including ATP. Transportation (includes loading & unloading) of required materials from any designated location to work site and vice versa as per the instructions of the job engineer is part of the scope. The area covered shall be within ATP & Refinery Area.

1.2.13. Transportation of scrap/debris from the work site, weighment and dumping at designated location as instructed by the job engineer is included in the job scope.

1.2.14. Agency shall carry out the jobs as instructed by the Job Engineer at any elevation. The agency shall provide required scaffolding for comfortable working and completion of the job.

Scaffolding to be erected with 1-1/2" dia. Steel tubular pipe with suitable and safe clamping arrangement. Distance between adjacent vertical members shall not be more than six feet and distance between adjacent horizontal members shall not be more than three feet. Proper MS Gratings to be laid on Horizontal pipe and the gratings must be tied to the Horizontal members by GI wire.

In all cases, rates for Scaffolding are included in the respective item rates, unless otherwise specified.

1.2.15. Agency has to ensure that all manpower deployed for the job shall be covered under the provision of all statutory acts like ESI, EPF, Minimum wages, etc. and agency shall submit proofs of the same on demand to the Manager Onsite. Agency's proprietor/authorized representative shall sign the temporary photo pass along with the concerned workmen which will be certified by CISF for entry into Refinery.

1.2.16. Unless otherwise specified, no idling charges are payable for any idling of agency's manpower & Equipment due to non-availability of inspection, non-availability of work permits due to operational constraints, non-availability of materials required for the job.

1.2.17. Corporation will arrange to dismantle control instruments or their components that interfere with the work of the agency and reinstall on completion of work. Agency shall inform the corporation about any such item interfering in their work.

1.2.18. HPCL reserves the right to split/off-load the job, if progress of work is found satisfactory at any stage and assign the same to any other agency as deemed fit and all the consequential expenses in this regard shall be borne by the agency.

1.219. Agency shall be prepared to cut gaskets from sheets in case of non-availability of gaskets




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1.2.20. Agency shall be prepared to cut corroded bolts of the flanged joints and replace with new / serviced bolts during arresting flange leaks, blinding, de-blinding, etc. at no extra cost

Agency shall not resort to cutting the bolts to open the joint unless the threads are damaged / corroded.

1.2.21. Any damage to the HPCL's chain pulley blocks shall be repaired / replaced by the Agency free of cost. Also, agency shall thoroughly clean, grease the chain pulley blocks after and before handing over to HPCL. For opening of bigger size bolts, torque wrench shall be used, if required. Torque wrench shall be issued by HPCL. In case of damage to the torque wrench, the agency shall repair / replace free of cost.

1.2.22. A job is said to be completed only when housekeeping of that job area is completed. Unless housekeeping is not completed, respective job completion challan/certificate will not be approved/issued. Agency to segregate ferrous & non-ferrous scrap, as adviced by Job Engineer. Scrap/un- useful material shall be shifted immediately after completion housekeeping to respective scrap yard or designated area within Refinery/ATP as advised by Job Engineer.

Agency to submit material reconcilation sheet for each job along with job completion challan and upon advice of Job Engineer, agency to handover unused material to Warehouse.

1.2.23.In case any electrodes/filler wire/other consumables supplied by HPCL, when agency fails to arrange the same within specified time limit, amount equivalent to material supplied by HPCL and 15% handling charges will be deducted from monthly RA bills. However, it is considered as non-compliance to PO terms by agency and are not always entertained.

1.3. SAFETY, HEALTH & ENVIRONMENT: ===================================== 1.3.1. The agency shall provide all their personnel with the requisite personal protective equipment

like safety shoes, protective clothing, safety helmet, safety belts, gloves, safety goggles, adequate lighting in the work area. Failing to comply with this shall result in stoppage of work. Agency shall ensure to use minimum safety PPE as per IS specifications for all workmen engaged as applicable for the job (Refer Annexure-V: SWP-01 for IS Specifications). Details of minimum PPE required for various jobs are mentioned in Annexure-VI: SWP-02 and agency shall abide by the guidelines given in these Annexures. Agency may approach Maintenance Onsite Planning for details of suppliers of PPE conforming to IS standards, if required.




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1.3.2. Agency has to designate a safety supervisor, having minimum 3 years of refinery experience and well versed with Refinery Safety Procedures and Practices. The safety supervisor has to be certified by Fire & Safety Dept. Agency shall deploy such qualified safety supervisors during the course of work to ensure the jobs carried out are in compliance with Refinery safety requirement and as per procedure. Qualification and Criteria for Safety Supervisor are mentioned in Annexure-XIV attached with this enquiry. It may be noted that penalty shall be levied on the contractor for violation of safety for each incident. Penalty amount will be decided by HPCL and shall be binding on the agency.

1.3.3. Agency shall ensure to abide SHE (Safety, Health, Environment) guidelines described as per Annexure-IV which is attached along with this tender enquiry.

1.3.4. Agency shall ensure that the age of workmen deployed to carryout various jobs in the Refinery is in between 18 to 58 years. As per Factories act, workmen below 18 years are not allowed to work in Factory/Refinery. HPCL will not issue the gate passes for the workmen whose age is below 18 years and above 58 years to work in the Refinery.

1.3.5. Agency shall ensure that all the workmen employed by him are medically fit and will submit the Fitness certificate as per attachment (Physical Fitness Certificate Format (Annexure-IX) along with this tender enquiry. The fitness certificates shall be submitted while applying for gate passes. The certificate shall be issued by registered Doctor and the certificate shall be not older than 3 months to the date of submission of certificate.

1.3.6. Agency to abide by the up-to-date Refinery's safety rules and regulations as long as jobs are taken up. In case any deviation is taken by agency from prevailing Safety rules & regulations, penalty is levied on agency. The penalty amount is finalized by Job Engineer / F&S Officer based on the nature and severity of deviations taken or observed. The type of deviations and approx. penalty amounts are indicated in Annexure-X (attached along with this tender enquiry). This penalty amount is deducted from agency's RA bill or to be paid by agency in the form of DD/Cheque etc. upon advice of Job Engineer.

1.3.7. Agency shall submit the Antecedent Verification Report of his workmen from the respective Police Station and same should be submitted to HPCL, VR-HR department for obtaining the gate entry Photo passes to work in the Refinery. A specimen copy of letter addressed to Police Station (Annexure-XI) is enclosed along with this tender enquiry for agency's ready reference.

1.3.8. Agency's supervisor shall conduct a Safety pep talk in field with their workmen on daily basis and this Safety pep-talk shall consists of Safety rules and regulations to be followed while carrying out the assigned jobs. Agency shall maintain a record noting all the points discussed in Safety pep-talk on daily basis and that record shall be endorsed by all the workmen and Job Engineer.




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1.3.9. The maximum speed limit for motor vehicle within the Refinery premises is 25 KMPH. Vehicle and mobile equipment shall be driven cautiously and shall follow all traffic regulations and road signs. Vehicle driver shall have valid Refinery license issued by Fire & Safety Department.

1.3.10. Agency shall ensure to have a valid Refinery Driving License approved by F&S Dept. for all their Vehicle Drivers. To obtain new F&S approved driving license for their drivers, agency shall deposit a non-refundable amount of Rs.500/- in favour of F&S Dept., Visakh Refinery, HPCL and to do test drive in presence of F&S officer. Agency shall submit copies of Driving license issued RTA Dept. and Eye vision test certificate (duly endorsed by Refinery-Dispensary) to F&S for obtaining Refinery Driving License. Agency's vehicle drive shall always carry this valid License while driving the vehicle within Refinery premises.

1.3.11. Agency shall produce valid Vehicle Healthiness Certificate from RTA/authorised institution on the demand of HPCL for their vehicle engaged vide this order.

1.3.12. Agency shall ensure 100% compliance with Provisions of Atomic Energy (Radiation Protection) Rules-2004 for Radiography Agencies (Refer Annexure-XII for rules).

1.3.13. Agency shall ensure to have ready availability of fire extinguishers like DCP cylinders and fire retardant cloth of minimum 4 Sq.Mtr. for carrying out hot work jobs especially welding & gas cutting jobs. Stand by Fire hoses and nozzles for any hot work to be arranged by the agency. Specifications of Fire Retardant cloth & suggested vendors are mentioned in Annexure-XIII.

1.3.14. The agency shall arrange for lighting at work spots on its own and must ensure that adequate lighting is made available for carrying out the jobs on round the clock basis.

1.3.15. Agency shall use only those lifting tools and tackles (in their scope of supply) which are certified for intended usage by relevant statutory authority at any particular point of time Agency shall furnish test reports to that regard.

1.3.16. Agency shall strictly comply with electrical compliance requirement for its equipment and human safety. Agency shall ensure 100% compliance with following guidelines for usage of any electrical equipment¿s in allocated agency shed in the Refinery.

- Electrical Panel dummy holes shall always be plugged. - Sand buckets shall be provided near power panel. - Ensure proper glanding for incoming and outgoing cables. - Separate earthing to be done for each equipment. - Adequate lighting shall be provided in shed especially near electrical equipment¿s like

power panels. - Ensure the ELCBs used always in good condition. - Proper approach shall always be provided to reach panel and to operate the panel without

any obstructions.




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1.3.17. Agency's shall ensure stenciling of their company name & other details on each and every equipment owned by them. All equipment brought by the agency shall be subjected to pre-use checks with respect to safety, condition and usability. The agency shall be required to submit a statement regarding the same prior to use.

1.3.18. Use of Wood within the Refinery is prohibited. Agency shall use steel in place of wood wherever required for the jobs like shuttering, crane movement, etc. In case any job requires usage of only wood, approval of F&S to be taken for the same prior to use.

1.3.19. Agency shall 100% comply with following guidelines/requirements for grit blasting jobs in Blasting Yard. Agency shall not be permitted to work in blasting yard unless the below mentioned items are complied.

- Valid Permit to be displayed as long as work is in progress in yard. - Relevant test certificates with due date are to be available for Hopper, Fire Extinguisher,

etc. - Fire hose in charged condition laid on road shall be covered with metal ramp for vehicle

movement on the road. - Area to be barricaded to prevent dust. For this, canopy / shelter to be used. - Compressor being used shall have spark arrester. Agency shall ensure no oil/diesel leaks

from the compressor unit. - Slag blaster shall use hood - Helpers shall use all applicable PPE: Dust Masks, Goggles, Boiler suits, etc. - Fine dust shall be sieved from the slag 1.3.20. Agency shall ensure to deploy adequate no. of qualified & well experienced Job supervisors

& Safety supervisors to carryout out various jobs simultaneously at various locations in various units or in same unit. Agency's Job Supervisor(s) shall report daily Manager(s)-Onsite to schedule day to day jobs. HPCL will reserve the right to deduct applicable amount (at the rate of Rs.1000/- per 12 hr shift per supervisor) from agency's RA Bill(s) for no. of days Job Supervisor & Safety Supervisor are not deployed.

1.3.21. Agency shall ensure to pay Penalty levied towards taking safety deviation(s) within stipulated time. Incase penalty is not paid in time, double the penalty amount will be deducted from RA Bills without any further intimation to the agency. Agency shall ensure to avoid safety deviation which will be viewed very seriously by HPCL.

1.3.22. Agency shall possess & maintain minimum 2 nos. Trunk Radios/Walkie Talkies for communication purpose. Agency's site in-charge/Supervisor shall carry this Walkie Talky for communicating with HPCL in the Refinery. Also, agency shall maintain a valid email id for regular correspondence throughout the contract period.




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1.3.23. Proper confinement using Tin/GI & Gasket sheets covered with Fire Retardant cloths shall be made for hot work jobs like Welding, Gas cutting, Grinding, Chipping, etc. to eliminate fall of sparks on live lines/equipment/oily floors.

1.3.24. While working at heights, agency shall carry out their tools & tackles in the protective bags to avoid falling. Also, tools like spanners, screw drivers, etc. shall be tied to work cloth of workmen while working at heights.

1.3.25. Agency's workmen shall undergo 'VERTIGO" test and necessary certificate approved by Registered Doctor shall be submitted to the Refinery F&S prior working at heights. Only the workmen who passed VERTIGO test and obtained F&S approval are allowed to work at heights.

1.3.26. Agency shall ensure to report the any incident first to F&S Dept. and causalities if any are to be taken first to Refinery Dispensary. Also, agency shall report any safety deviation first to Job Engineer.

1.3.27. All workmen of agency shall wear 'Boiler Suit/Cover All' dress as long as they are working inside the Refinery.

1.3.28. All workmen of agency shall possess a valid "Safety Training Card" issued by F & S dept. after attending safety training conducted by F & S. Gate passes will be issued only to workers/personnel having this valid training card.

1.3.29. All safety belts/welding machines to be used by the agency should be submitted to F & S for approval and tagging. Safety belts and welding machines that are tagged by F & S will be allowed to be used in refinery.

1.3.30. CCOE approved spark arresters shall be fixed to the exhaust of equipment like Cranes, Hydras, Tractors, and Diesel Generators and other equipment (which are having Diesel Engines).

1.3.31. All contractor equipment, tools and tackles shall be offered to F & S for periodical inspection. Any defective Equipment, tools and tackles shall not be used and shall be removed from the Refinery. Details of Contractor Equipment Safety assurance plan is mentioned in Annexure-VII attached with this tender.

2.0. HPCL's SCOPE OF SUPPLY: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 2.1. HPCL shall supply the following free of cost: 2.1.1. CS & SS Plates 2.1.2. Piping and pipe fittings, boiler tubes, tube fittings, valves, plugs, ferrules along with

Gaskets and gasket sheets, gland packing material 2.1.3. CS, SS anchor rods, hexmesh, SS plate for strip fabrication, refractory and insulation

material.




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2.1.4. All hardware including bolts, nuts and washers. 2.1.5. Crane and forklift 2.1.6. Electrical power from the nearest available power source points. Agency to make necessary

arrangements for onward distribution to the work spot strictly as per our Electrical Department Rules and Regulations.

3.0. CONTRACTOR's SCOPE OF SUPPLY/WORK: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 3.1. Skilled manpower with round the clock supervision for carrying out jobs safely and as per

procedure/instructions of the job engineer. 3.2. All tools and tackles and all consumables required to complete the job. 3.3. Fire water fittings / hoses, water hoses, DCP, CO2 Cylinders as approved by HPCL fire and

safety 3.4. All personal protective equipment including safety helmets, safety belts (double harness

type), safety shoes, goggles, ear plugs, face masks and hand gloves etc. 3.5. Scaffolding material including 1.5" dia pipes and clamps, gratings etc. 3.6. All required Tools & tackles, Rigging equipment, Chain pulley blocks, Wire ropes, D

Shackles etc. Agency to note that all the lifting equipment shall have necessary statutory certification and the same are to be submitted to Maintenance department, prior to job commencement.

3.7. Graphite and holdtite 3.8. All required machinery including welding machines, grinding machines (both flexible and

angle), buffing machine, tube bending machine etc. 3.9. Gas cutting equipment sets with cylinders as required. 3.10. Air, water and steam hoses. 3.11. Grit blasting and copper slag blasting units (inclusive of grit material, copper slag, air

compressor, hoses, nozzles) with fuel and skilled operators and supervision. 3.12. Tube rolling equipment, hydrotest pumps, wire brushes etc. 3.13. CS & SS welding electrodes (list of electrodes to be used is attached with this PO), DP

testing kit, WFMPT Kit 3.14. All required resources for SR & radiography 3.15. Hand lamps with 24 V transformers, metallic switchboards with ELCB, welding / electrical

cables etc. 3.1.16. All electrical equipment like electric panels used for power connection shall be provided with

ELCB, Source sign writing, danger sign boards, plugs for dummy holes and to be properly earthed.

3.1.17. Bundle supports, sleepers, Nylon slings and vaccum testing equipment




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3.1.18. All refractory chipping and application tools, equipment and appliances including Paddle mixers, Gunniting equipment, Industrial vaccum cleaner etc.

3.1.19. Diesel driven compressor with accessories, operator and diesel. Using of open type diesel tanks for running any compressor/pump is prohibited inside the refinery. Agency shall use compressors/pumps with closed type diesel tanks only.

3.1.20. Tractor Trailor, Jeep and trolleys and Hydra. Drivers/Operators of any vehicle should have valid license from Refinery Fire & Safety Department and non-compliance to this may force HPCL to take any action against agency at their risk and cost.

3.1.21. All other resources required to complete the job in its entirety. 4.0. VALIDITY OF THE ORDER: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 4.1. ONE YEAR from the date of LOA/ PO, whichever is earlier. 5.0. JOB TO COMMENCE: ~~~~~~~~~~~~~~~~~~~~~~~~~~ 5.1. As advised by HPCL. 6.0. MOBILISATION TIME: ~~~~~~~~~~~~~~~~~~~~~~~~~~ 6.1. Within 10 days from the date of LOA/ PO, whichever is earlier, for the initial mobilization.

Subsequent mobilizations shall be done as per the advice of HPCL. 7.0. JOB TO COMPLETE: ~~~~~~~~~~~~~~~~~~~~~~~~~ 7.1. As advised by HPCL. 8.0. PRICE REDUCTION CLAUSE: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 8.1. Not Applicable. 9.0. PAYMENT SCHEDULE / TERMS: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 9.1. Monthly RA Bills, payable through e-Payment.




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9.2. For the jobs completed, as per the duration for submission of bills agreed to (upto 25th of every month), running bills numbered, dated and indicating clearly the period of measurement covered, should be submitted in the Box provided in the Disbursement Section for every month during first week of month.

9.3. Incase no jobs are executed in any month; agency shall submit NIL statement for that month

to the Manager-Onsite Planning. Agency's RA Bills shall be in computerized format to aid faster checking and processing of the bills.

10.0. SECURITY DEPOSIT: ~~~~~~~~~~~~~~~~~~~~~~~~ 10.1. The tenderer, with whom the contract is decided to be entered into and intimation is so given will have to make a security deposit of one percent (1%) of the total contract value in the form of account payee crossed demand draft drawn in favour of the Owner, within 15 days from the date of intimation of acceptance of their tender, failing which the Owner reserves the right to cancel the Contract and forfeit the EMD. 10.2. 1% of PO/Contract value as Security deposit will be acceptable in the form of Demand draft up to Rs. 50,000/- and in the form of Demand draft / Bank guarantee beyond Rs. 50,000/-. 10.3. Composite PBG for 10% of PO value towards Security Deposit and Performance bank guarantee shall be accepted (in lieu of retention money); which shall be valid up to a period of 3 months beyond the expiry of Defect liability period. Demand Draft should be drawn on Scheduled Banks, other than co-operative bank. 11.0. GUARANTEE: ~~~~~~~~~~~~~~~~~ 11.1. Agency shall guarantee the work executed/material supplied for a period of 12 months from

the date of completion of the job. Any damage or defect that may arise or lie undiscovered at the time of completion of the job shall be rectified or replaced by the agency at their own cost. The decision of the Engineer In charge/Owner shall be the final and binding on the agency undertaking this job, as to whether the defect has to be rectified or replaced.

11.0. RETENTION: ~~~~~~~~~~~~~~~~~~~ 11.1. 10% of the total value of the Invoice will be deducted and retained by the Owner as retention

money on account of any damage/defect liability that may arise for the period covered under the defect liability period clause of the Contract free of interest. Any damage or defect that may arise or lie undiscovered at the time of issue of completion certificate connected in any way with the equipment or materials supplied by contractor or in workmanship shall be rectified or replaced by the contractor at his own expense failing which the Owner shall be




Page 23


entitled to rectify the said damage/defect from the retention money. Any excess of expenditure incurred by the Owner on account of damage or defect shall be payable by the Contractor. The decision of the Owner in this behalf shall not be liable to be questioned but shall be final and binding on the Contractor.

12.0. WORKS CONTRACT TAX: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 12.1. If the Works Contract Tax (WCT) is included in the price, please specify the percentage of

WCT included in the rate quoted in the Un-Priced bid. In such cases, HPCL requires a valid Tax Invoice displaying WCT quantum and AP VAT Registration No.

13.0. CONTACT PERSONS: ============================

13.1. FOR TECHNICAL QUERIES: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

Mr. V Rameshbabu, Senior Manager, Maintenance - Onsite. Tel: 0891-2894278 Fax: 0891-2577499 e-mail: [email protected] 13.2. FOR COMMERCIAL QUERIES: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

Mr.A.K. Ganguly ;Sr.Manager - Materials / Mr.V. Naveen Kumar ; Officer - Purchase Materials Department Tel: 0-891 / 2894309 & 2894312 Fax: 0-891 / 2577139 E-Mail: [email protected] & [email protected] 14.0. NOTES TO TENDERES: ~~~~~~~~~~~~~~~~~~~~~~~~~~~ 14.1. HPCL-VR’s "General Terms and Conditions of Works Contracts" and "Safety Regulations

for Contractors" forms an integral part of this tender. 14.2. Tenderer's offer should be valid for a period of 120 DAYS from the date of opening of the

Unpriced Bids. 14.3. Tenderer's offer is liable for rejection if it does not comply with the RFQ format or if it is

incomplete.




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14.4. Women workforce are not allowed inside the Refinery. 14.5. Manual Transport of load is limited to a maximum weight of 50 Kgs. 14.6. Use of hand drawn trolleys by agencies to shift the materials is not permitted in the Refinery. 14.7. All workmen engaged by the Tenderer for working at height shall have Medical certificate of

fitness for working at heights. 14.8. HPCL reserves the right to suspend the execution of the Purchase Order, in the event of

strike, accidents or any other contingencies, which are beyond HPCL's control. 14.9. Purchase / Price Preference: Purchase / Price preference, as applicable, shall be given to

Central Government Public Sector Enterprises and NSIC registered Units (only those who forward valid NSIC certificate, which clearly indicates the items for which they are registered), as per the existing and prevailing government guidelines, rules and regulations.

14.9.1. The prevailing Government of India guidelines for units registered under NSIC regarding exemption of Tender Fees, EMD & Security Deposit and Price Preference will be applicable. However relevant supporting documents must be furnished for claiming the same.

14.9.2. The prevailing Government of India guidelines for Central Public Sector Undertakings regarding exemption of EMD & Purchase preferences shall be applicable.

14.10. HPCL takes no responsibility for delay of non-receipt of EMD/ Exemption Details sent by

post or by any other means. EMD/ Exemption Details received after the due date and time will be rejected. Telex / Fax / E-mail offers are not acceptable.

14.11. The Tenderer should furnish on their letter-head a Declaration that they have not been

banned or de-listed by any government or Quasi-Government agencies or PSUs. If this Declaration is not furnished / submitted, the Tenderer’s Bid will be considered as non-responsive, and the Bids of such Tenderers shall be rejected. This declaration should be uploaded along with the other Unpriced Bid documents. Format of declaration is provided in page no.31 of 37.

14.12. The EMD shall be refunded to the unsuccessful bidders. The EMD of the successful bidder

would be released on submission of Security Deposit. The Security Deposit shall be returned after satisfactory completion of entire contract.

14.13. The offers of the agencies not meeting the prequalification criteria shall be rejected.




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14.14. GRIEVANCE REDRESSAL: There is a Grievance Redressal Mechanism in the Corporation for Tenderers participating in the tender, the details of which are available on the Corporation's website.

14.15. Bills will be paid by e-payment. 14.15.1. For the purpose of e-payment [EFT], the Tenderer(s) shall ensure that all the requisite

details prescribed by the Finance Department of HPCL-VR have been submitted/ updated. The correspondence regarding the registration for e-payment, should be addressed to

Mr.LeeladharVemula; Officer- Finance (E-Mail:[email protected]), with a copy to Mr.S. Ramesh, Manager - Finance, (E-Mail: [email protected]) and

Mr.M Akbar; Sr. Manager - Finance (E-Mail:[email protected]).

* * * * *


GENERATORS & OTHER IBR JOBS Annexure I : Annexure I : Annexure I : Annexure I : FORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMD


(On Non-Judicial stamp paper of appropriate value) TO : HINDUSTAN PETROLEUM CORPORATION LIMITED

VISAKH REFINERY Malkapuram Visakhapatnam - 530011

IN CONSIDERATION OF MESSRS. HINDUSTAN PETROLEUM CORPORATION LIMITED a Government of India Company registered under the Companies Act, 1956, having its registered office at 17, Jamshedji Tata Road, Bombay-20 (hereinafter called "The Corporation" which expression shall include its successor in business and assigns) issued a tender on Messrs. ............................................ a partnership firm/sole proprietor business/a company registered under the Companies Act, 1956 having its office at (hereinafter called "the Tenderer" which expression shall include its executors, administrators and assigns) against Tender No......................... dated ........... (hereinafter called "the tender" which expression shall include any amendments/ alterations to "the tender" issued by "the Corporation") for the supply of goods to/execution of services for "the Corporation" and "the Corporation" having agreed not to insist upon immediate payment of Earnest Money for the fulfillment of the said tender in terms thereof on production of an acceptable Bank Guarantee for an amount of R....... (Rupees ................................. only). 1. We, ................................................ Bank having office at ..................................(hereinafter referred to as "the Bank" which expression shall include its successors and assigns) at the request and on behalf of "the Tenderer" hereby agree to pay to the Corporation without any demur on first demand an amount not exceeding R...........(Rupees ...................................... only) against any loss or damage, costs, charges and expenses caused to or suffered by "the Corporation" by reason of non-performance and fulfillment or for any breach on the part of "the Tenderer" of any of theterms and conditions of the said "tender". 2. We, ......................... Bank further agree that "the Corporation" shall be sole Judge whether the said "Tenderer" has failed to perform or fulfill the said "tender" in terms thereof or committed breach of any of the terms and conditions of "the order" and the extent of loss,damage, cost, charges and expenses suffered or incurred or would be suffered or incurred by "the Corporation" on account thereof and we waive in favour of "the Corporation" all the rights and defences to which we as guarantors and/or "the Tenderer" may be entitled to. 3. We, ......................... Bank further agree that the amount demanded by "the Corporation" as such shall and binding on "the Bank" as to "the Bank" 's liability to pay and the amount demanded and "the Bank" to undertake to pay "the Corporation" the amount so demanded on first demandand without any demur notwithstanding any dispute raised by "the Tenderer" or any suit or other legal proceedings including arbitration pending before any court, tribunal orarbitrator relating thereto, our liability under this guarantee being absolute and unconditional.

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GENERATORS & OTHER IBR JOBS Annexure I : Annexure I : Annexure I : Annexure I : FORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMD


4. We, ......................... Bank furtheragree with "the Corporation" that "the Corporation" shall have the fullest liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the terms and conditions of the said "tender"/or to extend time of performance by "the Tenderer" from time totime or to postpone for any time to time any of the powersexercisable by "the Corporation" against "the Tenderer" andto forbear to enforce any of the terms and conditions relating to "the tender" and we shall not be relieved from our liability by reason of any such variation or extension being granted to "the Tenderer" or for any forbearance, actor ommission on the part of "the Corporation" or any indulgence by "the Corporation" to "the tenderer" or by any such matter or things whatsoever which under the law relatingto sureties would but for this provision have the effect of relieving us. 5. NOTWITHSTANDING anything hereinbefore contained, our liability under this Guarantee is restricted to R .........(Rupees......................... only). Ourliability under this guarantee shall remain in force until expiration of six months from the due date of opening of thesaid "tender". Unless a demand or claim under this guarantee is made on us in writing within said period, that is, on orbefore .................................... all rights of"the Corporation" under the said guarantee shall be forfeitedand we shall be relieved and discharged from all liabilities thereunder. 6. We, ......................... Bank further undertake not to revoke this guarantee during its currency except with the previous consent of "the Corporation" in Writing. 7. We, ......................... Bank lastlyagree that "the Bank"'s liability under this guarantee shall not be affected by any change in the constitution of "the Tenderer". 8. "The Bank" has power to issue this guarantee in favour of "the Corporation" in terms of the documents and/or the Agreement/Contract or MOU entered into between "the Tenderer" and "the Bank" in this regard. IN WITNESS WHEREOF the Bank has executed this document on this ............ day of .................

For ........................ Bank

(by its constituted attorney)

(Signature of a person authorised to sign on behalf of "the Bank")

* * * * * * * * *

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GENERATORS & OTHER IBR JOBS Annexure II : DECLARATIONAnnexure II : DECLARATIONAnnexure II : DECLARATIONAnnexure II : DECLARATION

Seal of the Vendor Signature & Name of the Authorised

Signatory with Date


We, ____________________________________________ (Name of the company) hereby

declare that we have not been banned or delisted by any Indian Government or Quasi – India

Government agencies or Indian Public Sector Undertakings / Enterprises.

Sign

Name & Company Stamp

Note 1: If the Tenderer has been banned or delisted by any Indian Government or Quasi –

Indian Government agencies or Indian Public Sector Undertakings / Enterprises, this fact must

be clearly stated.

Note 2: If this declaration is not given, the bid will be rejected as non-responsive.

* * * * * * * * *

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Annexure - III to RFQ: 12000438-HD-46002/VNK


GENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTS

Seal of the Vendor

Signature & Name of the Authorised Signatory with Date

Visakh Refinery

1. PRELIMINARY

1.1 This is a Contract for execution of __________________ work at Visakh Refinery. (Please fill up the

blanks)

1.2 The tenderer for the abovementioned item of work is____________________________. (please give the

name and address of the tenderer)

1.3 The terms and conditions mentioned hereunder are the terms and conditions of the Contract for the

execution of the work mentioned under item 1.1 above.

1.4 It is the clear understanding between Hindustan Petroleum Corporation Limited and the tenderer

______________________________________ that (name and address of the tenderer) in case the tender of

____________________________________________________ ______________________ is (name and address

of the tenderer) accepted by Hindustan Petroleum Corporation Limited and an intimation to that effect is so issued

and also a Purchase Order is placed with _____________________________________________

________________________ (name and address of the tenderer) this document will be termed as a Contract

between the parties and terms and conditions hereunder would govern the parties interest.

1.5 Interpretation of Contract Documents: All documents forming part of the Contract are to be taken

mutually explanatory. Should there be any discrepancy, inconsistency, error or omission in the contract, the

decision of the Owner/Engineer-in-Charge/Site-in-Charge shall be the final and the contractor shall abide by the

decision. The decision shall not be arbitrable. Works shown upon the drawings but not mentioned in the

specification or described in the specifications without being shown on the drawings shall nevertheless be deemed

to be included in the same manner as if they are shown in the drawings and described in the specifications.

1.6 Special conditions of Contract: The special conditions of contract, if any provided and whenever and

wherever referred to shall be read in conjunction with General Terms and Conditions of contract, specifications,

drawings, and any other documents forming part of this contract wherever the context so requires.

Notwithstanding the subdivision of the documents into separate sections, parts, volumes, every section, part or

volume shall be deemed to be supplementary or complementary to each other and shall be read in whole. In case

of any misunderstanding arising the same shall be referred to decision of the Owner/ Engineer-in-Charge/Site-in-

Charge and their decision shall be final and binding and the decision shall not be arbitrable. It is the clear

understanding that wherever it is mentioned that the Contractor shall do/perform a work and/or provide facilities

for the performance of the work, the doing or the performance or the providing of the facilities is at the cost and

expenses of the work not liable to be paid or reimbursed by the Owner.

2. DEFINITIONS

In this contract unless otherwise specifically provided or defined and unless a contrary intention appears from the

contract the following words and expressions are used in the following meanings;

2.1 The term "Agreement" wherever appearing in this document shall be read as "Contract".

2.2 The "Authority" for the purpose of this Contract shall be the Chairman and Managing Director or any

other person so appointed or authorised.

2.3 The "Chairman and Managing Director" shall mean the Chairman and Managing Director of HINDUSTAN

PETROLEUM CORPORATION LIMITED or any person so appointed, nominated or designated and holding the office

of Chairman & Managing Director.

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2.4 The "Change Order" means an order given in writing by the Engineer-in-Charge or by Owner to effect

additions to or deletion from or alterations into the Work.

2.5 The "Construction Equipment" means all appliances and equipment of whatsoever nature for the use in

or for the execution, completion, operation or maintenance of the work except those intended to form part of the

Permanent Work.

2.6 The "Contract" between the Owner and the Contractor shall mean and include all documents like enquiry,

tender submitted by the contractor and the purchase order issued by the owner and other documents connected

with the issue of the purchase order and orders, instruction, drawings, change orders, directions issued by the

Owner/Engineer-in-Charge/Site-in-Charge for the execution, completion and commissioning of the works and the

period of contract mentioned in the Contract including such periods of time extensions as may be granted by the

owner at the request of the contractor and such period of time for which the work is continued by the contractor

for purposes of completion of the work.

2.7 "The Contractor" means the person or the persons, firm or Company whose tender has been accepted by

the Owner and includes the Contractor's legal heirs, representative, successor(s) and permitted assignees.

2.8 The "Drawings" shall include maps, plans and tracings or prints thereof with any modifications approved

in writing by the Engineer-in-Charge and such other drawings as may, from time to time, be furnished or approved

in writing by the Engineer-in-Charge.

2.9 The "Engineer-in-Charge or Site-in-Charge" shall mean the person appointed or designated as such by the

Owner and shall include those who are expressly authorized by the owner to act for and on its behalf.

2.10 "The Owner" means the HINDUSTAN PETROLEUM CORPORATION LIMITED incorporated in India having

its Registered office at PETROLEUM HOUSE, 17, JAMSHEDJI TATA ROAD, BOMBAY – 400020 and Marketing office

at ____________________________________________ or their successors or assignees.

2.11 The "Permanent Work" means and includes works which form a part of the work to be handed over to

the Owner by the Contractor on completion of the contract.

2.12 The "Project Manager" shall mean the Project Manager of HINDUSTAN PETROLEUM CORPORATION

LIMITED, or any person so appointed, nominated or designated.

2.13 The "Site" means the land on which the work is to be executed or carried out and such other place(s) for

purpose of performing the Contract.

2.14 The "Specifications" shall mean the various technical and other specifications attached and referred to in

the tender documents. It shall also include the latest editions, including all addenda/corrigenda or relevant Indian

Standard Specifications and Bureau Of Indian Standards.

2.15 The "Sub-Contractor" means any person or firm or Company (other than the Contractor) to whom any

part of the work has been entrusted by the Contractor with the prior written consent of the Owner/Engineer-in-

Charge/Site-in-Charge and their legal heirs, representatives, successors and permitted assignees of such person,

firm or Company.

2.16 The "Temporary Work" means and includes all such works which are a part of the contract for execution

of the permanent work but does not form part of the permanent work confirming to practices, procedures

applicable rules and regulations relevant in that behalf.

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2.17 The "Tender" means the document submitted by a person or authority for carrying out the work and the

Tenderer means a person or authority who submits the tender offering to carry out the work as per the terms and

conditions.

2.18 The "Work" shall mean the works to be executed in accordance with the Contract or part thereof as the

case may be and shall include extra, additional, altered or substituted works as maybe required for the purposes of

completion of the work contemplated under the Contract.

3. SUBMISSION OF TENDER

3.1 Before submitting the Tender, the Tenderer shall at their own cost and expenses visit the site, examine

and satisfy as to the nature of the existing roads, means of communications, the character of the soil, state of land

and of the excavations, the correct dimensions of the work facilities for procuring various construction and other

material and their availability, and shall obtain information on all matters and conditions as they may feel

necessary for the execution of the works as intended by the Owners and shall also satisfy of the availability of

suitable water for construction of civil works and for drinking purpose and power required for fabrication work etc.

Tenderer, whose tender may be accepted and with whom the Contract is entered into shall not be eligible and be

able to make any claim on any of the said counts in what so ever manner for what so ever reasons at any point of

time and such a claim shall not be raised as a dispute and shall not be arbitrable.

A pre-bid meeting may be held as per the schedule mentioned in the tender.

3.2 The Tenderer shall be deemed to have satisfied fully before tendering as to the correctness and

sufficiency of his tender for the works and of the rates and prices quoted in the schedule of quantities which rates

and prices shall except as otherwise provided cover all his obligations under the contract.

3.3 It must be clearly understood that the whole of the conditions and specifications are intended to be

strictly enforced and that no work will be considered as extra work and allowed and paid for unless they are clearly

outside the scope, spirit, meaning of the Contract and intent of the Owner and have been so ordered in writing by

Owner and/or Engineer-in-Charge/Site-in-Charge, whose decision shall be final and binding.

3.4 Before filling the Tender the Contractor will check and satisfy all drawings and materials to be procured

and the schedule of quantities by obtaining clarification from the Owner on all the items as may be desired by the

Tenderer. No claim for any alleged loss or compensation will be entertained on this account, after submission of

Tender by the Tenderer/Contractor and such a claim shall not be arbitrable.

3.5 Unless specifically provided for in the tender documents or any Special Conditions, no escalation in the

Tender rates or prices quoted will be permitted throughout the period of contract or the period of actual

completion of the job whichever is later on account of any variation in prices of materials or cost of labour or

due to any other reasons. Claims on account of escalation shall not be arbitrable.

3.6 The quantities indicated in the Tender are approximate. The approved schedule of rates of the contract

will be applicable for variations upto plus or minus 25% of the contract value. No revision of schedule of rates will

be permitted for such variations in the contract value, including variations of individual quantities, addition of new

items, alterations, additions/deletions or substitutions of items, as mentioned above. Quantities etc. mentioned

and accepted in the joint measurement sheets shall alone be final and binding on the parties.

3.7 Owner reserve their right to award the contract to any tenderer and their decision in this regard shall be

final. They also reserve their right to reject any or all tenders received. No disputes could be raised by any

tenderer(s) whose tender has been rejected.

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3.8 The Rates quoted by the Tenderer shall include Costs and expenses on all counts viz. cost of materials,

transportation of machine(s), tools, equipments, labour, power, Administration charges, price escalations, profits,

etc. etc. except to the extent of the cost of material(s), if any, agreed to be supplied by Owner and mentioned

specifically in that regard in condition of Contract, in which case, the cost of such material if taken for preparation

of the Contractor's Bill(s) shall be deducted before making payment of the Bill(s) of the Contractor. The description

given in the schedule of quantities shall unless otherwise stated be held to include wastage on materials, carriage

and cartage, carrying in and return of empties, hoisting, setting, fitting and fixing in position and all other expenses

necessary in and for the full and complete execution and completion of works and in accordance with good

practice and recognised principles in that regard.

3.9 Employees of the State and Central Govt. and employees of the Public Sector Undertakings, including

retired employees are covered under their respective service conditions/rules in regard to their submitting the

tender. All such persons should ensure compliance to the respective/applicable conditions, rules etc. etc. Any

person not complying with those rules etc. but submitting the tender in violation of such rules, after being so

noticed shall be liable for the forfeiture of the Earnest Money Deposit made with the tender, termination of

Contract and sufferance on account of forfeiture of Security Deposit and sufferance of damages arising as a result

of termination of Contract.

3.10 In consideration for having a chance to be considered for entering into a contract with the Owner, the

Tenderer agrees that the Tender submitted by him shall remain valid for the period prescribed in the tender

conditions, from the date of opening of the tender. The Tenderer shall not be entitled during the said validity

period, to revoke or cancel the tender without the consent in writing from the Owner.

In case the tenderer revokes or cancels the tender or varies any of terms of the tender without the Consent of the

Owner, in writing, the Tenderer forfeits the right to the refund of the Earnest Money paid along with the tender.

3.11 The prices quoted by the Tenderer shall be firm during the validity period of the bid and Tenderer

agrees to keep the bid alive and valid during the said period. The Tenderers shall particularly take note of this

factor before submitting their tender(s).

3.12 The works shall be carried out strictly as per approved specifications. Deviations, if any, shall have to be

authorised by the Engineer-in-Charge/Site-in-Charge in writing prior to implementing deviations. The price

benefit, if any, arising out of the accepted deviation shall be passed on to the Owner. The decision of Engineer-in-

Charge shall be final in this matter.

3.13 The contractor shall make all arrangements at his own cost to transport the required materials outside

and inside the working places and leaving the premises in a neat and tidy condition after completion of the job to

the satisfaction of Owner. All materials except those agreed to be supplied by the Owner shall be supplied by the

contractor at his own cost and the rates quoted by the Contractor should be inclusive of all royalties, rents, taxes,

duties, octroi, statutory levies, if any, etc. etc.

3.14 The Contractor shall not carry on any work other than the work under this Contract within the Owner’s

premises without prior permission in writing from the Engineer-in-Charge/Site-in-charge.

3.15 The Contractor shall be bound to follow and ensure compliance to all the safety and security regulations

and other statutory rules applicable to the area. In the event of any damage or loss or sufference caused due to

non-observance of such rules and regulations, the contractor shall be solely responsible for the same and shall

keep the Owner indemnified against all such losses and claims arising from the same.

3.16 At any time after acceptance of tender, the Owner reserves the right to add, amend or delete any work

item, the bill of quantities at a later date or reduce the scope of work in the overall interest of the work by prior

discussion and intimation to the Contractor. The decision of Owner, with reasons recorded therefor, shall be final

and binding on both the Owner and the Contractor. The Contractor shall not have right to claim compensation or

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Visakh Refinery

damage etc. in that regard. The Owner reserves the right to split the work under this contract between two or

more contractors without assigning any reasons.

3.17 Contractor shall not be entitled to sublet, sub contract or assign, the work under this Contract without the

prior consent of the Owner obtained in writing.

3.18 All signatures in tender document shall be dated as well as all the pages of all sections of the tender

documents shall be initialled at the lower position and signed, wherever required in the tender papers by the

Tenderer or by a person holding Power of Attorney authorising him to sign on behalf of the tenderer before

submission of tender.

3.19 The tender should be quoted in English, both in figures as well as in words. The rates and amounts

tendered by the Tenderer in the Schedule of rates for each item and in such a way that insertion is not possible.

The total tendered amount should also be indicated both in figures and words with the signature of tenderer.

If some discrepancies are found between the rates given in words and figures of the amount shown in the tender,

the following procedure shall be applied:

(a) When there is a difference between the rates in figures and words, the rate which corresponds to the

amount worked out by the tenderer shall be taken as correct.

(b) When the rate quoted by the tenderer in figures and words tallies but the amount is incorrect, the rate

quoted by the tenderer shall be taken as correct.

(c) When it is not possible to ascertain the correct rate in the manner prescribed above the rate as quoted in

words shall be adopted.

3.20 All corrections and alterations in the entries of tender paper will be signed in full by the tenderer with

date. No erasures or over writings are permissible.

3.21 Transfer of tender document by one intending tenderer to the another one is not permissible. The

tenderer on whose name the tender has been sent only can quote.

3.22 The Tender submitted by a tenderer if found to be incomplete in any or all manner is liable to be rejected.

The decision of the Owner in this regard is final and binding. In case of any error/discrepancy in the amount

written in words and figures, the lower amount between the two shall prevail.

4. DEPOSITS

a) EARNEST MONEY DEPOSIT (EMD)

The tenderer will be required to pay a sum as specified in the covering letter, as earnest money deposit along with

the tender either thru a crossed demand draft or a non-revokable Bank Guarantee in favour of Hindustan

Petroleum Corporation Limited, from any Scheduled Bank (other than a Co-Operative Bank) payable at Mumbai in

favour of Hindustan Petroleum Corporation Limited, Mumbai in the proforma enclosed. The earnest money

deposit will be refunded after finalisation of the contract.

Note: Public sector enterprises and small scale units registered with National Small Scale Industries are exempted

from payment of Earnest Money Deposit. Small scale units registered with National Small Scale Industries should

enclose a photocopy of their registration certificate with their quotation to make their quotation eligible for

consideration. The Registration Certificate should remain valid during the period of the contract that may be

entered into with such successful bidder. Such tenderers should ensure validity of the Registration Certificate for

the purpose.

b) SECURITY DEPOSIT:

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The tenderer, with whom the contract is decided to be entered into and intimation is so given will have to make a

security deposit of one percent (1%) of the total contract value in the form of account payee crossed demand draft

drawn in favour of the Owner, within 15 days from the date of intimation of acceptance of their tender, failing

which the Owner reserves the right to cancel the Contract and forfeit the EMD.

1% of PO/Contract value as Security deposit will be acceptable in the form of Demand draft up to Rs.50,000/- and

in the form of Demand draft / Bank guarantee beyond Rs.50,000/-.

Composite Performance Bank Guarantee (CPBG) for 10% of PO value towards Performance Bank Guarantee

inclusive of Security Deposit shall be accepted (in lieu of deduction of retention money); such CPBG shall be valid

up to a period of 3 months beyond the expiry of defect liability period.

Demand Draft should be drawn on Scheduled Banks, other than co-operative bank.

5. EXECUTION OF WORK

All the works shall be executed in strict conformity with the provisions of the contract documents and with such

explanatory details, drawings, specifications and instructions as may be furnished from time to time to the

Contractor by the Engineer-in-Charge/ Site-in-Charge, whether mentioned in the Contract or not. The Contractor

shall be responsible for ensuring that works throughout are executed in the most proper and workman-like

manner with the quality of material and workmanship in strict accordance with the specifications and to the entire

satisfaction of the Engineer-in- Charge/Site-in-Charge.

The completion of work may entail working in monsoon also. The contractor must maintain the necessary work

force as may be required during monsoon and plan to execute the job in such a way the entire project is

completed within the contracted time schedule. No extra charges shall be payable for such work during monsoon.

It shall be the responsibility of the contractor to keep the construction work site free from water during and off the

monsoon period at his own cost and expenses.

For working on Sundays/Holidays, the contractor shall obtain the necessary permission from Engineer

Incharge/Site Incharge in advance. The contractor shall be permitted to work beyond the normal hours with prior

approval of Engineer-In-Charge/Site-In-Charge and the contractors quoted rate is inclusive of all such extended

hours of working and no extra amount shall be payable by the owner on this account.

5.a. SETTING OUT OF WORKS AND SITE INSTRUCTIONS

5.a.1. The Engineer-in-Charge/Site-in-Charge shall furnish the Contractor with only the four corners of the work

site and a level bench mark and the Contractor shall set out the works and shall provide an efficient staff for the

purpose and shall be solely responsible for the accuracy of such setting out.

5.a.2. The Contractor shall provide, fix and be responsible for the maintenance of all necessary stakes,

templates, level marks, profiles and other similar things and shall take all necessary precautions to prevent their

removal or disturbance and shall be responsible for consequences of such removal or disturbance should the same

take place and for their efficient and timely reinstatement. The Contractor shall also be responsible for the

maintenance of all existing survey marks, either existing or supplied and fixed by the Contractor. The work shall be

set out to the satisfaction of the Engineer-in-Charge/Site-in-Charge. The approval thereof or joining in setting out

the work shall not relieve the Contractor of his responsibility.

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5.a.3. Before beginning the works, the Contractor shall, at his own cost, provide all necessary reference and

level posts, pegs, bamboos, flags ranging rods, strings and other materials for proper layout of the work in

accordance with the scheme, for bearing marks acceptable to the Engineer-in-Charge/Site-in-Charge. The Centre

longitudinal or face lines and cross lines shall be marked by means of small masonary pillars. Each pillar shall have

distinct marks at the centre to enable theodolite to be set over it. No work shall be started until all these points are

checked and approved by the Engineer-in-Charge/Site-in-Charge in writing. But such approval shall not relieve the

contractor of any of his responsibilities. The Contractor shall also provide all labour, materials and other facilities,

as necessary, for the proper checking of layout and inspection of the points during construction.

5.a.4. Pillars bearing geodetic marks located at the sites of units of works under construction should be

protected and fenced by the Contractor.

5.a.5. On completion of works, the contractor shall submit the geodetic documents according to which the work

was carried out.

5.a.6. The Engineer-in-Charge/Site-in-Charge shall communicate or confirm his instructions to the contractor in

respect of the executions of work in a "work site order book" maintained in the office having duplicate sheet and

the authorised representative of the contractor shall confirm receipt of such instructions by signing the relevant

entries in the book.

5.a.7. All instructions issued by the Engineer-in-Charge/Site-in-Charge shall be in writing. The Contractor shall

be liable to carry out the instructions without fail.

5.a.8. If the Contractor after receipt of written instruction from the Engineer-in-Charge/ Site-in-Charge requiring

compliance within seven days fails to comply with such drawings or 'instructions' or both as the Engineer-in-

Charge/Site-in-Charge may issue, owner may employ and pay other persons to execute any such work whatsoever

that may be necessary to give effect to such drawings or `instructions' and all cost and expenses incurred in

connection therewith as certified by the Engineer-in-Charge/ Site-in-Charge shall be borne by the contractor or

may be deducted from amounts due or that may become due to the contractor under the contract or may be

recovered as a debt.

5.a.9. The Contractor shall be entirely and exclusively responsible for the horizontal and vertical alignment, the

levels and correctness of every part of the work and shall rectify effectually any errors or imperfections therein.

Such rectifications shall be carried out by the Contractor, at his own cost.

5.a.10. In case any doubts arise in the mind of the Contractor in regard to any expressions, interpretations,

statements, calculations of quantities, supply of material rates, etc. etc., the contractor shall refer the same to the

Site-in-Charge/ Engineer-in-Charge for his clarification, instructions, guidance or clearing of doubts. The decision

of the Engineer-in-Charge/Site-in-Charge shall be final and the contractor shall be bound by such a decision.

5.a.11. "The Contractor shall take adequate precautions, to ensure that his operations do not create nuisance or

misuse of the work space that shall cause unnecessary disturbance or inconvenience to others at the work site".

5.a.12. "All fossils, coins articles of value of antiquity and structure or other remains of geological or

archaeological discovered on the site of works shall be declared to be the property of the Owner and Contractor

shall take reasonable precautions to prevent his workmen or any other persons from removing or damaging any

such articles or thing and shall immediately inform the Owner/ Engineer-in-Charge/Site-in-Charge."

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5.a.13. "Contractor will be entirely and exclusively responsible to provide and maintain at his expenses all lights,

guards, fencing, etc. when and where even necessary or/as required by the Engineer-in-Charge/Site-in-Charge for

the protection of works or safety and convenience to all the members employed at the site or general public."

5.b. COMMENCEMENT OF WORK

The contractor shall after paying the requisite security deposit, commence work within 15 days from the date of

receipt of the intimation of intent from the Owner informing that the contract is being awarded. The date of

intimation shall be the date/day for counting the starting day/date and the ending day/date will be accordingly

calculated. Penalty, if any, for the delay in execution shall be calculated accordingly.

Contractor should prepare detailed fortnightly construction programme for approval by the Engineer-in-Charge

within one month of receipt of Letter Of Intent. The work shall be executed strictly as per such time schedule. The

period of Contract includes the time required for testing, rectifications, if any, re-testing and completion of work in

all respects to the entire satisfaction of the Engineer-in-Charge. A Letter of Intent is an acceptance of offer by the

Owner and it need not be accepted by the contractor. But the contractor should acknowledge a receipt of the

purchase order within 15 days of mailing of Purchase Order and any delay in acknowledging the receipt will be a

breach of contract and compensation for the loss caused by such breach will be recovered by the Owner by

forfeiting earnest money deposit/bid bond.

5.c. SUBLETTING OF WORK

5.c.1. No part of the contract nor any share or interest thereof shall in any manner or degree be transferred,

assigned or sublet, by the Contractor, directly or indirectly to any firm or corporation whatsoever, without the

prior consent in writing of the Owner.

5.c.2. At the commencement of every month the Contractor shall furnish to the Engineer-in-charge/Site-in-

Charge list of all sub-contractors or other persons or firms engaged by the Contractor.

5.c.3 The contract agreement will specify major items of supply or services for which the Contractor proposes

to engage sub-Contractor/sub-Vendor. The contractor may from time to time propose any addition or deletion

from any such list and will submit the proposals in this regard to the Engineer-in-charge/Designated officer-in-

charge for approval well in advance so as not to impede the progress of work. Such approval of the Engineer-in-

charge/Designated officer-in-charge will not relieve the contractor from any of his obligations, duties and

responsibilities under the contract.

5.c.4. Notwithstanding any sub-letting with such approval as resaid and notwithstanding that the Engineer-in-

Charge shall have received copies of any sub-contract, the Contractor shall be and shall remain solely to be

responsible for the quality and proper and expeditious execution of the works and the performance of all the

conditions of the contract in all respects as if such subletting or sub-contracting had not taken place and as if such

work had been done directly by the Contractor.

5.c.5 Prior approval in writing of the Owner shall be obtained before any change is made in the constitution of

the contractor/Contracting agency otherwise contract shall be deemed to have been allotted in contravention of

clause entitled “sub-letting of works” and the same action may be taken and the same consequence shall ensue as

provided in the clause of “subletting of works”.

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5.d EXTENSION OF TIME

1) If the Contractor anticipates that he will not be able to complete the work within the contractual

delivery/ completion date (CDD), then the Contractor shall make a request for grant of time extension clearly

specifying the reasons for which he seeks extension of time and demonstrating as to how these reasons were

beyond the control of the contractor or attributable to the Owner. This request should be made well before the

expiry of the Contractual Delivery/ Completion Date (CDD). If such a request for extension is received with a

Bank Guarantee for the full

2) Liquidated Damages amount calculated on the Total Contract Value, the concerned General Manager of

the Owner shall grant a Provisional extension of time, pending a decision on the request.

3) The concerned General Manager of the Owner shall expeditiously decide upon the request for time

extension and decide the levy of liquidated damages within a maximum period of 6 months from the CDD or

date of receipt of the request, whichever is later.

4) Grant of any extension of time shall be by means of issuance of a Change Order.

5) In order to avoid any cash crunch to the Contractor, a Bank Guarantee could be accepted against LD, as

stated above. Once a decision is taken, the LD shall be recovered from any pending bills or by encashment of

the BG. Any balance sum of Contractor or the BG (if LD is fully recovered from the bills) shall be promptly

refunded/returned to the Contractor.

5.e. SUSPENSION OF WORKS

5.e.1. Subject to the provisions of this contract, the contractor shall if ordered in writing by the Engineer- in-

Charge/Site-in-Charge for reasons recorded suspend the works or any part thereof for such period and such time

so ordered and shall not, after receiving such, proceed with the work therein ordered to suspended until he shall

have received a written order to re-start. The Contractor shall be entitled to claim extension of time for that

period of time the work was ordered to be suspended. Neither the Owner nor the Contractor shall be entitled to

claim compensation or damages on account of such an extension of time.

5.e.2. In case of suspension of entire work, ordered in writing by Engineer-in-Charge/Site-in-Charge, for a period

of 30 days, the Owner shall have the option to terminate the Contract as provided under the clause for

termination. The Contractor shall not be at liberty to remove from the site of the works any plant or materials

belonging to him and the Employer shall have lien upon all such plant and materials.

5.e.3. The contract shall, in case of suspension have the right to raise a dispute and have the same arbitrated

but however, shall not have the right to have the work stopped from further progress and completion either by the

owner or through other contractor appointed by the owner.

5.f. OWNER MAY DO PART OF WORK

Not withstanding anything contained elsewhere in this contract, the owner upon failure of the Contractor to

comply with any instructions given in accordance with of entire work, place additional labour force, tools,

equipment and materials on such parts of the work, as the Owner may decide or engage another Contractor to

carryout the balance of work. In such cases, the Owner shall have the right to deduct from the amounts payable to

the Contractor the difference in cost of such work and materials with ten percent overhead added to cover all

departmental charges. Should the total amount thereof exceed the amount due to the contractor, the Contractor

shall pay the difference to the Owner within 15 days of making demand for payment failing which the Contractor

shall be liable to pay interest at 24% p.a. on such amounts till the date of payment.

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5.g. INSPECTION OF WORKS

5.g.1. The Engineer-in-Charge/Site-in-Charge and Officers from Central or State Government will have full power

and authority to inspect the works at any time wherever in progress, either on the site or at the Contractor's

premises/workshops of any person, firm or corporation where work in connection with the contract may be in

hand or where the materials are being or are to be supplied, and the Contractor shall afford or procure for the

Engineer-in-Charge/Site-in-Charge every facility and assistance to carryout such inspection. The Contractor shall,

at all times during the usual working hours and at all other times at which reasonable notice of the intention of the

Engineer-in-Charge/Site-in-Charge or his representative to visit the works shall have been given to the Contractor,

either himself be present to receive orders and instructions, or have a responsible agent, duly accredited in

writing, present for the purpose. Orders given to the Contractor's agent shall be considered to have the same

force as if they had been given to the Contractor himself. The Contractor shall give not less than seven days notice

in writing to the Engineer-in-Charge/Site-in-Charge before covering up or otherwise placing beyond reach of

inspection and measurement any work in order that the same may be inspected and measured. In the event of

breach of above, the same shall be uncovered at Contractor's expense for carrying out such measurement and/or

inspection.

5.g.2. No material shall be removed and despatched by the Contractor from the site without the prior approval

in writing of the Engineer-in-charge. The contractor is to provide at all times during the progress of the work and

the maintenance period proper means of access with ladders, gangways, etc. and the necessary attendance to

move and adapt as directed for inspection or measurements of the works by the Engineer-in-Charge/Site-in-

Charge.

5.h. SAMPLES

5.h.1. The contractor shall furnish to the Engineer-in-charge/Site-in-Charge for approval when requested or

required adequate samples of all materials and finishes to be used in the work.

5.h.2. Samples shall be furnished by the Contractor sufficiently in advance and before commencement of the

work so as the Owner can carry out tests and examinations thereof and approve or reject the samples for use in

the works. All material samples furnished and finally used/applied in actual work shall fully be of the same quality

of the approved samples.

5.i. TESTS FOR QUALITY OF WORK

5.i.1. All workmanship shall be of the respective kinds described in the contract documents and in accordance

with the instructions of the Engineer-in-Charge / Site-in- Charge and shall be subjected from time to time to such

tests at Contractor's cost as the Engineer-in-Charge/Site-in-Charge may direct at the place of manufacture or

fabrication or on the site or at all or any such places. The Contractor shall provide assistance, instruments, labour

and materials as are normally required for examining, measuring and testing any workmanship as may be selected

and required by the Engineer-in-Charge/Site-in-Charge.

5.i.2. All the tests that will be necessary in connection with the execution of the work as decided by the

Engineer-in- charge/Site-in-Charge shall be carried out at the contractors cost and expenses.

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5.i.3. If any tests are required to be carried out in connection with the work or materials or workmanship to be

supplied by the owner, such tests shall be carried out by the Contractor as per instructions of Engineer-in-

Charge/Site-in-Charge and expenses for such tests, if any, incurred by the contractor shall be reimbursed by the

Owner. The contractor should file his claim with the owner within 15 (fifteen) days of inspection/test and any

claim made beyond that period shall lapse and be not payable.

5.j. ALTERATIONS AND ADDITIONS TO SPECIFICATIONS, DESIGNS AND WORKS

5.j.1. The Engineer-in-Charge/Site-in-Charge shall have powers to make any alterations, additions and/or

substitutions to the schedule of quantities, the original specifications, drawings, designs and instructions that may

become necessary or advisable or during the progress of the work and the Contractor shall be bound to carryout

such altered/extra/new items of work in accordance with instructions which may be given to him in writing signed

by the Engineer-in-Charge/Site- in-Charge. Such alterations, omissions, additions or substitutions shall not

invalidate the contract. The altered, additional or substituted work which the Contractor may be directed to

carryon in the manner as part of the work shall be carried out by the Contractor on the same conditions in all

respects on which he has agreed to do the work. The time for completion of such altered added and/or

substituted work may be extended for that part of the particular job. The rates for such additional altered or

substituted work under this Clause shall, be worked out in accordance with the following provisions:

5.j.2. If the rates for the additional, altered or substituted work are specified in the contract for similar class of

work, the Contractor is bound to carryout the additional, altered or substituted work at the same rates as are

specified in the contract.

5.j.3. If the rates for the additional, altered or substituted work are not specifically provided in the contract for

the work, the rates will be derived from the rates for similar class of work as are specified in the contract for the

work. In the opinion of the Engineer-in- Charge/Site-in-Charge as to whether or not the rates can be reasonably so

derived from the items in this contract, will be final and binding on the Contractor.

5.j.4. If the rates for the altered, additional or substituted work cannot be determined in the manner specified

above, then the Contractor shall, within seven days of the date of receipt of order to carry out the work, inform

the Engineer-in-Charge/ Site-in-Charge of the rate at which he intends to charge for such class of work, supported

by analysis of the rate or rates claimed and the Engineer-In-Charge/ Site-in-Charge shall determine the rates on the

basis of the prevailing market rates for both material and labour plus 10% to cover overhead and profit of labour

rates and pay the Contractor accordingly. The opinion of the Engineer-in-Charge/Site-in-Charge as to current

market rates of materials and the quantum of labour involved per unit of measurement will be final and binding on

the contractor.

5.j.5. The quantities indicated in the Tender are approximate. The approved schedule of rates of the contract

will be applicable for variations of up to +25% of the estimated contract value. No revision of schedule of rates will

be permitted for such variations in the contract value, even for variations of individual quantities, addition of new

items, alterations, additions/deletions or substitutions of items, as mentioned above.

(Already covered under Clause No. 3.6)

5.j.6. In case of any item of work for which there is no specification supplied by the Owner and is mentioned in

the tender documents, such work shall be carried out in accordance with Indian Standard Specifications and if the

Indian Standard Specifications do not cover the same, the work should be carried out as per standard Engineering

Practice subject to the approval of the Engineer-in-Charge/ Site-in-Charge.

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5.k. PROVISIONAL ACCEPTANCE

Acceptance of sections of the works for purposes of equipment erection, piping, electrical work and similar usages

by the Owner and payment for such work or parts of work shall not constitute a waiver of any portion of this

contract and shall not be construed so as to prevent the Engineer from requiring replacement of defective work

that may become apparent after the said acceptance and also shall not absolve the Contractor of the obligations

under this contract. It is made clear that such an acceptance does not indicate or denote or establish to the fact of

execution of that

5.l. COMPLETION OF WORK AND COMPLETION CERTIFICATE

As soon as the work is completed in all respects, the contractor shall give notice of such completion to the site in

charge or the Owner and within thirty days of receipt of such notice the site in charge shall inspect the work and

shall furnish the contractor with a certificate of completion indicating:

a) defects, if any, to be rectified by the contractor

b) items, if any, for which payment shall be made in reduced rates

c) the date of completion.

5.m. USE OF MATERIALS AND RETURN OF SURPLUS MATERIALS

5.m.1. Not withstanding anything contained to the contrary in any or all of the clauses of this contract, where

any materials for the execution of the contract are procured with the assistance of Government either by issue

from Government stocks or purchase made under orders or permits or licences issued by Government, the

contractor shall use the said materials economically and solely for the purpose of the contract and shall not

dispose them of without the permission of the Owner.

5.m.2. All surplus (serviceable) or unserviceable materials that may be left over after the completion of the

contract or at its termination for any reason whatsoever, the Contractor shall deliver the said product to the

Owner without any demur. The price to be paid to the Contractor, if not already paid either in full or in part,

however, shall not exceed the amount mentioned in the Schedule of Rates for such material and in cases where

such rates are not so mentioned, shall not exceed the CPWD scheduled rates. In the event of breach of the

aforesaid condition the contractor shall become liable for contravention of the terms of the Contract.

5.m.3. The surplus (serviceable) and unserviceable products shall be determined by joint measurement. In case

where joint measurement has failed to take place, the Owner may measure the same and determine the quantity.

5.m.4. It is made clear that the Owner shall not be liable to take stock and keep possession and pay for the

surplus and unserviceable stocks and the Owner may direct the Contractor to take back such material brought by

the Contractor and becoming surplus and which the Owner may decide to keep and not to pay for the same.

5.n. DEFECT LIABILITY PERIOD

The contractor shall guarantee the work executed for a period of 12 months from the date of completion of the

job. Any damage or defect that may arise or lie undiscovered at the time of completion of the job shall be rectified

or replaced by the contractor at his own cost. The decision of the Engineer In-charge/Site-Incharge/Owner shall be

the final in deciding whether the defect has to be rectified or replaced.

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Equipment or spare parts replaced under warranty/guarantees shall have further warranty for a mutually agreed

period from the date of acceptance.

The owner shall intimate the defects noticed in writing by a Registered A.D. letter or otherwise and the contractor

within 15 days of receipt of the intimation shall start the rectification work and complete within the time specified

by the owner failing which the owner will get the defects rectified by themselves or by any other contractor and

the expenses incurred in getting the same done shall be paid by the Contractor under the provision of the

Contract.

Thus, defect liability is applicable only in case of job/works contract (civil, mechanical, electrical, maintenance etc. )

where any damage of defect may arise in future (i.e. within 12 months from the date of completion of job) or lie

undiscovered at the time of completion of job.

In other words, in case of service contracts (like car hire etc.) where there is no question of damage or defect

arising in future, the defect liability clause is not applicable.

5.o. DAMAGE TO PROPERTY

5.o.1. Contractor shall be responsible for making good to the satisfaction of the Owner any loss of and any

damage to all structures and properties belonging to the Owner or being executed or procured by the Owner or of

other agencies within the premises of the work of the Owner, if such loss or damage is due to fault and/or the

negligence or willful acts or omission of the Contractor, his employees, agents, representatives or sub-contractors.

5.o.2. The Contractors shall indemnify and keep the Owner harmless of all claims for damage to Owner's

property arising under or by reason of this contract.

6. DUTIES AND RESPONSIBILITIES OF CONTRACTOR

6.a. EMPLOYMENT LIABILITY TOWARDS WORKERS EMPLOYED BY THE CONTRACTOR

6.a.1 The Contractor shall be solely and exclusively responsible for engaging or employing persons for the

execution of work. All persons engaged by the contractor shall be on Contractor's payroll and paid by Contractor.

All disputes or differences between the Contractor and his/their employees shall be settled by Contractor.

6.a.2. Owner has absolutely no liability whatsoever concerning the employees of the Contractor. The

Contractor shall indemnify Owner against any loss or damage or liability arising out of or in the course of his/their

employing persons or relation with his/their employees. The Contractor shall make regular and full payment of

wages and on any complaint by any employee of the Contractor or his sub-contractor regarding non-payment of

wages, salaries or other dues, Owner reserves the right to make payments directly to such employees or sub-

contractor of the Contractor and recover the amount in full from the bills of the Contractor and the contractor

shall not claim any compensation or reimbursement thereof. The Contractor shall comply with the Minimum

Wages Act applicable to the area of work site with regard to payment of wages to his employees and also to

employees of his sub contractor.

6.a.3. The Contractor shall advise in writing or in such appropriate way to all of his employees and employees of

sub-contractors and any other person engaged by him that their appointment/employment is not by the Owner

but by the Contractor and that their present appointment is only in connection with the construction contract with

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Owner and that therefore, such an employment/appointment would not enable or make them eligible for any

employment/appointment with the Owner either temporarily or/and permanent basis.

6.b. NOTICE TO LOCAL BODIES

The contractor shall comply with and give all notices required under any Government authority, instruction, rule or

order made under any act of parliament, state laws or any regulations or by-laws of any local authority relating to

the works.

6.c. FIRST AID AND INDUSTRIAL INJURIES

6.c.1. Contractor shall maintain first aid facility for his employees and those of his sub-contractors.

6.c.2. Contractor shall make arrangements for ambulance service and for the treatment of all types of injuries.

Names and telephone numbers of those providing such services shall be furnished to Owner prior to start of

construction and their name board shall be prominently displayed in Contractor's field office.

6.c.3. All industrial injuries shall be reported promptly to owner and a copy of contractor's report covering each

personal injury requiring the attention of a physician shall be furnished to the Owner.

6.d. SAFETY CODE

6.d.1. The Contractor shall at his own expenses arrange for the Safety provisions as may be necessary for the

execution of the work or as required by the Engineer-in-Charge in respect of all labours directly or indirectly

employed for performance of the works and shall provide all facilities in connections therewith. In case the

contractor fails to make arrangements and provide necessary facilities as aforesaid, the Owner shall be entitled to

do so and recover the cost thereof from the Contractor.

6.d.2. From the commencement to the completion of the works, the contractor shall take full responsibility for

the care thereof and of all the temporary works (defined as meaning all temporary works of every kind required in

or for the execution, completion or maintenance of the works). In case damage, loss or injury shall happen to the

works or to any part thereof or to temporary works or to any cause whatsoever repair at his (Contractor's) own

cost and make good the same so that at the time of completion, the works shall be in good order and condition

and in conformity in every respect with the requirement of the contract and Engineer-in-Charge's instructions.

6.d.3. In respect of all labour, directly or indirectly employed in the work for the performance of the

Contractor's part of this agreement, the contractor shall at his own expense arrange for all the safety provisions as

per relevant Safety Codes of C.P.W.D Bureau of Indian Standards, the Electricity Act/I.E. Rules. The Mines Act and

such other Acts as applicable.

6.d.4. The Contractor shall observe and abide by all fire and safety regulations of the Owner. Before starting

construction work, the Contractor shall consult with Owner's Safety Engineer or Engineer-in-Charge/Site-in-Charge

and must make good to the satisfaction of the Owner any loss or damage due to fire to any portion of the work

done or to be done under this agreement or to any of the Owner's existing property.

6.d.5. The Contractor will be fully responsible for complying with all relevant provisions of the Contract Labour

Act and shall pay rates of Wages and observe hours of work/conditions of employment according to the rules in

force from time to time.

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6.d.6. The Contractor will be fully responsible for complying with the provision including documentation and

submission of reports on the above to the concerned authorities and shall indemnify the Corporation from any

such lapse for which the Government will be taking action against them.

6.d.7. Owner shall on a report having been made by an inspecting Office as defined in the Contract Labour

Regulations have the power to deduct from the money due to the Contractor any sum required or estimated to be

required for making good the loss suffered by a worker(s) by reasons of non-fulfillment of conditions of contract

for the benefit of workers no-payment of wages or of deductions made from his or their wages which are not

justified by the terms of contract or non observance of the said contractor's labour Regulation.

6.e. INSURANCE AND LABOUR

Contractor shall at his own expense obtain and maintain an insurance policy with a Nationalised Insurance

Company to the satisfaction of the Owner as provided hereunder.

6.e.1. EMPLOYEES STATE INSURANCE ACT

i. The Contractor agrees to and does hereby accept full and exclusive liability for the compliance

with all obligations imposed by Employees State Insurance Act,1948, and the Contractor further

agrees to defend indemnify and hold Owner harmless from any liability or penalty which may be

imposed by the Central, State or local authority by reason of any asserted violation by

Contractor, or sub-contractor of the Employees' State Insurance Act, 1948 and also from all

claims, suits or proceedings that may be brought against the Owner arising under, growing out of

or by reason of the work provided for by this contract whether brought by employees of the

Contractor, by third parties or by Central or State Government authority or any political sub-

division thereof.

ii. The Contractor agrees to file with the Employees State Insurance Corporation, the Declaration

forms and all forms which may be required in respect of the Contractor's or sub-contractor's

employee whose aggregate emuneration is within the specified limit and who are employed in

the work provided or those covered by ESI Act under any amendment to the Act from time to

time.

The Contractor shall deduct and secure the agreement of the sub-contractor to deduct the employee's

contribution as per the first schedule of the Employee's State Insurance Act from wages and affix the employee's

contribution cards at wages payment intervals. The Contractor shall remit and secure the agreement of the sub

contractor to remit to the State Bank of India, Employee's State Insurance Corporation Account, the Employee's

contribution as required by the Act.

iii. The Contractor agrees to maintain all records as required under the Act in respect of employees

and payments and the Contractor shall secure the agreement of the sub contractor to maintain

such records. Any expenses incurred for the contributions, making contribution or maintaining

records shall be to the Contractor's or sub-contractor's account.

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iv. The Owner shall retain such sum as may be necessary from the total contract value until the

Contractor shall furnish satisfactory proof that all contributions as required by the Employees

State Insurance Act, 1948, have been paid.

v. WORKMAN'S COMPENSATION AND EMPLOYEE'S LIABILITY INSURANCE

Provide Insurance for all the Contractor's employees engaged in the performance of this contract. If any of the

work is sublet, the Contractor shall ensure that the sub-contractor provides workmen's compensation and

Employer's Liability Insurance for the latter's employees who are not covered under the Contractor's insurance.

vi. AUTOMOBILE LIABILITY INSURANCE

Contractor shall take out an Insurance to cover all risks to Owner for each of his vehicles plying on works of this

contract and these insurances shall be valid for the total contract period. No extra payment will be made for this

insurance. Owner shall not be liable for any damage or loss not made good by the Insurance Company, should

such damage or loss result from unauthorised use of the vehicle. The provisions of the Motor Vehicle Act would

apply.

vii. FIRE INSURANCE

Contractor shall within two weeks after award of contract insure the Works, Plant and Equipment and keep them

insured until the final completion of the Contract against loss or damage by accident, fire or any other cause with

an insurance company to be approved by the Employer/Consultant in the joint names of the Employer and the

Contractor (name of the former being placed first in the Policy). Such Policy shall cover the property of the

Employer only.

6.e.2. ANY OTHER INSURANCE REQUIRED UNDER LAW OR REGULATION OR BY OWNER

i. Contractor shall also provide and maintain any and all other insurance which may be required

under any law or regulations from time to time. He shall also carry and maintain any other

insurance which may be required by the Owner.

ii. The aforesaid insurance policy/policies shall provide that they shall not be cancelled till the

Engineer-in-Charge has agreed to their cancellation.

iii. The Contractor shall satisfy to the Engineer-in-Charge/Site-in-Charge from time to time that he

has taken out all insurance policies referred to above and has paid the necessary premium for

keeping the policies alive till the expiry of the defects liability period.

iv. The contractor shall ensure that similar insurance policies are taken out by his sub-contractor (if

any) and shall be responsible for any claims or losses to the Owner resulting from their failure to

obtain adequate insurance protections in connection thereof. The contractor shall produce or

cause to be proceed by his sub-contractor (if any) as the case may be, the relevant policy or

policies and premium receipts as and when required by the Engineer-in-Charge/Site-in-Charge.

6.e.3. LABOUR AND LABOUR LAWS

i. The contractor shall at his own cost employ persons during the period of contract and the

persons so appointed shall not be construed under any circumstances to be in the employment

of the Owner.

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ii. All payments shall be made by the contractor to the labour employed by him in accordance with

the various rules and regulations stated above. The contractor shall keep the Owner indemnified

from any claims whatsoever inclusive of damages/costs or otherwise arising from injuries or

alleged injuries to or death of a person employed by the contractor or damages or alleged

damages to the property.

iii. No labour below the age of eighteen years shall be employed on the work. The Contractor shall

not pay less than what is provided under the provisions of the contract labour (Regulations and

Abolition) Act, 1970 and the rules made thereunder and as may be amended from time to time.

He shall pay the required deposit under the Act appropriate to the number of workman to be

employed by him or through sub contractor and get himself registered under the Act. He shall

produce the required Certificates to the Owner before commencement of the work. The Owner

recognises only the Contractor and not his sub contractor under the provisions of the Act. The

Contractor will have to submit daily a list of his workforce. He will also keep the wage register at

the work site or/and produce the same to the Owner, whenever desired. A deposit may be taken

by the Owner from the Contractor to be refunded only after the Owner is satisfied that all

workmen employed by the Contractor have been fully paid for the period of work in Owner's

premises at rates equal to or better than wages provided for under the Minimum Wages Act.

The contractor shall be responsible and liable for any complaints that may arise in this regard and

the consequences thereto.

iv. The Contractor will comply with the provisions of the Employee's Provident Fund Act and the

Family Pension Act as may be applicable and as amended from time to time.

v. The Contractor will comply with the provisions of the payment of Gratuity Act, 1972, as may be

applicable and as amended from time to time.

vi. IMPLEMENTATION OF APPRENTICES ACT, 1961

The Contractor shall comply with the provisions of the Apprentices Act, 1961 and the Rules and Orders issued

thereunder from time to time. If he fails to do so, his failure will be a breach of the contract and the Engineer-in-

Charge may, at his discretion, cancel the contract. The Contractor shall also be liable for any pecuniary liability

arising on account of any violation by him of the provision of the Act.

vii. MODEL RULES FOR LABOUR WELFARE

The Contractor shall at his own expenses comply with or cause be complied with Model rules for Labour Welfare

as appended to those conditions or rules framed by the Government from time to time for the protection of health

and for making sanitary arrangements for worker employed directly or indirectly on the works. In case the

contractor fails to make arrangements as aforesaid the Engineer-in-Charge/Site-in-Charge shall be entitled to do so

and recover the cost thereof from the contractor.

6.f. DOCUMENTS CONCERNING WORKS

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6.f.1. All documents including drawings, blue prints, tracings, reproducible models, plans, specifications and

copies, thereof furnished by the Owner as well as all drawings, tracings, reproducibles, plans, specifications design

calculations etc. prepared by the contractor for the purpose of execution of works covered in or connected with

this contract shall be the property of the Owner and shall not be used by the contractor for any other work but are

to be delivered to the Owner at the completion or otherwise of the contract.

6.f.2. The Contractor shall keep and maintain secrecy of the documents, drawings etc. issued to him for the

execution of this contract and restrict access to such documents, drawings etc. and further the Contractor shall

execute a SECRECY agreement from each or any person employed by the Contractor having access to such

documents, drawings etc. The Contractor shall not issue drawings and documents to any other agency or individual

without the written approval by the Engineer-in-Charge/Site-in- Charge.

6.f.3. Contractor will not give any information or document etc. concerning details of the work to the press or a

news disseminating agency without prior written approval from Engineer-in-charge/Site-in-Charge. Contractor

shall not take any pictures on site without written approval of Engineer-in-Charge/Site-in-Charge.

7. PAYMENT OF CONTRACTOR'S BILLS

7.1. Payments will be made against Running Accounts bills certified by the Owner's Engineer-in-Charge/Site-in-

Charge within 15 days from the date of receipt of the bill.

7.2. Running Account Bills and the final bill shall be submitted by the Contractor together with the duly signed

measurements sheet(s) to the Engineer-in-Charge/ Site-in-Charge of the Owner in quadruplicate for certification.

The Bills shall also be accompanied by quantity calculations in support of the quantities contained in the bill along

with cement consumption statement, actual/theoretical, wherever applicable duly certified by the Engineer-in-

Charge/ Site-in-Charge of the Owner.

7.3. All running account payments shall be regarded as on account payment(s) to be finally adjusted against

the final bill payment. Payment of Running Account Bill(s) shall not determine or affect in any way the rights of the

Owner under this Contract to make the final adjustments of the quantities of material, measurements of work and

adjustments of amounts etc.etc. in the final bill.

7.4. The final bill shall be submitted by the Contractor within one month of the date of completion of the work

fully and completely in all respects. If the Contractor fails to submit the final bill accordingly Engineer-in-

Charge/Site-in-Charge may make the measurement and determine the total amount payable for the work carried

out by the Contractor and such a certification shall be final and binding on the Contractor. The Owner/Engineer-

in-Charge/Site-in-Charge may take the assistance of an outside party for taking the measurement, the expenses of

which shall be payable by the Contractor.

7.5. Payment of final bill shall be made within 30 days from the date of receipt of the certified bill by the

Disbursement Section of the owner.

7.6. Wherever possible, payment shall be tendered to the contractor in electronic mode (e-payment) through

any of the designated banks. The contractor will comply by furnishing full particulars of Bank account (mandate)

to which the payments will be routed. Owner reserves the right to make payment in any alternate mode also.

7.a. MEASUREMENT OF WORKS

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7.a.1. All measurements shall be in metric system. All the works will be jointly measured by the representative

of the Engineer-in-Charge/Site-in-Charge and the Contractor or their authorised agent progressively. Such

measurement will be recorded in the Measurement Book/Measurement Sheet by the Contractor or his authorized

representative and signed in token of acceptance by the Owner or their authorised representative.

7.a.2. For the purpose of taking joint measurement, the Contractor/representative shall be bound to be present

whenever required by the Engineer-in-Charge/Site-in-Charge. If, however, they are absent for any reasons

whatsoever, the measurement will be taken by the Engineer-in-Charge/Site-in-Charge or his representative and

the same would be deemed to be correct and binding on the Contractor.

7.a.3. In case of any dispute as to the mode of measurement for any item of work, the latest Indian Standard

Specifications shall be followed. In case of any further dispute on the same the same shall be as per the

certification of an outside qualified Engineer/ Consultant. Such a measurement shall be final and binding on the

Owner and the Contractor.

7.b. BILLING OF WORKS EXECUTED

The Contractor will submit a bill in approved proforma in quadruplicate to the Engineer-in-Charge/Site-in-Charge

of the work giving abstract and detailed measurement for the various items executed during a month, before the

expiry of the first week of the succeeding month. The Engineer-in-Charge/Site-in-Charge shall take or cause to be

taken the requisite measurements for the purpose of having the bill verified and/or checked before forwarding the

same to the disbursement office of the Owner for further action in terms of the Contract and payment thereafter.

The Engineer-in-Charge/Site-in-Charge shall verify the bills within 7 days of submission of the Bill by the

Contractor.

7.c. RETENTION MONEY

10% of the total value of the Running Account and Final Bill will be deducted and retained by the Owner as

retention money on account of any damage/defect liability that may arise for the period covered under the defect

liability period clause of the Contract free of interest. Any damage or defect that may arise or lie undiscovered at

the time of issue of completion certificate connected in any way with the equipment or materials supplied by

contractor or in workmanship shall be rectified or replaced by the contractor at his own expense failing which the

Owner shall be entitled to rectify the said damage/defect from the retention money. Any excess of expenditure

incurred by the Owner on account of damage or defect shall be payable by the Contractor. The decision of the

Owner in this behalf shall not be liable to be questioned but shall be final and binding on the Contractor.

Thus, deduction towards retention money is applicable only in case of job/works contracts (civil, mechanical,

electrical, maintenance etc.) where any damage or defect may arise in future (i.e. within 12 months from the date

of completion of job) or lie undiscovered at the time of issue of completion certificate.

7.d. STATUTORY LEVIES

7.d.1. The Contractor accepts full and exclusive liability for the payment of any and all taxes, duties, octroi,

rates, cess, levies and statutory payments payable under all or any of the statutes etc.

Variations of taxes and duties arising out of the amendments to the Central / State enactments, in respect of

sale of goods / services covered under this bid shall be to HPCL’s account, so long as :

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• They relate to the period after the opening of the price bid, but before the contracted completion

period ( excluding permitted extensions due to delay on account of the contractors, if any) or the

actual completion period, whichever is earlier; and

• The vendor furnishes documentary evidence of incurrence of such variations, in addition to the

invoices/documents for claiming Cenvat /Input Tax credit, wherever applicable.

All contributions and taxes for unemployment compensation, insurance and old age pensions or annuities now or

hereafter imposed by Central or State Governmental authorities which are imposed with respect to or covered by

the wages, salaries or other compensations paid to the persons employed by the Contractor and the Contractor

shall be responsible for the compliance with all obligations and restrictions imposed by the Labour Law or any

other law affecting employer-employee relationship and the Contractor further agrees to comply and to secure the

compliance of all sub-contractors with all applicable Central, State, Municipal and local laws, and regulations and

requirements of any Central, State or Local Government agency or authority.

Contractor further agrees to defend, indemnify and hold harmless from any liability or penalty which may be

imposed by the Central, State or Local authorities by reason of any violation by Contractor or sub-contractor of

such laws, regulations or requirements and also from all claims, suits or proceedings that may be brought against

the Owner arising under, growing out of, or by reasons of the work provided for by this contract by third parties, or

by Central or State Government authority or any administrative sub-division thereof. The Contractor further

agrees that in case any such demand is raised against the Owner, and Owner has no way but to pay and

pays/makes payment of the same, the Owner shall have the right to deduct the same from the amounts due and

payable to the Contractor. The Contractor shall not raise any demand or dispute in respect of the same but may

have recourse to recover/receive from the concerned authorities on the basis of the Certificate of the Owner

issued in that behalf.

7.d.2. The rates quoted should be inclusive of all rates, cess, taxes and sales tax on works contracts wherever

applicable. However, wherever the sales tax on works contract is applicable and is to be deducted at source, the

same will be deducted from the bills of the Contractor and paid to the concerned authorities. The proof of such

payments of sales tax on works contract will be furnished to the contractor.

7.d.3. Income tax will be deducted at source as per rules at prevailing rates, unless certificate, if any, for

deduction at lesser rate or nil deduction is submitted by the Contractor from appropriate authority.

7.d.4. The contractor shall provide accurate particulars of PAN number as required, to enable issuance of TDS

(Tax Deduction at Source) certificate.

7.e. MATERIALS TO BE SUPPLIED BY CONTRACTOR

7.e.1. The Contractor shall procure and provide the whole of the materials required for construction including

tools, tackles, construction plant and equipment for the completion and maintenance of the works except the

materials viz. steel and cement which may be agreed to be supplied as provided elsewhere in the contract. The

contractor shall make arrangement for procuring such materials and for the transport thereof at their own cost

and expenses.

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7.e.2. The Owner may give necessary recommendation to the respective authority if so desired by the

Contractor but assumes no responsibility of any nature. The Contractor shall procure materials of ISI

stamp/certification and supplied by reputed suppliers borne on DGS&D list.

7.e.3. All materials procured should meet the specifications given in the tender document. The Engineer-in-

charge may, at his discretion, ask for samples and test certificates for any batch of any materials procured. Before

procuring, the Contractor should get the approval of Engineer-in-Charge/Site-in-Charge for any materials to be

used for the works.

7.e.4. Manufacturer's certificate shall be submitted for all materials supplied by the Contractor. If, however, in

the opinion of the Engineer-in-Charge/Site-in-Charge any tests are required to be conducted on the material

supplied by the Contractor, these will be arranged by the Contractor promptly at his own cost.

7.f. MATERIALS TO BE SUPPLIED BY THE OWNER

7.f.1. Steel and Cement maybe supplied by the Owner to the contractor against payment by Contractor from

either godown or from the site or within work premises itself and the contractor shall arrange for all transport to

actual work site at no extra cost.

7.f.2. The contractor shall bear all the costs including loading and unloading, carting from issue points to work

spot storage, unloading, custody and handling and stacking the same and return the surplus steel and cement to

the Owner's storage point after completion of job.

7.f.3. The contractor will be fully accountable for the steel and cement received from the Owner and contractor

will give acknowledgement/receipt for quantity of steel and cement received by him each time he uplifts cement

from Owner's custody.

7.f.4. For all computation purposes, the theoretical cement consumption shall be considered as per CPWD

standards.

7.f.5. Steel and Cement as received from the manufacturer/stockists will be issued to the contractor.

Theoretical weight of cement in a bag will be considered as 50 Kg. Bags weighing upto 4% less shall be accepted by

the contractor and considered as 50 Kg. per bag. Any shortage in the weight of any cement bag by more than 4%

will be to the Owner's account only when pointed out by the Contractor and verified by Engineer-in-Charge/Site in

Charge at the time of Contract or taking delivery.

7.f.6. The contractor will be required to maintain a stock register for receipt, issuance and consumption of steel

and cement at site. Cement will be stored in a warehouse at site. Requirement of cement on any day will be taken

out of the warehouse. Cement issued shall be regulated on the basis of FIRST RECEIPT to go as FIRST ISSUE.

7.f.7. Empty cement bag shall be the property of the Contractor. Contractor shall be penalised for any

excess/under consumption of cement. The penal rate will be twice the rate of issue of cement for this work.

7.f.8. All the running bills as well as the final bills will be accompanied by cement consumption statements

giving the detailed working of the cement used, cement received and stock-on-hand.

7.f.9. The Contractor will be fully responsible for safe custody of cement once it is received by him and during

transport. Owner will not entertain any claims of the contractor for theft, loss or damage to cement while in their

custody.

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7.f.10. The contractor shall not remove from the site any cement bags at any time.

7.f.11. The Contractor shall advise Engineer-in-charge/Site-in-charge in writing atleast 21 days before exhausting

the Cement stocks already held by Contractor to ensure that such delays do not lead to interruptions in the

progress of work.

7.f.12. Cement shall not be supplied by the Owner for manufacturing of mosaic tiles, precast cement jali and any

other bought out items which consume cement and for temporary works.

7.f.13. Cement in bags and in good usable condition left over after the completion of work shall be returned by

the contractor to the Owner. The Owner shall make payment to the Contractor at the supply rate for such stocks

of cement they accept and receive. Any refused stock of cement shall be removed by the Contractor from the site

at his cost and expenses within 15 days of completion of the work.

8. PAYMENT OF CLAIMS AND DAMAGES

8.1. Should the Owner have to pay money in respect of claims or demands as aforesaid the amount so paid

and the costs incurred by the Owner shall be charged to and paid by the Contractor and the Contractor shall not be

entitled to dispute or question the right of the Owner to make such payments notwithstanding the same may have

been without his consent or authority or in law or otherwise to the contrary.

8.2. In every case in which by virtue of the provisions of Workmen's Compensation Act, 1923, or other Acts,

the Owner is obliged to pay Compensation to a Workman employed by the Contractor in execution of the works,

the Owner will recover from the Contractor the amount of compensation so paid and without prejudice to the

rights of Owner under the said Act. Owner shall be at liberty to recover such amount or any part thereof by

deducting it from the security deposit or from any sum due to the Contractor whether under this contract or

otherwise. The Owner shall not be bound to contest any claim made under Section 12 sub section (1) of the said

Act, except on the written request of the Contractor and upon his giving to the Owner full security for all costs for

which the owner might become liable in consequence of contesting such claim.

8.a. ACTION AND COMPENSATION IN CASE OF BAD WORK

If it shall appear to the Engineer-in-Charge/Site-in-Charge that any work has been executed with bad, imperfect or

unskilled workmanship, or with materials, or that any materials or articles provided by the Contractor for

execution of the work are not of standards specified/inferior quality to that contracted for, or otherwise not in

accordance with the contract, the CONTRACTOR shall on demand in writing from the Engineer-in-Charge/Site-in-

Charge or his authorised representative specifying the work, materials or articles complained of, notwithstanding

that the same may have been inadvertently passed, certified and paid for, forthwith rectify or remove and

reconstruct the work so specified and at his own charge and cost and expenses and in the event of failure to do so

within a period of 15 days of such intimation/ information/knowledge, the Contractor shall be liable to pay

compensation equivalent to the cost of reconstruction by the Owner. On expiry of 15 days period mentioned

above, the Owner may by themselves or otherwise rectify or remove and re-execute the work or remove and

replace with others, the materials or articles complained of as the case may be at the risk and expenses in all

respects of the Contractor. The decision of the Engineer-in- Charge/ Site-in-Charge as to any question arising

under this clause shall be final and conclusive and shall not be raised as a dispute or shall be arbitrable.

8.b. INSPECTION AND AUDIT OF CONTRACT AND WORKS

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This project is subject to inspection by various Government agencies of Government of India. The contractor shall

extend full cooperation to all the Government and other agencies in the inspection of the works, audit of the

Contract and the documents of Contract Bills, measurements sheets etc. etc. and examination of the records of

works and make enquiries interrogation as they may deem fit, proper and necessary. Upon inspection etc. by such

agencies if it is pointed out that the contract work has not been carried out according to the prescribed terms and

conditions as laid down in the tender documents and if any recoveries are recommended, the same shall be

recovered from the contractors running bills/final bill/from ordered/suggested Security Deposit/retention money.

The Contractor shall not rise any dispute on any such account and the same shall not be arbitrable.

9. CONTRACTOR TO INDEMNIFY THE OWNER

The Contractor shall indemnify the Owner and every member, officer and employee of the Owner, also the

Engineer-in-Charge/Site-in-Charge and his staff against all the actions, proceedings, claims, demands, costs,

expenses, whatsoever arising out of or in connection with the works and all actions, proceedings, claims, demands,

costs, expenses which may be made against the Owner for or in respect of or arising out of any failure by the

Contractor in the performance of his obligations under the contract. The Contractor shall be liable for or in respect

of or in consequence of any accident or injury to any workmen or other person in the employment of the

Contractor or his sub contractor and Contractor shall indemnify and keep indemnified the Owner against all such

damages, proceedings, costs, charges and expenses whatsoever in respect thereof or in relation thereto.

10. LIQUIDATED DAMAGES

i) In case of any delay in completion of the work beyond the CDD, the Owner shall be entitled to

be paid Liquidated Damages by the Contractor. The liquidated damages shall be initially at the

rate of 0.5% (half percent) of the total contract value for every week of the delay subject to a

maximum of 5% of the total contract value. The liquidated damages shall be recovered by the

Owner out of the amounts payable to the Contractor or from any Bank Guarantees or Deposits

furnished by the Contractor or the Retention Money retained from the Bills of the Contractor,

either under this contract or any other contract.

ii) The Contractor shall be entitled to give an acceptable unconditional Bank Guarantee in lieu of

such a deduction if Contractor desires any decision on a request for time extension.

iii) Once a final decision is taken on the request of the Contractor or otherwise, the LD shall be

applicable only on the basic cost of the contract and on each full completed week(s) of delay

(and for part of the week, a pro-rata LD amount shall be applicable).

iv) This final calculation of LD shall be only on the value of the unexecuted portion/quantity of

work as on the CDD.

v) Contractor agrees with the Owner, that the above represents a genuine pre-estimate of the

damages which the Owner will suffer on account of delay in the performance of the work by

Contractor. The Contractor further agrees that the LD amount is over and above any right

which owner has to risk purchase under Clause 12.4 and any right to get the defects in the

work rectified at the cost of the contractor.

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11. DEFECTS AFTER TAKING OVER OR TERMINATION OF WORK CONTRACT BY OWNER

The Contractor shall remain responsible and liable to make good all losses or damages that may occur/appear to

the work carried out under this Contract within a period of 12 months from date of issue of the Completion

Certificate and/or the date of Owner taking over the work, which ever is earlier. The Contractor shall issue a Bank

Guarantee to the Owner in the sum of 10% of the work entrusted in the Contract, from any nationalised Bank

acceptable to the Owner and if however, the Contractor fails to furnish such a Bank Guarantee the Owner shall

have right to retain the Security Deposit and Retention Money to cover the 10% of the Guarantee amount under

this clause and to return/refund the same after the expiry of the period of 12 months without any interest

thereon.

12. TERMINATION OF CONTRACT

12.1. The owner may terminate the contract at any stage of the construction for reasons to be recorded in the

letter of termination.

12.2. The Owner inter alia may terminate the Contract for any or all of the following reasons that the contractor

a) has abandoned the work/Contract.

b) has failed to commence the works, or has without any lawful excuse under these conditions suspended

the work for 15 consecutive days.

c) has failed to remove materials from the site or to pull down and replace the work within 15 days after

receiving from the Engineer written notice that the said materials or work were condemned and/or rejected by the

Engineer under specified conditions.

d) has neglected or failed to observe and perform all or any of the terms acts, matters or things under this

Contract to be observed and performed by the Contractor.

e) has to the detriment of good workmanship or in defiance of the Engineer's instructions to the contrary

sub-let any part of the Contract.

f) has acted in any manner to the detrimental interest, reputation, dignity, name or prestige of the Owner.

g) has stopped attending to work without any prior notice and prior permission for a period of 15 days.

h) has become untraceable.

i) has without authority acted in violation of the terms and conditions of this contract and has committed

breach of terms of the contract in best judgement of the owner.

j) has been declared insolvent/bankrupt.

k) in the event of sudden death of the Contractor.

12.3. The owner on termination of such contract shall have the right to appropriate the Security Deposit,

Retention Money and invoke the Bank Guarantee furnished by the contractor and to appropriate the same

towards the amounts due and payable by the contractor as per the conditions of Contract and return to the

contractor excess money, if any, left over.

12.4. In case of Termination of the contract, Owner shall have the right to carry out the unexecuted portion

of the work either by themselves or through any other contractor(s) at the risk and cost of the Contractor. In

view of paucity of time, Owner shall have the right to place such unexecuted portion of the work on any

nominated contractor(s). However, the overall liability of the Contractor shall be restricted to 100 % of the total

contract value.

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12.5. The contractor within or at the time fixed by the Owner shall depute his authorised representative for

taking joint final measurements of the works executed thus far and submit the final bill for the work as per joint

final measurement within 15 days of the date of joint final measurement. If the contractor fails to depute their

representative for joint measurement, the owner shall take the measurement with their Engineer-in-Charge/Site-

in-Charge or any other outside representatives. Such a measurement shall not be questioned by the Contractor

and no dispute can be raised by the Contractor for purpose of Arbitration.

12.6. The Owner may enter upon and take possession of the works and all plant, tools, scaffoldings, sheds,

machinery, power operated tools and steel, cement and other materials of the Contract at the site or around the

site and use or employ the same for completion of the work or employ any other contractor or other person or

persons to completion of the work or employ any other contractor or other person or persons to complete the

works. The Contractor shall not in any way object or interrupt or do any act, matter or thing to prevent or hinder

such actions, other Contractor or other persons employed for completing and finishing or using the materials and

plant for the works. When the works shall be completed or as soon thereafter the Engineer shall give a notice in

writing to the Contractor to remove surplus materials and plant, if any, and belonging to the Contractor except as

provided elsewhere in the Contract and should the Contractor fail to do so within a period of 15 days after receipt

thereof the Owner may sell the same by public auction and shall give credit to the contractor for the amount

realised. The Owner shall thereafter ascertain and certify in writing under his hand what (if anything) shall be due

or payable to or by the Owner for the value of the plant and materials so taken possession and the expense or loss

which the Owner shall have been put to in procuring the works, to be so completed, and the amount if any, owing

to the Contractor and the amount which shall be so certified shall thereupon be paid by the Owner to the

Contractor or by the Contractor to the Owner, as the case may, and the Certificate of the Owner shall be final and

conclusive between the parties.

12.7. When the contract is terminated by the Owner for all or any of the reasons mentioned above the

Contractor shall not have any right to claim compensation on account of such termination.

13. FORCE MAJEURE

13.1. Any delay in or failure of the performance of either part hereto shall not constitute default hereunder or

give rise to any claims for damage, if any, to the extent such delays or failure of performance is caused by

occurrences such as Acts of God or an enemy, expropriation or confiscation of facilities by Government authorities,

acts of war, rebellion, sabotage or fires, floods, explosions, riots, or strikes. The Contractor shall keep records of

the circumstances referred to above and bring these to the notice of the Engineer-in-Charge/Site-in-Charge in

writing immediately on such occurrences. The amount of time, if any, lost on any of these counts shall not be

counted for the Contract period. Once decision of the Owner arrived at after consultation with the Contractor,

shall be final and binding. Such a determined period of time be extended by the Owner to enable the Contractor

to complete the job within such extended period of time.

13.2. If Contractor is prevented or delayed from the performing any of its obligations under this Agreement by

Force Majeure, then Contractor shall notify Owner the circumstances constituting the Force Majeure and the

obligations performance of which is thereby delayed or prevented, within seven days of the occurrence of the

events.

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14. ARBITRATION

14.1 All disputes and differences of whatsoever nature, whether existing or which shall at any time arise

between the parties hereto touching or concerning the agreement, meaning, operation or effect thereof or to the

rights and liabilities of the parties or arising out of or in relation thereto whether during or after completion of the

contract or whether before after determination, foreclosure, termination or breach of the agreement (other than

those in respect of which the decision of any person is, by the contract, expressed to be final and binding) shall,

after written notice by either party to the agreement to the other of them and to the Appointing Authority

hereinafter mentioned, be referred for adjudication to the Sole Arbitrator to be appointed as hereinafter provided.

14.2. The appointing authority shall either himself act as the Sole Arbitrator or nominate some officer/retired

officer of Hindustan Petroleum Corporation Limited (referred to as owner or HPCL) or a retired officer of any

other Government Company in the Oil Sector of the rank of Ch. Manager & above or any retired officer of the

Central Government not below the rank of a Director, to act as the Sole Arbitrator to adjudicate the disputes

and differences between the parties. The contractor/vendor shall not be entitled to raise any objection to the

appointment of such person as the Sole Arbitrator on the ground that the said person is/was an officer and/or

shareholder of the owner, another Govt. Company or the Central Government or that he/she has to deal or had

dealt with the matter to which the contract relates or that in the course of his/her duties, he/she has/had

expressed views on all or any of the matters in dispute or difference.

14.3. In the event of the Arbitrator to whom the matter is referred to, does not accept the appointment, or is

unable or unwilling to act or resigns or vacates his office for any reasons whatsoever, the Appointing Authority

aforesaid, shall nominate another person as aforesaid, to act as the Sole Arbitrator.

14.4. Such another person nominated as the Sole Arbitrator shall be entitled to proceed with the arbitration

from the stage at which it was left by his predecessor. It is expressly agreed between the parties that no person

other than the Appointing Authority or a person nominated by the Appointing Authority as aforesaid, shall act

as an Arbitrator. The failure on the part of the Appointing Authority to make an appointment on time shall only

give rise to a right to a Contractor to get such an appointment made and not to have any other person

appointed as the Sole Arbitrator.

14.5. The Award of the Sole Arbitrator shall be final and binding on the parties to the Agreement.

14.6. The work under the Contract shall, however, continue during the Arbitration proceedings and no payment

due or payable to the concerned party shall be withheld (except to the extent disputed) on account of initiation,

commencement or pendency of such proceedings.

14.7. The Arbitrator may give a composite or separate Award(s) in respect of each dispute or difference

referred to him and may also make interim award(s) if necessary.

14.8. The fees of the Arbitrator and expenses of arbitration, if any, shall be borne equally by the parties unless

the Sole Arbitrator otherwise directs in his award with reasons. The lumpsum fees of the Arbitrator shall be

Rs.40,000/- per case for transportation contracts and Rs.60,000/- for engineering contracts and if the sole

Arbitrator completes the arbitration including his award within 5 months of accepting his appointment, he shall

be paid Rs.10,000/- additionally as bonus. Reasonable actual expenses for stenographer, etc. will be

reimbursed. Fees shall be paid stagewise i.e. 25% on acceptance, 25% on completion of

pleadings/documentation, 25% on completion of arguments and balance on receipt of award by the parties.

14.9. Subject to the aforesaid, the provisions of the Arbitration and Conciliation Act, 1996 or any statutory

modification or re-enactment thereof and the rules made thereunder, shall apply to the Arbitration proceedings

under this Clause.

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Seal of the Vendor


Visakh Refinery

14.10. The Contract shall be governed by and constructed according to the laws in force in India. The parties

hereby submit to the exclusive jurisdiction of the Courts situated at Visakhapatnam for all purposes. The

Arbitration shall be held at Visakhapatnam and conducted in English language.

14.11. The Appointing Authority is the Functional Director of Hindustan Petroleum Corporation Limited.

15. GENERAL

15.1. Materials required for the works whether brought by the or supplied by the Owner shall be stored by the

contractor only at places approved by Engineer-in-Charge/Site-in-Charge. Storage and safe custody of the material

shall be the responsibility of the Contractor.

15.2. Owner and/or Engineer-in-Charge/Site-in-Charge connected with the contract, shall be entitled at any

time to inspect and examine any materials intended to be used in or on the works, either on the site or at factory

or workshop or at other place(s) manufactured or at any places where these are laying or from which these are

being obtained and the contractor shall give facilities as may be required for such inspection and examination.

15.3. In case of any class of work for which there is no such specification supplied by the owner as is mentioned

in the tender documents, such work shall be carried out in accordance with Indian Standard Specifications and if

the Indian Standard Specifications do not cover the same the work should be carried out as per standard

Engineering practice subject to the approval of the Engineer-in-Charge/Site-in-Charge.

15.4. Should the work be suspended by reason of rain, strike, lockouts or other cause the contractor shall take

all precautions necessary for the protection of the work and at his own expense shall make good any damages

arising from any of these causes.

15.5. The contractor shall cover up and protect from injury from any cause all new work also for supplying all

temporary doors, protection to windows and any other requisite protection for the whole of the works executed

whether by himself or special tradesmen or sub- contractors and any damage caused must be made good by the

contractors at his own expense.

15.6. If the contractor has quoted the items under the deemed exports, then it will be the responsibility of the

contractor to get all the benefits under deemed exports from the Government. The Owner’s responsibility shall

only be limited to the issuance of required certificates. The quotation will be unconditional and phrases like

“subject to availability of deemed exports benefit” etc. will not find place in it.

16. Integrity Pact: Effective 1st

September, 2007, all tenders and contracts shall comply with the

requirements of the Integrity Pact (IP) if the value of such tenders or contracts exceed Rs.1 crore. Failure to sign

the Integrity Pact shall lead to outright rejection of bid.

17. Grievances of parties participating or intend to participate in the tender shall be addressed in writing to the

officer designate of the Grievance Redressal Cell where the tenders have to be submitted within the stipulated

period. Detailed mechanism of Grievance Redressal is available on the HPCL website

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SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS

FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS

ANNEXURE - IV

HINDUSTAN PETROLEUM CORPORATION LIMITED

VISAKH REFINERY

VISAKHAPATNAM

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OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS RFQ 12000438-HD-46002/VNK

ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS

INDEX

INTRODUCTION ............................................................................................. 3

1. ORIENTATION MEETING ........................................................................ 4

2. GENERAL RULES .................................................................................... 4

3. SECURITY CONTROLS: .......................................................................... 6

4. CHANGE HOUSE AND TOILET FACILITIES ........................................... 7

5. CAFETERIA FACILITIES .......................................................................... 8

7. SMOKING REGULATIONS ....................................................................... 9

8. BATTERY OPERATED EQUIPMENT & ELECTRICAL ITEMS ............... 9

9. PHOTOGRAPHY ...................................................................................... 9

10. TRAFFIC REGULATIONS ........................................................................ 9

11. CONTRACTOR’S EQUIPMENT ............................................................. 11

12. HOUSE KEEPING .................................................................................. 15

13. WORK PERMIT SYSTEM ....................................................................... 15

14. PERSONAL PROTECTIVE EQUIPMENT............................................... 18

15. REPORTING OF ACCIDENTS/ INCIDENTS .......................................... 19

16. FIRST AID FACILITY .............................................................................. 20

17. FIRE FIGHTING EQUIPMENT ................................................................ 20

18. REPORTING OF FIRE / EMERGENCY PROCEDURES:....................... 21

19. SAFETY PRACTICES AT WORK PLACES ........................................... 23

20. PENALTY FOR NON-COMPLIANCE ..................................................... 52

21. SAFETY MANAGEMENT SYSTEM FOR CONTRACTORS ................... 54

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SAFETY REGULATIONS FOR CONTRACTORS

INTRODUCTION Safety of personnel and property is of prime importance to the management of HPCL, Visakh Refinery. In order to achieve this objective, rules and procedures have been established to prevent accidents that may result in injury to persons or damage to property. The rules and procedures summarized below will assist the contractors in protecting their own employees and property as well as to the HPCL employees and property. This booklet is a part of ‘Contractor Safety Management System’ of HPCL, Visakh Refinery and shall form part of every work order. Some of the important work procedures and safe practices to be followed by contractors while working in the Visakh Refinery Operational area of Hindustan Petroleum Corporation Limited (hereinafter called Company) are listed out in this manual.

The term contractors covers all agencies / persons who render service to the company within its premises in effecting supplies of any description, operating transport or heavy equipment, performing work of any nature or engaging in any activity in response to orders placed by or at the invitation of the company.

It should be clearly understood that all regulations applicable to contractor given herein, are only typical but not exhaustive. Contractors should obtain specific instructions pertaining to their jobs as and when necessary from concerned company officer. The contractor shall comply with the Safety Manual in addition to this booklet. The contractor will have access to the Safety Manual, which is available with the sponsoring department. On demand company will supply copy of Safety Manual.

These safety regulations are treated as an integral part of the contract document and the contractor shall be held responsible for their and their sub contractor’s employees concerning familiarization, strict adherence to these regulations and any additional safety requirements. . It is the responsibility of the contractor to ensure that all their workers thoroughly familiarize with these procedures and strictly follow them.

Any violation of the safety regulations by the contractor may lead to infringement, penalties or cancellation of the contract if, corrective measures are not taken immediately after having been informed of the same by the Company.

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1. ORIENTATION MEETING

Prior to commencement of the work, key personnel of the contractor and his sub-contractors shall attend an orientation meeting with the representatives from sponsoring dept. and HPCL- Fire & Safety to discuss matters related to safety aspects of the job. Contractor to mobilize their crew and workmen two days advance to attend the safety training conducted by HPCL.

2. GENERAL RULES

2.1. The contractor shall be responsible for all employees working for him and should explain to them the Safety Regulations and other relevant company procedures.

2.2. The contractors shall abide by the applicable statutes viz., the factories act, E.S.I. act, MSIHC rules, gas cylinder rules, workmen’s compensation act, and other central/state government rules pertaining to contractor’s work in a continuous process chemical industry

2.3. The contractor will follow Refinery safety systems and regulations as advised

2.4. The contractor shall maintain their activities in Environment friendly manner and assist HPCL to maintain established systems under ISO 14001 programme.

2.5. The contractor and/or his authorized supervisor shall :

2.5.1. Take instructions from the concerned company supervisor before starting any work in the company premises.

2.5.2. The contractor should submit the detailed execution scheme for critical/ high risk job and get it approved by concerned company supervisors before execution.

2.5.3. Consult the concerned company supervisor in the event of difficulty or problem relating to the assigned job or for any clarification pertaining to company procedures.

2.5.4. Ensure that all personnel working under him work safely and do not create any hazard, panic, un authorized propaganda, etc.

2.5.5. Contractor is held responsible not only for employees working for him (Ref. 3.1) but also persons calling on him or doing business with him in the company premises, Ex. Sub contractors, technical consultants, vendors etc.

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2.5.6. Be responsible for explaining all company instructions related to the persons mentioned in (3.3.4&3.3.5) above and ensuring their compliance.

2.5.7. Be responsible for explaining to his sub-contractors/agents and ensuring their compliance with Safety Rules and practices contained herein.

2.5.8. Ensure that all persons under his responsibility and connected with his work confine to the designated work place only.

2.5.9. In case of electrical work specifically in sub-stations the job should be done in the presence of company electrical section representative.

2.5.10. If two contractor agencies are working within 6 meters radius then they should bring to the notice of permit issuer. This is to ensure safety of workers and equipment.

2.6. Prior to commencement of work, contractor shall furnish his office and home addresses and telephone numbers to the company supervisor to facilitate urgent communication in case of emergency.

2.7. Contractor shall not employ any person below the age of 18 years and above the age of 58 years on company assigned jobs and above the age of 45 for carrying out jobs at height (>12m)

2.8. To avoid confusion arising from multiplicity of instructions, contractor shall receive instruction only from the designated Company Supervisor, except in situation of emergency.

2.9. The contractor shall maintain Attendance / leave Record and other records as given in “The Factories Act” and be able to produce them on demand.

2.10. Contractor shall ensure that the skilled manpower, as per job requirement, are employed and job supervisor is experienced and is minimum diploma holder in his discipline (Mechanical, Electrical/ Civil/ Instrumentation etc.)

2.11. Contractor shall ensure that all the workmen and supervisors working under him are covered under ESI scheme.

2.12. Contractor shall ensure that all the workmen employed by him are medically fit and will submit the Fitness certificate on demand. The fitness for working at height would cover medical certification of health assessment parameters in the format given in annexure –I.

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2.13. Contractor shall not engage any worker for more than 16 hours of continuous duty on a day/

2.14. Identification/ Information/ cautions tags affixed to any system/ equipment are not to be tampered or removed under any circumstances.

2.15. Compressed air or any hydrocarbon shall not be used for cleaning clothes.

2.16. Female workers are not to be employed by the contractor.

2.17. Company representative and F&S officer are authorized to correct any conditions which they may consider hazardous. In case of emergency however, all company supervisors are authorized to act directly with contractor supervisor or workmen. \

2.18. The contractor has to provide identification badge to the persons working under him. A blue colour helmet, safety shoe and boiler suits to be used by contractor personnel.

2.19. The contractor has to provide a board at the worksite giving the details as per “The Labor act.”

3. SECURITY CONTROLS:

3.1. Contractor’s personnel are permitted within Refinery premises only on possession of valid security pass.

3.2. It is the responsibility of the contractor or his supervisor to collect the required number of security passes each day/shift from the security office, distribute them to the personnel assigned for work.

3.3. Organize and regulate the entry of security pass-holders in an orderly fashion at the security gate.

3.4. Contractor’s personnel shall be in possession of the issued security personnel passes while inside the company premises and shall produce the same immediately on demand.

3.5. Security passes are not transferable.

3.6. The contractor shall ensure that his workmen do not trespass though the Operating areas. Trespassing through tank dikes, operating areas and unauthorized areas would be considered as violation and a fine of Rs. 100/- would be laid on the person. If the trespassing is repeated the contractor would be taken for penal action.

3.7. Contractor shall be responsible for safe conduct and orderly behavior of his personnel while inside company premises.

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3.8. Entry or exit of contractors property, be it materials, tools or equipment, into or from company premises shall be regulated by suitable documentation in the Material Movement Register maintained by the company at the security gate. Gate passes are not issued for outgoing item belonging to the contractor.

3.9. Security of Contractor’s materials, tools and equipment and company issued items shall be the responsibility of the contractor.

3.10. Separate Vehicle/equipment passes shall be obtained by the contractor from the security office for his equipment for entering into company premises.

3.11. Company representative will authorize issuance of required number of security passes to contractors, at least 24 hours prior intimation is required for issuance of additional passes. Passes are valid for specific period for which they are issued.

3.12. Passes issued in the name of one contractor shall not be used by workmen belonging to any other contractor.

3.13. At the commencement of each month, Contractors shall submit to the Company’s Security Manager a list of names of workmen employed by him with address and ESI number for arranging gate passes. These lists shall be kept updated throughout the month. On completion of the job or at the time specified, contractor shall return all the passes to company security manager and account for losses if any.

3.14. Mobile phones, pagers, cameras, laptops and data storage devises like pen drives are strictly not allowed inside the refinery. Only walkie talkies are allowed inside the refinery with prior permission

4. CHANGE HOUSE AND TOILET FACILITIES

4.1. Change house and toilet facilities designated for company personnel are not available to contractor’s personnel.

4.2. Maintenance of contractor’s Change room and Toilet facilities meant for contract workmen shall be the responsibility of the contractors.

4.3. Contractor’s personnel shall not wear loose/fluttering clothes like lungi or dhotis and their dress shall be free from oil or chemicals.

4.4. Open areas, pipe tracks, drains etc shall not be used for Toilets. Contractors shall advise their workers to use designated toilet facility.

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5. CAFETERIA FACILITIES

5.1. Company cafeteria facilities are not available to contractors’ personnel. The contractor worker may utilize the cafeteria facility, which is earmarked for them on payment basis.

5.2. Contractors’ personnel are permitted to bring their food inside the Refinery; however, their dining shall be restricted to the designated area. The contractor shall be responsible for keeping the dining area clean and tidy.

5.3. Contractor personnel should not use the pipe tracks, OWS pits and operating areas etc as dining and rest areas. Contractor to ensure the same.

6. CONTRACTOR SHELTER & YARDS

6.1. Contractor's Shelter, Storage yard or any temporary facility within HPCL Premises shall comply with the following conditions:

6.2. It should be a prefabricated portable metallic bunker and prior approval from HPCL to be taken before placing the bunker .

6.3. Similarly prior approval must be taken from HPCL before placing any metallic tool box and the tool box shall clearly indicate the name of the contractor, address, contact number along with HPCL’s supervisor name and contact details. Usage of non metallic bunkers/tool boxes is strictly prohibited.

6.4. At all times the contractor's assigned area shall be kept clean and tidy, waste is to be disposed to designated facilities with in refinery daily so as not to create any unsafe conditions.

6.5. The material to be stacked in neat and orderly manner preventing any blockage to the contractors shed. Access way to be clear and unobstructed.

6.6. The Contractor at his own cost shall provide fire, safety and first aid appliances as per The Factories Act requirements. The adequacy quality and prevails will be verified by the HPCL Personal. The contractor to ensure that F&S equipment are checked and certified by HPCL.

6.7. The Company shall have the right to inspect the facility at any time, even after working hours in case it is required for safety reasons.

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6.8. Contractor shall display a signboard at their Office/shed indicating company name, contract number, title, and period and sponsoring HPCL division/department.

6.9. Contractor shall maintain his shed in proper order and ensure that all flammable materials are stored properly. Contractor shall ensure that power is switched off to his shed before leaving company premises.

6.10. All electrical fittings in the contractors shed should be should be suitable for use as per the area classification, they should be maintained well, No loose electrical wiring is permitted .

7. SMOKING REGULATIONS

Smoking is prohibited inside company premises. Safety matches and cigarette lighters are not permitted inside the refinery. These are to be deposited at Security gate.

8. BATTERY OPERATED EQUIPMENT & ELECTRICAL ITEMS

8.1. Non-intrinsically safe battery operated items e.g. flash lights, mobile telephones; pagers etc. are not permitted inside the refinery by the contractor personnel. The same to be deposited at gate before entry into refinery.

8.2. Electrically operated tools and equipment should be suitable for use as per the area classification. Non explosion proof or non-intrinsically safe equipment shall not be used without a hot work permit.

9. PHOTOGRAPHY

Photography by the Contractor personnel is prohibited in refinery premises.

10. TRAFFIC REGULATIONS

10.1. Use of vehicles in side refinery is strictly on need basis. All contract drivers would have to attend driving test for obtaining refinery driving permit. A driver coming for a refinery driving permit should approach F&S with a recommendation letter from his head of the department that the vehicle is required for Project / maintenance work. He shall be submitting the following documents.

10.1.1. Original RTA license for verification

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10.1.2. Photocopy of the RTA license

10.1.3. Copy of gate pass

10.1.4. Clearance from company medical officer

10.1.5. Pay a one time processing fee of Rs. 500/- to finance and bring the challan.

10.1.6. Two stamp sized colour photos.

10.2. All vehicles entering or leaving the Refinery premises shall come to a complete halt at the security gates and shall be offered for checking by the security personnel.

10.3. The maximum speed limit for motor vehicles within the company premises is 25 KMPH Vehicles and mobile equipment shall be driven cautiously and shall follow all traffic regulations and road signs.

10.4. Contractors’ vehicles or mobile equipment shall not enter refinery operating units unless authorized by a hot work permit, strictly on need base approach.

10.5. Two wheelers are not allowed inside Refinery premises.

10.6. Transport vehicles permitted inside the refinery premises shall have flame/spark arrestors of CCOE approved design or manufacturer

10.7. Transport vehicles permitted inside the refinery premises shall be parked in the designated parking area only.

10.8. Vehicles or other mobile equipment shall not be parked in any manner that will block fire hydrant, fire equipment, building exists and walkways etc.

10.9. It shall be the responsibility of the contractor to ensure that materials are properly stacked in the transport vehicles to avoid items dropping from the vehicle while in transit.

10.10. Transporting of materials / equipment which project beyond the periphery of the transport vehicles shall have exclusive company permit and cautionary tags like red flag shall be conspicuously display on the projecting items. Proper supporting/tied covering to be made so that loading material does not fall.

10.11. Loitering inside Refinery premises is strictly prohibited.

10.12. Walk on walkway wherever provided, in the absence of which walk on the left side of the road.

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10.13. Bicycle may be allowed to ply inside the refinery strictly on need basis; double riding on bicycle is not permitted.

10.14. Contractor’s vehicles and bicycles shall normally be parked outside the main gate, company assume no responsibility for the security for contractor vehicles in case of theft.

10.15. Contractor‘s vehicles shall be allowed inside the refinery premises only if, in possession of a valid vehicle pass. Vehicle passes shall be issued by Security on approval by company representative.

10.16. Contractor vehicle drivers shall obtain necessary refinery driving license from Fire & Safety Department while driving inside the refinery

10.17. Crane, Hydra Operator should not allow anybody to sit on vehicle body. They should necessarily have reversing horn.

10.18. Materials being shifted by Trailer truck should be tied properly.

10.19. Men and material shall not be transported together on the same vehicle.

10.20. Contractor to ensure that road is not blocked up at any point of time due to vehicle movement, loading and unloading activities. Necessary road closure permit to be obtained from F&S. Always open up the roads in case of emergency sirens, ensure space for the movement of emergency vehicles. Blockage of roads without valid permit would call for penal action.

11. CONTRACTOR’S EQUIPMENT

11.1. Agency shall follow the Annexure IV – SWP06 : ‘Contractor Jobs equipment safety assurance ’ for bringing the various equipments, tools and tackles inside HPCL-VR.

11.2. All mobile and stationary equipment, tools, safety appliances and machinery under contractors’ control and operating in the company premises shall have valid certification applicable to each of them and equipment shall be in healthy working condition for safe operation. On demand by company Supervisor, Company Supervisor having right to reject equipment and that rejected equipment should be transported out of refinery, the contractor shall produce the test certificate of his equipment.

11.3. Use of equipment involving power, hoisting, and towing, pushing, carrying, high temperature/pressure shall be subject to prior permission from the company supervisor before actual application.

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11.4. Written company permits where indicated, shall be obtained without fail prior to any action or operation.

11.5. Preparation for any equipment activity, where indicated, shall be performed as stipulated by the company supervisor.

11.6. Equipment fitted with pneumatic or solid rubber tyres only shall be permitted on Refinery roads. Vehicle’s equipment fitted with steel tyres are not permitted on Refinery roads.

11.7. Use of Company Equipment

11.7.1. Contractor shall not use company equipment and tools without obtaining permission from the supervisor responsible for the equipment or tool.

11.7.2. Contractors shall assume full responsibility for proper care of company equipment and tools which are made available to them for the execution of their work and return such equipment and tools in good working order.

11.7.3. In case of any damage to the equipment company shall recover from contractors full cost of repairs / cost of replacement.

11.8. Handling of Cylinders

11.8.1. A Gas cylinder is a closed metal container intended for storage and transportation of compressed gas, designed not to be fitted to a special transport or under carriage, and having a volume exceeding 500 ml. but not exceeding 1000 litres. The following has to be taken into consideration while handling the cylinders.

11.8.2. Marking on cylinders – every gas cylinder should be clearly and permanently marked in accordance with the following particulars

11.8.2.1. Owner’s and Inspector’s marking and rotation number

11.8.2.2. Specification to which manufactured

11.8.2.3. Symbol to indicate nature of heat treatment

11.8.2.4. Date of last hydrostatic test or hydrostatic stretch test.

11.8.2.5. Working pressure and test pressure

11.8.2.6. Tare weight inclusive of valve weight

11.8.2.7. Water capacity

11.8.2.8. Manufactured by

11.8.2.9. Gas cylinder for

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11.8.2.10. Quantity & Srl. Nos

11.8.3. Cylinder colour – Cylinder should be painted with the appropriate identification colour

11.8.4. Following warning messages should be displayed on the cylinder.

11.8.4.1. Do not change the colour of the cylinder

11.8.4.2. This cylinder should not be filled with any gas other than the one it now contains.

11.8.4.3. No flammable material should be stored in the immediate vicinity or in the store room in which it is kept.

11.8.4.4. No oil or similar lubricant should be used at the valve or other fittings of this cylinder

11.8.4.5. Look for the next date of test, which is marked on a metal ring inserted between the valve and the neck of the cylinder and if this date is over, the cylinder shall not be accepted.

11.8.5. Prohibition of smoking, fire, lights and dangerous substances –There should be no smoking, no fire or hot work, no matches, fires or other appliances which cause ignition/ explosion at anytime in proximity to a place where any cylinder for any flammable gas is being filled, stored or handled.

11.8.6. Handling and use of cylinders

11.8.6.1. Cylinders should be handled with care and properly supported

11.8.6.2. They should not be allowed to fall on one another.

11.8.6.3. Trolleys’ with end cradles of adequate strength should be used

11.8.6.4. Sliding, dropping or playing with cylinder is prohibited.

11.8.6.5. LPG cylinders should always be kept in an upright position and so placed that they cannot be knocked over.

11.8.6.6. Cylinders used in horizontal position should be secured against rolling.

11.8.6.7. There should be no flame, light, fire, welding or smoking in proximity to any cylinder.

11.8.6.8. Working places should not be classified as places for purposes of licensing.

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11.8.7. Storage of cylinders

11.8.7.1. Cylinders should be stored in a cool, dry, ventilated space under cover, away from boilers, open flames, steam pipes or any potential sources oh heat,and such source of storage shall be easily accessible.

11.8.7.2. The storage shed /room should be of fire proof construction.

11.8.7.3. Thin walled cylinders like LPG cylinders and DI cylinders should not be stacked in horizontal position.

11.8.7.4. Cylinders containing flammable and toxic gases shall be kept separated from each other.

11.8.7.5. Cylinders should not be stored under conditions which will cause corrosion.

11.8.7.6. Cylinders should not be stored along with any combustible material.

11.8.7.7. Empty cylinders should be segregated from the filled ones and all the valves should be tightly shut.

11.8.8. Transportation of cylinders

11.8.8.1. Cylinders filled with any compressed gas should not be transported by bicycle or any other two wheeled mechanically propelled vehicle.

11.8.8.2. Cylinders should not project beyond the slides or ends of the vehicle by which they are transported.

11.8.8.3. Cylinders filled with any compressed gas should not be transported along with any other articles of highly flammable or corrosive nature.

11.8.8.4. Cylinders should be adequately secured to prevent their falling off vehicle.

11.8.8.5. Cylinders containing flammable gases should not be transporting along with the cylinders containing any other type of permanent gases.

11.8.8.6. Cylinders containing toxic or corrosive gas should not be transported along with food stuffs

11.8.8.7. Valves of cylinders should be adequately protected against damage with valve caps rings, etc, while in transit.

11.8.8.8. Transportation of leaking cylinders is prohibited.

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11.8.8.9. Use trolleys for minor movements within the yard or unit.

12. HOUSE KEEPING

12.1. Maintain good house keeping around work area.

12.2. Always keep work place clean and orderly, good housekeeping help to prevent accidents.

12.3. While transferring flammable / toxic material from one container to another, avoid spilling; however, should there be any spillage, it shall be disposed off as directed by the Company Supervisor.

12.4. On completion of work, all surplus materials / equipment / tools shall be removed from site. Company supplied surplus items to be returned to warehouse and site should be thoroughly cleaned.

12.5. Throughout any job, housekeeping at Contractor’s work spots shall be of a standard acceptable to company.

12.6. Following completion of work, contractor shall clean up job sites to Company’s satisfaction. And obtain certificate from operations department as per format attached along with tender.

12.7. Debris shall be disposed off at designated location(s). Metal scrap and other salvageable materials belonging to the company shall be moved to the Refinery Salvage Yard.

12.8. In case the agency/contractor fails to move the scrap to refinery scrap yard, twice the cost of moving the material shall be back charged on vendor apart from other penalties at the discretion of the HPCL Supervisor.

12.9. Unauthorized dumping of the scrap will attract a penalty of Rs 10,000/- in each instance.

13. WORK PERMIT SYSTEM

The purpose of a permit is to give written permission to contractor to carry out a particular job at specific location on a particular equipment or facility. Company representative after ensuring that the equipment /area is safe to carry out the specified work will issue a permit to work within the specified time. For detail about “Work permit system”, please refer our manual on the said subject.

13.1. Cold work permit

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Cold work permits are issued for carrying out work that is Non hazardous and does not pose the danger of fire or danger of life by asphyxiation , electrocution , exposure to gases/chemicals or working at heights under difficult conditions.

13.2. Hot work permit

13.2.1. Performance of work which (i) constitutes a potential fire hazard or (ii) interferes with normal fire fighting operations (iii) poses danger of life shall require a hot work permit.

13.2.2. Typical examples of hot work permits are:

13.2.2.1. Arc welding equipment, gas cutting and welding torches, soldering equipment, any type of electric heating devices, blow torches.

13.2.2.2. Usage of diesel generator

13.2.2.3. Grinding wheels

13.2.2.4. Electric drills and other electric equipment including non-explosion proof lights, connections and extension cords.

13.2.2.5. Shot and grit blasting and similar spark producing surface preparation

13.2.2.6. Stress relieving pre heating and induction heating

13.2.2.7. Location and operating welding equipment, internal combustion engines or any other equipment which may create a source of ignition in hazardous area.

13.2.2.8. Concrete chipping

13.2.2.9. Making entry for inspection, cleaning or repairs inside

13.2.2.9.1. storage tanks

13.2.2.9.2. Process and yard vessels, towers, drums, exchanger shells etc.

13.2.2.9.3. Furnace and boilers

13.2.2.9.4. Excavations, dyke cutting, valve box, sewer or sump where a man’s head may be below grade level

13.2.2.9.5. Sumps in oil separator system

13.2.2.10. Driving any automotive equipment inside process and utility areas, tank farm, adjacent to any sumps in the oil separator and

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adjacent to the hydrocarbon pump houses and flare stack areas.

13.2.2.11. Entry into or hot work on vessel , drums, sections of the pipelines etc. that contained oil , chemicals or toxic products even at approved area.

13.2.2.12. Going to the roof of floating roof tanks when product level is below three meters from top of tank

13.2.2.13. Radiography

13.2.2.14. Rock blasting

13.2.2.15. Stopping of steam leaks on live line by using Pneumatic drill

13.2.2.16. Hot tapping

13.2.2.17. Working under water, Ex: Dredging / shell cleaning at HLPH/LLPH

13.3. Extended Work Permit

A permit issued for maximum of 30 days is called as “Extended Permit”. Extended work permits for longer duration may be issued where the work is of a continuous nature and long duration subject to the area / plant having been positively isolated and facilities declared gas free.

Example: Tank repairs, Project Works away from operating area.

13.4. GUIDELINE ON WORK PERMIT SYSTEM

13.4.1. All activities within Company premises except in exempted areas like Offices, Maintenance shop including garage need authorization by company and work shall not commence without a written valid work permit.

13.4.2. Work permits are to be signed by the supervisor responsible for the operation of the equipment / unit or area concerned as Issuer and concerned company supervisor as Receiver.

13.4.3. The contractor shall ask the company representative for issuing the permit.

13.4.4. Each permit will have details about the nature of work and validity. If the contractor supervisor is in doubt he may ask for

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additional information regarding safe working procedure to the Issuer / Receiver of the permit.

13.4.5. Permits are valid only if all check list items in the permit are covered and signed by the authorized company supervisor and their validity holds good only for the duration specified.

13.4.6. If work is to be continued beyond specified time, permit shall be revalidated.

13.4.7. Permit shall be in the possession of contractors’ personnel in plastic folder at work site , for display in multiple locations, photocopies in plastic folder should be available at each site for entire duration of work.

13.4.8. All conditions and precautions stipulated in the permit shall be strictly adhered to, by the contractors’ personnel.

13.4.9. In the event of a hazardous situation developing during the course of work, the matter shall be immediately reported to the nearest company employee and permit returned to the issuing authority and there is any change in plan/methodology involving execution should inform to issuer and receiver. Work shall recommence only on restoration of the permit by the same authority.

13.4.10. In the event of an emergency at work site, any company employee is authorized to withdraw the permit and hand it over to the issuing authority.

13.4.11. On completion of work or on expiry of validity, the permit shall be returned to the issuing authority.

13.4.12. If the Contractor personnel found working without a valid permit, a serious action as deemed fit will be taken.

13.4.13. While all job need a safety review by contract safety supervisor permit issue will some times depends on a detailed job safety / hazard analysis for critical item performed by company. The out come of JSA take precautions, PPE and timely of the job is to be adhered to periodic checks by contractor safety supervisor should be submitted.

14. PERSONAL PROTECTIVE EQUIPMENT

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14.1. Agency shall strictly follow Annexure II - ‘SWP02 :Requirement of basic minimum PPE’ & Annexure I - ‘SWP01 : Specification of PPEs’

14.2. All necessary personal safety equipment as considered adequate by the company supervisor should be made available for the use to the persons employed at the site. These should be maintained in a condition suitable for immediate use. The contractor should take adequate steps to ensure proper use of equipment by those concerned. Contractor to submit the list of equipment and take the approval from company supervisor. Agency shall strictly follow Annexure II, ‘SWP02 :Requirement of basic minimum PPE’ & Annexure I ‘SWP01 : Specification of PPEs’

14.3. Those engaged in welding and cutting works shall be provided with protective equipment such as Welder’s helmet, leather hand gloves etc.

14.4. Proper training shall be provided to workers for usage of Personal protective equipment.

14.5. Personal protective and safety equipment shall conform to HPCL PPE Specifications and sample to be produced to HPCL Fire & Safety department for approval if asked.

14.6. Contractor to ensure the safety equipment are checked and certified for condition by F&S personnel.

14.7. Boiler suits

14.7.1. All workers engaged for T&I shall wear boiler suits of contractor specific color approved by HPCL.

14.7.2. Boiler suits shall be made of good quality pure cotton cloth like Aravind mills, alpha or of similar quality.

14.7.3. The boiler suit cloth shall be 100% cotton

14.7.4. Reflectors shall be stitched on the boiler suits

14.8. Over and above all the specified safety regulations, job specific PPE stipulated by the permit are mandatory.

15. REPORTING OF ACCIDENTS/ INCIDENTS

15.1. All the accidents/ incidents minor/ major and near misses shall be immediately reported in writing to the company supervisor.

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15.2. All formality as per statutory regulations shall be carried out by the contractor where warranted.

15.3. Contractor shall assist the company supervisor in investigating the accident/ incident and furnish all details regarding the accident/ incident.

15.4. Contractor shall pay all incidental and medical expenses for the injured and compensation, as per Govt.rules, in case of injury or fatality.

16. FIRST AID FACILITY

16.1. In the event of an injury to contractor personnel in company premises, injured shall be brought to company dispensary. Subsequent medical treatment and /or hospitalization shall be arranged by the contractor at his expenses.

16.2. Company Ambulance is not available for injured or sick persons of the contractor except with prior permission from HOD- Fire & Safety/ Manager- Production (shifts).

16.3. In the event of hospitalization of any contractor personnel, the contractor shall inform the details about the treatment being given to the company supervisor and shift Fire & Safety officer on telephone no. 2894851

16.4. Contractor supervisor shall accompany the worker to the dispensary in case of any injury to the worker. The details of the injured worker are to be produced to F&S.

17. FIRE FIGHTING EQUIPMENT

17.1. The contractor has to provide adequate fire fighting equipment as specified by the company supervisor at work site carrying out hot work.

17.2. ISI marked DCP extinguisher of 10 KG capacity, charged fire water hose of 38 mm size with spray nozzle are the general types of fire fighting equipment to be provided at work site

17.3. The fire fighting equipment available at site shall be in good working condition and periodically tested / checked as specified by Fire & Safety personnel of the refinery.

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17.4. The fire fighting equipment shall have a mark of identification of the contractor. DCP/ CO2 extinguishers shall be marked with the name of the contractor, date of last HT and HT due date.

17.5. 18.5 The fire fighting equipment shall be tested and certified by HPCL. Contractor to ensure the same.

18. REPORTING OF FIRE / EMERGENCY PROCEDURES:

18.1. In case of fire are spotted in the refinery premises, it shall be immediately reported to the nearest company employee who in turn shall dial “77” and inform about fire.

18.2. In the absence of any company employee, contractor supervisor shall dial phone “77”revealing the person’s identity and report about the fire, its location and nature.

18.3. Contractor personnel can also report a fire through Manual Call Points (MCP) provided at various locations round the refinery. MCP unit comprises of a micro switch enclosed in a box. The whole assembly is covered from all sides except from the front side. The front side is sealed with a breakable glass cover. The glass cover is fixed in such a way that the actuating micro cover is kept depressed so long as the glass cover is intact.

18.4. In case of fire emergency, the MCP box has to be opened up, the glass cover of the micro switch is to be broken, open the telephone box and use the telephone. The telephone communication can be made using hand set provided in the MCP box.

18.5. Communicate the fire emergency in the way given.

18.5.1. Lift the hand set and wait for acknowledgement from Fire house.

18.5.2. Caller to identify himself (Name, Contractor, Designation etc.)

18.5.3. Give the exact location and description of fire emergency.

18.5.4. Wait till Fire house repeats the message.

18.5.5. Caller to confirm the accuracy of the message (location of fire) as repeated by the Fire house person.

18.6. Fire emergency is sounded in wailing fashion for one minute. On sounding of refinery fire alarm, the contractor personnel shall stop their work immediately secure the place and move to the nearest assembly

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point away from refinery equipment keeping the road clear for free movement of emergency vehicles and persons. Wait for the sounding of all clear siren.

18.7. Assembly points are located at the following areas in Refinery and ATP area. Contractor supervisor should communicate the nearest assembly point to workers daily before the start of work

18.8. Assembly points – Refinery

18.8.1. SOUTH OF OLD ADMIN BUIDLING 18.8.2. SOUTH OF MAINTENANCE SHOP 18.8.3. SOUTH EAST OF CDU-III 18.8.4. SOUTH WEST OF HLPH PUMPS 18.8.5. SOUTH WEST OF SS-50 18.8.6. SOUTH OF IFO TANKS 18.8.7. NORTH OF CRWETP (NEAR ATP GATE) 18.8.8. REFINERY FIRE HOUSE 18.8.9. NORTH OF FABRICATION YARD (NORTH BOUNDARY) 18.8.10. SOUTH OF ETP-IV 18.8.11. SOUTH WEST OF TANK-D5 18.8.12. NORTH WEST OF SS-12A 18.8.13. NORTH OF BLOCK-B 18.8.14. EAST OF SS-14 18.8.15. WEST OF SS-6B 18.8.16. SOUTH OF LPG C/R 18.8.17. SOUTH OF TANK-191 18.8.18. EAST OF NEW ADMIN BUILDING 18.8.19. BLOCK-A 18.8.20. BLOCK-C 18.8.21. DM PLANT 18.8.22. MS BLOCK 18.8.23. FIRE&SAFETY 18.8.24. MOI CONTROL ROOM

18.9. Assembly points – ATP

18.9.1. NORTH OF VVPL OFFICE 18.9.2. SOUTH EAST OF TANK-211 18.9.3. NORTH WEST OF TANK- 120-T-213 B (NORTH

BOUNDARY) 18.9.4. NORTH WEST OF TANK- 120-T-210 (WEST BOUNDARY) 18.9.5. SOUTH WEST OF TANK- 120-T-209 A 18.9.6. NORTH WEST OF TANK- 120-T-206 A (WEST

BOUNDARY) 18.9.7. NORTH WEST OF TANK- 120-T-201 D (CRUDE TANK) 18.9.8. NORTH EAST OF TANK- 120-T-201 C (CRUDE TANK)

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18.9.9. NORTH OF REFINERY TO ATP GATE (SOUTH BOUNDARY)

18.10. Cold work should also be stopped in affected unit, but in all other processing units cold work can continue. They shall remain there till instructions for leaving the area are issued by company supervisor.

18.11. Fire emergency siren repeated 3 times after a gap of 30 seconds constitutes onsite emergency siren.

18.12. In case of Onsite emergency (disaster siren), contractor personnel shall stop their work, secure the work place and move towards the nearest assembly point. At the assembly point there would be a head count followed by evacuation. Contractor should evacuate his employees from the refinery premises using company arranged or own vehicle from the assembly point.

18.13. The All clear signal is the steady sounding of the refinery siren for one minute. After the all clear is signaled contractor personnel can resume back to work.

18.14. In case of emergency siren, all the vehicles should be immediately stopped by moving to the side of the road with out blocking any fire hydrant points and ensure sufficient space is available for the moment of fire tenders & rescue vehicles.

19. SAFETY PRACTICES AT WORK PLACES

19.1. Precautions against the fall of materials, persons, collapse of structures and precautions for working in confined space:

19.2. Precautions should be taken such as the provision of fencing, look-out men or barriers to protect any person against injury by the fall of materials, Proper access ladder, working plat form scaffolding railing use of safety nets, tools or such other equipment as necessary must be used.

19.3. Where necessary to prevent danger, guys, stays or supports should be used or other effective precautions should be taken to prevent the collapse of structures or parts of structures that are being erected, maintained, repaired, dismantled or demolished.

19.4. All openings through which workers are liable to fall shall be kept effectively covered or fenced and displayed prominently.

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19.5. As far as practicable, guardrails and toe-boards should be provided to protect workers materials and tools from falling from elevated workplaces.

19.6. Adequate rescue arrangements like ladders, ropes, baskets, ambulance, breathing apparatuses, etc. is to be made available and rescue drill conducted by contract personnel in presence of HPCL representative.

19.7. CONFINED SPACE :

19.7.1. A confined space is any vessel which has the following characteristics

19.7.1.1. Limited openings for entry and exit

19.7.1.2. Unfavorable natural ventilation

19.7.1.3. Not designed for continuous occupancy

19.7.1.4. Presence of contaminants and lack of oxygen

19.7.2. examples include towers, drums, tanks, large line, Vessels, boilers, storage tanks, large diameter piping etc, manhole, sewer or valve box, sump , excavation more than 1.2 meter deep, entry on floating roof tanks when the roof is more than 3 meter down from the top, space located below ground level such as pits, drains, channels etc.

19.7.3. Before entry into any confined space the contractor to ensure the vessel is positively isolated by means of blinds, made HC / Toxic gas free by depressurizing, steam purging, nitrogen purging, water wash etc. All electrical sources disconnected, switches removed locked and tagged, Belt and chain drives, mechanical linkages on shaft driven equipment disconnected, Mechanical moving parts inside the confined space secured.

19.7.4. Proper ventilation must be provided to get minimum 19.5% of oxygen in air.

19.7.5. Confined space must be tested for the presence of percentage of oxygen in air and the concentration of toxic gases and HC in air. The testing to be carried out prior to entry as well as during the course of the work. Continuous gas monitoring to be do incase of JSA recommendations. The gas test readings are to be entered in a register for future reference.

19.7.6. Hot work permit is required to be obtained prior to entry into a confined space.

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19.7.7. A standby person must be assigned and always be present at the entrance of the confined space. A record of all work permits issued and number of authorized entrants in the confined space has to be maintained with the stand by personnel. A stand by personnel should not have any other jobs other than being stand by. He must be trained in the emergency procedures and should be well versed with the emergency contact numbers.

19.7.8. All the Emergency equipment, must be readily available and in good working condition.

19.7.9. When entering from the top, and if this is the only means of access, a lifeline must be worn by the person entering into confined space.

19.7.10. There shall be no Hydrogen sulfide or any other toxic gases present, Carbon monoxide shall not exceed 5 PPM.

19.7.11. No hot work should be permitted unless the Explosive meter reading is zero. Vessel entry, where no hot work is to be carried out, may be permitted under extra precautionary measures based on the careful analysis of the potential hazards if combustible gases are up-to 5% of lower explosive limit (LEL). Entry with an air supplied mask may be permitted with LEL of up to 20%. The oxygen level should be at least 19.5 % vol. and the concentration of toxic gases below the threshold limits.

19.7.12. Electrical lamps with guard and voltage limited to 24 V shall be used for lighting.

19.7.13. Before entering gas test (presence of Hydrocarbon vapors, CO, H2S, other toxic gases, Oxygen deficiency shall be carried out by the Operations technician to ensure that concentrations of such gases are below the allowable limit. The allowable limits are as follows:

19.7.13.1. HC -20% of LEL ( Max)

19.7.13.2. CO -5 P PM( Max)

19.7.13.3. H2S -2 PPM ( Max)

19.7.13.4. O2- Not less than 19.5 % in air

19.7.14. Special precautions like wetting with water must be taken where there are materials like pyrophoric iron (Iron sulphide), Acetylides or polymers present which may ignite spontaneously.

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19.8. WORKING IN CONFINED SPACES

19.8.1. Following safety practices for working in confined space like towers, columns, tanks, pits and other vessels should be followed in addition to the safety guidelines for specific jobs like scaffolding, cutting/welding etc.

19.8.2. Ensure proper and accessible means of exit before entry inside a confined space.

19.8.3. The number of persons allowed inside the vessel should be limited to avoid overcrowding.

19.8.4. When the work is going on in the confined space, there should always be one man standby (attendant) at the nearby man way.

19.8.5. Ensure adequate ventilation or use respiratory devices.

19.8.6. Depending upon need, necessary respirator system, like BA set, air line respirators etc. shall be worn by the contractor employees. these equipment shall be arranged by company.

19.8.7. Use 24V flameproof lamp fittings only for illumination.

19.8.8. The gas cylinders used for cutting/welding shall be kept outside.

19.8.9. All cables, hoses, welding equipment etc., shall be removed from confined space at end of each work day, even if the work is to be resumed in the same space the next day.

19.8.10. Communication should be always maintained between the worker and the attendant.

19.8.11. A checklist should be prepared and used to check the safety and functional aspects of the equipment and the concerned activity. The check listing activity should be carried out prior to the commencement of the job.

19.9. LIGHTING

19.9.1. Where natural lighting is not adequate, working light fittings or portable hand-lamps should be provided at workplace on the construction site where a worker will do a job.

19.9.2. Emergency lighting should be provided for personnel safety during night time to facilitate standby lighting source, if normal system fails.

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19.9.3. Artificial lighting should not produce glare or disturbing shadows.

19.9.4. Lamps should be protected by guards against accidental breakage.

19.9.5. The cables of portable electrical lighting equipment should be of adequate size & characteristics for the power requirements and of adequate mechanical strength to withstand severe conditions in construction operations.

19.9.6. No loose or open cable joints are allowed.

19.9.7. Portable lights

19.9.7.1. All single fixtures portable hand lamp shall be of weather proof type.

19.9.7.2. Only the standard approved string lights may be used where Hot Work is authorized, either by a Hot Work Permit or by designing of the area as open for Hot Work at all times.

19.9.7.3. PORTABLE electric single or multitude outlet extension cords (plug boards) hand lights and string lights should be inspected at regular intervals.

19.9.7.4. AUTHORIZED person must make all repairs to refinery flashlights only.

19.9.7.5. ONLY 24volts portable lamps with guard shall be used in confined spaces.

19.10. PLANT, MACHINERY, EQUIPMENT AND HAND TOOLS

19.10.1. General Provisions

19.10.1.1. Plant, machinery and equipment including hand tools, both manual and power driven, should:

19.10.1.2. be of proper design and construction, taking into account health, Safety and ergonomic principles.

19.10.1.3. be maintained in good working order;

19.10.1.4. be used only for work for which they have been designed.

19.10.1.5. be operated only by workers who have been authorized and given appropriate training.

19.10.1.6. be provided with protective guards, shields or other devices as required.

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19.10.1.7. Adequate instructions for safe use should be provided.

19.10.1.8. Safe operating procedures should be established and used for all plant, machinery and equipment.

19.10.1.9. Where trailing cables or hose pipes are used they should be kept as short as practicable and not allowed to create a hazard.

19.10.1.10. All moving parts of machinery and equipment should be enclosed or adequately guarded.

19.10.1.11. Every power-driven machine and equipment should be provided with adequate means, immediately accessible and readily identifiable to the operator, of stopping it quickly and preventing it from being started again inadvertently.

19.10.1.12. Operators of plant, machinery, equipment and tools should be provided with PPEs, including suitable ear protection where ever necessary.

19.10.2. Hand Tools:

19.10.2.1. Hand tools should be repaired by competent persons.

19.10.2.2. Heads of hammers and other shock tools should be dressed or ground to a suitable radius on the edge as soon as they begin to mushroom or crack.

19.10.2.3. When not in use and while being carried or transported sharp tools should be kept in sheaths, shields, chests or other suitable containers.

19.10.2.4. Only insulated or non conducting tools should be used on or near live electrical installations.

19.10.2.5. Only non-sparking tools should be used near or in the presence of flammable or explosive dusts or vapours.

19.10.2.6. Do not carry hand tools by hand while climbing up the ladder or to height always use tool bags.

19.10.2.7. Crowbars and spaded used for excavtion activity are to be of insulated and non conducting type.

19.10.3. Pneumatic Tools:

19.10.3.1. Operating triggers on portable pneumatic tools should be:

19.10.3.1.1. So placed as to minimize the risk of accidental starting of the machine.

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19.10.3.1.2. So arranged as to close the air inlet valve automatically when the pressure of the operator's hand is removed.

19.10.3.2. Hose and hose connections for compressed air supply to portable pneumatic tools should be:

19.10.3.2.1. Designed and tested for the pressure and service for which they are intended;

19.10.3.2.2. Fastened securely on the pipe outlet and equipped with the safety chain, as appropriate.

19.10.3.3. Pneumatic shock tools should be equipped with safety clips or retainers to prevent dies and tools from being accidentally expelled from the barrel.

19.10.3.4. Pneumatic tools should be disconnected from power and the pressure in hose lines released before any adjustment or repair is made.

19.10.3.5. All the tools should be placed in toolbox and protected unit area can not be used as storage.

19.10.4. Hydrojetting machine

19.10.4.1. Work permit system manual shall be followed and stipulated work permit

19.10.4.2. Wearing Safety shoes and helmet is mandatory for working in the refinery. The jet operator and the foot pedal operator both shall use face shield with helmet , PVC hand gloves , gum shoes and apron while working

19.10.4.3. Tarpaulin sheets shall be tied on all three sides with the help of temporary structural members to prevent any injury to the surrounding personnel during actual blasting

19.10.4.4. The rigid lance shall be used along with the gun type trigger and flexible lance with foot operated valve and at no point they will be bypassed

19.10.4.5. In case of any abnormal sound during operation, the machine shall be stopped immediately and the matter informed to the Job Engineer.

19.10.4.6. Proper barricading shall be done to prevent anyone from coming into the vicinity of the high pressure jet if this operation is carried out outside the hydro jetting yard.

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19.10.5. Electrical Tools:

19.10.5.1. All portable electrical tools shall be provided with ELCB. The ELCB to be checked up regularly by contractor’s electrician and a record of the same to be maintained.

19.10.5.2. All electrical tools should be earthed, unless they are "all insulated" or "double insulated" tools which do not require earthing.

19.10.5.3. All electrical tools should get inspected and maintained on a regular basis by a competent electrician and complete records kept.

19.10.6. Engines:

19.10.6.1. Engines should:

19.10.6.1.1. Be installed so that they can be started safely and the maximum safe speed cannot be exceeded.

19.10.6.1.2. Have controls for limiting speed.

19.10.6.1.3. Have devices to stop them from a safe place in an emergency.

19.10.6.2. IC engines should not be run in confined spaces.

19.10.6.3. Engine exhausts to be fitted with spark arrestors to prevent any spark propagation.

19.10.6.4. Do not try to fill fuel when engine is in running condition.

19.10.6.5. Do not leave the engines unattended and in running condition. All the rotating parts in the engines are to be provided with guards. Do not try to open the radiators when the engine is running, this may cause spillage of hot water.

19.10.6.6. Ensure mufflene arrangement integrated fuel tanks in use with the engines.

19.10.7. Ladder & Stairways:

19.10.7.1. Ladders must be visually inspected by the user for defects prior to commencement of the job. Defective ladders must not be used and must be tagged as defective and put out of use until repaired.

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19.10.7.2. A straight ladder must be placed with its feet approximately 1/4th of the ladder length away from the line that is vertical with the top support.

19.10.7.3. Straight ladders must be secured at the bottom and tied at the top to prevent slipping.

19.10.7.4. When ascending or descending ladders, the user must face the ladder and keep a firm grip on the rungs. Always maintain a three point contact with the ladder.

19.10.7.5. Only non-metallic ladders shall be used in electrical substations and when working in close proximity to exposed electrical circuits.

19.10.7.6. Ladders must not be placed in front of doors, in passage ways, or in the vicinity of vehicular traffic unless appropriate barriers and warning signs are erected.

19.10.7.7. Portable ladders must be taken out and stored properly when the job is over

19.10.7.8. To permit visual inspection for defects, ladders must not be painted or varnished.

19.10.7.9. Do not carry tools and materials while ascending or descending ladders. Instead use tool bags.

19.11. EXCAVATION

19.11.1. All excavation work should be planned and the method of excavation and the type of support work required should be decided considering the following:

19.11.2. the stability of the ground;

19.11.3. the effect of excavation on the adjoining buildings, structures or roadways;

19.11.4. to prevent hazard, the gas, water, electrical and other public utilities should be shut off or disconnected, if necessary;

19.11.5. presence of underground pipes, cable conductors, etc.,

19.11.6. the position of culvert/bridges, temporary roads and spoil heaps should be determined;

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19.11.7. Before digging begins on site, all excavation work should be planned and the method of excavation and the type of support work required decided.

19.11.8. All excavation work should be supervised.

19.11.9. While excavating trenches exceeding 1.5m depth proper slope shall be provided. Proper shoring shall be provided to prevent cave-in or slides for deep excavation more than 2 meters in depth.

19.11.10. As far as possible, excavated earth should not be placed within one meter of the edge of the trench or depth of trench whichever is greater.

19.11.11. Adequately anchored stop blocks and barriers should be provided to prevent vehicles being driven into the excavation.

19.11.12. Barricade at 1m height (with red & white band/self glowing caution board) should be provided for excavations. Provide proper access to all excavation. For trenches of 4 feet or more in depth shall be provided with one access ladder.

19.11.13. Necessary precautions should be taken for underground utility lines like cables, sewers etc. and necessary approvals/clearances from the concerned authorities shall be obtained before commencement of the excavation job.

19.11.14. Water shall be pumped/bailed out, if any accumulates in the trench. Necessary precautions should be taken to prevent entry of surface water in trenches.

19.11.15. During rains, the soil becomes loose. Additional precaution against collapse of side wall shall be taken.

19.11.16. In case of mechanized excavation, precaution shall be taken to not to allow anybody to come within one meter of extreme reach of the mechanical shovel. The mechanized excavator shall be operated by a well-trained experienced operator.

19.11.17. When not in operation, the machine shall be kept on firm leveled ground with mechanical shovel resting on ground. Wheel or belt shall be suitably jammed to prevent any accidental movement of the machine. Suitable precautions as per manufacturer guidelines should be taken for dozers, graders and other heavy machines.

19.11.18. Before operating mechanical excavators always ensure ground stability. Do not park or move vehicle in loose soil.

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19.11.19. In case of blasting, IS: 4081-1986 & Indian Explosive Act and rules for storage, handling and carrying of explosive materials and execution of blasting operation shall be strictly followed.

19.12. ELECTRICAL

19.12.1. Only persons having valid licenses should be allowed to work on electrical facilities.

19.12.2. No person should be allowed to work on live circuit. The same, if unavoidable, special care and authorization need to be taken.

19.12.3. Treat all circuits as "LIVE" unless ensured otherwise.

19.12.4. Electrical "Tag Out" procedure "MUST" be followed for carrying out maintenance jobs.

19.12.5. Display voltage ratings prominently with "Danger" signs.

19.12.6. Put caution/notice signs before starting the repair works.

19.12.7. Proper grounding to be ensured for all switch boards and equipment including Portable ones prior to taking into service.

19.12.8. Make sure that electrical switch boards, portable tools, equipments (like grinding machine etc.) don't get wet during their usage. If it happens, stop the main supply, make the tools dry and then only use them. Check proper earthing.

19.12.9. Don't overload the electrical system, Use only proper rated HRC fuses

19.12.10. Industrial type extension boards and Plug sockets are only to be used.

19.12.11. ELCB of tripping current rating of 30 mA shall be used for all connections. Use insulated 3-pin plug tops.

19.12.12. All power supply cables should be laid properly and neatly so that they don't cause hindrance to persons working and no physical damage also takes place to the cables during various construction activities.

19.12.13. All Power cables to be properly terminated using glands and lugs of proper size and adequately crimped.

19.12.14. Spark-proof/flame proof type electrical fittings shall be used in Fire Hazard zones.

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19.12.15. Check installations of steel plates/pipes to protect underground cables at crossings.

19.12.16. Don't make any unsafe temporary connections, naked joints/wiring etc.

19.12.17. Ensure that temporary cables are free from cuts, damaged insulation, kinks or improper insulated joints.

19.12.18. Check at periodic intervals the condition of electrical equipment, ELCB’s, earthing and record for the same to be maintained by the electrician.

19.12.19. All switchboards should be of MS structure only and incoming source should be marked.

19.12.20. Hand lamps should not be of more than 24V rating.

19.12.21. Fire extinguishers and sand buckets (DCP/CO2) should be kept near temporary switch boards.

19.12.22. All parts of electrical installations should be so constructed, installed and maintained as to prevent danger of electric shock, fire and external explosion.

19.12.23. Cable marking and routing to be clearly marked. No loose cables are allowed at the electrical panels.

19.12.24. Electrical panel rooms and sheds should not be used as store house. Do not store any other combustible materials, work cloths, tools and tackles in the electrical panel sheds.

19.12.25. Good house keeping to be ensured at temporary electrical panels and sheds.

19.12.26. SPECIFICATIONS FOR USAGE OF WELDING MACHINES:

19.12.26.1. The ON/OFF switch of the machine shall be in good operable condition and shall be of correct size.

19.12.26.2. The terminal box shall be properly housed so that water entry is avoided

19.12.26.3. The welding cable connecting studs on the machine shall be in good condition.

19.12.26.4. The machine shall have a distinct earthing provision to which a separate cable shall be connected securely at one end and to the mains grid at the other end.

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19.12.26.5. The name- plate of the machine shall be clear.

19.12.26.6. The input cable shall not have joints and shall be in healthy condition.

19.12.26.7. The machine shall be overhauled thoroughly once in six months and the date of overhaul shall be displayed prominently on the machine.

19.12.27. NOTES TO SPECIFICATIONS FOR WELDING M/C :

19.12.27.1. All unwanted entries to the machine shall be properly sealed.

19.12.27.2. When the machine is used in running units / hazardous locations, flame proof plugs of correct size shall be used.

19.12.27.3. If water falls on the machine, input power shall be switched off and the machine shall be thoroughly checked and megger tested before energizing the machine.

19.12.28. SPECIFICATIONS FOR SWITCH BOARDS :

19.12.28.1. The board shall be made of totally non flammable material MS.

19.12.28.2. All the entries and sides of the board shall be securely sealed with Moniplast compound.

19.12.28.3. The top cover of the board shall be properly secured on all sides with adequate number of screws.

19.12.28.4. The top cover and bottom box shall be in healthy condition i.e. without cracks, pinholes etc.

19.12.28.5. The input flexible copper cable shall be of three-core type with appropriate color code (red, black and green), in good condition and of adequate size such that it can safely carry a min load of 16AMPS.

19.12.28.6. The cable entry shall be properly sealed with correct size of gland.

19.12.28.7. At the input there shall be an ELCB of continuous rating 16Amps and leakage current of size 30 mA.

19.12.28.8. There shall be an earthing point welded to the inside of the board to which all the individual earths of all the sockets

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shall be connected. The green lead of the input cable shall be connected securely to this earthing point. The other end of the green lead shall be connected to the mains earthing grid.

19.12.28.9. All the plugs and sockets shall be of industrial type, metal clad. 3 pin of size 10A/20A. There shall be a separate earthing lead connected to the earthing pin of the plug.

19.12.28.10. There shall not be more than three outgoing points and the cables shall be of standard wire like Finolex and connected securely and dressed neatly.

19.12.29. NOTES TO SPECIFICATIONS FOR SWITCH BOARDS

19.12.29.1. When not in use the input power to the board shall be kept in off condition.

19.12.29.2. The board shall not be used in rains and near water sprays. If water/liquid enters the board, it should be ensured that the inside of the board is totally dry and shall be megger tested before energizing the board.

19.12.29.3. The outgoing points, which are not in use, shall be fully covered.

19.12.30. FOR TEMPORARY ELECTRICAL PANELS

19.12.30.1. Provide RCCB and ELCB for each panel.

19.12.30.2. Should provide rubber sheet for shock protection. All electrical panels should be marked and identified, a record of the same to be maintained.

19.12.30.3. Fire Extinguisher (DCP / CO2) and sand bucket should be provided at every electrical panel.

19.12.30.4. Every electrical panel should be adequately protected from rain by means of weather guard.

19.12.30.5. Test lamp should be provided at the panel for ELCB checking.

19.12.30.6. ELCB checking register should be maintained at each and every electrical panel by the contractor’s electrician.

19.12.30.7. Ensure electrical panel is earthed and earthing is OK.

19.12.30.8. Access way to the electrical panels should be clear. Do not use panel room for storage of materials.

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19.12.30.9. Request for temporary power supply.

REQUEST FOR TEMPORARY POWER SUPPLY:

(TO BE FILLED BY THE JOB ENGINEER AND TO BE APPROVED BY THE CONCERNED

MANAGER. SEPARATE FORMS TO BE FILLED FOR DIFFERENT TEMPORARY POWER

PANELS.)

1.0 TEMPORARY

POWER REQUIRED

AT:

2.0 AGENCY TO WHOM

POWER IS TO BE

GIVEN:

M/S.

3.0 IS POWER TO BE

GIVEN FREE OF

COST:

YES* / NO

( * IF POWER IS TO BE GIVEN ON CHARGEABLE BASIS, CONTRACTOR

SHOULD BRING THREE PHASE ENERGY METER WITH VALID CALIBRATION

CERTIFICATE.)

4.0 POWER

REQUIREMENT**

(IN KW / VA / AMPERES)

THREE PHASE:_________________

SINGLE PHASE:_________________

** IF THE LOAD

REQUIREMENT IS

MORE THAN 63A / 36KW, 3-PHASE, PLEASE ENTER

THE DETAILS

HERE.

WELDING MACHINES:_________NOS. RATING:_________

HYDRO-JETTING M/C: _________NOS. RATING:_________

DRILLING M/C : ____________ _NOS. RATING:_________

NO. OF HANDLAMPS : ________ NOS. RATING:_________

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OTHERS (PL. SPECIFY) : _______________________________

_______________________________

5.0 JOB FOR WHICH

POWER IS TO BE

GIVEN:

6.0 HPCL PO NO. AND DATE:

7.0 TEMPORARY

POWER

REQUESTED BY:

(JOB ENGINEER)

(SIGNATURE WITH DATE:)

8.0 REQUEST

APPROVED BY:

(MANAGER)

(SIGNATURE WITH DATE:)

9.0 WO NO. AND

DATE:

WO PRIORITY: 0 / 1 / 2 / 3

CHECKLIST FOR TEMPORARY POWER SUPPLY:

(TO BE FILLED DURING JOINT SITE VISIT AFTER COMPLIANCE TO THE CONDITIONS, BY

THE CONTRACTOR.)

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1

Panel Condition (Physical Checkup)

CHECK IF PANEL BODY IS RUSTED, STRUCTURE IS OK, ALL COMPONENTS

ARE FIRMLY CONNECTED TO THE BODY, ETC.

Panel Structure : RUSTED / NOT RUSTED

Panel Components: RUSTED / NOT RUSTED

Connections: TIGHT / LOOSE

2 Components used are acceptable make:

General make of the components to be in line with acceptable vendors (GEC, ALSTOM, L&T, DATAR, SIEMENS)

STANDARD MAKE / NON-STANDARD MAKE

3

Proper fuses are used as per rating of feeder

(Wire fuses shall not be used. Fuse rating should match with the power requested under Sl. No.4.0 of Part-1 and should be able to take care of any downstream overload/fault. )

FUSE MAKE:_________________________

FUSE RATING: _______ A

FUSE BASE RATING: _______ A

SWITCH RATING: _______ A

4 Proper earthing is provided for the temporary panel. (Two distinct earthing to be provided for the panel, which should be connected to the earthing grid from the power source. The earth conductor size should be at-least half the size of the main power cable.)

SIZE OF MAIN CONDUCTOR:_______________

SIZE OF EARTH CABLE: _________________

NO. OF EARTHS

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PROVIDED: _________ nos.

5 Shed is provided over the temporary power panel to prevent rain water directly falling on panel. (All outdoor panels are to be provided with shed.)

YES / NO

6 All the opening in the panel are plugged/sealed.

YES / NO

7 Danger board is provided on the panel. (Standard DANGER sign with the symbol of skull and bones and the voltage rating (415V) to be provided. The word DANGER should be in English, Hindi and Telugu.)

YES / NO

8 Sand bucket & fire extinguisher is provided. (Not required in fabrication yard, where the same is available in the Contractor’s shed.)

YES / NO / NOT REQUIRED

9 Rubber mats are provided in front of the panel of safely standing on them for operating the switches.

YES / NO

10 Contractor has provided Electrician with valid wire man license, for monitoring the temporary panel.

(Copy of the wire-man license should be attached to this format.)

YES / NO

11 30mA leakage rating ELCBs are provided in the outgoing feeders. (if outgoing feeders are not having ELCBs, the incomer should be an RCBO/RCCB of adequate load rating and 30mA leakage rating.)

YES / NO

12 Lamp is provided for indication and illumination in the temporary panel shed.

YES / NO

13 No other material is stored in the shed.

YES / NO

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We have jointly inspected the temporary panel & the shed and found it to be complying / not complying with the above safety regulations and conditions.

(Contractor)

(Job Engineer)

(Maint. Electrical)

19.13. LIFTING EQUIPMENT: Following are the general guidelines to be followed with regard to all types of handling and lifting equipment in addition to the guidelines for specific type of equipments dealt later on.

19.13.1. There should be a well-planned safety programme to ensure that all the lifting appliances and lifting gear are selected, installed, examined, tested, maintained, operated and dismantled with a view to preventing the occurrence of any accident;

19.13.2. All lifting appliances shall be examined by competent persons at frequencies as specified in "The Factories act". Copies of test certificate shall be produced to sponsoring department and fire & safety.

19.13.3. Check thoroughly quality, size and condition of all lifting tools like chain pulley blocks, slings, U-clamps, D-shackles etc. before putting them in use.

19.13.4. Safe lifting capacity of all lifting & handling equipment, tools and shackles should be got verified and certificates obtained from competent authorities before its use. The safe working load shall be marked on them.

19.13.5. Check periodically the oil, brakes, gears, horns and tyre pressure of all moving equipments like cranes, forklifts, trailers etc as per manufacturer's recommendations working of controls, switches etc.

19.13.6. Check the weights to be lifted and accordingly decide about the crane capacity, boom length and angle of erection.

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19.13.7. Allow lifting slings as short as possible and check for packings at the friction points.

19.13.8. While lifting/placing of the load, no unauthorized person shall remain within the radius of the boom and underneath the load.

19.13.9. Prior to lifting, check the condition of earth, soil/concrete for its fitness to lift the load

19.13.10. While loading, unloading and stacking of pipes, proper wedges shall be placed to prevent rolling down of the pipes.

19.13.11. Control longer jobs being lifted up from both ends using guide ropes.

19.13.12. Only trained operators and riggers should carry out the job. While the crane is moving or lifting the load, the trained rigger should be there for keeping a vigil against hitting any other object.

19.13.13. During high wind conditions and nights, lifting of heavy equipments should be avoided. If unavoidable to do erection in night, operator and rigger should be fully trained for night signaling. Also proper illumination should be there.

19.13.14. Allow crane to move on hard, firm and leveled ground.

19.13.15. Crane and Hydra should not be used for material movement.

19.13.16. When crane is in idle condition for long periods or unattended, crane boom should either be lowered or locked as per manufacturer's guidelines.

19.13.17. Hook and load being lifted shall remain in full visibility of crane operators, while lifting, to the extent possible.

19.13.18. Don't allow booms or other parts of crane to come within 3 meters reach of overhead electrical cables.

19.13.19. No structural alterations or repairs should be made to any part of a lifting appliance, which may affect the safety of the appliance without the permission and supervision of the competent person.

19.13.20. Crane operators and riggers certificate & experience to be provided to HPCL.

19.13.21. Do not do any alterations to load in movement or while load is being lifted.

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19.13.22. All the lifting equipment such as wire ropes, web slings, chains etc are to be physically checked for any visible damage prior to every use.

19.13.23. Always ensure job plan is present while carrying out any critical lifting and heavy loads.

19.14. WORKING AT HEIGHTS

19.14.1. While working at a height of more than 2 meters, ISI marked full body safety harness with double lanyard shall be used. Condition of the safety belt shall be checked before each use of the belt and record of the same to be maintained.

19.14.2. Safety belts should be of the following specifications.

19.14.3. IS: 3521 marked full-body safety belt with double harness, belt made of nylon with 40 mm x 3 mm shoulder strap having double folded stitches , o-ring buckles made of stainless steel and 2.5 meter long two polyamide ropes of 12 mm dia with self closing hook of stainless steel attached to it for anchoring with scaffold pipe of # 50mm .

19.14.4. Worker should be well trained on usage of safety belt especially about the usage of the two harnesses at the time of ascending/descending.

19.14.5. Safety belts should be well maintained cleaned up regularly of oil, grease and dirt. Damaged safety harnesses should be identified and removed from usage.

19.14.6. Do not carry tools while ascending and descending to heights. All tools should be carried in tool kits to avoid their falling.

19.14.7. If the job is on fragile/sloping roof, roof walk ladders shall be used. F& S department should be informed prior to doing job to ensure that adequate safety precautions are taken.

19.14.8. Provide lifeline wherever required.

19.14.9. Additional safety measures like providing Fall Arrestor type Safety belt, fire retardant safety net proper access and scaffolding working platform with hand rails etc., should be provided depending upon site conditions, job requirements as mentioned by HPCL time to time.

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19.14.10. Don't throw or drop material/equipment from height, instead of that lower the materials and vice versa.

19.14.11. When hauling /lifting operations are in progress, the grade area to be barricaded with red and white colour caution tape.

19.14.12. Avoid working at two elevations at the same locations, if needed to perform proper safety review and precautions undertaken to be approved by HPCL.

19.14.13. Refinery standard to be strictly adhered to while laying scaffolding for work at heights.

19.14.14. Access ladder, work platform, hand railing and guard railing to be provided with scaffolding that is erected. Scaffolding pipes should not be dropped from height while dismantling or erection.

19.14.15. Do not use scaffolding clamps as steps for climbing a scaffold. Always hook up the safety belt to the pipe above your height, so that in case of a fall there will be no swinging and hitting against near by structure.

19.15. RADIOGRAPHY

19.15.1. Whenever a contract for industrial radiography is awarded to any industrial radiography agency, the Contractor shall ensure that:

19.15.1.1. The radiography agency is duly authorized by RSD, AERB to work at the particular site of Contractor

19.15.1.2. The radiography agency carries out the radiography work by adhering to requirements of AERB Safety Code on Industrial Radiography (AERB/SC-IR, 2001)

19.15.1.3. The radiographer who will be engaged by radiography agency for carrying out radiography work of radiography agency is certified by BARC/AERB

19.15.1.4. the radiographer has a functional radiation survey meter and makes use of it during radiograph

19.15.1.5. The radiographer cordons sufficient area to control access of unauthorized person during radiography at the site.

19.15.1.6. The radiography work is supervised by Radiological Safety Officer (RSO)/site-in-charge, if any, of the Contractor.

19.15.2. During field radiography, all the area which falls in the radiation zone as per survey meter readings has to be barricaded

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and people evacuated from the area. A flickering light and caution notice should be displayed.

19.15.3. The Contractor shall be responsible for providing adequate illumination, scaffolding and other facilities required to facilitate the safe radiography work by radiography agency.

19.15.4. Special permission/permit should be taken for radiography from area-in-charge.

19.15.5. As far as possible, field radiography should be done only during night time when there is little or no occupancy there.

19.15.6. Radiation warning signals should be pasted all along the cordoned off area.

19.15.7. Entry into the restricted area by unauthorized persons should be strictly prohibited during exposure. Ensure contractor supervisors presence at the barricading area for warning trespassers.

19.15.8. The radiation level along with the cordon should be monitored by a suitable and well-calibrated radiation survey meter. Radiation level outside the storage room should not exceed 0.25 mR/hr.

19.15.9. All personnel working with radiography sources should wear dosi meters and appropriate protective equipment and film badges issued by BARC.

19.15.10. Protection facilities such as radiation hazard placards and means of cordon off shall be available at each site.

19.15.11. The Contractor shall verify that the radiography agency has emergency plans, preparedness and contact numbers in case of emergency/incidents involving radiography devices.

19.15.12. The package containing radiography cameras and sources should never be carried by public transport like bus, train etc.

19.15.13. The Contractor shall ensure that the radiography devices (camera(s)) with source are brought in or moved out of the site with appropriate gate pass mentioning details of the equipment. The proper records of incoming and out going of radiography devices are maintained at storage room and at security department.

19.15.14. Radiography material, source and cameras should not be stored inside the refinery. On completion of radiography the

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contractor should take back the source and cameras, transportation as per BARC instructions.

19.15.15. In case of an accident (due to loss or of damage to radiography source), action should be taken in line with BARC Safety Rules/Guidelines.

19.15.16. Radiography should be carried out under the supervision and control of Radiation Safety Officers (RSO).

19.16. GRIT/SHOT BLASTING

19.16.1. Grit/sort blasting should be used only after approval from competent person.

19.16.2. Air Compressor used for sand/shot blasting/painting should have guard and positioned away from the work place.

19.16.3. Exhaust of the prime mover, if IC engine is used, should be directed away from the work place and should not damage any other equipment, cables, and structures. Spark arrestor should be fixed on the exhaust.

19.16.4. In case of motor driven compressor, the body of the motor as well as the compressor to be properly earthed.

19.16.5. The hoses used for compressed air should be of proper quality, and health of the same to be ensured through regular check/ test.

19.16.6. The operator of sand/shot blasting/painting should wear suitable PPE's including hood with air connection.

19.16.7. Covering eduction arrangement etc., measures to be taken to suppress dust/spray particle.

19.16.8. When these activities are done in confined places, adequate measure to be taken for proper ventilation. The compressor, engines shall be located outside the confined space and only the hoses taken in.

19.16.9. The hopper used for sand/short blasting should be tested once in a year for 1.5 times of normal operating pressure by compitent person and Test certificates to be maintained.

19.16.10. All the rotating parts in the equipment shall be provided with guards.

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19.16.11. The sand blasting area to be covered on four sides so that dust does not spread over. All workmen to be provided with dust masks.

19.17. GAS CUTTING, WELDING, brazing

19.17.1. Ensure that only approved and well-maintained apparatus, such as torches, manifolds, regulators or pressure reducing valves, and acetylene generators, be used.

19.17.2. The work piece should be connected directly to Power supply, and not indirectly through pipelines/structures/equipments etc.

19.17.3. All cables, including welding and ground cables, shall be checked for any worn out or cracked insulation before starting the job. Ground cable should be separate without any loose joints.

19.17.4. All gas cylinders shall be properly secured in upright position.

19.17.5. Acetylene cylinder key for opening valve shall be kept on valve stem, while cylinder is in use, so that the acetylene cylinder could be quickly turned off in case of emergency. Use flash back arrestors at cutting torch to prevent back-fire in acetylene/oxygen cylinder.

19.17.6. Use trolleys for oxygen & acetylene cylinder and chain them.

19.17.7. proper colour code shall be used for oxygen and acetylene cylinders and hoses.

19.17.8. Ensure that hoses are free from burns, cuts and cracks and properly clamped.

19.17.9. During cutting/welding, use proper type goggles/face shields.

19.17.10. The first cut or weld to be undertaken in the presence of company supervisor.

19.17.11. Liquefied petroleum gas cylinders and cylinders containing liquefiable gases shall always be kept in an upright position and shall be so placed that they cannot be knocked over.

19.17.12. A hammer should never be used for opening cylinder valves

19.17.13. If a leak in the valve cannot be rectified by tightening the gland nut or the spindle, the cylinder shall be removed to an open

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space where it is least dangerous to life and property and the filler shall be informed. In the case of LPG cylinder, the safety cap shall be fixed to arrest the leak and the cylinder shall be moved to an open space.

19.17.14. Domestic LPG Cylinders shall not be used for gas welding/cutting job. Only industrial LPG cylinders/private LPG cylinders to be used.

19.17.15. Cylinders heads should be protected when not in use.

19.17.16. Keep regulators, hoses, torches and other fittings free from grease, oil or other combustible substances.

19.17.17. Never use lubricants on oxy fuel gas equipment.

19.17.18. Never substitute oxygen for compressed air.

19.17.19. Make sure a confined area is well ventilated and gas freed before entry. Never carry any cylinders into a confined area.

19.17.20. Cylinders should not be subjected to falls, shock or undue heating.

19.17.21. Acetylene cylinders shall not be allowed to pass through a copper rich material as it forms explosive substances.

19.17.22. Do not take fuel gas Cylinders in trenches.

19.17.23. Proper regulator with pressure gauge shall be used for both Fuel gas and Oxygen cylinders.

19.17.24. Make sure Jubilee clamps are used for fixing hoses. GI wires should not be used for tying, as tubes will get cut.

19.17.25. Adequate and proper ventilation should be provided to keep the fuel gas concentration below the danger limit and to avoid prolonged exposure to fumes.

19.17.26. Flash back: If the tip of the nozzle is obstructed oxygen can flow back into the acetylene pipe and likely to cause explosion. Always keep the tip of the nozzle unobstructed.

19.17.27. Prior to commencement of the job, tubes, cutting torch condition should be checked and any damages/faulty equipment should be replaced.

19.17.28. The cutting torch shall be serviced monthly basis. Ensure that only approved and well-maintained apparatus, such as torches, manifolds, regulators or pressure reducing valves, and acetylene generators, be used.

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19.17.29. The work piece should be connected directly to Power supply, and not indirectly through pipelines / structures / equipment etc.

19.17.30. Domestic LPG cylinders shall not be used for gas welding/cutting job. Only industrial LPG cylinders/private LPG cylinders to be used.

19.18. BARRICADING

19.18.1. Contractor shall erect and maintain barricades required in connection with his operation to guard the followings.

19.18.1.1. Excavations

19.18.1.2. Hoisting areas

19.18.2. Areas adjudged hazardous by Contractors’ or Owner’s Inspectors.

19.18.3. Contractor’s employee and those of its sub-contractors shall become acquainted with Owner’s barricading practice and shall respect the provision thereof.

19.18.4. Barricades and hazards adjacent to but not located in normal routes of travel shall be marked by red flasher lanterns at nights.

19.18.5. Demolition of Buildings:

19.18.5.1. Before taking up the demolition work, a comprehensive site survey must be carried out considering the protection of the surrounding buildings/structures/equipment/utilities and service etc.

19.18.5.2. The electrical power supply to the building shall be disconnected prior to starting demolition.

19.18.5.3. All gas, water and steam service lines shall be positively isolated.

19.18.5.4. The structure to be demolished should be adequately fenced and cordoned off and suitable boards shall be provided warning the public about the danger.

19.18.5.5. For demolition of the building, the glasses in door and windows, loose objectives, projected parts shall be removed first.

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19.18.5.6. Scaffolding used for the demolition operation should be independent of the structure to be demolished.

19.18.5.7. Stair with hand railing should be kept in position as long as possible to provide access.

19.18.5.8. Workers should strictly use Safety belts while working at height, Safety helmets, Safety shoes and other safety gears like safety gloves etc.

19.18.5.9. The demolished materials should not be thrown from height, it should be lowered by the hoist and winch.

19.18.5.10. If the demolitions are carried out by the machines like power shovels, bulldozer etc., safety measures relevant to the operation and use of such machines should be adhered to.

19.18.5.11. The cold work permit shall be taken.

19.19. Hot Work on all Welded Lines

Prior to starting work on welded line (Ex. product shipping lines) which cannot be blinded close to the point where the hot work is to be performed, the following procedure must be observed.

19.19.1. The line must be properly cleared of products and isolated from other operating equipment by blanking. If there is any doubt about the presence within the line, a pilot hole must be drilled by cold cutting.

19.19.2. When it has been determined that there is no pressure, the line must be cold cut, unless specifically authorized by the operations supervisor to do otherwise.

19.19.3. Once a section of the line has been cut out and removed and the line vented, plugs must be inserted in each of the open ends of the pipe, at the cut before hot work is performed. A proper plug must seal the pipe completely.

19.19.4. An alternate method of plugging the end of a pipe line for hot work is to insert, blocks or pieces of solid carbon dio oxide (dry ice) into the container. The dry ice gives off CO2 gas, which makes the atmosphere in the pipe incapable of supporting combustion. In addition, the dry ice cools any residual oil in the pipe below the point where it can give off combustive vapors. The plug must be at least six feet long and must be at least five feet back from the point of hot

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work. Necessary care shall be taken so that the temperature of pipeline does not drop below sub zero during dry ice blanketing.

19.19.5. A vent must be provided through each plug as described above to prevent any pressure build-up. The vent must discharge at least 20 feet away from the plug end.

19.19.6. Plugs must be inspected during the course of job, especially if any hammering is being done, to make sure that they completely block the pipe at all times.

19.20. Tank Repairs:

19.20.1. General:

19.20.1.1. There will be a detailed hydrocarbon & water presenting of tank by HPCL Operations followed by blinding.

19.20.1.2. Necessary hazard related instructions given by the HPCL Operations and Maintenance engineer should be considered while tank repair.

19.20.1.3. Work Permit system should be rigidly followed for all work of tank cleaning and repairs.

19.20.1.4. Respiratory protective equipment should be maintained in good operating condition.

19.20.1.5. Ensure that gas-testing equipment is in good operating condition and proper. Procedures for testing are followed.

19.20.2. Entry into Tank.

19.20.2.1. No entry should be permitted inside the tank, until all lines the tank are blinded / isolated.

19.20.2.2. Every effort should be made to clean the tank from outside, to the extent possible.

19.20.2.3. Appropriate respiratory protective equipment, personal protective equipment and clothing should be used during cleaning operations.

19.20.2.4. No-entry should be permitted if the hydrocarbon gas presence is above 5% of Lower Explosive Limit and oxygen percentage less than 19.5% by volume in air with hydrocarbon gases.

19.20.2.5. While men are working inside a tank, a standby should be posted outside at the manhole, to keep a close watch and call for any assistance that may be required.

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19.20.2.6. Air blower must continue during cleaning operation.

19.20.3. Hot Work.

19.20.3.1. Prior to hot work, all combustibles, liquid hydrocarbons, sludge, scales, deposits etc should be completely removed. Carefully examine linings, pontoons and tank bottoms and legs for trapped oil.

19.20.3.2. Combustible gas indicator should read zero.

19.20.4. Closing Tank.

19.20.4.1. When the tank is to be buttoned up after the work is completed, ensure that no one is left inside the tank and no material is left behind.

19.20.4.2. The tank should be offered for inspection prior to buttoning up. For this purpose a specific permit for buttoning up to be made.

20. PENALTY FOR NON-COMPLIANCE

The penalty system is instituted to ensure safety compliance (HPCL- Fire & Safety shall decide whether an infringement is minor or major for violations which, are not listed below).

20.1. Violations: The penalty system is divided into two categories, Minor and Major. (HPCL - Fire & Safety shall decide whether an infringement is minor or major for violations which are not listed below). Examples given are situation specific and what is minor in a particular context may be a major deviation in another situation.

20.1.1. Minor violation: Examples

20.1.1.1. Not wearing personal protective equipment (PPE) at work site.

20.1.1.2. Minor traffic violation (wrong parking, over speeding)

20.1.1.3. Blocking of emergency equipment or exits.

20.1.1.4. Using unapproved scaffolding Etc.

20.1.2. Major violation: Examples

20.1.2.1. Smoking in the refinery, carrying matches or lighter and mobile telephone.

20.1.2.2. Working without valid work permit.

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20.1.2.3. Not wearing proper breathing apparatus when instructed.

20.1.2.4. Not providing shoring / sloped excavation for the deep pits.

20.1.2.5. Not providing fire extinguisher / fire hoses for hot work.

20.1.2.6. Repeating minor violations more than twice.

20.1.2.7. Major traffic violation.

20.1.2.8. Found guilty negligent driving resulting in a vehicle accident.

20.1.2.9. Entering classified area without permit.

20.1.2.10. Not complying with written instruction on the work permit.

20.2. Infringement Report Procedure:

Manager and above of Fire & Safety department are authorized to issue infringement report to the sponsoring department

The sponsoring department shall take action and provide feedback to fire & safety (If more or less severe action was taken other than recommended, details of same shall be provided.)

20.3. TABLE OF PENALTY STAGES

VIOLATION FIRST SECOND THIRD

MINOR Caution Notice Penalty Rs. 1000 /-

Penalty Rs. 3000/-

MAJOR Penalty Rs. 3000/-

Penalty Rs. 10,000/-

on holiday list

( duration will be decided by General Manager- Opns / Proj. )

Major accident /

Penalty Rs, 1 lakhs

Penalty Rs. 5 lakhs

on holiday list

( duration will be

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fire decided by General Manager- Opns / Proj. )

Note : HPCL reserves the right to impose more severe penalty, i.e. suspend/terminate the contract / employee, his supervisor or the site manager.

21. SAFETY MANAGEMENT SYSTEM FOR CONTRACTORS

The contractors shall have well defined Safety Management System as given below.

21.1. Written Safety Program

21.1.1. Contractors must have a written safety program. A written safety program need not be lengthy, but should include following items:

21.1.1.1. Safety Policy Statement

21.1.2. Safety Goals & Objectives

21.1.3. The program should establish the safety goals and objectives of the firm and a method of measuring it. Action plans should be developed for use in achieving the goals and objectives.

21.1.4. Site Safety Organization and Responsibilities

The program should establish responsibilities for managers, supervisors, safety representatives, and the employees. There should be at least one qualified and experienced Safety Engineer /Supervisor depending on the size of the organization exclusively responsible for safety implementation/Co-ordination. He shall be free from any other responsibility. And safety representative qualification will be verified by the Fire and Safety department. Depending upon the nature and size of the job, minimum strength of the safety personnel shall be as follows:

EMPLOYEE STRENGTH

(including sub-contractor)

SAFETY STAFF

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NO OF EMPLOYEES UPTO 30 ONE ( 1 ) SAFETY SUPERVISOR

NO. OF EMPLOYEES : 30 TO 75

ONE (1) SAFETY ENGINEER AND ONE (1) SUPERVISOR

NO. OF EMPLOYEES : 75-250

ONE (1) SAFETY ENGINEER + TWO (2) SAFETY SUPERVISOR

NO. OF EMPLOYEES : > 250 -500

TWO (2) SAFETY ENGINEERS + THREE (3) SAFETY SUPERVISORS

NO OF EMPLOYEES > 500 DEPLOYMENT WILL BE MORE THAN THE

REQUIREMENTS SPECIFIED ABOVE AND

CONTRACTOR TO PROPOSE DEPENDING

LOCATION AND MOBILISATION AND TAKE

PRIOR APPROVAL OF HPCL.

a) No. of employees mentioned above represent the maximum number employees estimated to be engaged at the site on any day by the Contractor and their sub-contractor(s)

b) A major contractor is one who has employed more than 60 workers engaged in a Project or maintenance activity. The contractors shall have well defined Safety Management System as given below.

c) Contractor shall provide additional Safety Personnel and fire watches as directed by HPCL depending upon need. Safety personnel should be identifiable and should wear green jacket.

d) Each contractor should have a safety supervisor as a minimum irrespective of no of workmen

e) For every 30 workmen a safety supervisor should be appointed and present for multiple location job with in a radius of 50 meter.

f) Effective communication system shall be maintained by all contractors using intrinsically safe walkie-talkies

g) All Safety Officers and supervisors will be having recognized qualification and experience. HPCL would verify their credentials by checking documents and also personal interaction.

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h) No job will be attempted without a job safety analysis by contract safety officers/supervisor and contract job engineers. Each safety supervisors will be reporting near misses and personally supervise corrections undertaken and ensure preventive measures to prevent recurrence.

21.2. Orientation of New Employees

21.2.1. Each employee should receive a safety orientation prior to beginning work. The orientation should include provisions of the written safety program and procedures applicable to the proposed work. The orientation also should include the following :

21.2.2. Clarification of the safety responsibilities for contractor, subcontractor, employee and all construction site personnel.

21.2.3. Clarification of safety expectations from the employee.

21.2.4. Safety rules - explain the company rules.

21.2.5. First aid facilities - state where first aid facilities are located and how first aid facilities are to be utilized.

21.2.6. Accident reporting - explain the procedure for reporting accidents and injuries.

21.2.7. Tool box meetings- state when and where held, who is to attend, and that attendance at meetings is mandatory.

21.2.8. Personal protective equipment - when such equipment is specified for a work assignment, its use in mandatory and not optional.

21.2.9. Reporting unsafe acts or conditions - employees should be encouraged to report unsafe acts or conditions to their supervisors so these may be corrected.

21.2.10. On completion of Orientation Training program, contractor employee to pass the test. The successful candidate only will be issued the “Safety training card”.

21.3. Safety Rules Enforcement Procedure:

21.3.1. There must be a procedure for enforcing safety rules. This procedure should be written, and should be enforced equally among supervisors, managers, workers and other parties on the site. It should spell out what situations will result in immediate discharge and what actions will be taken on first or subsequent incidents involving violations of a less serious nature.

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21.3.2. There should be a written notice when a safety violation occurs. If disciplinary action is involved, each violation should be written up in detail, discussed with the disciplined employee.

21.4. Training to Contractor Supervisor :

21.4.1. HPCL – Fire & Safety Department will be organizing Fire & Safety training program for the Contractor Supervisors on regular basis. It is the responsibility of the contractor to ensure that the concerned supervisors / Safety Engineer / Safety Supervisor attend the training. All these training programs will be organized at the cost of HPCL, Training cards will be issued by Fire & Safety dept. The content of the program is

21.5. Training & Tool box/Safety Meetings:

21.5.1. Contractor Management responsibilities include establishing practices and procedure and ensuring that each employee is trained regarding work hazards and the methods by which these hazards can be controlled.

21.5.2. On some safety subjects, toolbox meetings are the primary source of safety training for employees. They should conform to the following basic guidelines :

21.5.3. The meetings should be conducted daily, before work begins for the day or shift. It should last from 5-10 minutes. Additional meetings also may be warranted during the week.

21.5.4. The subject material to be discussed should be typed, reproduced and recorded & feedback taken from workmen.

21.5.5. The subject material should be pertinent to the type of work being performed.

21.5.6. The meeting should be conducted, for each craft by their supervisor at a predetermined place, using the subject material provided.

21.5.7. When deemed appropriate, the craft supervisor should add particularly relevant topics to the discussion, gathered from accidents, lessons learnt etc. in consultation with Safety Engineer.

21.5.8. Employees speaking different languages Telugu, English, Hindi will be identified and grouped. Information shall be communicated to them accordingly in appropriate language for better communication.

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21.5.9. The project manager and/or safety manager/engineer should regularly attend these meetings to audit and visually display their support for safety on the job.

21.5.10. In addition to toolbox meetings, Contractor should conduct periodical Safety Training all employees. The training program shall at least include the following;

21.5.10.1. Safe Work Procedure & Practices

21.5.10.2. Work Permit System

21.5.10.3. Entry into Confined Space

21.5.10.4. Use of Personal Protective Equipment

21.5.10.5. Working at Height

21.5.10.6. First Aid

21.5.10.7. Fire Fighting

21.5.10.8. Hazardous Material (chemicals & toxic gases)

21.5.10.9. Emergency Response Action and Alarms Including Evacuation Procedure.

21.5.11. The Contractor shall arrange the training of their own and maintain documentation of the same. The documentation should include the names of those trained, course content, date & time and the names of the instructors HPCL will periodically review the Contractor’s training record to verify that training is being conducted which meets the criteria.

21.6. Job Site Inspections:

21.6.1. Job safety inspections are visible signs to employees that safety is working. In addition, they provide for the identification of areas of potential loss and can be used to constantly monitor the effectiveness of the Accident Prevention Program. As with all safety activities, the inspection process needs to have well-defined objectives and designated participants as follows.

21.6.2. Contractor should make a safety audit of the work area at least once a week using an inspection CHECK LIST.

21.6.3. All safety personnel, including designated safety representatives, should make daily inspection of the work area. The

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inspection should be routine, planned, and designed to include communications with specific people in the work place, rather than just a visual site check.

21.6.4. Job supervisors also should make daily inspection of their work areas for the specific purpose of correcting unsafe acts or hazardous condition.

21.6.5. Regularly planned inspection should go beyond routine visual site checks. The result of these inspections should be used for setting goals for future improvements.

21.6.6. These inspections should make use of detailed checklists, developed for each item such as electrical facilities, lock-out systems, scaffolding, fire prevention, personal protective equipment, hazardous material handling, housekeeping, hand and power tools, maintenance practices and machine or equipment guarding. There should be effective systems for monitoring the progress on action plan developed based on the audits.

21.7. Accident Investigation Procedure:

21.7.1. An effective accident investigation and a reporting procedure is an essential part of any effective safety program.

21.7.2. Contractor should have his own accident investigation procedure in addition to his responsibilities as per HPCL Accident Reporting/Investigation Procedure.

21.7.3. The procedure outlined in the safety program should call for an inspection by the immediate supervisor of the person involved in the accident. A form should be completed that indicates what happened, the basic cause of the accident and action taken to prevent the recurrence of similar incident.

21.7.4. Corrective action should be taken as soon as practical after the investigation is complete.

21.8. Contractor Responsibility for Supervision

21.8.1. Upon award of the contract and prior to commencement of job, the contractor shall furnish “BIO DATA “ of all their Supervisors and skilled or un-skilled workers. All personnel deployed by contractor for the job must have completed safety training in HPCL Safety Dept.

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21.8.2. Contractor shall deploy qualified and experienced supervisor and other man power, which are well conversant with the safety regulations of the refinery the electricians to be deployed on the job should have Wireman License.

21.8.3. Contractor all supervisor must be given safety training/demonstration with the help of our Fire & Safety Dept. and should acquire knowledge of fire prevention and should be able to make use of Fire Extinguishers

21.8.4. Contractor shall route the application for Gate passes for their Supervisors though concerned department to safety section and obtain gate passes from CISF contractors to take clearance from Fire & safety section to ensure that all their supervisors are properly trained.

21.8.5. Contractor shall deploy adequate no. of supervisors including specific safety supervisor during the period of execution of the contracts awarded to him.

21.8.6. Contractor must familiarize him self from HPCL Engineer In-Charge about all known potential fire, explosion toxic release hazards related to his contract. He in turn will ensure that same information has been passed to his supervisor and workmen Proper record of such dissemination of information must be made by the contractor and submit to the Engineer-In-Charge failing which further continuation of work may be withheld.

21.8.7. Contractor must ensure that all his supervisors are properly trained. Document is to be maintained showing that each employee has received and understood from his supervisor necessary training The record should contain the supervisor’s name who has provided training to the employees, employees name who has received training, date of training, topic and the means used to verify that the employee has understood the training.

21.8.8. Contractor must provide at least one full time on site safety coordinator when the contractor has engaged manpower in excess of 50 in contract activities in the refinery. If the manpower is less then 50, the onsite safety co-ordination responsibilities shall be assumed by any one of the contractor’s other supervisory staff. In both cases, the contractor must specify in writing the name of such persons to the Engineer-In-Charge.

21.8.9. Contractor safety coordinator or his supervisor responsible for safety as the case may be shall conduct at his work site, and

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document formal safety inspections and audits at least once in a week. Such documents shall be submitted to Engineer-In-Charge for his review and record.

21.8.10. Contractors, supervisors must attend all scheduled safety meetings as would be intimated to him by Engineer-In-Charge.

21.8.11. Before stating work under any contract , the contractor must ensure that a job specific safety procedures/ field practices as required over and above the safety permit conditions are prepared and followed He should also ensure that all supervisors and workers involved understand and follow these procedures/field practices.

21.8.12. Contractor must ensure that in his work site:

21.8.12.1. Appropriate display boards are put displaying sign for site safety, potential hazards and precautions required.

21.8.12.2. Safety performance display boards are provided.

21.8.12.3. Housekeeping/Scrap removed is done on daily basis.

21.8.13. Contractor shall put all efforts to deploy minimum manpower to execute the jobs in stipulated time by using modern techniques and mechanization. The contractor deploying minimum manpower will be given preference.

21.9. Restrictions in use of man power, and normal timings for work.

21.9.1. Contractor shall put all efforts to deploy minimum man power to execute the work awarded to their in stipulated time by using modern techniques & mechanization.

21.9.2. Contractors deploying minimum manpower will be given due weights while renewing his registration.

21.9.3. No contractor employee shall normally work for more then 8 hours a day and not more then 48 hours in a week of seven days . After every 48 hours of a working, an employee must get one full day rest.

21.9.4. The normal duty timings for contractor employees shall be between 8.00 AM and 4-15 PM.

21.9.5. Contractor employees would not be allowed to work on Sunday and refinery holidays.

21.9.6. Any deviation from above shall be with express permission from the Engineer-In-Charge.

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21.10. Injury Notification and Investigation

21.10.1. Contractor must report to HPCL supervisor on the job any injury sustained by any of his employees or any near miss or any hazardous /dangerous incident at his work site with in the refinery premises. Hiding of any accident or near miss would be viewed as serious misconduct.

21.10.2. Arrange to provide FIRST AID immediately to the injured employee.

21.10.3. Keep and maintain proper records of all such incidents in respect of personnel /work site.

21.10.4. Submit to the engineer-in-charge a first information report as per prescribed Performa with in 4 hours of the incident.

21.10.5. Arrange to immediately investigate the incident and furnish with in 24hours a written investigation report in prescribed performs to HPCL Engineer-in –charge.

21.11. Requirement during Submission of Tender:

21.11.1. Complete work injury records per year for the last three years and total man hours worked per year for the last three years.

21.11.2. Safety assurance plan

21.11.3. Quotation must clearly indicate the number of Supervisors and skilled workers, which will be deployed for the job, from time to time during execution of the contract.

21.11.4. The above information will be taken in to view during tender evaluation.

21.12. Display Boards at Site:

21.12.1. Contractor must provide and maintain Display boards in the work site.

21.12.2. Appropriate display board displaying information as per HPCL “Work Site Display Board” Specification.

21.12.3. Safety Performance score board.

21.13. Participation in Safety Activities:

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21.13.1. Contractor must attend all scheduled safety meetings as would be intimated to him by the Engineer- in-Charge.

21.13.2. Contractor also must ensure that al his employees participated in safety promotional activities organized in the refinery

Note :

• Every employee other than HPCL employee or a casual visitor entering in the refinery would be governed by the above conditions.

• The term supervisor would mean any person who oversees the work of a group of workmen. All other persons would be considered as workmen.

• Violation of any of the special conditions of safety would attract penal actions including termination of the contract/ registration.

• Meticulous adherence to these requirements would be documented by the engineer-in-charge on conclusion of the work and placed in the dosser of the contractor. This performance would be given adequate weights at the time of renewal of the registration.

• Any dispute arising out of these conditions shall be referred by the engineers-in –charge to the head of the refinery fire and safety department.

21.14. Record Keeping:

21.14.1. Records are required to support activities of Contractor safety programs for both control and audit purposes. Records to be maintained at the job site should include the following:-

21.14.2. First aid log of all first aid cases reported and treated, showing date, name of injured, job nature of injury and type of treatment given.

21.14.3. Accident investigation report for each accident.

21.14.4. Safety meetings or toolbox meeting records or minutes showing date of meeting, who attended, the subjects discussed and who conducted the meeting.

21.14.5. Job site inspection reports and status of the action plans.

21.14.6. Records to show dates, name of participants and subject of training programs.

21.14.7. Crane or equipment inspection / test records.

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21.14.8. Fire fighting equipment inspection / test record

21.15. FIRST AID & MEDICAL SERVICES

21.15.1. It is good practice for at least one person on each project to possess a first aid card.

21.15.2. First aid boxes shall be available at contractor sheds.

CONTRACTORS' MONTHLY SAFETY REPORT

FOR(MONTH-YR):

CONTRACTOR:

CONTRACT DETAILS :

CONTRACT

START DATE:

DATE OF LAST

LTA:

THIS MONTH CUMULATIVE

TOTAL SINCE LAST

LTA

MAN-HOURS

CODE THIS MONTH CUMULATIVE

TOTAL

LOST TIME ACCIDENT LTA

LOST WORK DAYS LWD

NO LOST TIME ACCIDENT NLTA

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DANGEROUS OCCURRENCES DO

NEAR-MISS INCIDENTS NM

INFRINGEMENT

NOTIFICATIONS

TOOLBOX MEETING

SAFETY TRAINING

SAFETY AUDIT

SAFETY INSPECTIONS

CARRIED OUT

DETAILS OF ACCIDENT, NEAR-MISS OR DANGEROUS OCCURRENCE

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PHYSICAL FITNESS CERTIFICATE

1. NAME OF THE AGENCY / SUB

CONTRACTOR

2. NAME OF THE EMPLOYEE

3. AGE / SEX

4. PRESENT HEALTH HISTORY

5. PREVIOUS HEALTH HISTORY

6 MEASUREMENTS

HEIGHT IN CMS.

WEIGHT IN KGS.

CHEST

INSPIRATION

EXPIRATION

_____________________________

_____________________________

_____________________________

_____________________________

7. BLOOD PRESSURE

8. HEART

9. LUNGS

10. ABDOMEN

LIVER

SPLEEN

_____________________________

_____________________________

11. LIMPTH GLANDS

12. HYDROCELE

13. HERNIA

14. VERICOSITY

15. EYES:

WITHOUT GLASSES WITH GLASSES

RIGHT EYE LEFT EYE RIGHT EYE LEFT EYE

FAR VISION 6/ 6/ 6/ 6/

NEAR VISION P P P P

16. PHYSICAL DEFORMITIES

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REMARKS OF THE DOCTOR :

SIGNATURE / STAMP WITH REGISTRATION NO.

All the contractors/agencies shall take the responsibility of ensuring that all of its workers/supervisors/employees are aware of the location of assembly points

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HINDUSTAN PETROLEUM CORPORATION LTD.

VISAKH REFINERY

INFRINGEMENT REPORT

From : Manager- Fire & Safety Date :

To : Manager- ………………………….

GIVEN BELOW ARE VIOLATION DETAILS OF SAFETY REGULATIONS / SITE INSTRUCTIONS

COMMITTED BY AN EMPLOYEE/CONTRACTOR WORKING FOR YOUR DIVISION. NAME: EMP. NO :

OCCUPATION: COMPANY :

LOCATION: COMPANY CODE :

DATE: TIME:

SUPERVISOR NAME/JOB TITLE:

DETAILS OF INFRINGEMENT:

IMMEDIATE ACTION TAKEN:

Previous violations:

This violation is: Minor (First/Second/Third) Major (First/Second/Third)

Action recommended: Written warning Penalty Rs. ____________

Other_______________________________________

Please advise action taken as per the penalties for Safety Violations on or before ………..

MANAGER- FIRE & SAFETY

CC: DEPT. HEAD CC : CASH OFFICE I/C , PLEASE COLLECT THE CASH UNDER A/C. 46000100.582190. .

NOTE : COMPANY CODE OF THE EMPLOYEE/ CONTRACTOR SHALL BE GIVEN BY THE

CONCERNED MANAGER.

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fg-e^-tdM U'f

VISAKH REFINERYFIRE & SAFETYDEPARTMENT

Doc. No. SWP-01Ref. F&S/SMRev.ODate: May 24, 2010Page: Page 1 of 3

SAFE WORK PRACTICESSPECIFICATION OF PERSONAL PROTECTIVE

EQUIPMENT

1.0 OBJECTIVE:

The objective of this SWP is to specify the standard for Personal ProtectiveEquipment (PPE) to be used in the Refinery premises.

2.0 SCOPE:

This SWP is applicable to all the Personal Protective Equipment.

3.0 RESPONSIBILITY:

a. The respective Executing Department is responsible to ensure that the PPE asspecified by this SWP is used by all the personnel (company employees andcontractor employees) involved in the jobs handled by the department.

b. PPE not conforming to the standard specified by this SWP is not permitted tobe used. Respective Departments are required to ensure this.

4.0 SPECIFICATION OF THE PERSONAL PROTECTIVE EQUIPMENT

In Visakh Refinery premises the Personal Protective equipment used shall beconforming to the Specifications as per the respective Standard provided in the Tablebelow:

SI. No.

4.14.1.1

4.1.2

4.2

4.2.1

4.2.2

PPE TYPE

Head ProtectionSafety Helmet

Welder's Helmet integrated with faceshield fitted with filter glassEye protection (For protection againstflying particles & fragments, materialand molten metal splashes, harmfuldust, gases or vapors and aerosols,harmful radiation)Dust proof goggles (Clear - Plaingoggles / Dark - Smoked goggles)Chemical goggles (Panoramic viewgoggles)

SPECIFICATION ASPER

IS:2925

IS: 1 1 79 & IS 5983

IS: 5983 /EN 166 /ANSI Z 87.1)

IS: 5983 /EN 166 /ANSI Z 87.1)

Page 99 of 209




EQUIPMENT

SI. No.

4.2.3

4.2.4

4.2.5

4.34.3.1

4.44.4.1

4.4.2

4.4.3

4.54.5.1

4.5.2

4.5.3

4.5.4

4.5.5

4.5.6

4.5.7

4.64.6.1

4.6.2

4.74.7.1

4.8

PPE TYPE

Eye cup goggles (Gas cutting / Furnacegoggles)Welding goggles (Electric Arc weldinggoggles)Cover all goggles (Zero powered safetygoggles)Ear ProtectionEar Muffs/Ear Plugs

Face ProtectionFace Shield

Electrical Arc Flash Protection Face shieldHelmet with face shield

Hand ProtectionGeneral purpose hand gloves (Withleather inner)Electrical hand gloves

Neoprene hand gloves for chemicalhandlingWelders leather gloves

PVC hand glovesHy flex hand glovesKevlar hand glovesFoot ProtectionSafety Shoe with PVC sole

Safety shoe with PU sole (light weight)

Fall ProtectionFull body harness (Double lanyard)

Body Protection

SPECIFICATION ASPER

IS: 5983 /EN 166 /ANSI Z 87.1)

IS: 5983 /EN 166 /ANSI Z 87.1)

IS: 5983 / EN 1 66 /ANSI Z 87.1)

IS: 9167

IS:8521

CE markedIS:8521

IS:6994 / CE marked

IS:4770

CE marked

IS 6994 / CE marked

CE markedCE markedCE marked

18:14544

IS: 15298 (Parti& Part 2)

IS:3521

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EQUIPMENT

SI. No.

4.8.1

4.8.2

4.8.3

4.8.4

PPE TYPE

PVC hood Acid & Alkali proof

PVC yellow color splash proof coat andpant

Full body apron with hood

PVC gum boots

SPECIFICATION ASPER

HOOD PVC withprotected Ventilatorbreathers and replicableacrylic visor acid andalkali proof.

PVC yellow color SplashProof Coat And Pant

Full body apron withhood suitable for theperson of height 173 to178cmAcceptable Brands andMake:1) Dupont make modelTychem-TF145T6/CS2) Microgard makemodel Microchem -3000

PVC Gum Boot, WhiteColor.

PreparedBy

ApprovedBy

Sign

NameDesignationSignNameDesignation

c^^-yyya— r-rr'K.V.Singh

Senior Manager-F&Stt )C£xf Q/-l%C» C£^ '

V.V.R.NarasifflharnGM-Operations

(Appointed as Factory Manager as perClause 7 of Factories Act 1948)

Page 101 of 209


Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 1 of 8

SAFE WORK PRACTICESMINIMUM PERSONAL PROTECTIVE EQUIPMENT

FOR VARIOUS ACTIVITIES

1.0 OBJECTIVE:

To specify the minimum Personal Protective Equipment (PPE) required for variousactivities and operations.

2.0 DESCRIPTION OF THE OBJECTIVE

• This SWP specifies the minimum PPE required for an activity or operation. Theminimum here means "at least". It does not mean that the minimum is enough bydefault.

• Depending on the environmental conditions and circumstances of carrying outthat activity or operation, additional or modified PPE may be required to be used.This assessment should be done through a "Job Hazard Analysis" prior to startingthe activity or the operation.

• The quality & specification of the PPE shall be as specified in SWP-01.

3.0 SCOPE:

a. This SWP is applicable to all the activities and operations carried out inthe premises of Visakh Refinery.

b. This SWP is limited to specifying the PPEs for the common activities.

c. For special activities which are not mentioned in this SWP, the PPErequirement is to be developed during the Job hazard Analysis inconsultation with F&S.

d. This SWP does not provide all the precautions for the mentioned activities.It only provides PPE required. For other precautions for an activity, referto the relevant Standing Instruction, Advisory, MSDS or the OperatingManual.

4.0 DEFINITIONS

a. The phrases operation, maintenance are used in generic sense and there is noreference to any specific department. No role definition is intended to be made inthis SWP from that perspective. At various times the activities could be performedby different departments to a lower or higher extent depending on thecircumstances. Whosoever does that activity must use the required PPE.

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b. Basic Minimum PPE (BM - PPE):

In the refinery for entering any Plant or carrying out any activity in the field, threeminimum PPE are required. These PPE are:

BM - PPEs

1.2.3.

Safety Helmet.Safety Shoes.Hand Glovesleather palm.

with

These PPE must be always used.

c. Additional PPE (A - PPE):

These are the PPEs which are to be used in addition to the BMPPE based on thejob, environment and circumstances.

d. Modified PPE (M - PPE):

In activities where the BM-PPE or A-PPE quality, material or shape is to be of adifferent kind to suit the requirements of that activity. This normally is areplacement of the corresponding PPE of either BM-PPE or A-PPE.

5.0 RESPONSIBILITY:

a. The responsibility of ensuring the usage of the adequate PPE lies with therespective Department and the individual involved in the activity.

b. In case any activity is not covered in this SWP, the respective Division Headshould seek advice from F&S Department giving details of the specificrequirements.

6.0 ACTIVITIES & MINIMUM PPE REQUIREMENT:

TABLE - 6.1

SI No.

6.16.1.1

ACTIVITY PPE TO BE USED FOR THE ACTIVITYBASIC - PPE A - P P E M - P P E

OPERATIONALWalk around in thePlant Area except and

BM - PPE Dust proofgoggles (Clear -

Page 103 of 209



SAFE WORK PRACTICES

MINIMUM PERSONAL PROTECTIVE EQUIPMENTFOR VARIOUS ACTIVITIES

SI No.

6.1.2

6.1.3

6.1.4

6.1.5

6.1.6

6.1.7

6.1.8

6.1.9

ACTIVITY

declared High NoiseAreas

Walk around in thePlant Area includingHigh Noise areas

Operational activity(excluding those specifically

mentioned in this table) in

Plant except in declaredHigh Noise Area.Operational activity(excluding those specifically

mentioned in this table) in

declared High NoiseArea.

Burners removal,installation in Furnaces(or in any Direct FiredEquipment)Observing of Fire boxflames (or any directfired equipment)Hot Liquid Sampling

Draining of liquid, gas,unplugging of bleeders.

Chemicals storage,

PPE TO BE USED FOR THE ACTIVITYBASIC - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

A -PPEPlain goggles /Dark - Smokedgoggles)a. Dust proof

goggles (ClearPlain

goggles / DarkSmoked

goggles)b. Ear Muffs /

Ear PlugsDust proofgoggles (ClearPlain goggles /Dark - Smokedgoggles)a. Dust proof

goggles (ClearPlain

goggles / DarkSmoked

goggles)b. Ear Muffs /

Ear PlugsEar Muffs / EarPlugs

Ear Muffs / EarPlugs

Additional PPE as

M-PPE

a. Helmet withface Shield

b. Kevlar HandGloves

Helmet with faceShield

a. Helmet withface Shield

b. Kevlar HandGloves


a. Neoprene

Page 104 of 209



SAFE WORK PRACTICES


SI No.

6.1.10

6.1.11

6.26.2.1

6.2.2

6.2.3

ACTIVITY

dispensing, pumpingand other handlingoperations

Fresh caustic , spentcaustic and otherchemical vessels orequipment purging,steaming, venting,draining operations (toatmos)Powder form catalysthandling


BM - PPE

BM - PPE

A -PPEper respectiveMSDS

ChemicalCartridgeRespirator

a. Dust proofgoggles (Clear- Plain goggles)

b. Dust maskC. Additional PPF.

as per respectiveMSDS

M-PPE

hand Glovesb. Helmet With

face Shield


MAINTENANCE ACTIVITIESWalk around in thePlant Area except anddeclared High NoiseAreas

Walk around in thePlant Area includingHigh Noise areas

Tightening of anyjoints on piping system,column, exchanger,vessel. Declared highnoise area. ( Whileequipment in service)

BM - PPE

BM - PPE

BM - PPE

Dust proofgoggles (Clear -Plain goggles /Dark - Smokedgoggles)a. Dust proof

goggles (Clear -Plain goggles /Dark - Smokedgoggles)

b. Ear Muffs /Ear Plugs

a. Dust proofgoggles (Clear- Plain goggles)


a. Helmet Withface Shield

b. In case ofchemical service:Neoprene handgloves

c. In case ofservice above50 degree C :Kevlar handgloves

Page 105 of 209





SI No.

6.2.4

6.2.5

6.2.6

6.2.7

6.2.8

6.2.9

6.2.10

6.2.11

6.2.12

6.2.13

ACTIVITY

Opening of joints forsegregation blinding ofany piping, column,exchanger or any otherequipment systemWelding operations

Gas cutting operations

Grinding operations

Workshop Operationslike lathe machine,hammering, turning,and drilling.Positioning at 2 metersabove ground or abovea permanent platform.Repairs and Maintenancejobs on pumps and otherequipment in Rotarysection within workshop.

Hydro testing activity

Hydro-jetting activity

Isolation andenergisation of panels


BM - PPE

BM - PPE

BM-PPE

BM - PPE

BM-PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

A -PPE

Eye cup goggles

Dust proofgoggles (Clear /Plain goggles)

Full body safetyharness withdouble lanyard.

PVC coat and pant

M-PPEHelmet with faceshield

a. Welders Helmetintegrated withface shield fittedwith filter glass.

b. Welder's leatherhand gloves.

Welder's leatherhand glovesa. Helmet with

face shield,b. Welders leather

hand Gloves.Ansell Protufhand gloves orDotted handgloves

Ansell Protufhand gloves orDotted handglovesHelmet with faceshield

Helmet with faceshielda. Electrical arc flash

protection handgloves

b. Electric Arc Flashprotection Faceshield with helmet

Page 106 of 209





SI No.

6.2.14

6.2.15

6.2.16

6.2.17

6.2.18

6.2.19

6.2.20

6.2.21

6.2.22

6.2.23

ACTIVITY

Panel PM checks

Motor PM checks

Motor PM checks(High noise area)

IR testing

IR testing (High noisearea)

Excavations in cablepresence

132 KV switch yardisolator opening

Instrumentation worksin workshopInstrumentation worksin fieldHandling of debris/scraps - by hand

PPE TO BE USED FOR THE ACTIVITYBASIC - PPEBM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

A -PPE

Dust proofgoggles (Clear -Plain)a. Dust proof

goggles(Clear - Plaingoggles),


Ear Muffs / EarPlugs

Dust proofgoggles (ClearPlain goggles)Full body safetyharness withdouble lanyard

a. Dust proofgoggles (Clear -Plain goggles)

b. Dust Mask.

M-PPEa. Electrical arc

flash protectionhand gloves,

b. Electric Arc Flashprotection Faceshield withhelmet

Hy flex handgloves

Hy flex handgloves

Electric Arc Flashprotection FaceshieldElectric Arc Flashprotection FaceshieldPVC gum boot

a. Electrical arcflash protectionhand gloves

b. Electrical arc flashprotection face shield

Hy flex handgloves

Hy flex handgloves

a. PVC gum bootsb.PVC hand gloves

with inner cottonlining

Page 107 of 209



SAFE WORK PRACTICES


SI No.

6.2.24

6.2.25

6.2.26

6.2.27

6.2.286.2.29

6.2.30

6.2.31

6.2.32

6.2.33

6.2.34

6.2.35

ACTIVITY

Scrap area works

P2 wrapping usingblow lamp for heatingpurpose to carry out P2Wrapping of pipelinesDry handling of bricks,mud, mortar etc.Wet handling of bricks,mud, mortar etc.

Excavation jobsConcrete chipping jobsManualConcrete chipping jobs(Pneumatic)Fixing of Aluminumsheets for insulationpurpose

Insulation Mineralwool handling jobs

Painting jobs at gradelevel

Painting jobs at heightmore than 2 meters.

Shot / Grit blasting

PPE TO BE USED FOR THE ACTIVITYBASIC - PPEBM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPEBM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

BM - PPE

A -PPE


b. Dust Mask.

Ear Muffs


b. Dust maska. Dust proof

goggles (Clear -Plain goggles)

b. Dust maska. Dust proof

goggles (ClearPlain goggles)

b. Dust maska. Full body

safety harnesswith doublelanyard

b. Dust proofgoggles (ClearPlain goggles)

c. Dust mask

M-PPE

Helmet with Faceshield.

PVC gum boots

a. PVC gum boots,b. PVC handgloves with innercotton lining.PVC gum bootsHelmet with faceshieldHelmet with faceshield

Shot blasting hoodand suit with air

Page 108 of 209





SI No. ACTIVITY PPE TO BE USED FOR THE ACTIVITYBASIC - PPE A -PPE M-PPE

line supplyconnected tovortex air cooler.

PreparedBy

ApprovedBy

SignNameDesignationSignNameDesignation

âÂU-rrr-HCV.Siligh

Senior Manager-F&SfÔTW^c^ _.

V.V.R.NarasirnHatnGM-Operations

(Appointed as Factory Manager as perClause 7 of Factories Act 1948)

Page 109 of 209

Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery

SWP – 06 CONTRACTOR JOB EQUIPMENT

SAFETY ASSURANCE

HINDUSTAN PETROLEUM CORPORATION LTD. VISAKH REFINERY

POST BOX – 15, MALKAPURAM VISAKHAPATNAM – 530011

(ANDHRA PRADESH) INDIA

Page 110 of 209

VISAKH REFINERY FIRE & SAFETY DEPARTMENT

Doc. No. SWP - 06 Rev. 0 Date : 08/03/11 Page 1 of 2

SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE

TABLE OF CONTENTS

DOCUMENT NO. TITLE LATEST

REV. NO. REV. DATE

NO OF PAGES

CATEGORY - 1 : MATERIAL HANDLING EQUIPMENT

SWP – 06 Contractor job equipment safety assurance 0 08/03/11 6 SWP – G

6.1 Manual of Equipment Checklist Formats

0 08/03/11 4

CL – 1.1 Manual of equipment checklist – Hydra 0 08/03/11 2 CL – 1.2 Manual of equipment checklist – Crane 0 08/03/11 2 CL – 1.3 Manual of equipment checklist – JCB / Proclainer 0 08/03/11 2 CL – 1.4 Manual of equipment checklist – Fork Lift 0 08/03/11 2 CL – 1.5 Manual of equipment checklist– Chain Pulley Block 0 08/03/11 1 CL – 1.6 Manual of equipment checklist – Wire rope sling 0 08/03/11 1 CL – 1.7 Manual of equipment checklist – Synthetic web sling 0 08/03/11 1 CL – 1.8 Manual of equipment checklist – Manila rope 0 08/03/11 1

CATEGORY - 2 : MATERIAL TRANSPORT EQUIPMENT

CL – 2.1 Manual of equipment checklist – Tractor 0 08/03/11 2 CL – 2.2 Manual of equipment checklist – Chemical Tanker 0 08/03/11 2 CL – 2.3 Manual of equipment checklist – Tyre mounted trolley 0 08/03/11 1 CL – 2.4 Manual of equipment checklist – Trailer 0 08/03/11 1 CL – 2.5 Manual of equipment checklist – Truck 0 08/03/11 2 CL – 2.6 Manual of equipment checklist – LMV 0 08/03/11 2

CATEGORY - 3 : WELDING & GRINDING EQUIPMENT

CL – 3.1 Manual of equipment checklist – Diesel generator 0 08/03/11 1 CL – 3.2 Manual of equipment checklist – Welding Machine 0 08/03/11 1 CL – 3.3 Manual of equipment checklist – Welding cables 0 08/03/11 1 CL – 3.4 Manual of equipment checklist – Welding holder 0 08/03/11 1 CL – 3.5 Manual of equipment checklist - Temporary electrical

panel 0 08/03/11 1

CL – 3.6 Manual of equipment checklist – Electrical Switch board 0 08/03/11 1 CL – 3.7 Manual of equipment checklist – Grinding machine 0 08/03/11 1

CATEGORY - 4 : GAS CUTTING EQUIPMENT

CL – 4.1 Manual of equipment checklist – Gas cutting torch 0 08/03/11 1 CL – 4.2 Manual of equipment checklist – Gas supply hose 0 08/03/11 1 CL – 4.3 Manual of equipment checklist – Gas cylinder regulator 0 08/03/11 1 CL – 4.4 Manual of equipment checklist – Gas cylinder 0 08/03/11 1 CL – 4.5 Manual of equipment checklist – Gas cylinder trolley 0 08/03/11 1

CATEGORY - 5 : ACCESS & EGRESS EQUIPMENT

CL – 5.1 Manual of equipment checklist – Scaffolding pipe and its fittings

0 08/03/11 1

CL – 5.2 Manual of equipment checklist – Portable Step Ladder 0 08/03/11 1 CL – 5.3 Manual of equipment checklist – Ladder

0

08/03/11 1

Page 111 of 209

VISAKH REFINERY FIRE & SAFETY DEPARTMENT

Doc. No. SWP - 06 Rev. 0 Date : 08/03/11 Page 2 of 2


TABLE OF CONTENTS

DOCUMENT NO. TITLE LATEST

REV. NO. REV. DATE

NO OF PAGES

CATEGORY - 6 : FIRE FIGHTING EQUIPMENT

CL - 6.1 Manual of equipment checklist – DCP extinguisher 0 08/03/11 1 CL – 6.2 Manual of equipment checklist – CO2 extinguisher 0 08/03/11 1 CL – 6.3 Manual of equipment checklist – Fire hose 0 08/03/11 1 CL – 6.4 Manual of equipment checklist – Firefighting nozzle 0 08/03/11 1

CATEGORY - 7 : HAND TOOLS & TACKLES

CL - 7.1 Manual of equipment checklist – All Types of Wrenches & Spanners

0 08/03/11 1

CL - 7.2 Manual of equipment checklist – Chisel 0 08/03/11 1 CL - 7.3 Manual of equipment checklist – Hammer 0 08/03/11 1 CL - 7.4 Manual of equipment checklist – Screw Driver 0 08/03/11 1 CL - 7.5 Manual of equipment checklist – Plier 0 08/03/11 1 CL - 7.6 Manual of equipment checklist – Spreader 0 08/03/11 1 CL - 7.7 Manual of equipment checklist – Crimping Tool 0 08/03/11 1 CL - 7.8 Manual of equipment checklist – Jack Hammer 0 08/03/11 1 CL - 7.9 Manual of equipment checklist – Driller 0 08/03/11 1

CATEGORY - 8 : CIVIL WORKS EQUIPMENT

CL - 8.1 Manual of equipment checklist – Crow bar 0 08/03/11 1 CL - 8.2 Manual of equipment checklist – Shovel 0 08/03/11 1 CL - 8.3 Manual of equipment checklist – Spade 0 08/03/11 1 CL - 8.4 Manual of equipment checklist – Gamela 0 08/03/11 1 CL - 8.5 Manual of equipment checklist – Concrete mixer 0 08/03/11 1

CATEGORY - 9 : MISCELLANEOUS EQUIPMENT

CL - 9.1 Manual of equipment checklist – Hydro testing pump 0 08/03/11 1 CL - 9.2 Manual of equipment checklist – Blow Lamp 0 08/03/11 1 CL - 9.3 Manual of equipment checklist – De-watering pump 0 08/03/11 1 CL - 9.4 Manual of equipment checklist – Air Compressor 0 08/03/11 1 CL - 9.5 Manual of equipment checklist – Jack 0 08/03/11 1 CL - 9.6 Manual of equipment checklist- Grass cutting machine 0 08/03/11 1 CL - 9.7 Manual of equipment checklist – Fire proof Tarpaulin 0 08/03/11 1

SWP- F 6.1 List of equipment, tools & tackles planned for use in HPCL-VR

0 08/03/11 1

SWP- F 6.2 Equipment, tools & tackles gate entry plan 0 08/03/11 1 SWP- F 6.3 Equipment safety clearance certificate 0 08/03/11 1 SWP- R 6.1 Contact address of Fire & Safety department 0 08/03/11 1

Page 112 of 209

VISAKH REFINERYFIRE & SAFETY DEPARTMENT

Doc. No. SWP-06Ref. F&S-SM

Date: March, 2011Date:

Page: Page 1 of 6

SAFE WORK PRACTICES

CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE

1.0 OBJECTIVE:

To ensure that the Job-Equipment available with all the contractors are safe for use.

2.0 DESCRIPTION OF THE OBJECTIVE

a. Contractors employed by the Visakh Refinery use equipment, tools and tackles of different makeand age. It is required to ensure that these equipment are safe for use and do not cause injuries tothe personnel and other untoward incidents.

b. It is required that the contractors ensure that all features and safety mechanisms of theirequipment, tools and tackles are in order and meet the required standards.

c. It is required to ensure that at the time of allowing entry into the Refinery, all the Job-Equipmentshould be checked to conform to the required standards. The non conforming equipment shouldnot be allowed into the Refinery.

d. Also, the Job-Equipment must be offered for periodic inspection to HPCL (or an agencyappointed by HPCL). Deficiencies must be corrected and usage of defective equipment, tools &tackles shall be discontinued and removed from the refinery premises.

e. This SWP is intended to lay down the process to achieve the objective.

3.0 SCOPE & APPLICABILITY

a. This SWP is applicable to all the Contractors of Visakh Refinery.

b. This SWP is applicable to the equipment, tools and tackles used by the Contractor within

HPCL - VR premises.

4.0 RESPONSIBILITY :

The responsibility of ensuring the implementation of the elements of this SWP is as detailed in the"Process" below.

Page 113 of 209


Doc. No. SWP-06Ref. F&S-SMRev .0Date: March, 2011Page: Page 2 of 6

SAFE WORK PRACTICES


5.0 PROCESS

SI No. ACTIVITY

REFERENCE

RESPONSIBILITY

5.1 ASSURANCE OF COMPULSORY REQUIREMENTS OF CONTRACTOR JOB

EQUIPMENT, TOOLS & TACKLES5.1.1 The contractor shall ensure that the equipment,

tools and Tackles which is planned to be used inHPCL premises shall meet all the requirements asper

the

"Manual

of

Equipment

ChecklistFormats"

SWP-G-6.1 Contractor

5.1.2 •

Each Equipment, Tools & Tackle shall bechecked against the Checklists provided inthe

"Manual

of

Equipment

ChecklistFormats" before bringing for entry into the


Refinery premises .•

This Manual is provided to the contractor tohelp in ensuring that all features are provided,repaired as necessary before the equipment isbrought to the HPCL Gate and offered forInspection. This will help in efficient entry ofthe equipment.

•

The

contractor

should

prepare

additionalcopies as required and use one checklist foreach equipment.

•

At the entry point only visual check of all therequired features will be done by HPCL. Thefunctionality of the feature will need to bechecked prior to entry by the contractor.

5.2 PLANNING FOR EQUIPMENT FIRST TIME ENTRY INTO THE REFINERY

ON AWARD OF PURCHASE ORDER5.2.1 •

The equipment, Tools and Tackles plannedfor entry into HPCL-VR premises is checkedand ensured that it satisfies the requirement asper

Satisfaction

wrt

the

"Manual

ofEquipment Checklist Formats ",

•

After the above, following documents areprepared and submitted to HPCL :

a.

"List of Equipment Tools & TacklesPlanned for Use in HPCL-VR " on theletter Head of the Contractor. (Morethan one such lists can be given withnumbering)

b.

"Equipment, Tools &Tackles GateEntry Plan".

c.

Filled checklist of each equipment asper "Manual of Equipment ChecklistFormats"

SWP-G-6.1

SWP-F-6.1

SWP-F-6.2

SWP-G-6.1

Contractor

Page 114 of 209


Doc. No. SWP-06Ref. F&S-SMRev.0Date: March, 2011Page: Page 3 of 6

SAFE WORK PRACTICES


Si No. ACTIVITY REFERENCE RESPONSIBILITY5.2.2 The

above

documents

can

be

submitted

infollowing modes :

a.

Signed Scanned Copies by e-mail.b.

Signed copies by Fax.c.

Signed Copies by Post , courier.d.

Signed copies delivery in person to Fireand Safety Office. (Either the main office orthe office at the Equipment Entry Gate)

However, in all cases they must reach at least 3

Contractor

working days before the planned entry date.5.2.3 "Contact Address of Fire & Safety Department"

is available. In case of change, the Contractor isinformed.

SWP-R-6.1 By HPCL F&S.

5.2.4 On receipt of the Documents HPCL will provideacknowledgement through e-mail or on a copy ofthe submitted documents if provided.

By HPCL F&S

5.3 FIRST TIME ENTRY INTO THE REFINERY5.3.1 The first entry of the equipment should always be

done on a working day between 09.00 hrs to15.00 hrs only. Prior planning shall be done toensure this.

Contractor

5.3.2 One day confirmatory advance Notice shall begiven to HPCL intimating the arrival of theequipment either by e-mail, Fax, Telephone to theFire and Safety Office.

SWP-R-6.1 Contractor

5.3.3 As the Equipment arrives at the gate, the gateOffice

Fire

and

Safety

personnel

shall

beinformed by Telephone or in person.

Contractor

5.3.4 HPCL will verify that all the equipment broughtto the

gate

is

as

per the

already

submitted"Equipment, Tools &Tackles Gate Entry Plan"and "List of Equipment Tools & Tackles Plannedfor Use in HPCL-VR".

SWP-F-6.1SWP-F-6.2

HPCL F&S

5.3.5 The equipment shall be inspected just outside theequipment entry gate.

SWP-G-6.1 HPCL F&S withContractor support.

5.3.6 Appropriate

Tagging,

stickering

(as

proof ofinspection) shall be carried out by HPCL for theequipment, Tools and tackles. The accepted andrejected equipment will be tagged or stickereddifferently.

For information to theContractor

5.3.7 Only those equipment, tools and tackles whichconform

to

the

features

of their

respectivechecklists provided in the "Manual of EquipmentChecklist Formats" will be allowed to be takeninto the Refinery

SWP-G-6.1 For information to theContractor

Page 115 of 209


Doc. No. SWP-06Ref. F&S-SMRev.ODate: March, 201 1Page: Page 4 of 6

SAFE WORK PRACTICES


Sl No. ACTIVITY REFERENCE RESPONSIBILITY5.3.8 Equipment, tools and tackles not conforming to

the

respective

checklist

in

the

"Manual

ofEquipment

Checklist

Formats"will

not

beallowed entry into the Refinery.


5.3.9 For the Equipment, Tools and Tackles which areallowed entry, HPCL will issue a "EquipmentSafety Clearance Certificate".

Note :

SWP-F-6.3 For information to theContractor

This safety Clearance is not sufficient for final gateentry. Subsequent security clearance is also to beobtained.

5.3.10 After

the

clearance,

further

entry

for

theequipment is to be done with necessary Securityprocedures of HPCL. The "Equipment SafetyClearance Certificate" is to be attached with theGate Pass for equipment entry (MDF). (Withoutthis, the equipment, tools and tackles will not beallowed entry)

Note :

1.

HPCL will not allow any entry of the equipment,tools and tackles which do not conform to theirrespective checklists.

2.

The rejected equipment, tools and tackles will hestickered, tagged with different colour stickers orTags.

3.

It is in the interest of the contractor to ensure thatbefore bringing the equipment to the Entry gate, allrequirements

should

he

met

to

avoidinconvenience.

4.



5.4 QUARTERLY INSPECTION OF THE EQUIPMENT TOOLS & TACKLES5.4.1 Once inside the Refinery and on the job, HPCL

will carry out quarterly "on-location " inspectionof the equipment, tools and tackles. For eachinspection one week advance notice shall begiven.

For information to thecontractor

5.4.2 As preparation for the Inspection, on receipt ofthe

notice,

the

contractor

shall

advise

thelocations

of the

equipment

through

the jobsupervisor.


•.yJ td in 4C^

Page 116 of 209


Doc. No. SWP-06Ref. F&S-SMRev.ODate: March, 2011Page: Page 5 of 6

SAFE WORK PRACTICES


Si No. ACTIVITY REFERENCE RESPONSIBILITY5.4.3 For each Inspection, Contractor representative

shall accompany the HPCL officer to each of theequipment, tool, tackles location and facilitate theinspection. This inspection shall be done wrt thecorresponding

"Equipment

Safety

ClearanceCertificate" which were issued and the checklistsprovided in the "Manual of Equipment ChecklistFormats"

SWP-F-6.3SWP-G-6.1


5.4.4 Re-tagging and stickering will be done for theequipment tools and tackles found fit for use.


5.4.5. In case of any equipment, tool and tackle, unfitfor usage during this inspection, HPCL will stopthe usage of the equipment.


5.4.6 The equipment so identified will be tagged "Unfitfor use" and cannot be used from that instant. Therespective

HPCL

user

department

will

beinformed

accordingly

in

person

and through"Internal Memo"

For compliance byContractor

5.4.7 The Contractor will be given notice for repairingand restoring normalcy wrt to the equipmentwithin a time of maximum one week. In case ofnon-rectification within this period, the respectiveequipment will need to be taken out of thecompany premises within a days notice.

For compliance bycontractor

5.4.8 Contractor should ensure that all the equipment,tools

and

tackles

are

maintained

in

goodcondition.

For compliance bycontractor

5.5 ADDITIONAL ENTRY REQUIREMENTS DU RING JOB EXECU TION5.5.1 This approach is to be used after the first entry of

equipment.

There

could

be

requirement

ofequipment

entry

item

by

item

subsequentlydepending on the job requirements. This is to beused for that purpose.

Contractor

5.5.2 Each Equipment, Tools & Tackle planned forentry and use in HPCL-VR" shall be checkedagainst the Checklists provided in the "Manual ofEquipment Checklist Formats"


5.5.3 One Day advance Notice on Contractors letterHead shall be given for the equipment tools andtackles entry. Following information should beincluded in the letter---- Name of the equipment-Tool-tackle, Make, I.D.No., Quantity.

Contractor

5.5.4 As the Equipment arrives at the gate, Fire andSafety

gate

Office

shall

be

informed

byTelephone or in person.

SWP-R-6.1 Contractor

Page 117 of 209


Doc. No. SWP-06Ref. F&S-SMRev.0Date: March, 2011Page: Page 6 of 6

SAFE WORK PRACTICES


SI No. ACTIVITY REFERENCE RESPONSIBILITY5.5.5 The equipment shall be offered for inspection at

the area outside the gate.Contractor

5.5.6 Appropriate

Tagging,

stickering

(as

proof ofinspection) shall be carried out by HPCL for theequipment,

Tools

and

tackles.

Accepted

andrejected equipment will have different type oftagging or stickering.

For information to theContractor

5.5.7 Only those equipment, tools and tackles whichconform

to

the

features

of their

respectivechecklists provided in the "Manual of EquipmentChecklist Formats" will be allowed to be takeninto the Refinery.


5.5.8 Equipment, tools and tackles not conforming tothe

respective

checklist

in

the

"Manual

ofEquipment

Checklist

Formats"

will

not

beallowed entry into the Refinery.


5.5.9 For the Equipment, Tools and Tackles which areallowed entry, HPCL will issue a "EquipmentSafety Clearance Certificate".Note :



5.5.10 Further entry for the equipment is to be done withnecessary Security procedures of HPCL. The"Equipment Safety Clearance Certificate" is to beattached with the Gate Pass for equipment entry(MDF). (Without this, the equipment, tools andtackles will not be allowed entry)

Note :

1.

HPCL will not allow entry of the equipment, toolsand

tackles

which

do

not

conform

to

theirrespective checklists.

2.

It is in the interest of the contractor to ensure thatbefore bringing the equipment to the Entry gate, allrequirements

should

be

met

to

avoidinconvenience.


P drepareBy

Sign

Name K.V.Smgh

Designation Senior Mana er-F&S

ApprovedBy

Sign C_^Q

GNU _^Name V.V.R.Narasim am

Designation GM-Operations(Appointed as Factory Manager as perClause 7 of Factories Act 1948)

Page 118 of 209

VISAKH REFINERY F&S DEPARTMENT

Doc No: SWP-G-6.1 Ref Doc : SWP -06 Rev. : 0 Date : 15/3/2011 Page 1 of 4


MANUAL OF EQUIPMENT CHECKLIST FORMATS

1.0 OBJECTIVE:

a. This guideline specifies the minimum safety requirements of different Equipment, Tools & Tackles being used inside refinery by the contractor during the course of execution of the job.

b. Equipment are permitted inside the refinery provided they meet the requirements set in the Guideline.

c. This manual contains safety checklists for different equipment that will be used by the contractor during the course of execution of job inside refinery.

d. The responsibility of adhering to the requirements of the guide line lies with the contractor.

2.0 SCOPE & APPLICABILITY

2.1 Equipment Category and coverage Following equipment and their categories are covered in this guideline: Category Description Names of the Equipment Covered No. of

Equipment Covered

1 Material Handling Equipment

Hydra, Crane, JCB/ Poclain, Fork Lift Chain Pulley Block, Wire Rope Sling, Synthetic Web Sling, Manila Rope

8

2 Material Transport Equipment

Tractor, Chemical tanker, Tyre Mounted Trolley, Trailer, Truck, LMV.

6

3 Welding & Grinding Equipment.

Diesel generator, Welding Machine, Welding cable, Welding Holder, Temporary Electrical Panel, Electrical Switch Board, Grinding Machine.

7

4 Gas Cutting Equipment. Gas Cutting Torch, Gas Supply Hose, Gas Cylinder Regulator, Gas Cylinder, Gas Cylinder Trolley.

5

5 Access & Egress Equipment

Scaffolding Pipes & Fittings, Portable Step Ladder, Ladder.

3

6 Fire Fighting Equipment DCP Extinguisher, CO2 Extinguisher, Fire Hose, Fire Fighting Nozzle

4

7 Hand Tools and Tackles All types of Wrenches and Spanners, Chisels, Hammers, Screw drivers, Pliers, Spreaders, Crimping tool, Jack Hammer, Driller

9

8 Civil Works Equipment Crow bar, Shovel, Spade, Gamela, Concrete Mixer

5

9 Miscellaneous Equipment Hydro-testing Pump, Blow lamp, De-watering Pump, Air compressor, Jack, Grass cutting machine, Fire proof tarpaulin

7

Page 119 of 209





2.2 Applicability of this guideline

a. At any point of time, the latest revision of this Guideline will be applicable.

b. HPCL will revise this guideline from time to time. The contractors will be informed through mail or e-mail and Notice Boards at gate & Fabrication Yard.

3.0 Abbreviations: 4.0 MANUAL OF EQUIPMENT CHECKLIST FORMATS

S.NO Checklist Number Equipment Category - 1 : Material handling Equipment

1 CL-1.1 Hydra 2 CL-1.2 Crane 3 CL-1.3 JCB or Poclain 4 CL-1.4 Forklift 5 CL-1.5 Chain Pulley block 6 CL-1.6 Wire rope Sling 7 CL-1.7 Synthetic web sling 8 CL-1.8 Manila Rope

Category - 2 : Material Transport Equipment

9 CL-2.1 Tractor 10 CL-2.2 Chemical Tanker 11 CL-2.3 Tyre Mounted Trolley 12 CL-2.4 Trailer 13 CL-2.5 Truck 14 CL-2.6 LMV

Category - 3 : Welding & Grinding Equipment

15 CL-3.1 Diesel Generator 16 CL-3.2 Welding Machine 17 CL-3.3 Welding Cable 18 CL-3.4 Welding Holder 19 CL-3.5 Temporary Electrical Panel 20 CL-3.6 Electrical Switch board 21 CL-3.7 Grinding machine

Page 120 of 209





S.NO Checklist Number Equipment Category - 4 : Gas Cutting Equipment

22 CL-4.1 Gas cutting torch 23 CL-4.2 Gas Supply hose 24 CL-4.3 Gas cylinder regulator 25 CL-4.4 Gas cylinder 26 CL-4.5 Gas cylinder Trolley

Category - 5 : Access & Egress Equipment

27 CL-5.1 Scaffolding pipes & fittings 28 CL-5.2 Portable step Ladder 29 CL-5.3 Ladder

Category - 6 : Fire Fighting Equipment

30 CL-6.1 DCP Extinguisher 31 CL-6.2 CO2 Extinguisher 32 CL-6.3 Fire Hose 33 CL-6.4 Firefighting nozzle

Category - 7 : Hand Tools & Tackles

34 CL-7.1 All Types of Wrenches & Spanners 35 CL-7.2 Chisel 36 CL-7.3 Hammer 37 CL-7.4 Screw Driver 38 CL-7.5 Plier 39 CL-7.6 Spreader 40 CL-7.7 Crimping Tool 41 CL-7.8 Jack Hammer 42 CL-7.9 Driller

Category - 8 : Civil Works Equipment

43 CL-8.1 Crow bar 44 CL-8.2 Shovel 45 CL-8.3 Spade 46 CL-8.4 Gamela 47 CL-8.5 Concrete Mixer

Page 121 of 209





S.NO Checklist Number Equipment Category - 9 : Miscellaneous Equipment

48 CL-9.1 Hydro-testing Pump 49 CL-9.2 Blow Lamp 50 CL-9.3 De-watering Pump 51 CL-9.4 Air Compressor 52 CL-9.5 Jack 53 CL-9.6 Grass cutting machine 54 CL-9.7 Fire proof Tarpaulin

* * *

Page 122 of 209


CHECK LIST OF CATEGORY – 1

MATERIAL HANDLING EQUIPMENT

S.NO Format Number Equipment 1 CL-1.1 Hydra 2 CL-1.2 Crane 3 CL-1.3 JCB or Poclain 4 CL-1.4 Forklift 5 CL-1.5 Chain Pulley block 6 CL-1.6 Wire rope Sling 7 CL-1.7 Synthetic web sling 8 CL-1.8 Manila Rope

Page 123 of 209


Doc No: CL- 1.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2

SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY

ASSURANCE

MANUAL OF EQUIPMENT CHECKLIST

Date: Contractor Name: Equipment ID: PO NO & Date:

S.NO CHECK LIST STATUS IDENTIFIED

DEFECTS / REMARKS

OK NOT OK

Documents: 1 RTO Registration document

(Submit a copy of each item)

2 RTO fitness certificate (Submit a copy of each item)

3 Load Test Certificate (Submit a copy of each item)

4 Load test certificate for lifting tools and tackles (Submit a copy of each item)

5 Heavy vehicle license for hydra driver (Submit a copy to HPCL-VR F&S)

6 Refinery driving permission for hydra driver

Safety features: 7 Load test date marked on the body

8 Safe working load marked near each hook

9 Latching of hydra hooks in working condition

HYDRA


Page 124 of 209


Doc No: CL- 1.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2


ASSURANCE

MANUAL OF EQUIPMENT CHECKLIST S.NO CHECK LIST STATUS IDENTIFIED

DEFECTS / REMARKS

OK NOT OK

10 Guarding to rotating parts a. Pulley belt b. Radiator fan

11 Body physical condition in good condition: a. Driver seat b. Body cover well maintained with painting. c. Top cover above driver seat. d. Tyres are not bald and without retreading. e. Tools box physically good and lockable. f. No engine oil leakage.

12 Self-ignition in working condition.

13 PESO approved spark arrester fixed to the exhaust.

14 Horn and lights are in working conditions

15 Good housekeeping in Hydra operator cabin

CONTRACTOR OFFICIAL

SIGNATURE NAME DESIGNATION STAMP

Page 125 of 209


Doc No: CL-1.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2


ASSURANCE


CRANE

MATERIAL HANDLING EQUIPMENT Date: Contractor Name: Equipment ID: PO NO & Date:

S.NO CHECK LIST STATUS IDENTIFIED

DEFECTS/ REMARKS

OK NOT OK






5 Heavy vehicle license for Crane driver (Submit a copy to HPCL-VR F&S)

6 Refinery driving permission for Crane driver


8 Guarding to rotating parts: a. Pulley belt b. Radiator fan

9 Latching of Crane hooks in working condition

Page 126 of 209




ASSURANCE


S.NO CHECKLIST STATUS IDENTIFIED DEFECTS/ REMARKS

OK NOT OK

10

Self-ignition in working condition.



13 Jacks in working condition and no physical damage.

14 Crane limit switches in working condition


16 Good housekeeping in Crane operator

cabin

CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP

Page 127 of 209




ASSURANCE



S.NO STATUS IDENTIFIED

DEFECTS / REMARKS

OK NOT OK






5 Heavy vehicle license for JCB or Poclain driver (Submit a copy to HPCL-VR F&S)

6 Refinery driving permission for JCB or Poclain driver



JCB/POCLAIN


Page 128 of 209




ASSURANCE


S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS

OK NOT OK

9 Guarding to rotating parts a. Pulley belt b. Radiator fan

10 Latching of JCB / Poclain hooks in working condition





15 Good housekeeping in JCB or Poclain cabin


Page 129 of 209




ASSURANCE



S.NO CHECKLIST STATUS IDENTIFIED

DEFECTS / REMARKS

OK NOT OK





4 Load test certificate for lifting tools and tackles. (Submit a copy of each item)

5 Heavy vehicle license for Forklift driver (Submit a copy to HPCL-VR F&S)

6 Refinery driving permission for Forklift driver



9 Latching of Forklift hooks in working condition

FORKLIFT


Page 130 of 209




ASSURANCE



OK NOT OK

10 Guarding to rotating parts: a. Pulley belt b. Radiator fan



13 PESO approved spark arrester fixed to

the exhaust.


15 Good housekeeping in Forklift operator

cabin

CONTRACTOR OFFICIAL


Page 131 of 209


Doc No: CL-1.5 Ref Doc : SWP -06 Rev. : 0 Date: 18/03/11 Page 1 of 1


ASSURANCE




DEFECTS / REMARKS OK NOT OK

Documents: 1 Test Certificate of Chain pulley block

available (Submit copy to HPCL-VR F&S)

Safety Features: 2 Chain pulley block shall be IS 3832

2005 marked.

3 Chain pulley blocks to be numbered and identified

4 Load test date and SWL marked on the chain pulley block

5 Latching provided to chain pulley block hook in working condition.

6 Chain to be free on ant signs of damage, Wear & tear.

CONTRACTOR OFFICIAL


CHAIN PULLEY BLOCK


Page 132 of 209




ASSURANCE MANUAL OF EQUIPMENT CHECKLIST

Date:

Contractor Name: Equipment ID:

PO NO & Date:

S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK

Documents: 1 Load test Certificate of wire rope sling

available (Submit copy to HPCL-VR F&S)

Safety Features: 2 Wire rope sling to be numbered and

identified.

3 Load test date and SWL marked on the body of the rope

4 Wire rope sling to be free of any signs of physical damage, wear & tear etc.


WIRE ROPE SLING


Page 133 of 209




ASSURANCE




OK NOT OK

Documents: 1 Load test certificates of synthetic web

sling (Submit copy to HPCL-VR F&S)

Safety Features: 2 Synthetic web sling to be numbered and

identified

3 Load test date and SWL to be marked on the web sling.

4 Synthetic web slings to be free from signs of wear and tear, physical damage and chemical burns etc.

5 Evidence of any acid or caustic burns, charring on any part of surface

6 Broken or worn out stitches

7 Condition of eye lets

(Check for any worn out signs)

CONTRACTOR OFFICIAL


SYNTHETIC WEB SLING


Page 134 of 209


Doc No: CL - 1.8 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1


ASSURANCE




Safety Features: 1 All Manila ropes numbered and

identified

2 Physical condition of the rope free from defects

3 Rope free from broken strands, wear & tear, punctures, snags

4 Evidence of any acid or caustic burns, charring on any part of surface

CONTRACTOR OFFICIAL


MANILA ROPE


Page 135 of 209



MATERIAL TRANSPORT EQUIPMENT

S.NO Format Number Equipment 1 CL-2.1 Tractor 2 CL-2.2 Chemical Tanker 3 CL-2.3 Tyre Mounted Trolley 4 CL-2.4 Trailer 5 CL-2.5 Truck 6 CL-2.6 LMV

Page 136 of 209











3 Heavy vehicle license for tractor driver (Submit a copy to HPCL-VR F&S)

4 Refinery driving permission for tractor driver

Safety Features: 5 Guarding to rotating parts

a. Pulley belt b. Radiator fan



8 Horn and lights are in working conditions.

TRACTOR


Page 137 of 209






OK NOT OK

9 Good housekeeping in operator’s cabin.

10 Physical conditions: a. Driver seat b. Body cover is well maintained and sound in construction. c. Top cover above driver seat. d. Tyres are not bald and without retreading. e. Tools box physically good and lockable f. No engine oil leakage.

CONTRACTOR OFFICIAL


Page 138 of 209


Doc No: CL – 2.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2


ASSURANCE







3 Driver carrying dangerous or hazardous goods holds a driving license as per provisions of rule 9 of Central Motor Vehicle Rules. (Submit a copy to HPCL-VR F&S)

Safety Features: 4 Display of distinct class Label of the

hazardous material being transported with the following details:

a. The name and telephone number of the emergency services to be contacted

b. The name and telephone number of the consignor of the dangerous or hazardous goods.

5

Guarding to rotating part of radiator fan


CHEMICAL TANKER


Page 139 of 209




ASSURANCE


S.NO CHECKLIST STATUS IDENTIFIED DEFECTS/ REMARKS

OK NOT OK

7 Physical conditions: a. Tanker frame sound in construction and no make shift arrangement. b. Tanker control valves are in good working condition. c. Tanker lids with gaskets and without leaks. d. Tyres are not bald and without retreading. e. No engine oil leakage.


.


10 Good housekeeping in driver’s cabin.

CONTRACTOR OFFICIAL


Page 140 of 209







DEFECTS / REMARKS

OK NOT OK

Documents: 1 RTO Registration document.

(Submit copy to HPCL-VR F&S)

2 RTO fitness certificate. (Submit copy to HPCL-VR F&S)

Safety Features: 3 Physical Condition:

Body frame sound in construction and no make shift arrangement

Safety features:

4 Body is fully covered with metal sheet

5 Body side frame is fitted with provision

for fixing metal pipe in order to guide loaded materials

6 Tyres are not bald and without retreading.

7 Attached toeing hook is sound in construction

CONTRACTOR OFFICIAL


TYRES MOUNDED TROLLEY


Page 141 of 209




ASSURANCE




DEFECTS / REMARKS

OK NOT OK




Safety Features: 3 Physical conditions:

Body frame sound in construction and no make shift arrangement.

4 Body is fully covered with metal sheet.

5 Body side frame is fitted with provision

for fixing metal pipe in order to guide loaded materials.

6 Tyres are not bald and without retreading.

7 Attached toeing hook is sound in construction.

TRAILER



Page 142 of 209





Date: Contractor Name: Equipment ID:

PO NO & Date:





3 Light vehicle license for LMV driver (Submit a copy to HPCL-VR F&S)

4 Refinery driving permission for LMV driver.

Safety Features: 5 Guarding to rotating parts

a. Radiator fan

6 Physical conditions: a. Driver seat b. Body cover is well maintained and sound in construction. c. Tyres are not bald and with out retreading. d. Tools box physically good and lockable e. No engine oil leakage.

LMV


Page 143 of 209






OK NOT OK


8 PESO approved spark arrester fixed to the exhaust



CONTRACTOR OFFICIAL


Page 144 of 209





\ Date: Contractor Name: Equipment ID: PO NO & Date:






3

Heavy vehicle license for truck driver (Submit copy to HPCL-VR F&S)

4 Refinery driving permission for truck driver.

Safety Features: 5 Guarding to rotating parts radiator fan

6 Physical conditions: a. Body frame sound in construction and no make shift arrangement. b. Body is fully covered with metal sheet. c. Body back door sound in construction. d. Tyres are not bald and without retreading. e. No engine oil leakage.

TRUCK


Page 145 of 209






OK NOT OK





CONTRACTOR OFFICIAL


Page 146 of 209



WELDING & GRINDING EQUIPMENT

S.NO Format Number Equipment 1 CL-3.1 Diesel Generator 2 CL-3.2 Welding Machine 3 CL-3.3 Welding Cable 4 CL-3.4 Welding Holder 5 CL-3.5 Temporary Electrical Panel 6 CL-3.6 Electrical Switch board 7 CL-3.7 Grinding machine

Page 147 of 209







OK NOT OK

Safety features: 1 Diesel generator body physical condition:

a. Body cover

b. Plug points

c. Tyres are good and not retreaded or rollers with non-sparking arrangement

2 No leaks from fuel tank and connecting hoses and fittings

3 Guarding to rotating parts- a. Pulley belt b. Radiator fan

4 PESO approved spark arrestor fixed to the exhaust.

5 Alternator in place and in good working condition.

6 All electrical components to be free of defects

7 Stands for parking - in good condition.


DIESEL GENERATOR


Page 148 of 209



SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT

SAFETY ASSURANCE


Date:


PO NO & Date:

S.NO CHECKLIST STATUS

IDENTIFIED DEFECTS / REMARKS OK NOT OK

Safety features: 1 Physical condition of welding machine

body. a) Body cover

b) Plug points

c) Rollers with non-sparking & brake arrangement.

2 Ammeter & Voltmeter knob condition

3 Condition of cable connectors and lugs

4 Provision for body earthing provided

5 Welding machine stability for

machines with wheels check the condition of wheels.

6 Machine guarding in tact

7 Condition of electrical cables

CONTRACTOR OFFICIAL

SIGNATURE NAME DESIGNATION STAMP SIGNATURE

WELDING MACHINE


Page 149 of 209




ASSURANCE




DEFECTS / REMARKS OK NOT

OK Safety Features:

1 Condition of cable insulation shall be intact

2 Cable shall be free from cuts and damages

3 Lugs provided at cable ends for easier termination


WELDING CABLE


Page 150 of 209




ASSURANCE




Safety Features: 1 Ensure that the welding holder is free

from breakages.

2 The holder insulation to be in tact.

3 Squeeze grip system to be in condition.

4 The electrical cable attached to the holder shall be free of any cuts and damages.

5 Lugs provided on the cable. Condition of cable insulation.

CONTRACTOR OFFICIAL


WELDING HOLDER


Page 151 of 209




ASSURANCE



DIESEL GENERATOR



OK NOT OK

Safety Features: 1 Ensure that the physical condition of the

panel is OK.

2 Ensure that the Panel should be flame proof .

3 Panel to have provision for body earthing.

4 Panel should be equipped with 30 mA ELCB & MCB protection.

5 Panel should be painted, corrosion free and stable.

6 Electrical components in the panel shall be in good condition.\


Page 152 of 209




ASSURANCE




DEFECTS / REMARKS

OK NOT OK

Safety Features: 1 Electrical extension boards shall be in

good physical condition.

2 Extension board’s body shall be metallic.

3 Extension board’s shall be flame proof.

4 30mA ELCB protection to be provided to the extension boards

5 Plug sockets shall be provided with caps.

6 Wooden electrical extension boards are not allowed.

7 Connected cables are well insulated and having no cuts and damaged insulation.

8 No loose or damaged plug sockets fixed in switch board.


ELECTRICAL SWITCH BOARD


Page 153 of 209




ASSURANCE




OK NOT OK

Safety Features: 1 Grinding machine body shall be double

insulated type.

2 Guard provided to the grinding wheel.

3 Electrical cable connected shall be in good condition and free from cuts and joints.

4 Three pin plug shall be provided for plug connections.

5 Speed of the grinding wheel shall be marked on the body of the grinding machine.


GRINDING MACHINE


Page 154 of 209




ASSURANCE


Date: Contractor Name: Equipment ID: PO NO & Date: S.NO CHECKLIST STATUS IDENTIFIED

DEFECTS / REMARKS

OK NOT OK

Safety Features: 1 The torch shall be free from physical

defects

2 Gas cutting torch handle insulation in good condition

3 Nozzle free of foreign particles.

4 Flash back arrestor to be provided to the torch.

5 Valves of the torch to be in operating condition

GAS CUTTING TORCH

GAS CUTTING EQUIPMENT


Page 155 of 209




S.NO Format Number Equipment CL-4.1 Gas cutting torch CL-4.2 Gas Supply hose CL-4.3 Gas cylinder regulator CL-4.4 Gas cylinder CL-4.5 Gas cylinder Trolley

Page 156 of 209




ASSURANCE




Safety Features: 1 Hoses marked with IS 447 marking.

2 Hoses to be free of cuts, joints,

abrasions and signs of wear and tear

3 Hoses as per color coding specified in IS 447 (Oxygen – Blue & LPG / Acyteline – Red)

4 Hoses are fitted with jubilee clamps.

GAS SUPPLY HOSE



Page 157 of 209




ASSURANCE


Date:


PO NO & Date:


OK NOT OK

Safety Features: 1 Regulators shall be with IS 6901

marked

2 Regulator shall be specific to the gas cylinder.

3 Pressure gauges in the regulator shall be in working condition.

4 Flash back arrestor to be provided along with the regulator

5 No grease or any sort of lubrication to be provided on the regulator body.

6 Sign of any physical damage on the regulator


GAS CYLINDER REGULATOR


Page 158 of 209




ASSURANCE





1 Gas cylinder contents and color coding as per IS 4379

2 Cylinder body condition

3 Cylinder valve cap provided

4 Cylinder HT details marked

5 LPG cylinder shall be of Industrial gas cylinders only (Domestic LPG cylinders are not allowed)

6 Expiry date marked on the body for LPG Cylinders


GAS CYLINDER


Page 159 of 209




ASSURANCE


Date:


PO NO & Date:


OK NOT OK

Safety Features: 1 Gas cylinder contents and color coding

as per IS 4379

2 Cylinders shall be provided with valve caps.

3 HT details to be clearly marked on the cylinder body.

4 Expiry date to be marked on the body of LPG Cylinder.

5 LPG cylinder shall be of Industrial gas cylinders only (Domestic LPG cylinders are not allowed)

6 Gas cylinder key shall be provided with the cylinder

CONTRACTOR OFFICIAL


GAS CYLINDER TROLLEY


Page 160 of 209



ACCESS & EGRESS EQUIPMENT

S.NO Format Number Equipment 1 CL-5.1 Scaffolding pipes & fittings 2 CL-5.2 Portable step Ladder 3 CL-5.3 Ladder

Page 161 of 209




ASSURANCE


Date:


PO NO & Date:


OK NOT OK

Safety features: 1 Scaffolding pipes shall be of Min. 40

mm dia with 4 mm thickness

2 Scaffolding pipe material shall be of IS: 2750 and it shall be a single pipe without joints

3 Scaffolding fittings as per IS:3696

4 Scaffolding pipes shall be free from

physical damaged, corrosion and bends.

5 Scaffolding pipes well painted.

6 Scaffolding pipes shall be non - slippery

due to oil and grease

7 Couplings to be well maintained greased and kept in separate place other than scaffold pipes

8 Work platform gratings free from physical damage, wear and tear & signs of corrosion.

9 Gratings shall not be having sharp edges or protruding connections.


SCAFFOLDING PIPE & ITS FITTINGS


Page 162 of 209




ASSURANCE




Safety Features: 1 Portable step ladder shall be in good

physical condition.

2 It shall have locking provision for legs.

3 Rungs of the ladder shall be in good

working condition.

4 No alterations made to the original ladder.

5 Side rails and steps free of oil and grease

6 Inter distance between steps and rungs shall be 12”

7 Wooden step ladder not allowed inside Refinery

CONTRACTOR OFFICIAL


PORTABLE STEP LADDERS


Page 163 of 209




ASSURANCE


Date:


PO NO & Date:


OK NOT OK

Safety Features: 1 Are all the rungs, cleats, or steps in

good condition?

2 Are the side rails intact without cracks, bends, or sharp projections?

3 Is the ladder free of corrosion?

4 Are the side rails and steps free of oil or

grease?

5 Are the ropes on extension ladders intact without fraying or excessive wear?

6 Slippery material on the rungs of the ladder

7 Legs of the ladder on the same level

8 No alterations made to the original

ladder.

9 Inter distance between steps and rungs shall be 12”

10 Wooden ladder not allowed inside Refinery.


LADDERS


Page 164 of 209



FIRE FIGHTING EQUIPMENT

S.NO Format Number Equipment 1 CL-6.1 DCP Extinguisher 2 CL-6.2 CO2 Extinguisher 3 CL-6.3 Fire Hose 4 CL-6.4 Firefighting nozzle

Page 165 of 209




ASSURANCE


Date:


PO NO & Date:


OK NOT OK

Document: 1 Hydro-test certificate of 10 Kg DCP

extinguisher.

Safety Features: 2 10 Kg DCP Extinguisher shall be IS

2171 marked.

3 CO2 Cartridge inside the extinguisher shall have IS 4947 certification mark and manufacturers certificate.

4 CO2 cartridge unused. 5 DCP powder in free from bid or/ cake

formation.

6 Discharge hose, squeeze grip nozzle are in working condition and there is no sign of damage.

7 No sign of physical dent, bend & corrosion on the body of DCP extinguisher.

8 Name of the Contractor and HT done date to be clearly marked on the body of the extinguisher.

9 Cap piercing vent holes shall not be plugged.

10 Safety Clip available with DCP extinguisher.


DCP EXTINGUISHER

FIRE FIGTING EQUIPMENT

Page 166 of 209







DEFECTS / REMARKS

OK NOT OK

Document: 1 Hydro-test certificate of 4.5 Kg CO2

extinguisher.

Safety features: 2 4.5 Kg CO2 Extinguisher shall be IS

2878 marked.

3 No sign of damages to discharge hose.

4 Hand held discharge hose portion is

insulated and there is no sign of damage to insulation.

5 Cylinder valve shall be in operable condition and lock pin to be provided with the valve.

6 Name of the contractor and HT details to be marked on the Fire extinguishers body.

CONTRACTOR OFFICIAL


CO2 EXTINGUISHER


Page 167 of 209




ASSURANCE


Date:


PO NO & Date:


OK NOT OK

Safety features: 1 63 mm or 38 mm dia fire hose shall be

IS 636 marked of Type-B made of synthetic only.

2 Canvas hose is not allowed inside refinery.

3 The physical condition of the fire hose shall be free from pin holes, cuts, wear & tear.

4 The coupling shall be permanently binded to the hose with proper winding. No Temporary adjustment is allowed.

5 Male and female couplings shall be in good working condition and lugs shall be free to operate.

6 Gasket in female coupling shall be in working condition and good.

7 Free from physical damages and leaks.

8 Suitable F - rod for opening hydrant landing valve

CONTRACTOR OFFICIAL


FIRE HOSE


Page 168 of 209



HAND TOOLS AND TACKLES

S.NO Format Number Equipment 1 CL-7.1 All Types of Wrenches & Spanners 2 CL-7.2 Chisel 3 CL-7.3 Hammer 4 CL-7.4 Screw Driver 5 CL-7.5 Plier 6 CL-7.6 Spreader 7 CL-7.7 Crimping Tool 8 CL-7.8 Jack Hammer 9 CL-7.9 Driller

Page 169 of 209




ASSURANCE





Safety feature: 1 63 mm or 38 mm dia firefighting

nozzle

2 IS: 2871 marked.

3 Made of either gun metal or SS

4 Triple purpose nozzle and smooth to operate.

5 No sign of physical damage and nozzle inlet is suitable for fixing in hose coupling.


FIRE FIGHTING NOZZLE


Page 170 of 209




ASSURANCE




Safety Features: 1 Wrenches or Spanners shall be free

from oil, grease, dust and corrosion.

2 Wrenches should not have any physical damage.

3 No make shift arrangement or welding on the body.

4 Wrenches or Spanners heads are not rounded up.

CONTRACTOR OFFICIAL


ALL TYPES OF WRENCHES & SPANNERS

HAND TOOLS & TACKLES

Page 171 of 209




ASSURANCE




Safety Features: 1 Chisel shall be free from oil, grease,

dust and corrosion.

2 It should not have any physical damage.


4 Chisel holder grip should be in good condition (Carpenter chisel).

5 In case of RCC works and Reinforcement rod works chisel should have handle.

6 Chisel head should not be bushed.


CHISEL


Page 172 of 209




ASSURANCE




DEFECTS / REMARKS

OK NOT OK

Safety Features: 1 Hammer shall be free from oil, grease,

dust and corrosion.



4 Hammer head should have proper locking arrangement.

5 Hammer handle should be metal. No Wooden handle is allowed.

6 Hammer head shall not be round up or bald.

CONTRACTOR OFFICIAL


HAMMER


Page 173 of 209




ASSURANCE





Safety Features: 1 Screw driver shall be free from oil,

grease, dust and corrosion.



4 It should have proper gripping arrangement.

5 It shall not be blunt or bald.

CONTRACTOR OFFICIAL


SCREW DRIVER


Page 174 of 209




ASSURANCE


Date:


PO NO & Date:

S.NO CHECKLIST STATUS REMARKS

OK NOT OK

Safety Features: 1 Plier shall be free from oil, grease, dust

and corrosion.




5 The plier handle insulation shall be intact.

6 The plier nose shall not be round up or bald.

CONTRACTOR OFFICIAL


PLIER


Page 175 of 209




ASSURANCE


Date:

Contractor Name: Equipment ID: PO NO & Date:



Safety Features: 1 Spreader shall be free from oil, grease,

dust and corrosion.




5 It shall not be round up or bald.

CONTRACTOR OFFICIAL


SPREADER


Page 176 of 209




ASSURANCE


Date:


PO NO & Date:


Safety Features: 1 Crimping tool shall be free from oil,



3 No make shift arrangement on the body.


CRIMPING TOOL


Page 177 of 209




ASSURANCE


Date:


PO NO & Date:


OK NOT OK

Safety Features: 1 Jack Hammer shall be free from oil,



3 No make shift arrangement or welding

on the body.


5 Connected power cables are well insulated and having no cuts and damaged insulation

6 In case of pneumatic or hydraulic operated ensure that the tubes are properly connected and clamped.

7 The Jack hammer shall have on or off control switch at the tool itself.

8 Drill bits locking arrangement shall be sound.


JACK HAMMER


Page 178 of 209




ASSURANCE




DEFECTS / REMARKS

OK NOT OK

Safety Features: 1 Driller shall be sound in construction.



4 Connected power cables are well insulated and having no cuts and damaged insulation.

5 Drill bit locking arrangement shall be sound.

6 Guards provided to be in place.


DRILLER


Page 179 of 209



CIVIL WORKS EQUIPMENT

S.NO Format Number Equipment 1 CL-8.1 Crow bar 2 CL-8.2 Shovel 3 CL-8.3 Spade 4 CL-8.4 Gamela 5 CL-8.5 Concrete Mixer

Page 180 of 209




ASSURANCE





Safety Features: 1 Crow Bar shall be free from oil, grease,

dust and corrosion.



4 Hand grip area is to be properly insulated.

CONTRACTOR OFFICIAL


CROW BAR


Page 181 of 209




ASSURANCE


Date: Contractor Name: Equipment ID: PO NO & Date: S.NO CHECKLIST STATUS IDENTIFIED


Safety Features: 1 Spade shall be free from oil, grease,

dust and corrosion.




CONTRACTOR OFFICIAL


SPADE


Page 182 of 209




ASSURANCE


Date:


PO NO & Date:

S.NO CHECKLIST STATUS REMARKS OK NOT

OK Safety Features:

1 Shovel shall be sound in construction.

2 No make ship arrangement or welding on the body.


CONTRACTOR OFFICIAL SIGNATURE NAME STAMP

SHOVEL

Page 183 of 209




ASSURANCE





Safety Features: 1 Gamela shall be free from oil, grease,

dust and corrosion.


3 No damage or hole for bottom of the body.

4 Gamela should have no sharp edges.

CONTRACTOR OFFICIAL


GAMELA


Page 184 of 209




ASSURANCE


Date:


PO NO & Date:


Safety Features: 1 Tyres are good and not retreaded or

rollers with non-sparking arrangement.

2 No leaks from fuel tank and connecting hoses or fittings.

3 Guarding to rotating parts- a. Pulley belt b. Radiator fan

4 PESO approved spark arrestor fixed to the exhaust.

5 Alternator in place and in good working condition.

6 All electrical components to be free of defects.

7 Braking mechanism is in working condition.


9 No damage or hole for bottom of the

bowl.

10 Bowl should not have sharp fold edge.

11 Locking arrangement to the mixer bowl.


CONCRETE MIXER


Page 185 of 209



MISCELLANEOUS EQUIPMENT

S.NO Format Number Equipment 1 CL-9.1 Hydro-testing Pump 2 CL-9.2 Blow Lamp 3 CL-9.3 De-watering Pump 4 CL-9.4 Air Compressor 5 CL-9.5 Jack 6 CL-9.6 Grass cutting machine 7 CL-9.7 Fire proof Tarpaulin

Page 186 of 209




ASSURANCE





Safety Features: 1 Hydro-testing pump shall be free from

oil, grease, dust and corrosion.




HYDRO - TESTING PUMP


Page 187 of 209




ASSURANCE




Safety Features: 1 Blow lamp nozzle is in good condition.

2 Handle is fitted with insulated.

3 Lamp nozzle shall be free from dust.

4 Flash back arrestor to be provided to the blow lamp.

5 Hoses shall be attached using Jubilee clamps only.

6 Blow lamp valves shall be in operating condition.

CONTRACTOR OFFICIAL


BLOW LAMP


Page 188 of 209




ASSURANCE




DEFECTS / REMARKS

OK NOT OK

Safety Features: 1 De-watering Pump shall be free from

oil, grease, dust and corrosion.

2 It should not have any physical damage. 3 De watering pump shall be diesel driven

only. (No petrol driven or kerosene driven pumps are allowed in refinery)

4 Guarding provided to all rotating parts.

5 PESO approved spark arrestor to be

provided at the exhaust.

6 Hoses shall be fixed up with proper clamping arrangement.

7 Proper arrangement for easy handling & shifting of the pumps.


DE-WATERING PUMP


Page 189 of 209




ASSURANCE




Documents: 1 Test certificate of air compressor

2 Test certificate for hopper

Safety Features:

1 Tyres are good and not retreading or rollers with non-sparking arrangement.

2 No leaks from fuel tank and connecting hoses or fittings.

3 Guarding to rotating parts: a) Pulley belt b) Radiator fan

4 Body cover is well maintained and sound in construction.

5 No engine oil leakage.

6 Self-ignition is in working condition.

7 Lights are in working condition.


AIR COMPRESSOR


Page 190 of 209




ASSURANCE




Documents: 1 Test certificate for the jack.

Safety Features: 2 Jack shall be sound in construction.

3 Jack shall be free from oil, grease, dust

and corrosion.



6 Jack heads shall not be round up or bald.

7 No Hydraulic oil leakage from the jacks

CONTRACTOR OFFICIAL


JACK


Page 191 of 209




ASSURANCE





Safety Features: 1 Engine spark plug shall not be open and

should be of concealed construction.

2 Guards to be provided to the rotating parts.

3 The machine harness shall be physically good.

4 There should be no visible fuel leaks on the body of the machine.


GRASS CUTTING MACHINE


Page 192 of 209


Doc No: CL – 9.7 Ref Doc : SWP -

06 Rev. : 0 Date : 18/3/11 Page 1 of 1


ASSURANCE


Date:


PO NO & Date:


Documents: 1 Fire retardant test to be carried out as

per IS:11871 and test certificate to be submitted.

Safety Features: 2 Fire retardant blanket should be woven

with ceramic fibre yarn reinforced with SS -304 wire.

3 Fire retardant blanket should not have physical damage.

4 Thickness should be min 3 mm.

5 Eyelets along all four side at a interval

of two feet for anchorage.


FIRE PROOF TARPAULIN


Page 193 of 209

> Contractor Letter Head < . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date : ------------------------

List No

FORMAT NO: SWP-F-6.1

LIST OF EQUIPMENT, TOOLS & TACKLES PLANNED FOR USE IN HPCL -VR

P O NO DATE HPCL USER DEPARTMENT

We propose to use the following equipment in HPCL-VR premises. S.NO EQPT/ TOOL /TACKLE

NAME ID NO MAKE QTY

1 2 3 4 5 6 7 8 9 10 .. ..


Page 194 of 209

> Contractor Letter Head < . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date: ------------------------

First entry Additional entry

Tick in appropriate box

TO:

HOD-Fire & Safety

FORMAT NO: SWP - F - 6.2

EQUIPMENT, TOOLS & TACKLES GATE ENTRY PLAN We propose to bring the equipment, tools & tackles into HPCL Refinery as per the dates below and lists attached.

Planned Date of Entry

List as per Annexure No (Annexure –I, II, III etc.)

• I declare that all the equipment, tools & tackles have been personally verified by me to be

conforming to the requirement of checklist as per SWP-06-G-6.1

• I understand that equipment, tools & tackles not conforming to its checklist of SWP-06-G-6.1, shall not be allowed entry into HPCL Refinery. I am prepared to handle such circumstances.

Please arrange for inspection at the entry gate and issue “ Equipment Safety Clearance Certificate”.

CONTRACTOR OFFICIAL

SIGNATURE

NAME DESIGNATION STAMP

Page 195 of 209


Doc No: SWP- F- 6.3 Ref Doc : SWP -06 SAFE WORK PRACTICES


EQUIPMENT SAFETY CLERANCE CERTIFICATE

Page 1 of 1

To Date:

This has reference to your “Equipment, Tools & Tackles Gate Entry Plan”( SWP-F-6.2) dated ……………… Based on the above, at the time of gate entry your equipment were checked and following is advised. I. Equipment allowed to enter. Sr. No Equipment Name Equipment ID Equipment

make/Qty. Stamp

1 2 3

II. Equipment not allowed to enter. Sr.No Equipment Name Equipment ID Quantity Reason for

rejection Stamp

1 2 3

You are advised as follows:

1. Please ensure that the equipment allowed is maintained in the proper condition during its entire period of usage.

2. The equipment will be periodically checked by HPCL and if found unsuitable, you will have to discontinue its usage and remove from Refinery premises. (already informed to you through SWP-06).

3. This “Equipment Safety Clearance Certificate” is not sufficient for gate entry. Further Security clearance is to be obtained for final gate entry.

HPCL F&S Department

Signature Name Location Equipment Entry Gate Office Stamp

CC: User Department ( ----- )

Contractor Name PO No Date of PO HPCL User Department

Page 196 of 209


Doc No: SWP-06-R 6.1

Ref Doc : SWP -06


CONTACT ADDRESS OF FIRE & SAFETY DEPARTMENT

(For the purpose of SWP-06 only)

Location Contact details Timing of contact Gate Entry Office Officer’s Name: Mr.M.Siva Prasad

Address: Dy.Manager- F&S HPCL -Visakh Refinery PO: Malkapuram Post Box No: 15 South gate, Opposite to Kalyani Hospital. Visakhapatnam-530 011 Andhra Pradesh(India Tel No: E-mail: [email protected]

0900 to 1200 hrs & 1400 to 1530 hrs

F&S Main Office Officer’s Name: Mr.K.V.Singh Address: Sr.Manager- F&S HPCL – Visakh Refinery PO: Malkapuram Post Box No: 15 Visakhapatnam-530 011 Andhra Pradesh(India) Tel No: 0891-2740183/ 2894843 FAX No – 0891-2740183 E-mail: [email protected]

0800 to 1630 hrs

Approved by

Signature

Name K.V.Singh Designation Head Fire & Safety

Page 197 of 209

RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS,

STEAM GENERATORS & OTHER IBR JOBS Annexure VIII : FSAFETY, HEALTH & ENVIRONMEN

Seal of the

Vendor


Visakh Refinery

SAFETY HEALTH & ENVIRONMENT

SAFETY:

By enforcing & following 1. Training, motivation and counselling the workmen - by arranging pep talks.

2. Compliance of standards, codes and specifications and systems, procedures & practices -by introducing in contracts and surprise check.

3. Permit rules and regulations- Control of illegal, unauthorised & hazardous work through permit system.

4. by arranging pep talks. & by introducing in contracts and surprise check 5. Product safety & MSDS conditions by arranging training/ demonstrations. 6. Health surveillance. 7. Reporting near misses and control of incidents by recommendations. 8. Labour and Factories act. through contract conditions. 9. Lifting & hoisting machinery, equipments, instruments tools & tackles calibrations

through certificates. 10. Transfer of tools & tackles to heights in closed bags 11. Scaffolding pipes properly and of good condition, person with double harness safety

belts through safety tags & Inspection. 12. Welfare rules and regulations like ESI, PF, min. wages trhough contract conditions. 13. Maximizing usage of mechanized tools like torque wrenches, bolt tensioners, flange

spreaders. 14. Barricading critical incident potential area by double taping all around.

HEALTH:

1. Selection of right supervisors for the right job by qualifications and experience. 2. Health / medical fitness certificate for all labours. 3. Protect workers and others from flushing, steaming, spreads, drainings, refractory

mixing & gunniting, blast cleaning, hydro jetting, chemicals, harmful and poisonous gases, noise, heat, air pollution i.e. dust, burns, suffocation & irritation, by ensuring usage of All PPE.

4. Ventilation and air circulation to be provided for closed things by proper and sufficient number good air hoses, exhaust fans and lighting arrangement of 24volts supply.

5. Dehumidification for comfort and fatigue reduction. 6. Protection form radiations (arc welding), X rays (UV rays) by safety boards, isolation. 7. Egronomical protection for back, eyes, neck etc. for office people.

Page 198 of 209

RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS,

STEAM GENERATORS & OTHER IBR JOBS Annexure VIII : FSAFETY, HEALTH & ENVIRONMEN

Seal of the

Vendor


Visakh Refinery

8. Physical fitness each labour should get min. 06 hours of sleep by not allowing labours continuing more than 16 hrs of work.

9. Proper nutrition & hygiene ( provide tea & snacks and facility for lunch), clean drinking water, toilet facility, skin care ( boiler suits) and mental health by insurance clauses etc.

ENVIRONMENT:

1. Control toxic emissions/leaks in vehicles and generators by providing flame arrestors. 2. Chemical & hazards waste management. 3. Legal compliance like IBR, factory Inspectors by providing in contracts. 4. Proper Unloading, storage, housekeeping of flammable liquids, petroleum products,

hazardous chemicals, gas cylinders. 5. Control of use toxic, flammable, explosive, hazardous chemicals & gas cylinders, noise

producing tools & machines, corrosive and reactive substances, 6. Check for License for transportation of flammable and hazardous cylinders and

removing spill immediately by sand etc. 7. Controlling spreads of steam from flanges, hydro jetting by sheets/ tarpaulins. 8. Oil drains, flashings, release of hydrotest water in controlled / closed manner. 9. Following motor vehicles act by checking pollution certificates, following speed

controls, valid refinery licences, 10. Providing proper illumination by lighting, reduction of sound, noise & dust, gaseous

pollute by PPE. 11. Insurance policy under Public liability act for all employees. 12. Occupation health surveillance by medical certificates, providing first aid in HPCL

dispensary. 13. Incident/ accident management.( reporting, investigation, corrective action ). 14. Safety performance management by rewards through quizzes and punishment through

contracts.

15. Disposal of sludge, coke, loose wastes, refractories, Insulation wastes, cement etc in closed bags/ drums and transporting to safe designated areas.

Page 199 of 209


Visakh Refinery Annexure IX : Annexure IX : Annexure IX : Annexure IX : FORMAT FOR FORMAT FOR FORMAT FOR FORMAT FOR PHYSICAL FITNESS CERTIFICATEPHYSICAL FITNESS CERTIFICATEPHYSICAL FITNESS CERTIFICATEPHYSICAL FITNESS CERTIFICATE

Table 1 : Physical Fitness Certificate Format

1. Name of the agency / Sub contractor

2. Name of the employee

3. Age / Sex 4. Present health history 5. Previous health history

6. Measurements Height in Cms. Weight in Kgs. Chest Inspiration Expiration

_____________________________ _____________________________ _____________________________ _____________________________

7. Blood Pressure

8. Heart

9. Lungs 10. Abdomen

Liver Spleen

_____________________________ _____________________________

11. Limpth Glands

12. Hydrocele

13. Hernia

14. Vericosity 15. Eyes:

Without Glasses With Glasses Right Eye Left Eye Right Eye Left Eye Far Vision 6/ 6/ 6/ 6/ Near Vision P P P P

16. Physical Deformities Remarks of the Doctor :

Signature / Stamp with Registration no.

Page 200 of 209


GENERATORS & OTHER IBR JOBS Annexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCE

Seal of the Vendor


Visakh Refinery

1. PENALTY FOR NON-COMPLIANCE

1.1. The penalty system is divided into two categories, Minor and Major. (HPCL - Fire & Safety shall decide whether an infringement is minor or major for violations which are not listed below).

1.1.1. Minor violation: Examples

1.1.1.1. Not wearing personal protective equipment (PPE) at work

site. 1.1.1.2. Minor traffic violation (wrong parking, over speeding) 1.1.1.3. Blocking of emergency equipment or exits. 1.1.1.4. Using unapproved scaffolding Etc.

1.1.2. Major violation: Examples

1.1.2.1. Smoking in the refinery, carrying matches or lighter and

mobile telephone.

1.1.2.2. Working without valid work permit.

1.1.2.3. Not wearing proper breathing apparatus when instructed.

1.1.2.4. Not providing shoring / sloped excavation for the deep pits.

1.1.2.5. Not providing fire extinguisher / fire hoses for hot work.

1.1.2.6. Repeating minor violations more than twice.

1.1.2.7. Major traffic violation.

1.1.2.8. Found guilty negligent driving resulting in a vehicle accident.

1.1.2.9. Entering classified area without permit.

Page 201 of 209



Seal of the Vendor


Visakh Refinery

1.1.2.10. Not complying with written instruction on the work permit.

1.1.3. INFRINGEMENT REPORT PROCEDURE

1.1.3.1. Manager and above of Fire & Safety department are authorized to issue Infringement Report to the Concerned - Manager about the Safety Violation.

1.1.3.2. The sponsoring department shall take action and provide

feedback to Fire & Safety (Copy of the infringement Report is attached as Annexure-IV)

1.2. TABLE OF PENALTY STAGES

Table 1 : Table of Penalty Stages

VIOLATION FIRST SECOND THIRD MINOR Caution Notice Penalty Rs.1000/- Penalty Rs.3000/- MAJOR Penalty Rs.3000/- Penalty

Rs.10,000/- on holiday list*

1.2.1. * Duration will be decided by General Manager - Oprns / Proj.

1.2.2. Note: HPCL reserves the right to impose more severe penalty, i.e.

suspend/terminate the contractor/employee, his supervisor or the Site-in-charge.

2. REPORTING OF ACCIDENTS / INCIDENTS

2.1. All the accidents/incidents minor/major and near misses shall be immediately reported in writing to the company supervisor.

2.2. All formalities as per statutory regulations shall be carried out by the

contractor where warranted.

Page 202 of 209



Seal of the Vendor


Visakh Refinery

2.3. Contractor shall assist the company supervisor in investigating the

accident/incident and furnish all details regarding the accident/incident.

2.4. Contractor shall pay all incidental and medical expenses for the injured and compensation, as per Govt. Rules, in case of fatality.

Page 203 of 209



Visakh Refinery Annexure X : Annexure X : Annexure X : Annexure X : Application Format for verification of antecedentsApplication Format for verification of antecedentsApplication Format for verification of antecedentsApplication Format for verification of antecedents

(on the letterhead of the Party / Contractor)(on the letterhead of the Party / Contractor)(on the letterhead of the Party / Contractor)(on the letterhead of the Party / Contractor)

Date: To, The Station House Officer, ______________Police Station,

Visakhapatnam. Sub: - Verification of antecedents of workmen engaged by us. Dear sir, We have engaged following workmen for our job at M/s. Hindustan Petroleum Corporation Limited, Visakh Refinery, Visakhapatnam for the period of _____________________________.

Sl.No Name Address

1. 2. 3. 4. 5.

These workmen have been allowed inside the Refinery to perform the job on character certificate submitted by us for a period of one month, pending verification of the antecedents of these workmen. We request you to arrange to verify the antecedents of our above employees and submit the report to enable us to submit the same to HPCL Management. Thanking you,

Very truly yours, Authorized Signatory Name: Designation:

Page 204 of 209

RFQ No.12000438-HD-46002/VNK


Visakh Refinery

Annexure XII RADIOGRAPHY RULESAnnexure XII RADIOGRAPHY RULESAnnexure XII RADIOGRAPHY RULESAnnexure XII RADIOGRAPHY RULES

Provisions of Atomic Energy (Radiation Protection) Rules, 2004 for Radiography Agencies

Responsibilities of Radiography Agency (Contractor) for safety & security of radiography devices:

1) Whenever a contract for industrial radiography is awarded to any industrial radiography agency, the

Contractor/Radiography Agency shall ensure that:

a. The radiography agency is duly authorized by RSD, AERB to work at the particular site of

Contractor

b. The radiography agency carries out the radiography work by adhering to requirements of AERB

Safety Code on Industrial Radiography (AERB/SC-IR, 2001)

c. The radiographer who will be engaged by radiography agency for carrying out radiography work

of radiography agency is certified by BARC/AERB

d. the radiographer has a functional radiation survey meter and makes use of it during radiography

e. The radiographer cordons sufficient area to control access of unauthorized person during

radiography at the sit.

f. The radiography work is supervised by Radiological Safety Officer (RSO)/site-in-charge, if any, of

the Contractor.

2) The Contractor shall be responsible for providing adequate illumination, scaffolding and other facilities

required to facilitate the safe radiography work by radiography agency.

3) The Contractor shall inform well in advance to radiography agency about daily schedule of radiography

work and shall not insist upon the conduct of radiography work by radiography agency under adverse

conditions such as during heavy rains, storms when all the radiation safety precautions may not be taken.

4) The Contractor shall ensure that the radiography devices (camera(s)) with source are brought in or

moved out of the site with appropriate gate pass mentioning details of the equipment. The proper

records of incoming and out going of radiography devices are maintained at storage room and at security

department.

5) The Contractor shall provide to the radiography agency the safe and secure storage room as approved by

AERB, with round the clock effective physical security arrangements, for storing radiography devices,

emergency accessories and other associated equipment. It shall be ensured that adequate illumination is

present around source storage room during night and approach roads to the storage room are in good

condition.

6) The Contractor shall inform in writing to the HPCL Security Department or concern Section (say

Maintenance-Onsite) on details of personnel of radiography agency authorized to take out radiography

devices from the pit room along with their specimen signatures.

7) The radiography agency should verify that the radiography agency stores securely the radiography devices

inside the pit of the storage room when no work of radiography is carried out.

8) The Contractor shall verify that the radiography agency has emergency plans, preparedness and contact

numbers in case of emergency/incidents involving radiography devices.

****

Page 205 of 209


GENERATORS & OTHER IBR JOBS Visakh Refinery

Annexure XIII : Annexure XIII : Annexure XIII : Annexure XIII : SPECIFICATSPECIFICATSPECIFICATSPECIFICATIONS FOR FIRE RETARDENT BLANKETIONS FOR FIRE RETARDENT BLANKETIONS FOR FIRE RETARDENT BLANKETIONS FOR FIRE RETARDENT BLANKET

1. Application : For using as curtain against sparks generated from arc welding, gas cutting and

grinding works.

2. Specifications : Fire retardant blanket woven from ceramic fibre yarn reinforced with SS -304 wires.

Other specifications are as follows:

a). Thickness : 3.0 mm b). Width : 1 – 2 Meter c) Length : As specified in roll d) Weight : 1500 GSM(Gram per square meter) e) Max use temperature: 1260 0 C f) Anchor Methods : Eyelets along all four side at a interval of two feet for anchorage g) Test certificate : Fire retardant test to be carried out as per IS:11871 and test report to be submitted along with supply of materials. h) The party has to send sample piece of ( 0.5 M x 0 .5 M size) for verification by HPCL,Visakh Refinery along with quotation submission. Suggested parties:

1. M/s Murugappa Morgan Thermal Ceramics Ltd, New No.2, N.S.C Bose Road, Dare House Annexe 5th Floor, Chennai 600 001. India. Phone : +91-44-2530 6894(Direct) / Mobile : 09600077893 Fax : +91-44-2534 5985 E-mail : [email protected]

2. FIRETEX PROTECTIVE TECHNOLOGIES PVT. LTD. Dee-Kay Estate, Lake Road,

Near Bhandup Police Station, Bhandup (W), Mumbai - 400 078.

Tel: 022-41585959/ 25952901/02/03 Fax: (022) 25946179. E-mail: [email protected] . Website: www.frictionindia.com

Page 206 of 209


Annexure XIV : Annexure XIV : Annexure XIV : Annexure XIV : QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR

CONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISOR

Visakh Refinery

1. Safety Engineer

In case the strength of contractor workers including sub-contractor workers in more than 250 Nos., Safety Engg to be engaged by contractor who will own overall responsibilities of HSE Management of the particular contractor.

a. Qualification - Degree in Science / diploma in any Engg.

b. Technical qualification - Fire or Safety diploma / certificate from Govt. or private institute.

c. Experience - Minimum 3-5 years experience of working in construction site/ shutdown activities in the field of safety or minimum one T&I experience

d. Candidate is required to read, write and speak in English with fluency in Telugu or Hindi Language.

e. The bio data of the safety Engg. shall be submitted to HPCL safety division and only the personnel cleared by the safety division shall be engaged by the agency.

2. Safety Supervisor:

In case the strength of contractor workers including sub-contractor workers in more than 30 Nos., Safety supervisor to be engaged by contractor. Based on guideline of contactor safety regulations, the number of safety supervisors to be engaged.

a. Educational Qualification - Higher Secondary ( 10+2)

b. Technical qualification - Fire or Safety diploma / certificate from Govt. or private institute.

c. Experience - Minimum 2- 3 years experience of working in construction site/ shutdown activities in the field of safety or minimum one T&I experience

d. Candidate is required to read, write and speak in English with fluency in Telugu or Hindi Language.

e. The bio data of the safety supervisors shall be submitted to HPCL safety division and only the personnel cleared by the safety division shall be engaged by the agency. The Safety supervisor’s team shall be led by contractor Safety Engineer.

Page 207 of 209


Annexure XIV : Annexure XIV : Annexure XIV : Annexure XIV : QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR

CONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISOR

Visakh Refinery

f. The safety supervisors of the agency shall constantly coordinate with HPCL's Safety, Operations and executing departments for the smooth and safe execution of jobs.

Note: F&S will arrange one day training programme on Role & Responsibilities of Safety Enggs./Safety supervisors based on the request of executing department and will issue individual training card.

* * *

Page 208 of 209

Annexure XV to RFQ 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM

GENERATORS & OTHER IBR JOBS MINIMUM REMINIMUM REMINIMUM REMINIMUM RESOURCES TO BE MOBILISEDSOURCES TO BE MOBILISEDSOURCES TO BE MOBILISEDSOURCES TO BE MOBILISED

Visakh Refinery

Agency shall possess following minimum resources that are to be mobilised to site after PO placement for carrying out various piping jobs in various units simultaneously. 1. HPCL approved or reputed TPI (like EIL) approved welders - 2 nos. IBR certified Welders and 1 TIG welder 2. 2 nos. each of Skilled fitters, fabricator and Gas cutter/grinders 3. 8 nos. Helpers/Khalasis 4. 2 nos. Safety Supervisors 5. 2 nos. Job Supervisors 6. 5 nos. 1” Dia. air hoses of each 25 meters 7. 5 nos. 1” Dia. water hoses of each 25 meters 8. 5 nos. standard fire hoses 9. Fire Retardant cloths – 5 nos. (3’x 12’ size – 5 nos. and 6’ x 12’size – 5 nos.) 10. Temporary Power Panels – 2 nos. 11. Pneumatic / Electric Concrete Chipping Machines – 2 nos. 12. Welder Helmets – 3 nos. 13. DCP Fire Extinguishers – 3 nos. 14. Chain Blocks – 2 nos. (1 Ton Capacity – 1 no. and 3 Ton Capacity – 1 no.) 15. Full body type double harness safety belts – 6 nos. 16. System (CUPLOK) scaffolding material ( 60 nos. horizontals, 20 nos. Verticals, 20 nos. base plates, gratings of 10 Sq. Mtr.) 17. GI and Asbestos sheets – 10 nos. each (Size 1m x 2 m (approx.)) 18. Barricading Tapes – 10 nos. 19. Hydro testing pumps – 2 nos. 20. Vehicle – 1 no. for attending emergency jobs in the Refinery 21. 3 nos. Electric Welding machines & 1 no. DG Welding machine 22. Other PPE as mentioned in SWP-01 & SWP-02.

Page 209 of 209