engineering & projects st 8, shoorji...

HINDUSTAN PETROLEUM CORPORATION LIMITED, GRESHAM ASSURANCE BUILDING, 2nd ST FLOOR, Sir P. M. Road, FORT, MUMBAI 400 001

TENDER DOCUMENT FOR ATF TANK, PIPLINE, ENCLOSURE WALL AND LAND DEVELOPMENT WORKS AT SHAKURBASTI INSTALLATION

PAGE 1 OF 204 SIGNATURE AND STAMP OF TENDERER

HINDUSTAN PETROLEUM CORPORATION LIMITED ENGINEERING & PROJECTS

HINDUSTAN BHAWAN, 1ST FLOOR, 8, SHOORJI VALLAVDAS MARG,

BALLARD ESTATE, MUMBAI-400 001

TENDER NO. 8000043-HB-10002��

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TENDER DOCUMENT

FOR

DESIGN, FABRICAION, ERECTION, WELDING & TESTING OF

ABOVE GROUND TANK, PIPLINE, LAND DEVELOPMENT

AND PAINTING WORKS.

AT

SHAKURBASTI INSTALLATION




INDEX

Sr. No. DESCRIPTION A E – TENDER TERMS / INSTRUCTIONS TO BIDDERS B PROJECT / LOCATION DETAILS C INTRODUCTION AND JOB SCHEDULE D SPECIAL CONDITIONS OF THE CONTRACT/SPECIAL PAYMENT TERMS E DECLARATION F TIME SCHEDULE G TECHNICAL SPECIFICATIONS

� Scope of Work for Tankage Works � Technical Specification for Concrete and Reinforcement Works � Technical Specification for Civil Jobs � Technical Specification for Welding � Specifications for Fabrication of Above Ground Pipeline � Standard Specifications for Tank pads � Specification for Tank Fabrication � Inspection Test Plan for Tank Fabrication � Standard Specification For Shop & Field Painting � Specifications for Materials in contractor’s scope of supply � Technical Specifications for Sprinkler Nozzles � Technical Specifications for SORF Flanges � Technical Specification for Bends

H HEALTH, SAFETY AND ENVIRONMENT REQUIREMENT I E. M. D. FORMAT J GENERAL TERMS AND CONDITIONS K DRAWINGS




E – TENDER TERMS / INSTRUCTIONS TO BIDDERS

AS PER ATTACHMENT




PROJECT / LOCATION DETAILS PROJECT NAME:

DESIGN, FABRICAION, ERECTION, WELDING & TESTING OF ABOVE GROUND ATF TANK, ATF PIPLELINE, HYDRANT LINE, ENCLOSURE WALL, LAND DEVELOPMENT AND PAINTING WORKS.

SITE / LOCATION:

SHAKURBASTI INSTALLATION, NEW DELHI

ADDRESS: HINDUSTAN PETROLEUM CORPORATION LIMITED NEW ROHTAK ROAD NEW DELHI – 110 056 PH: 011 – 2522 0730 / 2522 2488

SITE INCHARGE NAME: & CONTACT NOS

1. Shri A K Behra - Manager-E&P Contact no - 09811418930 2. Shri D P Shrivastava – Exe. Project Engineer Contact no- 09868912278




DESIGN, FABRICAION, ERECTION, WELDING & TESTING OF ABOVE GROUND ATF TANK, ATF PIPLELINE, HYDRANT LINE, ENCLOSURE WALL, LAND DEVELOPMENT AND PAINTING WORKS

AT SHAKURBASTI INSTALLATION, NEW DELHI. INTRODUCTION OF WORK It is proposed to construct one no Tank, pipeline & miscellaneous work at existing Shakurbasti Installation, for storing Aviation Turbine Fuel (ATF). The scope includes the following items in the facilities proposed to be constructed at our Shakurbasti Installation.

1. Survey & plotting existing & final levels of area for establishing quantities of cutting/filling.

2. Design, Fabrication, Erection, Welding and testing etc complete, of one No. Cone Roof, Bottom Down, Tank of size-12.2 M DIA X 11 M HT as below:

• Erection of tank shell to be done as per jacking up method. • Design shall be as per IS 803/API650 only.

3. Dismantling / Demolishing of existing enclosure wall, Land Development in tank

farm area and Design & Construction of New Enclosure Wall.

4. Construction of Oil Water Separator.

5. Laying of ATF Pipeline for connecting new tank to existing pipeline.

6. Dismantling of Existing hydrant pipeline Header and Sprinkler Lines including padestals.

7. Laying of New Fire Fighting Header and Sprinkler Lines of specified sizes.

8. Design and Construction of concrete padestals for the ATF and hydrant piplines.

9. Painting of Tank and pipeline. Note: 1. Design and Fabrication Drawings of self supporting cone roof tank including

bottom plate cutting schedule/layout, Shell cutting Schedule/layout, Design and drawings of Sand pad foundation, Nozzle/Manhole/stair case orientation and any other applicable drawings as directed by Engineer-in-charge.

2. The Tanks to be constructed with Bottom Down (in the center) with a sump in the

center and water draw off piping with nozzle in the tank shell.




3. The Tank to be provided with Fast Flushing Arrangement as per specifications and approved drawings.

4. All the fabrication drawings showing the welding details including structural

supports for laying of pressure relief pipe line along with supports, fabrication details of center sump with water draw-off piping, Isometric and cross sectional drawings of P&I diagram to be submitted.

5. To establish the land filling /cutting quantities in the tank farm and enclosure wall

area, levels to be taken before and after the filling. Rate to include setting of Dumpy level / Theodolite and taking levels along with bench marking, etc. Complete. Grid layout drawing needs to be prepared and to be submitted for approval of Engineer in charge. Job shall be commenced only after clearance from EIC.

6. Shifting of any scrap materials lying at the constructional area including service station tanks to the designated place inside the depot premises at no extra cost. Job also includes site clearing from any debris, vegetation, bushes and trees, etc.

7. The contractor shall prepare a detailed date wise schedule of work/Bar Chart of the activities as per PO and submit to Engineer-In-Charge for approval before commencement of activities.

8. The Contractor has to give progress report with photographs every fortnight in hard copy as well as soft copy.

Before commencement of work the contractor shall prepare the fabrication drawings of tank construction based on the plate sizes and submit 4 copies of each drawing along with CD in AutoCAD 2000 to HPCL for approval within 2 weeks from the date of LOI/PO at no extra cost. Cutting of plates shall be commenced only after obtaining approved drawings from HPCL. The contractor shall submit 4 copies of as built drawing along with original tracings after completion of work at no extra cost. The same shall be submitted prior to submission of final bill by contractor.

After the job is completed, 4 copies of all the above drawings (As built) shall be submitted along with CD containing soft copy in AutoCAD 2002/2004 at no extra cost. The work needs to be carried out in the working depot premises for which precautions has to be taken to prevent any incidents due to presence of any gas while carrying out hot/cold work. Contractor needs to take hot / cold work permit on a daily basis. The contractor shall arrange for explosive meter and check for presence of flammable Vapour before undertaking hot work. Full time supervisor to be provided at work spot and work shall be carried out only after complying with all safety norms of the depot. All safety precautions to be taken for carrying out the above job like local fire screen, fire extinguishers, charged hydrant lines etc. as per requirement.




During the course of execution of the job, the contractor may create openings in the walls of the existing facilities (such as enclosure walls) to have free movement and access for men and machinery such as trucks, cranes etc. The opening has to be made good by the contractor at the end of the job at no extra cost. The contractor has to take necessary precaution for the safe transportation of the material. Before quoting for the said job the contractor is required to visit the site and make himself acquainted with the scope of the job and quote accordingly. The tenderer are required to go through the tender document thoroughly and carefully and offer their most competitive rates for the job. In case of any clarifications contractor may contact:

S. Gupta - Exe. Project Engineer – E&P, HINDUSTAN PETROLEUM CORPORATION LIMITED (A Government of India Enterprise), Engineering & Projects Department GRESHAM ASSURANCE HOUSE, 2 ND FLOOR, A-1595(3) 1 1-A SIR P M ROAD, 132 SHAHID B SINGH ROAD, FORT, MUMBAI - 400 001. PHONE NO. : 022 – 22608511, Fax No. 022- 2260 8555




Sl No DESCRIPTION SECTION 1

CIVIL JOBS FOUNDATION

1.0 EXCAVATION : Up to and including 2.0 m below NGL Excavation in any type of soil (except hard rock) for general site grading, tank pad foundation and for ring beam either by machinery or manually etc up to 2.0 m below NGL for all depths. Rate to be inclusive of following

• Taking co-ordinate wise spot levels @ 5m/cc intervals in grid pattern or as per direction of EIC, before commencing of excavation and after finishing the excavation work. Before commencing the excavation work layout of tank pad foundation to be ascertained by marking centre of each tank and periphery of the Sand pad foundation.

• Leveling, dressing and preparation of surface by rolling for commencing laying of Sand for foundation as specified in item no 2.

• Removal of all type of vegetation stems and roots to full extent. • Dewatering the excavated pit area if required with dewatering pump

provided by contractor. • Excavated Earth needs to be spread within tank farm area upto a fixed

level by spreading in layer and rolling the same. Balance earth to be disposed off elsewhere within the Depot premises or outside the depot premises to an unobjectionable area, which includes leveling the earth using roller or dump.

• Some of the Excavated Earth shall be dumped to form an Earthen Bund, similar to the existing one and to extend the existing earthen bund up to the newly constructed enclosure wall as per scope of this tender. No separate payment shall be made for this job.

Complete as per specifications and instructions of HPCL Engineer- in -Charge.

2.0 SAND FILLING FOR TANK PAD Supplying and filling best quality coarse sand approved by Engineer In-charge in layers of compacted thickness 150 mm each. Payment of all royalties, taxes, cess, etc to the Statutory Authority, loading, transportation, unloading, removal of debris, organic matter etc, spreading in layers, watering, rolling and compacting each layer with 2 MT roller till design compaction is achieved and finishing to slopes and grades as per drawings specifications and instructions of Engineer In Charge. Rate shall be applicable for all depths below NGL and upto 1.0 m above NGL /FGL and grades as per approved drawings.

CONCRETING Supply, mixing and laying various grade of concreting and meeting the technical specifications




3.0 PCC 1:3:6 Supplying and laying PCC 1:3:6, using 40 mm and down size crushed aggregate including providing formwork, mixing, compacting, and curing etc. All Complete as per specifications and drawings and instructions of HPCL-in-charge.

4.0 RCC 1:1.5:3 Providing, mixing and placing RCC 1:1.5:3 volumetric mix using 20 mm and down size graded crushed aggregate including providing and fixing necessary shuttering to all depth and heights, machine mixing, compacting by vibrators, curing, hacking the surface to receive plaster etc. complete for pedestals, tank apron, apron beam etc. Rate shall be exclusive of the cost of steel reinforcement, which will be paid under a separate item. Concrete shall conform to relevant specifications of IS 456 – Latest Edition. Rate also to include necessary Polythene sheets of approved quality to be placed before laying the concrete. NOTE FOR TANK APRON BEAM: Rate also to include necessary brick work in CM 1:5 required for shuttering on the inside face of the ring beam to match the slope and thickness of the tank apron. No separate measurement for brick work will be considered for payment purpose.

5.0 REINFORCEMENT STEEL Supply, fabrication TMT (Thermo Mechanically Twisted) steel reinforcement conforming to IS 1786, Fe - 415(latest edition, laying and tying with 20 SWG black annealed binding wire in position) as per instructions of Engineer in Charge. Rate to be inclusive of following: • Straightening, cutting, cold bending, tying with and placing in position, the

reinforcements etc . complete in all respects as per standard specification. • Laps, chairs, spacer bars and binding wire shall not be considered in

measurements for payment purposes.

RUBBLE SOLING Providing and laying 230 mm/ 150 mm thick dry trap rubble stone soling including hand packing, filling the interstices with chips, spalls and binding with grit and selected murrum, watering, compacting by hand ramming.

6.0 150 THICK SOLING 7.0 230 THICK SOLING 8.0 BRICK MASONRY

Providing and constructing brick using ‘class 50’ bricks conforming to IS: 1077-1986 including providing all openings and projections as per the drawing, raking the joints to 1 cm deep, scaffolding, soaking of bricks prior to use and curing etc complete as per specifications.




9.0 BRICK ON EDGE FOR EARTHEN BUND/PATHWAYS Providing and constructing brick on edge in CM 1:4 using bricks conforming to IS: 1077-1986 complete as per specifications. The bricks are to be laid with gap of 30-40 mm gap for grouting with 1:2:4 using 100 mm down aggregate. Rate to include supply and grouting with 1:2:4 CC in gaps and curing etc complete in all respects. The job has to be done with proper line and levels as per instructions. The job to be carried on the earthen bund and for pathways as per instructions of EIC.

10.0 PLASTER ON ENCLOSURE WALL Providing and applying 12 mm thick plaster in in CM 1:4. Item to include cost and all materials, labour, curing etc complete in all respects, to the satisfaction of the EIC/site incharge.

11.0 PLASTER IN DRAIN, OIL WATER SEPARATOR ETC. Providing and applying 12 mm thick plastering in CM 1:3 including smooth finishing with neat cement in single coat to drain surfaces, oil water separator including necessary scaffolding and curing etc. complete. Rate to include providing additional thickness of plaster if required to achieve perfect line and level without any extra cost.

12.0 C.I. COVERS FOR OWS CHAMBER Supply and installation of C.I. Covers for Oil Water Separator chambers as per attached technical specifications of required sizes.

13.0 ASPHALT CARPET Providing & laying 112 thickness mm compacted premix asphalt carpet including 12 mm thick seal coat on top of foundations. Thickness shall be built up by laying two layers of 50 mm each, followed by 12 mm seal coat as per procedure and material consumption given below Procedure for laying Asphalt carpet.

1. Dried tank foundation surface to be cleaned and apply a tack coat of hot 80/100 asphalt to it @ 0.5 kg/sqm.

2. Spreading the first layer to achieve consolidated/compacted uniform thickness of 50 mm by using 2 MT roller to the required grade and level.

3. Repeat steps 1 for receiving second layer premix asphalt. 4. Repeat step 2. 5. Repeat step 1 for receiving seal coat 6. Spread seal coat to achieve consolidated/compacted uniform

thickness of 12 mm by using 2 MT roller to the required grade and level.

Detail of material consumption

1. Materials to be consumed per 10 sqm of 50 mm thick premix asphalt carpet

• 20mm (3/4") stone metal: 0.34 cum




• 10mm (3/8") stone metal: 0.17 cum • Asphalt 80/100 : 25 kg • Solvent if required : 1.4 kg

2. Asphalt 80/100 grade to be consumed @ 80 Kg per 10 sqm along with 6 mm stone metals and coarse sand for 12 mm thick seal coat .

NOTE : Party to submit test certificate of asphalt from the reputed laboratory for each batch used. In case the premix is prepared at site using asphalt procured form any PSU no test certificate is required if a copy of purchase document including PSU certificate is submitted to HPCL.

SECTION-2:

FABRICATION, ERECTION & WELDING – BOTTOM, SHELL, ROOF ETC. FOR A/G TANKS

(FROM PLATES SUPPLIED BY HPCL) Plate work for Self supported Cone Roof Tanks with cone down bottom with

central collection sump of capacity 200 liters approximately. Job to be carried out as per Standard Specifications, codes specified, and duly approved design and drawing by HPCL Engineer in charge ( EIC ) Rate to be inclusive of following:

• Collecting details of steel plates to be supplied by HPCL from site, submission of welding sequence and preparation of cutting schedule for

o Bottom Plates, central collection chamber, shell, wind girders, roof etc.

o pad plates for nozzles, various tank appurtenances bearing plates for pipe supports, pads for structural bracings / supports provided to wind girders, datum plates etc.

o Shell and roof manhole neck, manhole pad plates, bolting neck, and cover plates including machine drilling of required number of holes for bolting and machine finished edges.

as per design submitted by the contractor & duly approved by HPCL Engineer in charge. • Taking approval of cutting schedule by EIC before commencing

fabrication work for each segment after incorporating changes if any during process of finalization of cutting schedule.

• Transportation of free issue plates from HPCL Storage yard to Work site/ Contractor's fabrication yard.

• Erection of tank shells will be carried out only by Jacking method for which hydraulic jacks will be arranged by the contractor.

• arranging all machineries, tools & tackles, cleats, wedges and clamps for fabrication erection and installation of various items as per the




scope of works and approved design / drawings by EIC, • Supplying all consumables like welding rods gaskets, nuts , bolts, stud

bolts, washers etc. • After completion of work reconciliation of free issue steel plates is to be

carried out. • Surplus full plates, off cuts and accountable scrap to be transported

back to HPCL stockyard as per direction of EIC • Carrying out spot radiography of shell joints using gamma ray as

detailed in API 650 & Appendix A / technical specs.

IMPOTANT NOTES : 1. Payment will be made for exact quantity of fabrication erection and

welding of steel plates carried out as per approved design and drawing only, Quantity given in the BOQ is approximate.

2. Method of inventory and recovery of steel plates issued by HPCL shall be as per relevant clause of SPECIAL TERMS AND CONDITIONS attached.

3. Only Following electrodes to be used for welding in construction of tank: a. E-6013 of brands like ESAB, S-Bond (Earlier Advani Orlikon – S), D&H

SECHERON or equivalent approved by Engineer – Incharge in writing for plate thick less than equal to 12 mm.

b. E-7018 of brands like ESAB, S-Bond (Earlier Advani Orlikon – S), D&H or approved equivalent for plate thick more than 12 mm and for shell to annual plate joint from inside and outside. Necessary preheating of electrodes to be arranged by the vendor.

4. If the Gamma ray source needs to be kept inside the location on a continuous basis, all precautions as stipulated by BARC needs to be strictly followed and approval shall be obtained from them before keeping the source inside the location.

14.0 BOTTOM PLATES

Sketch bottom plates of the tanks with 8 mm thick plates having slope towards the centre of the tank and water collection sump of 200 litre capacity and datum plate. Rate to include copper slag blasting the underside of bottom plates (soil side) to S.A 2.5 of Swedish Ivonsk Standard SIS 055900, supplying and applying 2 coats of High Build Coal Tar Epoxy(of approved make) of min DFT 100 microns per coat. NOTE: PRIOR TO COMMENCING LAYING OF BOTTOM PLATES,CONTRACTOR SHALL




ACCURATELY STAKE OUT THE CENTERLINE & PERIPHERY OF THE TANKS ON THE CONSTRUCTED PADS USING TOTAL STATION IN ACCORDANCE WITH APPROVED LAYOUT.IT SHALL BE THE SOLE RESPONSIBILITY OF CONTRACTOR TO RESOLVE ANY MISMATCHES AT THIS STAGE ITSELF.

15.0 SHELL PLATES Shell strakes of thickness varying from 6 mm to 8 mm and all pad plates, bearing plates attached to the shell.

16.0 ROOF PLATES Roof plates of thickness 6 mm / 5 mm and all pad plates, bearing plates attached to the roof.

SECTION- 3

STRUCTURAL STEEL WORK

REFERENCE SHALL BE MADE TO THE SPECIAL TERMS AND CONDITIONS FOR SCOPE OF SUPPLY AND OTHER DETAILED SPECIFICATIONS OF MATERIAL.

STRUCTURAL/PLATE WORK APPLICABLE FOR ITEM NO 17, 18, 19, 20, 21 & 22. Supply, fabrication, erection, inspection, testing and painting of Steel Structures / Plates for rolled sections, gratings and flats for curb angles, spiral stairways, landings, top platform, earthling connections cleats, wind girder bracings/ supports, stiffeners/ gussets for wind girder openings, stiffeners/roof structural for supporting roof etc as per approved design and drawings as per EIC. Rate to be inclusive of following:

• Preparation of fabrication drawings for individual items and obtaining HPCL EIC approval after incorporating all the changes as per advice of EIC.

• Supply of all materials, consumables, labour, equipments/ machinery, tools & tackles required to complete the work as per approved drawings, Scope of work and instructions of HPCL Engineer-in-Charge.

• Supply and fixing all nuts, bolts & washers wherever required, for which no separate measurement will be taken for payment purpose.

• Cleaning and Surface preparation for painting of structural. Copper slag blasting to achieve finished surface meeting S.A 2.5 of Swedish Ivonsk Standard SIS 055900 and carrying out painting as per technical specifications attached. Contractor to note that all structural and fittings used inside the tank will be painted as per internal painting specifications and outside will be as per External surface painting specifications, As per shade duly approved by EIC. Rate to be inclusive of painting and no separate measurement will be taken for painting for payment purposes.

17.0 ROOF STRUCTURALS




Roof Structural which includes curb angle, cleats, structural for supporting sprinkler / foam system, wind girder and all the structural required inside the tank for various purposes like supporting gauge well pipe and water draw off pipeline etc, complete as per approved fabrication drawing Note: Copper slag blasting of roof structural to be carried out before erection and a coat of primer to be applied before laying the roof plate. After completion of laying of roof plate, welding and fixing of roof appurtenances the finish coat to be applied. After cleaning and reapplying primer coat on the burnt out portion.

18.0 HAND RAILING etc. Structural steel for the hand rail of the spiral stairway, landing platforms, roof top railing excluding square rods.

19.0 MS SQUARE RODS MS square rods of 20 mm for supporting staircase hand rails.

MS GRATINGS Supply, fabrication, welding and erection of the following size MS gratings with MS flat in honey comb pattern as shown in the enclosed drawing. The Gratings shall be fabricated out of 25x5 MS flats(outer frame Straight flats) and 25x3 MS flats(Bent flats).

20.0 750 x 235 mm size gratings for all stairways with honeycomb pattern. 21.0 900 x 750 mm size grating for the top and mid landing platforms with honey

comb pattern. 22.0 Grating for tank catwalk of size as per EIC

SECTION- 4

TANK APPURTENANCES

REFERENCE SHALL BE MADE TO THE SPECIAL TERMS AND CONDITIONS FOR SCOPE OF SUPPLY AND OTHER DETAILED SPECIFICATIONS OF MATERIAL. All appurtenances to be fabricated in line with requirements of API-650 / IS 803.

SHELL APPURTENANCES: APPLICABLE FOR ITEM NO 23, 24, 25, 26 & 27 In addition to specific instructions mentioned against individual items. Supply, Fabrication, installation, welding, inspection and Radiography testing required for various shell appurtenances excluding for pad plates which is included in section 2 items for Plates. Rate to be inclusive of following :

• Preparation of fabrication drawing and obtaining approval from HPCL EIC.

• Supply of pipes nozzles/neck conforming to ASTM A 106 Gr B, sch 40 , SORF / Blind/ companion flanges conforming to ASTM A 105 class 150, holes drilled as per ANSI B 16.5, spiral wound metallic gaskets, stud bolts and nuts, washers where ever required as per design and approved drawing.




• Conducting air pressure test for reinforcing pads. • Supply of all consumables, machinery tool and tackles.

And completing all the jobs as per technical specifications, applicable codes/ standards, scope of work and instructions of HPCL EIC.

23.0 SHELL MANHOLES 600 mm nominal diameter shell manhole with neck ring, manhole cover plate with handle, bolting flange, spiral wound metallic gasket and stud bolts & nuts. Note: Rates to be exclusive of steel plates for fabrication of neck, neck flange & manhole cover which will be supplied by HPCL for this item.

SHELL INLET NOZZLE WITH ANTI SPLASH TROUGH Shell inlet nozzles of the following sizes using seamless pipes conforming to ASTM A 106 Grade XS, ASA class 150 forged steel SORF flanges with holes drilled as per ANSI-B-16.5 inside as well as outside, 300 mm/200 mm diameter x 600 mm length semi circular anti splash trough inside the tank as per applicable size of individual nozzle, spiral wound metallic gasket for external face where valve shall be mounted , and 2/3 mm thick Champion oil service gasket for internal trough, stud bolts nuts, & washers. Rate to be inclusive of following for Item No 24.0:

• Installation of two nos HPCL supplied gate valves of matching size of nozzle on each inlet by using spool pieces.

• Fabrication of two nos pipeline spool pieces of 1 mtr each, required for fixing of gate valves and connecting expansion line. One end of the second spool piece will be connected to pipeline. This flange joint shall be included in this item and shall not be paid separately. Pipes and flanges for spool pieces will be supplied by HPCL.


24.0 Shell Inlet 150 mm DIA SHELL OUTLET NOZZLE

Shell outlet nozzles of the following sizes using seamless pipes conforming to ASTM A 106 Grade XS, ASA class 150 forged steel SORF flanges with holes drilled as per ANSI-B-16.5 inside as well as outside, spiral wound metallic gasket for external face where valve shall be mounted , stud bolts nuts, & washers. Rate to be inclusive of following for Item no 25.0:

• Installation of two no HPCL supplied gate valves of matching size of




nozzle on each outlet by using spool pieces.

• Fabrication of two no pipeline spool pieces of 1 mtr each, required for fixing of gate valves and connecting expansion line. One end of the second spool piece will be This flange joint shall be included in this item and shall not be paid separately. Pipes and flanges for spool pieces will be supplied by HPCL.


25.0 Shell outlet 150 mm DIA WATER DRAW OFF NOZZLE

Water draw off nozzles of 80 mm diameter, using seamless pipes conforming to ASTM A 106 Grade XS, ASA class 150 forged steel SORF flanges with holes drilled as per ANSI-B-16.5 inside as well as outside, spiral wound metallic gasket for external face where valve shall be mounted , and 2/3 mm thick Champion oil service gasket for internal flange joint, stud bolts nuts, & washers.

Rate to be inclusive of following for item no 26.

• Installation of one no HPCL supplied gate valve of matching size of nozzle.

• Inside of the nozzle will be provided with a 80 mm flange joint for extending the water draw off line up to central sump.

And completing all the jobs as per technical specifications, applicable codes/ standards, scope of work and instructions of HPCL EIC

26.0 80 mm water draw off nozzle without extended bend 27.0 WATER DRAW-OFF PIPING

Supplying, fabricating, laying & welding of seamless pipe of SA 106 Grade B Sch XS, ASTM A 105 class for extending from one number water draw off nozzle to central sump with 90 deg elbow(ASTM Gr. WPB Sch XS) including supports from Floor of tank. Rate also to include welding of 6 mm plate at the end of the pipe.

ROOF APPURTENANCES: APPLICABLE FOR ITEM NO 28, 29, 30, 31& 32. In addition to specific instructions mentioned against individual items. Supply, Fabrication, installation, welding and inspection and radiography testing, required for various roof appurtenances excluding for pad plates which is included in section 2 items for Plates. Rate to be inclusive of following :

• Preparation of fabrication drawing and obtaining approval from HPCL EIC.

• Supply of pipes, nozzles, SORF / Blind/ companion flanges, spiral wound metallic gaskets, stud bolts and nuts, washers where ever required as per design and approved drawing.

• Conducting air pressure test for reinforcing pads.




• Supply of all consumables, machinery tool and tackles. And completing all the jobs as per technical specifications, applicable codes/ standards, scope of work and instructions of HPCL EIC

28.0 26

ROOF MANHOLES 600 mm nominal diameter shell manhole with neck ring, manhole cover plate with handle, bolting flange, 3 mm thick permanite gasket and stud bolts & nuts. Note: Rates to be exclusive of steel plates for fabrication of neck, neck flange & manhole cover which will be supplied by HPCL for this item.

29.0 ROOF VENT NOZZLES 300 mm diameter Roof vent nozzles (Goose neck type vent) as per attached specifications , Nozzle neck of minimum 14 mm thick,180 degree forged steel bend of sch. 40, ASA class 150 slip on flanges with holes drilled as per ANSI-B-16.5, nuts, stud bolts, washers spiral wound metallic gasket etc complete. Rate to include providing and fixing suitable SS mesh at the end of opening. Note: No of vents to be provided is as per design requirement and duly approved by EIC.

30.0 TEMPERATURE HATCH NOZZLE Temperature Hatch nozzles of 80 mm NB dia with Hatch , seamless pipe of ASTM A 106 Gr.B Sch XS , ASTM A 105 class 150 forged steel slip on flanges with holes drilled as per ANSI-B-16.5, spiral wound metallic gasket, stud bolts & nuts, flanges including fixing with blind flange. There is no pipe extending in to the tank.

31.0 GUAGE HATCH NORMAL Guage hatch of 200 mm diameter, MS ERW pipe, ASA class 150 forged slip on flanges with holes drilled as per ANSI-B-16.5 hinged aluminium cover with fire proof gaskets, nuts, bolts washers, including locking arrangement. Rate to include making provision to suit fixing the Temperature transmitter pipe in one number on each tank.

32.0 GUAGE WELL PIPES FOR CONE ROOF TANK Supply, fabrication, erection and welding of the slotted gauge well pipes conforming to IS: 1978 YST 210 grade. Rate to include supply, fabrication and welding of the neck rings, Gauge hatch of 200 mm diameter. With reinforcement pad plate, MS ERW pipe, bolting flanges, bottom brackets ASA class 150 forged slip on flanges with holes drilled as per ANSI-B-16.5, gasket, nuts, stud bolts, washers, and fabrication and connecting the well pipes with gauge hatches complete




SECTION- 5

TESTING OF TANKS

Conducting tests such as Vacuum box test, Dye penetrant test, Pneumatic test, diesel chalk test and Hydrotest as outlined in IS 803/API 650, OISD-129 and accompanying specifications:

33.0 BOTTOM TESTING : 12.2 M DIA X 11 M HT CONE ROOF Testing of the welding joints of the tank bottom with vacuum box method up to a vacuum of 5 psi (absolute). Rate to include arrangement of all equipment like glass box, compressor, rubber tubes complete as per specifications.

34.0 SHELL TESTING : 12.2 M DIA X 11 M HT CONE ROOF Hydrostatic testing of tank shell by filling water upto curb angle. Rate to include for Supply & filling of water up to curb angle, observing for weld joint leaks or plate leaks if any, hammering the joints as per the directions of Engineer-in-charge, decanting water after successful completion of testing, cleaning the bottom, shell and roof and drying it completely etc. as per specifications including diesel chalk test for the shell to bottom joint. NOTE: In case of any leaks observed during any of the above tests contractor shall decant the water up to 300 mm below the leak, repair the leak and again test the tank by filling the water to the satisfaction of the Engineer-in-charge. Contractor shall repeat the process till all the leaks are rectified.

35.0 ROOF TESTING 12.2 M DIA X 11 M HT CONE ROOF Testing the following tank roofs with vacuum box or by air compressor method to a pressure of 2.5 inches of water column. Compressor, manometer, hoses, water tube, valves etc. to be arranged by the contractor.

SECTION: 6

TANK CALIBRATION

36.0 CALIBRATION OF TANK BOTTOM 12.2 M DIA X 11 M HT CONE ROOF Physical calibration of the following diameter tank bottom by water meter up to the datum plate. Rate to include arrangement of equipment necessary pumping water, taking readings as directed and presenting the same etc. Complete including certification by proper authorities.

37.0 CALIBRATION OF TANK SHELL 12.2 M DIA X 11 M HT CONE ROOF Calibration of tank shell using strapping tape when the tank is full with water. Rate to include supply and erection of necessary scaffolding, platforms, taking readings at top, middle and bottom of each shell strake after applying sufficient pull by spring balance and presenting results as directed including certification by proper statutory authorities.




NOTE : 1) The strapping tape shall be arranged by Contractor. 2) Contractor shall carry out both bottom and shell calibration in the presence of the representatives of CPWD/ W&M and HPCL. The calibration charts shall be prepared by contractor and get the same certified by CPWD/ W&M. The contractor shall make all necessary arrangements for the visit of representatives from CPWD/ W&M. All statutory fees and any other expenses in this regard shall be borne by the contractor. Rate quoted in the above 2 items shall include certification by CPWD/ W&M. Certificates to be handed over to HPCL. Soft copy of calibration chart to be provided additionally.

SECTION-7

MISCELLANEOUS ITEMS

38.0 PRESSURE RELIEF LINE: 25MM DIA PIPING Supply, fabrication, testing, erection and painting of 25 mm diameter MS heavy duty Sch 80 thickness seamless pipeline from receipt/delivery line up to the top most shell of the fixed roof tank. Rate to include the following:

• Supply, fixing & welding of necessary MS forged slip on flanges, tees, elbows, stud bolts, nuts, GI heavy duty U clamps with GI nuts bolts and washers.

39.0 GATE VALVE

Supply and fixing of 25 mm diameter forged steel gate valves Class 800 with flanged ends of approved make

40.0 NON RETURN VALVE Supply and fixing of 25 mm diameter forged steel horizontal non-return valve class 800 with flanged ends of approved make.

TANK EARTHING 41.0 EARTHING PITS

Providing and constructing plate electrode type earthing pits conforming to IS- 3043 latest edition as per drawing enclosed, with all GI parts and B' class GI pipes of 65 mm diameter. Rate to include supply of all material necessary for earthing pit. Supplying and providing earthing connection plates on shell with 6 mm thick copper plates brazed with 6 mm thick CS plate, providing holes etc all complete as per drawings and instructions of HPCL engineer in charge. Supply and welding MS earthing boss to the tank shell at 500 mm above the bottom plate and connecting the boss with pit and electrode by 50 x 6 mm thick MS galvanised strip. Rate also to include carrying out megger testing of pits and issuing test certificate from licensed electrical contractor.




SPRINKLER SYSTEM Supply, fabrication, erection and testing of following size pipes for sprinkler system conforming to IS 1239, class C and fittings shall be ASTM A 234, Gr WPB, as per attached specs in the specified curvature and installing with necessary GI ‘U’ clamps supplied by the party on the periphery of tanks on angle support welded on the shell of the tanks. Job includes supply, fabrication, welding of necessary couplings to MS pipe for fixing 12mm sprinkler nozzles, fabrication and welding of angle supports (shall be paid separately under the structural steel item). The circular pipe to have flange joints every 12 m for ease of removal and replacement at a later date. Supplying and fixing necessary flanges, gaskets, nuts & stud bolts as per HPCL specs are in the scope of the vendor. For Item No 42 & 43 the rate to include surface preparation with copper slag blasting to the required standard, supply and application of 2 coats of primer and 2 coats of enamel paint as per detailed specifications.

42.0 80 mm diameter pipes, pipes as per IS 1239, class C, and pipe fittings of ASTM A 234, Gr WPB.

Supply, fabrication, erection and testing of following size pipes conforming to IS 1239, class C, and pipe fittings of ASTM A 234, Gr WPB for sprinkler system, as per attached specs for the vertical tap-off / connection for sprinkler lines / foam makers including installing necessary GI ‘U’ clamps/ stopper rods on the periphery of floating roof tanks and on support angles welded on the shell of the tanks (shall be paid separately under the structural steel item). All connecting flanges to be supplied and welded by the party. Rate to be inclusive of following

1. Preparation of external surfaces of pipelines by copper slag blasting thoroughly to S.A 2.5 of Swedish Ivonsk Standard SIS 055900-Latest edition to bare metal to ensure thorough cleaning of the surfaces to receive paints as per specifications.

2. 2 coats of Zinc Phosphate primer (minimum 50 micron DFT) over copper slag blasted surfaces and 2 coats of Enamel finish paint (min. 50 micron DFT) to achieve over all DFT of 100 Micron of approved makes mentioned in the detailed specifications and colour shade approved by Engineer in charge.

3. Contractor to arrange and keep at site the relevant Swedish photographic standards for inspection by HPCL Site in charge failing which permission to proceed with the work will not be granted. If the coating is damaged while handling the pipes the same need to be redone as per above and make good of the surface

43.0 100 mm diameter Vertical pipes for sprinkler system as per IS 1239, class C, and

pipe fittings of ASTM A 234, Gr WPB 44.0 SPRINKLER NOZZLES

Supply and installation of water sprinkler nozzles as per attached specs on the above installed water sprinkler line.




Note: Party to submit the design from a reputed fire fighting equipment manufacturer/ consultant for sprinkler / foam line sizing and selection of number / K value of the sprinkler nozzles provided at each level, as per the enclosed specs and obtain approval of Engineer In-charge before proceeding with the procurement activities.

45.0 FIRE SCREEN Design and erection of suitable fire screen upto 5 m height including supply of all civil and fabrication materials like structural steel, GI sheet, bolts, cement, sand, coarse aggregates and other tools and tackles and labour, reinforcement as per design. Design of the fire screen should be such that so as not to allow passing of light ray and should be structurally sound to withstand the wind loads in that area. Rate to include dismantling of fire screen and clearing the site / taking back after completion of tank fabrication. Job rate to include all civil jobs for foundation or elsewhere if required for erection of fire screens to ensure stability of the screens after obtaining necessary approval of HPCL EIC. The Fire screen including removal of complete foundation, levelling the area and Site cleaning shall be carried out by the contractor after the job is completed as directed by Engineer In-charge. Only 70% payment shall be released for design, supply and erection of Fire Screen and 30% Payment shall be released after the removal of fire screen including foundation, levelling and site cleaning.

SECTION-8:

PAINTING OF ABOVE GROUND TANKS PAINTING OF VERTICAL ABOVE GROUND STORAGE TANKS

Carrying out Copper slag blasting, application of primer coat of desired finish & DFT and application of finish coat of approved colour to achieve desired finish & DFT and other miscellaneous jobs as per detailed job schedule and technical specifications. The job also involves painting the complete inside of MS Tanks including bottom plate and shell up to full height and Roof Plate and Roof Structural, Gauge well pipe and other internal fittings etc. Contractor has to arrange all necessary scaffolding for all the heights for execution of the job at NO extra cost. The contractor has to take utmost care and shall follow all necessary safety measures during execution of the job. The colour scheme for the tanks for following items shall be done as approved by the Engineer-In-Charge: ATF Tank :

1. 600 mm from bottom of shell 2. Wind girder rim 3. Balance area of shell 4. Roof top Surface 5. Staircase & railings 6. Internal Surface (Bottom plate, full Shell, roof and roof structural, internal




pipes etc.) The contractor shall arrange for all materials, equipment, tools, power and water required for execution & completion of the job. The contractor shall submit copies of batch certificates of all paints being used in the work. Bidder to Note : Successful Bidder to report at Site with the following instruments / Details before commencement of job at the time of kick of meeting:

1. Calibrated Electronic Profile meter. 2. Calibrated Electronic Elcometer 3. Swedish Photographs for checking the surface along with Codes SIS-

055900-1967 / ISO-8501-1-1988. 4. List of all safety tools and equipments to be provided during execution. 5. List of Manpower to be deployed Skill wise / Location wise. 6. Location wise completion schedule for individual activities along with

Bar charts. 7. Written confirmation as to which make of primers and finish paints will be

used. 8. Sequence of activities and procedures to be followed for Copper slag

blasting, application of primer and finish paints duly approved by the Paint manufacturer.

9. Manufacturer test reports showing paint consumption per sqm. area. 10. A detailed calculation showing the working of consumption of primers

and finish paints as per the manufacturer recommendations. Other Important notes during execution of Job: 1) Contractor has to arrange for Calibrated Electronic Elcometer along

with Valid Calibration Certificate from appropriate statutory authority / Approved Lab at site for checking of paint thickness after each coat of primer/paint and the same to be kept at the site till the job is completed. Contractor will not be allowed to proceed with the next coat of paint unless the thickness of the painted surface is measured and recorded and is as per specifications.

2) Containers of Paint shall not be opened by the Contractor until approval is obtained from HPCL Engineer-in-charge.

3) All paints & primers to be used shall be of first / best quality approved make only.

4) Party to provide batch certificates for all paints being used in the work. 5) Party to arrange for technical inspection of Paint manufacturer and get

the quality of painting job certified by the authorised representative of the paint manufacturer. The inspection shall be carried out in 2-3 stages and at NO extra cost to HPCL.

COPPER SLAG BLASTING & PAINTING

Note : For Items where jobs of surface preparation and painting are inclusive in




the rates quoted, will not be considered for measurement /payment in this Section-8

46.0 COPPER SLAG BLASTING: Preparation of external & internal surfaces of tank shell, roof, roof structural, roof appurtenances, nozzles, tank body valves, wind girder & its railing, stiffener rings, internal pipes etc. by Copper Slag blasting thoroughly to S.A 2.5 of Swedish Ivonsk Standard SIS-05-5900- 1967 to bare metal to ensure thorough cleaning of surfaces to receive paints as per specifications. Note:

• Contractor to arrange and keep at site relevant Swedish photographic standards for inspection by HPCL Site In charge failing which permission to proceed with the work will not be granted.

• Please refer the Special terms & Conditions of the contract also. • Payment will be made on actual surface area of tank shell, roof

measured only once. • Providing and fixing pipe, double scaffolding in approved manner

EXTERNAL & INTERNAL PAINTING :

Applicable for item nos 47, 48, 49, 50, 51, 52, 53 & 54 in addition to specific instructions given in individual items. Rate to be inclusive of following:

• Mixing the paint properly & usage of thinner as per manufacturer's specifications

• Application of paint by Air less spray / brush and final coat with roller till uniform dry film thickness as specified is obtained.

• Arranging calibrated & certified elcometer to measure the film thickness at various stages of painting.

• Providing and fixing of pipe, double pipe scaffolding in approved manner

• Supply of all consumables, machinery tool and tackles. Note: Payment will be made on actual surface area of tank shell, roof measured only once.

47.0 PRIMER COAT FOR EXTERNAL SHELL / ROOF PAINTING: Supply and painting with DFT Bison high build zinc phosphate primer of Berger or approved equivalent in two coats for achieving 50 microns film thickness ( 25 microns in each coat ) to shell, roof, all shell/roof appurtenances, nozzles and tank body valves, spool pieces for expansion lines, stiffener / wind girder, etc.

48.0 ENAMEL PAINTING FOR EXTERNAL SHELL /ROOF : Supply and painting with first quality synthetic enamel paint of approved shade of Berger (Luxol H/G) or approved Make in two coats for achieving 50 microns film thickness (25 microns in each coat ) to shell and roof including all appurtenances..




Note: - Enamel paint banding of vertical plates/ rim of wind girder/stiffener ring will be measured and paid separately against item No 49 “Enamel Paint Banding.

49.0 ENAMEL PAINT BANDING : 600 mm wide Horizontal band on bottom shell & vertical plates of wind girders. Supply and painting with Luxol H/G synthetic enamel paint of Berger or other approved equivalent make of approved shade in 2 coats for achieving 50 microns film thickness ( 25 microns in each coat ) (Darker shade of approved colour code for the respective product)

50.0 HEADINGS (CORPORATION NAME) Supply & painting of corporation name on tanks etc in English/Hindi 600 mm size letters in the middle of the top shell of tank or as directed By Engineer in charge at site using enamel paint of approved colour in two coats.

51.0 LETTERING Supply of paint and painting the following details on the second shell of the tanks in black enamel paint in two coats.

i. Tank number : 230 mm height ii. Name of the product : 150 mm height iii. Tank capacity : 80 mm height iv. Safe Filling Height : 80 mm height v. Size of Tank : 80 mm height vi. Date Painted : 80 mm height vii. Date Commissioned : 80 mm height viii. Date of Hydrotesting : 80 mm height ix. Date of calibration : 80 mm height x. Date of Earthing Tested : 80 mm height xi. Due date of cleaning : 80 mm height xii. Water Draw Off : 80 mm height xiii. Tag No. : 80 mm height

In addition to the above, tank receipt, tank delivery Nozzles etc and other tank appurtenances (lettering of 100 mm size) shall be painted. Note: Rate to include painting of back ground with approved colour and shade.

52.0

LOGO : 2.4 M x 3.0 M size Logo for the above ground tanks on the top or penultimate shell as directed Supply of paint and painting the logo sign of the Corporation of the following size at the following places or as directed by Engineer in charge. Logo shall be painted as per the required colour code. Note: In case the logo size is changed, payment will be made in proportion to




the logo area. INTERNAL PAINTING:

NOTE: INTERNAL PAINTING TO BE CARRIED OUT FOR BOTTOM PLATE, COMPLETE SHELL, INSIDE OF ROOF AND ROOF STRUCURALS, INTERNAL PIPES ETC. COMPLETE WITH EPOXY PRIMER AND PAINT.

53.0 PRIMING COAT Supply and application of one coat 75 micron Epilux FRX Anticorrosive Primer of Berger or approved equivalent make to bottom & Full height of Shell. Rate to include wastages, mixing the paint properly as per manufacturer's specifications, applying with brush / air less spray gun till 75 micron DFT of paint thickness is obtained, testing for thickness, providing scaffolding etc. complete.

54.0 EPOXY PAINTING : Supply and painting with Epilux 78 HB TL of Berger or approved equivalent make to bottom & upto 2.0 mtr of shell from bottom in two coats for achieving 200 micron DFT ( 100 microns each coat ) of paint thickness is obtained, testing for thickness, providing scaffolding etc. complete.

SECTION-9:

ABOVE GROUND PIPELINE LAYING 55.0 PIPE SUPPORT

Providing and grouting 32 mm dia MS round bar for supporting pipelines including cutting and welding to HPCL supplied steel plates of 6-8 mm thickness as base to rod and supply and welding 10 mm dia holdfasts with L bend at 300 mm c/c. Rate to include painting the bars and base plate completely with two coats of red oxide primer and painting 2 coats of black enamel paint complete.

ABOVE GROUND PIPE LINE LAYING Laying, Installation, fabrication, welding (With 10% radiography with � – rays), of HPCL supplied pipelines of following size and placing on the pedestals, structural bridges/ catwalks over water drains including welding of pipes, bends, pipe line fittings etc., radiography test of 10% joints, carrying out repairs if any & re-radiography, pre-testing, hook-up with the pipeline on either end, hydro-testing of entire section of pipes including supply of all tools, tackles, machinery, equipments, instruments, manpower etc. for completion of the job. The scope of the job includes but not limited to the following:

• Receiving owner supplied materials, including handling, hauling/loading, transportation to work site, unloading and stringing.

• Cutting, bevelling, grinding, Edge preparation (including any

additional cutting, bevelling, grinding required for perfect fit up, between the edges of the pipes, bends etc ), aligning, fit-up, Welding of pipes as per approved technical specifications / procedures of this tender.




• Root run shall be with E-6010 Electrode and Intermediate & finished Welding shall be with E-6013 electrodes of ESAB or approved equivalent.

• Hook up with the main line/ above ground line including cutting,

bevelling, grinding, aligning, fit-up, tie-in welding, radiography, carrying out repair if any , joint coating with approved coating material & procedure, hydro-testing of entire section to a pressure of 10.5 kg/cm2 as specified in the technical specifications. Any leaks detected during hydrostatic testing shall be rectified at no extra cost as per approved procedure.

The rate also to include fabrication of any bends, mitre’s, tees and eccentric or concentric reducers other than the ones supplied by HPCL as required.

56.0 150 mm DIA A/G PIPELINE LAYING 57.0 50 mm DIA A/G PIPELINE LAYING FOR FAST FLUSH ARRANGEMENT

NOTE: This item is required for connecting Water Draw off nozzle of ATF Tank to the Fast Flush Drum and a return line from Fast Flush Drum to the pipe connected with the water draw off nozzle of the tank. Rate to be inclusive of supply of 4 nos 50 NB 150# SORF Flanges and welding & fixing of 2 nos SORF-SORF Flange joints complete as per technical specifications of Flange joint specified under separate item. No separate payment shall be made for these items.

FIRE WATER PIPELINE LAYING(ABOVE GROUND): Laying, Installation, fabrication, welding of HPCL supplied pipelines of following size and placing on the pedestals, structural bridges/ catwalks over water drains including welding of pipes, bends, pipeline fittings etc., carrying out repairs if any & re-testing the same, pre-testing, hook-up with the pipeline on either end, hydrotesting of entire section of pipes including supply of all tools, tackles, machinery, equipments, instruments, manpower etc. for completion of the job. The scope the job includes but not limited to the following:

• Receiving owner supplied materials, including handling, hauling/loading, transportation to work site, unloading and stringing.

• Cutting, bevelling, grinding, edge preparation (including any additional cutting, bevelling, grinding required for perfect fit up, between the edges of the pipes, bends etc ), aligning, fit-up, Welding of pipes as per approved technical specifications / procedures of this tender.

• Root, Intermediate & Finished welding shall be with E-6013

electrodes of ESAB or approved equivalent.




• Hook up with the main line/ above ground line including cutting,

bevelling, grinding, aligning, fit-up, tie-in welding, carrying out repair if any , joint coating with approved coating material & procedure, hydrotesting of entire section to a pressure of 10.5 kg/cm2 as specified in the technical specifications. Any leaks detected during hydrostatic testing shall be rectified at no extra cost as per approved procedure.

• The rate also to include fabrication of any bends, tees eccentric or

concentric reducers other than the ones supplied by HPCL.

58.0 250 MM DIA A/G FIRE WATER LINE 59.0 100 MM DIA A/G FIRE WATER LINE

Note 1.0) If leakage through the pipe seam joint is observed, contractor shall

remove the defective portion of the pipeline and replace with a new HPCL supplied pipe and retest it. The replaced portion of the pipeline will be paid extra.

2.0) Length of all pipeline shall be measured upto the neck of the flange only excluding bend length. Length of the flange shall not be measured as they are paid separately.

SLIP ON-SLIP ON FLANGE JOINT :

Providing flange joints including fixing and welding 2 runs (minimum) from outside and 1 run from inside. Rate shall also include supply and fixing 3 MM thick metallic fibre reinforced graphite coated gasket of approved make and rating, supply & fixing all stud & nuts of approved make, size & dia. with washers etc, complete. The job also includes supply & fixing braided copper tape of ½” width, with lugs crimped, stud & nuts on either side for electrical continuity. Two flanges shall constitute one flange joint. Flanges will be supplied by HPCL at HPCL Store which is inside the depot. Offered Rate should include Transfer of all flanges from store to work place.

60.0 100 MM DIA S/O FLANGE JOINT 61.0 150 MM DIA S/O FLANGE JOINT 62.0 250 MM DAI S/O FLANGE JOINT

SLIP ON-BLIND FLANGE JOINT Same as item for SLIP ON-SLIP ON FLANGE JOINT , but welding of one flange on one side and other side shall have blind flange.

63.0 150 MM DIA S/O BLIND JOINT VALVE FIXING :

Loading, transportation, handling, erection and fixing of the HPCL supplied CS Gate valves of following sizes from Owners store, including alignment, supplying & fixing of 3 mm thick metallic fibre reinforced graphite coated




gasket (of approved make & rating) conforming to IS 2712 on either side, supply & fixing all stud & bolts (conforming to ASTM A 193 B7 & A194 2H) of approved make & correct size & dia with washers etc,on either side, supply & fixing 2 nos. braided copper tape with crimped lug on both side of valve (connected to flange). Rate to include welding of one pair of SORF flanges on both sides for fixing of valves etc complete. The flanges will not be counted for payment purposes. NOTE: Whenever one side of the Valves /equipment have one HPCL supplied flange, it will be considered as one No. half joint since rate include supply & welding of two flanges per valve. No other price implication will be considered.

64.0 100 MM DIA GATE VALVE FIXING 65.0 150 MM DIA GATE VALVE FIXING 66.0 250 MM DIA GATE VALVE FIXING

COPPER SLAG BLASTING OF ABOVE GROUND PIPELINE : Preparation of external surfaces of pipelines by sand blasting thoroughly to S.A 2.5 of Swedish Ivonsk Standard SIS: 055900 latest edition to bare metal to ensure thorough cleaning of the surfaces to receive paints as per specifications. Rate to include loading, hauling, handling, transportation of the pipes. Note: Contractor to arrange and keep at site the relevant Swedish photographic standards for inspection by HPCL Site in charge failing which permission to proceed with the work will not be granted. If the coating is damaged while handling the pipes the same need to be redone as per above and make good of the surface.

67.0 100 MM DIA PIPELINE COPPER SLAG BLASTING 68.0 150 MM DIA PIPELINE COPPER SLAG BLASTING 69.0 250 MM DIA PIPELINE COPPER SLAG BLASTING

PAINTING ABOVE GROUND PIPELINE: Supply and painting with two coats of zinc phosphate primer (25 micron each coat) and two coats of black enamel paint (25 micron each coat) to all the pipelines, after necessary surface preparation, painting of Colour Code Bands, product name and arrow as mentioned/shown in the attached Technical specification, at places as directed at site. Rate to include painting of all fittings etc complete. Total thickness will be 100 microns. Payment shall be made based on running meter basis of pipelines painted. No separate payment shall be made for fittings. NOTE: 1.The paint used shall be of approved make 2.The colour shade code for products will be as under (confirming to IS 5- 1978) : (i) ATF : To be advised by HPCL EIC




(ii) Water : Fire red For fire fighting line painting shall be with Fire/PO red colour enamel paint instead of aluminium paint.

70.0 100 MM DIA PAINTING 71.0 150 MM DIA PAINTING 72.0 250 MM DIA PAINTING

DISMANTLING OF FIRE WATER LINE Dismantling of existing fire water line with pedestals around the tank farm including dismantling of valves/monitor/hydrants etc, transporting and storing / stacking at designated place as directed by EIC.

73.0 150 MM DIA FIRE WATER LINE 74.0 100 MM DIA FIRE WATER LINE 75.0 Dismantling and re-laying of 100 NB GI pipe for sprinkler line of existing tank

Job includes dismantling of pipline, shifing, stacking the pipes at designated place as per EIC, dismantling of padestels, Relaying of the same pipe on the newly constructed padestels as per instructions of EIC. Note: The construction of new padestels shall be paid extra in the respective items.

SUPPLY OF 90 DEG BENDS Supply of 90 Deg Bends of given sizes as per attached technical specifications.

76.0 SUPPLY OF 150 NB SIZE 90 Deg BEND 77.0 SUPPLY OF 100 NB SIZE 90 Deg BEND

SUPPLY OF 45 Deg BENDS Supply of 45 Deg Bends of given sizes as per attached technical specifications.

78.0 SUPPLY OF 150 NB SIZE 45 Deg BEND 79.0 SUPPLY OF 100 NB SIZE 45 Deg BEND

SUPPLY OF SORF FLANGES Supply of SORF Flanges of given sizes as per attached technical specifications.

80.0 SUPPLY OF 150 NB SORF FLANGES 81.0 SUPPLY OF 100 NB SORF FLANGES

SECTION-10:

FAST FLUSH ARRANGEMENT FOF ATF TANK 82.0 FAST FLUSH DRUM

Design, Supply (except 5mm thick plate), Fabrications and Erection of Fast Flush Drum & sump drum each of 200 Litres capacity of 5 mm thick MS conforming to IS 2062 Grade A. Lid cover shall be fabricated with 3 mm plate including supply of plate conforming to IS 2062 Grade A. Rate to include the following:

• Supply & fixing 100 mesh size strainer of SS, drilling necessary holes for 2” suction and delivery pipeline,

• Connection of drums to Water draw offs of Tanks at convenient




operational height including Structural / RCC supports, grouting etc. complete.

• Surface cleaning of entire drum both internal and external by Copper Slag blasting thoroughly to S.A 2.5 of Swedish Ivansk Standard SIS-05-5900- 1967 to bare metal to ensure thorough cleaning of surfaces to receive paints as per specifications.

• Providing and fixing scaffolding in an approved manner and cleaning of Tank Farm area after Copper Slag blasting is completed.

• After surface preparation the drum shall be painted both internal and external with one coat 75 micron Epilux FRX Anticorrosive Primer of Berger or approved equivalent make and two coats 100 micron DFT each Epilux 78 HB TL of Berger or approved equivalent make. The Copper slag blasting and painting shall be as per the Technical Specifications enclosed.

• Supply, & fabrication of 3 nos 50 NB nozzles welded with shell. 1 no 50 NB 150# SORF flange shall be welded with each nozzle for connecting pipline with the F/F Drum. Note:

• 5 mm Plate for above shall be supplied by HPCL • 50 NB pipe for fabrication Nozzles for above shall be supplied by

HPCL

SS BALL VALVES Supply & fixing of 150 class SS 304 Ball valves of following sizes for Fast Flush Drum and sampling sumps with suitable metallic gaskets, nuts / bolts etc. complete.

83.0 2” SS Ball Valves 84.0 ¾” SS Ball Valves 85.0 Supply, Fabrication and fixing of ¾” Scheduled 80 MS pipe including matching

Socket of ¾” with end caps complete as directed by EIC.




SPECIAL TERMS & CONDITIONS OF THE CONTRACT: 1. CEMENT:

1.1. Cement required for execution of jobs contained in this tender shall be arranged by the contractor at his own cost.

1.2. Cement shall be procured and brought at site at least 15 days in advance.

Sample from every batch of cement brought to site shall be tested for standard tests as per specifications in approved laboratory and the test certificates shall be submitted to Engineer-in-charge for verification. Only after obtaining approval of Engineer-in-charge the cement shall be put in to use. Manufacturer’s batch test certificate backed by factory’s invoice for the batch will also be acceptable for approval of cement. Contractor shall bring cement well in advance before full consumption of previous lot. No claims for extension of completion period for stoppage of works on account of non-availability of cement/delays in testing procedures will be entertained / accepted by HPCL.

1.3. For all computation purposes, the theoretical cement consumption shall be

considered as per CPWD standards. Cement cost shall be recovered for under cement consumption as per clause 1.4 below.

1.4. The contractor will be required to maintain a stock register for receipt, issuance

and daily construction of cement at site. Cement shall be regulated on the basis of FIRST RECEIPT to go as FIRST ISSUE. Cement not consumed within three months after bringing to site, shall not be used and shall be removed from site with prior written permission of Engineer-in-charge.

1.5. Empty cement bag shall be the property of the contractor. Contractor shall be

penalised for any UNDER consumption of cement. The penal rate shall be Rs. 5600 per MT.

1.6. 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.

1.7. Contractor shall construct suitable temporary godown at site for storage of cement under his lock and key. The contractor will be fully responsible for safe custody of cement. HPCL will not entertain any claims by the contractor for theft, loss or damage to cement. The contractor shall not remove from the site any cement bags at any time.

2. POWER: Power for the work will have to be arranged by the contractor. All deposits

for connection/meters for this purpose shall have to be arranged by the contractor at their cost. All the works by the contractor will be done in accordance with the Indian Electricity Act and rules framed there under and approved by the Engineer-in-charge. The temporary lines will be removed forthwith, after completion of work or




if there is a hindrance caused to other work due to the alignment of these lines, by the contractor who will re-route or remove the temporary lines at his own cost.

3. WATER: Water for the work / testing will have to be arranged by the contractor. 4. WATCHING & LIGHTING:

The contractor shall provide and maintain at his own expense all lights, guards, fencing and watching when and wherever deemed necessary by the Site Incharge for protection of the works or for the safety and convenience of those employees on the works or public.

5. STORAGE OF MATERIALS SUPPLIED BY HPCL:

The contractor shall provide and maintain proper temporary sheds of adequate capacity for storage of all project materials, free issue items and his own stores in good and water tight conditions at site. Contractor shall also protect adequately all other materials including tools and tackles supplied by the corporation during execution of work. Any damage / loss for material in the contractor's custody will be on his account and will be recovered from his running bill.

6. DRAWINGS

Drawings enclosed with the tender are typical drawings & is given for general guidelines for quoting and may vary at the time of execution depending on the site condition.

7. PAINTING WORKS Time for completion shall include the time required for mobilization, Erection of Scaffolding, Carrying out of stage wise technical inspections of Paint Manufacturer and obtaining certificates from them for surface preparation / Painting, Site cleaning, demobilization and carrying out the works as per requirements of Contract Document and instructions of HPCL Engineer-in-Charge.

8. MANUFACTURERS GUARANTEE

Contractor & Paint Manufacturer, whose paint party intend to use, will have to give joint Guaranty for a period of 3 years after defect liability period on 100 Rs Stamp paper in the prescribed format which shall be filled & submitted on award of contract

9. In case of contradiction between relevant Indian standards, GCC, Special

Conditions of Contract, Specifications, Drawings and Schedule of Rates, the following shall prevail in order of precedence.

i) Detailed Purchase Order along with Statement of Agreed Variations, if

any, and its enclosures . ii) Schedule of Rates with Quantities. iii) Fax of Intent (FOI)/Letter of Intent(LOI) iv) Drawings/ Data Sheets v) Scope of Work




vi) Standard Specifications vii) Special Conditions of Contract viii) General Conditions of Contract ix) Instructions to Bidders x) Relevant Indian Standards / Specifications.

10. Scope of Supply of Materials: The following is the scope of supply of material by HPCL/Contractor and the rates quoted shall be based on this.

HPCL’s Scope of Supply: •••• Steel Plates of all thickness for bottom, shell & roof for all tanks. •••• Steel plates required for fabrication of reinforcement pad plates for all shell and

roof appurtenances unless otherwise specified. •••• Datum plates under the gauge well pipes. •••• All tank body valves.

Contractor’s Scope of Supply: •••• All welding rods, erection material, scaffolding, grinding, bending, cutting

machines, labour etc. •••• All erection and construction material. •••• Plates for shell manhole covers with handles, bolting flanges, neck rings, all stud

bolts, nuts, gaskets, grease etc. •••• All seamless and ERW pipes for all appurtenances. •••• All gauge hatches with top cover of specified sizes. •••• Serrated raised face flanges suitable for nozzle sizes mentioned and as per

specifications. •••• All Structural steel required including bolts, nuts, washers etc. •••• Pressure Vents for A/G tanks •••• Any other material consumable/non-consumable not mentioned herein but

required for satisfactory completion of the job.




11. Recovery & Inventory of Steel Plates: Steel Plates required for fabrication and erection of the tanks as per HPCL’s scope of supply will be issued to the contractor with full measurements. Contractor shall sign and handover the material receipt statement after checking the same.

All the steel plates thus issued shall be strictly accounted by the contractor. All off cuts and unused plates shall be returned to HPCL’s store by contractor after weighment at their cost.

Non recoverable plates excluding off cuts shall not be more than 0.5% of the erected plate weight. Off cuts, unused plates not returned and any excess non recoverable pieces beyond 0.5% of the erected plate weight shall be recovered at twice the landed cost of plates from Contractor’s bills.

Contractor shall be fully responsible for correctness of sizes of plates indicated in the fabrication drawings prepared by them. In case any plate gets damaged or spoilt by the contractor due to their fault, cost of the same shall be recovered at twice the landed cost of plates from their bills.




12. SPECIAL PAYMENT TERMS Following payment shall be made to the contractor against the running bills subject to the rate awarded to him and the clause regarding retention money as per general terms and conditions.

Plate Work: 30 % after Fabrication

35 % after erection & welding 30 % after testing 5% on completion and acceptance of all jobs as per SOR. Structural Steel Works/Grating: 40 % after supply of material at site 20 % after fabrication 35 % after erection/welding/bolting 5 % on completion and acceptance of all jobs as per SOR.

Nozzles, manholes and all accessories: 95 % after fixing and welding

5% on completion and acceptance of all jobs as per SOR.

Calibration: 95 % on submission of duly approved calibration by CPWD in prescribed format.




5% on completion and acceptance of all jobs as per SOR.

Testing: 95 % on successful testing 5% on completion and acceptance of all jobs as per SOR.

Pipeline Work 80% after fabrication laying & welding 15 % after successful hydro-testing 5% on completion and acceptance of all jobs as per SOR.




DECLARATION




DECLARATION

(to be submitted along with unpriced bid)

M/s________________________________________hereby declare/clarify that we have not been banned or delisted by any Government or quasi Government agencies or Public Sector Undertakings.

Stamp & Signature of the Bidder NOTE: If a bidder has been banned by any Government or Quasi Government agencies or PSU’s, this fact must be clearly stated with details. If this declaration is not given along with the unpriced bid, the tender will be rejected as non-responsive.

CONTACT PARTICULARS NAME OF PERSON TEL NO. OFFICE TEL NO. RES. MOBILE NO. E-MAIL ID




TIME SCHEDULE

DESCRIPTION OF WORK: DESIGN, FABRICATION, ERECTION, TESTING AND

COMMISSIONING OF 1 NO 12.2 METER DIAMETER AND 11 METER HEIGHT TANK FOR STORING ATF, PIPLINE & CIVIL WORKS AT HINDUSTAN PETROLEUM CORPORATION LIMITED, SHAKURBASTI INSTALLATION,

LOCATION

COMPLETION PERIOD FROM DATE OF ISSUE OF LOI

SHAKURBASTI INSTALLATION

6 MONTHS

NOTE:

1) Time for completion shall be reckoned from the date of issue of Fax / Letter of Intent by HPCL.

2) Time for completion shall include the time required for mobilization, demobilization,

carrying out the works as per requirements of Contract Document and instructions of HPCL Engineer-in-Charge.




Tank fabrication Works:

Note: This scope covers requirements of Tankage jobs only and the job scope of pipeline / mechanical /civil jobs will be as per the SOR. 1.0 SCOPE OF WORK 1.1 Contractor’s Scope of Work:

The scope of work of Contractor shall include the following but not limited to the same. The scope of work shall also include other items / works required to complete the work in all respects as per specifications, standards, drawings, IS codes/API Standards & instructions of HPCL whether specifically mentioned or not in the tender document : i) The Contractor shall perform the work.

ii) Getting approvals from statutory authority/ local authority etc, if any required

except construction approvals from CCOE /local bodies which will be obtained by HPCL.

iii) The Shell and Wind Girders have been designed by HPCL as per API 650

(latest Edition).The Contractor shall independently verify the above design and confirm his verification and there upon the adequacy of the Free issue plates immediately upon award of the contract.

iv) Preparation of all detailed and working drawings including plate cutting diagrams

for various components of storage tanks & getting the same reviewed and approved by HPCL.

v) Preparation, Submission for Review and obtaining approval from HPCL for

Detailed Quality Assurance System plans / procedures developed by contractor basis Std. Inspection & Test Plan furnished in this tender / Scope of work / SOR / GTCC / SCC & other relevant codes. The same shall be reviewed / approved by HPCL prior to commencement of work. The required competent man power, machinery, tools, tackles, equipments, etc required to execute the work as per the Approved Quality assurance plan (QAP) shall be the responsibility of contractor. Due records will be maintained by contractor through out the work period as per instructions of Engineer-in- Charge.

vi) Time is the essence of this contract. Monthly/weekly Execution Plans will be

developed by Contractor in consultation with Engineer- in- Charge & execution of work as per these plans will be the sole responsibility of contractor.

vii) Procurement & Supply of materials & consumables as indicated in contractor’s

scope of supply. viii) Loading, transportation and handling of all free issue materials from Owner’s

stores to work site / Contractor’s store and fabrication yard as applicable including supply of all necessary tools, tackles, transportation and handling equipments, etc.




ix) Stripping / Removal of vegetation for fabrication yard at Site.

x) Deleted

xi) Fabrication, erection and testing including vacuum box testing, liquid penetrant test, diesel chalk test, etc of tank bottom-annular and sketch plates, shell, wind girders with gusset plate stiffeners and all other plate attachments including cutting of plates and structural of required size, edge preparation, rolling, fitting, aligning, welding etc. SHELL ERECTION SHALL BE STRICTLY BY JACKING UP METHOD ONLY.

xii) Supply, Fabrication and erection of various shell appurtenances and nozzles.

xiii) Supply, Fabrication and erection of Inlet and outlet troughs for Inlet and Outlet

nozzles.

xiv) Supply, Fabrication and erection of various Roof appurtenances and nozzles. Supply & fabrication of stairways, handrails, landing platforms, curb angle, bracing for foam dam, structural supports for wind girders, interconnecting walkways etc.

xv) Supply, fabrication, installation and testing of various roof appurtenances.

xvi) Supply, fabrication & erection of Gauge hatch with still well, still wells for level

transmitters, level switch & temperature instruments etc.

xvii) Supply, fabrication & erection of earth connection as per respective IS code.

xviii) DP / Diesel chalk/ Vacuum box test/ any other test on various components of tanks as per Specifications of this Tender document, requirements of IS/API standard & instructions from Engineer-in-Charge.

xix) Calibration of tanks and getting approval from CPWD/Legal Metrology authorities

of the State Govt using contractor’s own tape etc.

xx) Carrying out hydrostatic / water fill up test in accordance to OISD 129 / Standard Specifications of this Tender & keeping the records for same, pneumatic, vacuum & other test as specified in code / specifications & as per requirements of Engineer-in-Charge using contractor’s own equipment.

xxi) Accomplishment of any other item of work required to make the storage tanks

ready for commissioning and as per instruction of Engineer-in- Charge.

xxii) Assistance to HPCL for commissioning of the tanks including supply of manpower, supervision, labour with all required tools and spares. This commissioning assistance shall extend up to 24 hrs beyond completion of first Pump-in of product in to the tanks.

xxiii) Supply of all equipment, machineries, tools, tackles etc, labour and supervision

of all works at site.




xxiv) Clean-up job at site for all surplus material, debris, scrap, construction equipment etc as per direction of Engineer-in-charge.

xxv) Reconciliation of free issue steel / material and returning excess plates, off cuts

and scrap as per direction of Engineer-in-charge.

xxvi) Supply of Power and Water required for the job shall be the responsibility of the Contractor & will be in his scope. HPCL will not give any connection from their existing electrical or Water supply system Surplus water declared by HPCL in writing after Hydro test shall be disposed off by Contractor in an un-objectionable manner to HPCL & its neighbours.

xxvii) Contractor has to perform work in running installation with HOT/ COLD Permit in

accordance to OISD 105 and HPCL operational requirements. Complying & meeting all the safety rules & regulations as per standards & instructions of Engineer- in- Charge will be the sole responsibility of contractor.

xxviii) Supply of all required materials, supplying and providing Single/Double

scaffolding wherever required, Carrying out Copper Slag Blasting and surface preparation, primer and finish painting.

2.0 SCOPE OF SUPPLY

2.1 OWNER’S SCOPE OF SUPPLY

2.1.1 Subject to the provisions mentioned elsewhere in the tender document, HPCL

will issue the following materials free of charge from Stores at Site for the Steel plates required only for the following components of the tanks: - Bottom: Annular Ring & Sketch plates - Shell plates - Roof plates - Reinforcing pads for all shell /roof openings and manholes except cleanout

nozzle. - Datum plates for gauge well pipe.

- Primary/Secondary wind girder (For all C/R tanks only) including plate gussets/ plate stiffeners.

THE WEIGHT OF ABOVE PLATES WILL BE BASED ON SP. GR. OF STEEL @ 7.85. THAT IS, UNIT WEIGHT SHALL BE 7850 KG/CU.M.

2.1.2 SCRAP/ CUTTING ALLOWANCES FOR OWNER’S FREE ISSUE

MATERIALS

The plates will be issued by HPCL to the Contractor on Theoretical weight basis. At the end of the work, Reconciliation shall be also done on theoretical weight basis only.

A Tabulated statement showing the size wise plates issued and Total consumption will be prepared as per HPCL instructions. Based on the Total consumption in MT as a sum of individual size wise consumption for a particular site, generation of maximum 2.7% Returnable accountable scrap is allowed. The




Returnable Accountable scrap includes Off cuts and plates smaller than 2400mm perimeter .Off cut plates shall be of minimum perimeter 2400 mm generated as per approved cutting Schedules. Plates smaller than 2400mm in perimeter are also classified under Returnable Accountable Scrap. On an overall basis, the generation of accountable scrap shall be limited to 2.7% of total net consumption taken as a sum of net consumption for various sizes. However, the Contractor shall make an all out effort at the time of preparation of Drawings/ BOQ to limit the generation of Returnable Accountable Scrap to a minimum preferably less than 2.7%.It will be the responsibility of the Contractor to load, transport the accountable scrap, weigh at weighbridge including payment of weighbridge charges, return to HPCL Premises, Unloading and handing over to HPCL at their Store yard/ scrap yard as per instructions of HPCL Engineer-in-Charge. Apart from Accountable Scrap, the Contractor shall be allowed a maximum of 0.30% of Burnout Losses.

In case, the actual generation of Returnable Accountable scrap on overall basis is higher than 2.7% or burnout losses being greater than 0.30% of Overall consumption(Theoretical tonnage), then HPCL shall effect recovery @ Rs. 60,000/= per MT for excess scrap generation and/or burnout loss. It shall be therefore the sole responsibility of the Contractor to plan the cutting schedule to control his scrap generation within above limits.

2.2 CONTRACTOR’S SCOPE OF SUPPLY

The procurement and supply in sequence and at the appropriate time of all materials and consumables including structural steel (Plates & sections) required for completion of works as per drawings, specifications and standards shall entirely be the contractor’s responsibility. The items to be supplied by the contractor are in general but not limited to following:

A) All steel plates required for the components other than those where HPCL will be

supplying plates vide SOR.

B) All consumables such as electrodes, filler wires, acetylene, grease, oil, gases, electricity etc.

C) All structural steel sections wherever required for curb angles, Top wind girders

Supports/stiffeners/ extensions for stairways, Self supporting truss of C/R, Secondary wind girders, spiral stairways, landings , platforms, handrails, interconnecting walkway structural, Inlet and Outlet Nozzle Troughs, Gratings(which may be fabricated by the Contractor at a workshop/ factory outside HPCL premises), etc.

D) All seamless pipes for nozzle necks 300mm NB and below, internal pipes, Nozzle

necks for openings more than 300mm, Materials for Inlet / Outlet Nozzle troughs, vents, emergency drain, extension piping for roof drain, etc.

E) All pipe fittings, flanges, matching flanges and blind covers wherever specified for all

nozzles, brass items etc.




F) Stud Bolts, nuts and gaskets for roof & shell manholes, nozzles with blind cover / matching flange, bolts & nuts for roof structure and other structural works.

G) Gauge Hatch with cover. H) Deleted

I) Pipes, fittings, flanges, orifice plates, Foam makers/ Pourers and deflectors on point of

spray on shell and structural supports for Piping for Foam system

J) Deleted K) Internal Bolts & Gaskets. L) Strapping tapes & accessories for calibration.

M) Earth connections, support cleats for pipes, structural & cables.

N) Any Blind flanges, valves, nipples, plugs, bolts, nuts, gaskets, etc required for

conducting hydrostatic testing and any other test required by HPCL. O) All primer materials and painting materials, scaffolding, copper slag for Copper Slag

Blasting and related equipment for Painting.

Note:

1. Contractor should ascertain the exact quantity required as per drawings as well as in consultation with the engineer in charge before procurement of the same.

2. The materials procured by contractor should be in line with the specifications mentioned in the subsequent chapter i.e Specifications for Materials in Contractor’s scope of supply.

3. While every effort has been made to list all the supply items, it shall be the sole responsibility of the Contractor to review the list and seek clarifications, if any at the time of Unpriced Bid itself. HPCL undertakes to provide only Free Issue Steel plates for Fabrication and all the other items shall be supplied by the Contractor only. No claims/ disputes by the Bidder/ Contractor shall be entertained by HPCL at a later date.

3.0 DOCUMENTS / FABRICATION DRAWING DETAILS

The Contractor shall submit the detail fabrication drawings/ documents in the following sequence:

1. Drawing Index

2. General arrangement drawing of tank showing design data, basic dimensions,

thickness, nozzle & internal parts.




3. Bottom and annular ring layout.

4. Shell plate layout showing location of nozzles & their distances from weld seams.

5. Nozzle orientation on shell.

6. Details of wind girders.

7. Spiral stairway, ladder and platform.

8. Plate layout of Roof, roof support details, details of appurtenances on cone roof, etc.

9. Any other design calculations as per contract. 10. Orientation and details of nozzles on tank roof.

11. Details of shell & roof nozzles.

12. Details of tank internals like still wells, truss for self supporting roof

13. Plate cutting diagram for Free Issue Plates along with indicating anticipated the

critical scrap i.e. Burn oil losses & Accountable losses.

14. Material test certificate for items supplied by contractor.

15. Welding procedures & welders qualification reports.

16. Final Inspection certificate and Hydrostatic test report. 17. Calibration Charts in hard and soft copies

18. As - Built drawing showing details as listed in Sr. No 1 to 15 above in HARD/ SOFT COPIES.




TECHNICAL

SPECIFICATIONS

FOR

CIVIL JOBS




TECHNICAL SPECIFICATIONS - CIVIL - MATERIALS

1.0 WATER

1.1 Water used shall be clean and free from organic impurities etc . Potable water is generally considered satisfactory for construction and during purpose. Water for construction purpose shall be tested for suitability as per IS codes at the start of the project and also at every three months interval.

2.0 CEMENT

2.1.0 Cement used shall be any of following types with prior approval of Engineer in Charge :-

a) Ordinary or Low Heat Portland Cement conforming to IS:269-1976.

b) Rapid Hardening Portland cement conforming to IS:8041-1978.

c) Portland Blast Furnace Slag Cement conforming to IS:455-1976.

d) Portland Pozzolana cement conforming to IS:1489-1976.

e) White Portland cement conforming to IS:8042-19789.

f) Ordinary Portland Cement conforming to IS:8112 (43-Grade)

NOTE :-

i) Low Heat Portland cement conforming to IS:269-1976 shall be used with adequate precautions with

regard to removal of formwork etc.,

ii) White Portland cement is generally used for architectural and decorative purpose and is generally

meant for non structural use.

iii) Generally ordinary portland cement is used for construction purposes.

2.2.0 ORDINARY PORTLAND CEMENT

Shall conform to the requirements of IS 8112 (43 Grade).

2.2.1 Physical Requirements

i) Fineness :- Specific surface shall not be less than 2250cm2/gm.

ii) Soundness :- Expansion (unaerated) shall be not more than 10mm by Le Chatelier method. If it fails,

expansion of aerated sample shall not be more than 5mm. Expansion by Autoclave test shall not be more

than 0.8%.

iii) Setting Time :-

a) Initial : not less than 30 minutes.

b) Final : Not more than 10 hours.

iv) Compressive Strength of mortal cubes (1 cement :3 standard sand) shall not be less than following :

-- 330 kgf/cm2 at 168+/-2 hours

-- 430 kgf/cm2 at 672+/-4 hours




2.3.0 PORTLAND POZZOLANA CEMENT

Shall conform to the requirements of IS 1489-1976

2.3.1 Physical Requirements :-

i) Fineness :- Specific surface shall not be less than 3000 Sq. cm/gm.

ii) Soundness :- Expansion (unaerated) shall be not more than 10mm by Le Chatelier method. If it fails,

expansion of aerated sample shall not be more than 5mm. Expansion by Autoclave test shall not be more

than 0.8%

iii) Setting Time :-

a) Initial : not less than 30 minutes

b) Final : not more than 10 hours

iv) Compressive Strength of mortar cubes (1 cement : 3 standard sand) shall not be less than following :

--- 220 kgf/cm2 at 168+/-2 hours

--- 310 kgf/cm2 at 672+/-4 hours.

v) Drying shrinkage :- not more than 0.15%

2.4.0 TESTING

The details of test for cement shall be as given in IS:4031-1968 (Methods of physical tests for hydraulic

cement) and IS:4032-1968 (Method of chemical analysis of hydraulic cement).

3.0 AGGREGATES :

3.1.0 Aggregates shall consist of naturally occurring stones, gravel and sand and shall be hard, strong

dense durable clear and free from veins, adherent coating and injurious amounts of disintegrated pieces

and deleterious substances.

3.1.1 Aggregates shall not contain harmful organic impurities such as pyrites, laminated material, alkali,

seashells and organic impurities and those, which may attack the reinforcement when used in RCC work.

Aggregates shall not be chemically reactive with alkalis of cement.

3.2.0 FINE AGGREGATES :

3.2.1 Aggregates most of which passes 4.75mm size IS sieve is known as fine aggregates. The sum of

the percentage of all deleterious materials shall not exceed 5%.

3.2.2 Fine aggregates shall be either sand or crushed stone dust. However, generally sand is used as

fine aggregate for concrete or mortar. Two varieties of sand are available normally :




i) FINE SAND : This shall be natural river sand conforming to the requirements of IS:383-1970. Its grading

shall be within the limits of grading zone IV of the table shown below :

IS SIEVE PERCENTAGE PASSING FOR

-----------------------------------------------------------------------------

DESIGNATION GRADING GRADING GRADING GRADING

ZONE I ZONE II ZONE III ZONE IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100

2.36 mm 60-95 75-100 85-100 95-100

1.18 mm 30-70 55-90 75-100 90-100

600 micron 15-34 35-59 60-79 80-100

300 micron 5-20 8-30 12-40 15-50

150 micron 0-10 0-10 0-10 0-15

Note-Fine aggregate conforming to grading Zone IV shall not be used in reinforced concrete unless

ascertained for suitability by mix designing.

ii) COARSE SAND :-This shall be either river sand or pit sand conforming to the requirements of IS:383-

1970. It shall be clean, sharp, angular, strong and composed of hard silicious material. Its grading shall

be within the limits of zone I, II or III of the table shown above.

3.2.3 The maximum quanitity of silt content shall not exceed 8%.

3.2.4 TESTING :-

The details of test shall be as per IS:2386 (Part I) -1963 to IS:2386 (part VIII)-1963 (Methods of testing

aggregates for concrete).

3.3.0 COARSE AGGREGATES :-

3.3.1 Coarse aggregates used for concrete can be either stone, gravel (river bed shingle or pit gravel) or

brick. However, crushed stone shall be used as coarse aggregates for concretes.

3.3.2 STONE :-

This shall be crushed or broken from hard stone obtained from approved quarry. It shall be hard, strong,

dense, durable, clean and free from soft, thin, flat, elongated or laminated, flaky pieces and shall be

roughly cubical in shape. It shall be clean and free from dirt and any foreign matter. However the total

amount of deleterious materials shall not exceed 5% of its weight.




3.3.2.1 SIZE :- Graded aggregate of nominal sizes 40, 20, 16 or 12.5 mm shall conform to the

requirement of the table given below :

IS SIEVE PERCENTAGE PASSING FOR NMINAL SIZE OF

DESIGNATION 40 MM 20MM 16MM 12.5MM

---------------------------------------------------------------------------------------------------------------------------------

80.0 100 ------- ------- -------

40.0 95-100 100 ------- -------

20.0 30-70 95-100 100 100

16.0 ------- ------- 90-100 -------

12.5 ------- ------- ------- 90-100

10.0 10-35 25-55 30-70 40-85

4.75 0-35 0-10 0-10 0-10

2.36 ------- ------- ------- -----

3.3.2.2 Single size aggregate (ungraded) of nominal sizes 63, 40, 20, 16, 12.5 or 10mm shall conform to

the requirements of the table given below :-

---------------------------------------------------------------------------------------------------------------------------------

IS SIEVE PERCENTAGE PASSING FOR NOMINAL SIZE OF

DESIGNATION 63 40 20 15 12.5 10

MM MM MM MM MM MM

--------------------------------------------------------------------------------------------------------------------------------

80 100 ------- ------- ------- ------- -------

63 85-100 100 ------- ------- ------- -------

40 0-30 85-100 100 ------- ------- -------

20 0-5 0-20 85-100 100 -------

-------

16 ------- ------- ------- 85-100 100 -------

12.5 ------- ------- ------- ------- 85-100 -------

10.5 ------- 0-5 0-20 0-30 0-45 85-100

4.75 ------- ------- 0-5 0-5 0-10 0-20

2.36 ------- ------- ------- ------- ------- 0-5

---------------------------------------------------------------------------------------------------------------------------------

3.3.3 TESTING :

The details of test shall be as per IS : 2386 (part-I)-1963 to IS : 2386 (part VIII)-1963 (Methods of testing

aggregates for concrete).




4.0 BRICKS :-

4.1.0 Common burnt clay building bricks having compressive strength upto 400 kg/cm2 shall conform to

IS:1077-1976.

4.1.1 Burnt clay bricks having compressive strength more than 400 kg/cm2 shall conform to IS:2180-1978

4.1.2 Bricks shall be hand or machine moulded and free from cracks and flaws and nodules of free lime.

Bricks of 9 cm height shall be provided with frog of 1 to 2 cm deep on one of its flat sides. No frog is

required for 4 cm height bricks and extruded bricks.

4.2.0 CLASSIFICATION :-

4.2.1 Bricks shall be classified based on their compressive strength as given in table below :

--------------------------------------------------------------------------------------------

CLASS AVERAGE COMPRESSIVE

DESIGNATION STRENGTH NOT LESS THAN

KG/SQ. CM.

--------------------------------------------------------------------------------------------

350 350

300 300

250 250

200 200

175 175

150 150

125 125

100 100

75 75

50 50

35 35

-----------------------------------------------------------------------------------------------

4.2.1.1 Each class of brick shall be further divided into sub classes A and B based on tolerances and

shape.

4.2.1.2 Sub class A bricks shall be smooth rectangular faces with sharp corners and uniform colour.

4.2.1.3 Sub class B bricks may have slightly distorted and rounded edges.




4.2.1.4 The bricks of class designation 100 shall have smooth rectangular faces with sharp corners and

emit clear ringing sound when struck. Tolerances on dimensions upto +/-3% shall be permitted.

Dimension test to be carried out as per IS.

4.2.1.5 Bricks of class designation 75, 50 and 35 may be permitted to have slight distorted and rounded

edges provided no difficulty shall arise on this account in laying of uniform courses. Tolerances

on dimensions upto +/- 8% shall be permitted. Dimension test to be carried out as per IS.

4.3.0 PHYSICAL REQUIREMENTS :

4.3.1 Compressive Strength : This shall conform to table given above. Compressive strength of any

individual brick shall not fall below this minimum requirement by more than 20%.

4..3.2 Water Absorption :- Shall not be more than 20% upto class 125 and not more than 15% for higher

classes.

4.3.3 Efflorescence :- The rating of efflorescence shall not be more than moderate upto class 125 and not

more than slight for higher classes.

4.4.0 TESTING :-

The details of test shall be as per IS-3495-1976 Part I, II and III (Method of test of burnt clay building

bricks).

Part I : Determination of Compressive Strength

Part II : Determination of water absorption

Part III : Determination of efflorescence

Percentage of Deleterious materials (testing).

5.0 STEEL REINFORCEMENT :-

5.1.0 The steel reinforcement as specified shall be as follows :-

a) Mild steel and medium tensile bars - IS 432 Part I-1982.

b) Cold twisted HYSD bars IS 1786-1979.

MILD STEEL AND MEDIUM TENSILE STEEL :-

5.1.1.1 The physical requirements for mild steel, Grade I and II and medium tensile bars shall be as per

table below :




-------------------------------------------------------------------------------------------------------------------------

PROPERTY NOMINAL SIZE MILD STEEL MEDIUM

OF BARS ------------------- TENSILE

GR.I GR.II STEEL

-----------------------------------------------------------------------------------------------------------------------

i) ULTIMATE ALL SIZES 42 38 55

TENSILE

STRESS, KG/SQ. MM

MINIMUM

ii) YIELD UPTO & INCL. >

STRESS, 20 MM > 26 23.5 36

KG/SQ. MM

MINIMUM. UPTO AND )

INCL. 40 MM ) 24 21.5 34.5

OVER 40 MM 24 21.5 33

iii) ELONGATION, UNDER 10 MM 20 20 17

PERCENT

MINIMUM 10 MM & OVER 23 23 20

NOTE :- Mild steel Grade II is available in two varieties designated as ST 42-0 and ST 32-0. ST 42-0 only

shall be used conforming to above requirements. ST 32-0 shall not be used as reinforcement.

5.1.1.2 Note : Grade II mild steel bars shall not be used in the following conditions :

i) Where structures are located in earthquake zones subjected to severe damage.

ii) Where the structures are subjected to dynamic loading (other than wind loadings such as railway

and highway bridges).

iii) Where welding has to be employed for fabrication

iv) Where the design of structures are based on plastic theory.

5.1.1.3 WEIGHT :

The tolerance on weight for round and square bars shall be the following percentage of the weight

calculated based on unit weight of 0.785 kg/cm2/m run.

--- Upto and including 8mm - + 4%

--- Over 8mm - + 2.5%




5.1.1.4 TESTING

The details of test shall be as follows :

i) Tensile test : A-s per IS 226-1962 and IS 1608-1972.

ii) Bend test : As per IS 1599-1960.

5.1.2 COLD TWISTED BARS :

5.1.2.1 The physical requirements of all sizes of cold twisted bars whether plain or deformed shall be as

follows:

--- Tensile strength :- Minimum 49.5 kgf/sq. mm

--- 0.2% proof stress :- Minimum 42.5kgf/sq.mm

--- Elongation :- Minimum on guage length 5.65/60 where so is the cross sectional area of the test piece -

14.5%

5.1.2.2. WEIGHT :

The tolerance on the weight of the bars shall be the following percentages of the weight calculated on the

above :

--- Upto and including 8 mm - + 4%

--- Above 8mm - + 2.5%

5.1.2.3 TESTING :

The details of test shall be as per IS 226-1962, IS 1608-1972 and IS 1599-1974 for selection and

preparation of test samples, tensile test and bend test.

STRUCTURAL STEEL : SCOPE OF WORK : The work covered by this specification consists of supplying, fabricating and erecting of structural steel members for columns, beams, trusses, ladders, grills, doors etc., made out of RS joists, plates, angles, bars, flats, box sections etc., complete in strict accordance with the specifications and the applicable drawings. MATERIALS : All structural steel shall be of standard sections as marked on the drawings and shall be free from scale, blisters, laminations, cracked edges and defects of any sort. All structural steel and electrodes shall comply in all respects with I. S. for structural steel. WORKMANSHIP :




All workmanship shall be of first class quality in every respect to the greatest accuracy being observed to ensure that all parts will fit together properly on erection.

All ends shall be cut true to planes. They must fit the abutting surfaces closely. All stiffeners shall be fit tightly at both ends. All butt ends of compression members shall be in close contact through the area of the joints. The base connection shall be provided as shown on drawings and the greatest accuracy of

workmanship shall be ensured to provide the best connections. Figured dimensions on the drawings shall be taken. ERECTION AND MARKING : Erection and fabrication shall be according to I. S. 800-1984 section-11. During erection, the work shall be securely braced and fastened temporarily to provide safety for all erection stresses etc. No permanent welding shall be done until proper alignment has been obtained. Any parts which do not fit accurately or which are not in accordance with the drawings and specifications shall be liable to rejection and if rejected, shall at once be made good. Engineer-in-Charge shall have full liberty at all reasonable times to enter the contractor’s premises for the purpose of inspecting the work and no work shall be taken down, painted or despatched until it has been inspected and approved. The contractor shall supply free of charge all labour and tools required for testing of work. DELIVERY AT SITE : Contractor shall deliver the component parts of the steel work in an undamaged state at the site of the works and the Engineer-in-Charge shall be entitled to refuse acceptance of any portion which has been bent or otherwise damaged before actual delivery on work. PAINTING : Painting shall be strictly according to I. S. 1477-1971 ( Part-I-Pre-treatment ) and I. S.1477-1971(Part II-painting ) Painting shall be carried out on dry surfaces free from dust, scale etc. The paint shall be approved by the Engineer-in-Charge. Two coats of Synthetic Enamel paint of approved colour and make over two coats of red oxide primer shall be applied on steel, except where it is to be encased in concrete or where surfaces are to be field welded. WELDING : Welding shall be in accordance with I. S. 816-1969, I. S. 819-1957, I. S. 1261-1959, I. S. 1323-2982 and I. S. 9595-1989 as appropriate WELDING CONSUMABLE : Covered electrodes shall conform I. S. 814 (Part-II) - part II) 1974 or I. S. 1395-1972. Fill rods and wires for gas welding shall conform to I. S. 1278-1972.




The bare wire electrodes for submerged are welding shall conform to I. S. 7280-1974. The combination of arc and flush shall satisfy the requirements of I. S. 3613-1974. The filler rods and bare electrodes for gas shielded metal are welding shall conform to I. S. 6419-1971 and I. S. 6560-1972 as appropriate, TYPES OF WELDING : Are welding (direct or alternating current) or Oxyacetylene welding may be used. field welding may be used. field welding shall be by D. C. WELDING PROCEDURE: Welding should be done with the structural steel in flat position in a down hand manner wherever possible. Adequate steps shall be taken to maintain the correct arc length, rate of travel, current and polarity for the type of electrode and nature of work. Welding plant capacity shall be adequate to carry out the welding procedure laid down. Adequate means of measurement of the current shall be available either as a part of the welding plant or by the provision of a portable ammeter. In checking welding current, a tolerance of 10% or 30 amperes from the specified value, whichever is less, shall be permitted.

The welding procedure shall be such as to ensure that the weld metal can be fully and satisfactorily deposited through the length and thickness of all joints so that distortion and shrinkage stresses are reduced to the minimum and thickness of welds meet the requirements of quantity specified.

WORKMANSHIP : PREPARATION OF FUSION FACES : Fusion faces shall be cut by stearing machine or gas cutting and later dressed by filling or grinding so that they shall be free from irregularities such as would interfere with the deposition of the specified size of weld to cause the defects. Fusion faces and the surrounding surfaces shall be free from heavy slag, oil paint or any substance which might affect the quantity of the weld or impede the progress of welding. The welding face shall be free of rust and shall have metal shine surfaces. The parts to be welded shall be brought into as close contact as possible and the gap due to faulty workmanship or incorrect fit up shall not exceed 1/16”. If separation of 1/16” or more occurs locally, the size of the fillet weld shall be increased at such position by an amount of equal to the width of the gap. The parts to be welded shall be maintained to their correct position during welding. They shall be securely held in position by means of tack welds, service bolts, clamps or rings before commencing welding so as to prevent relative movement due to distortion, wind or any other cause. All welds shall be deposited in a pre-arranged order and sequence taking due account of the effects of distortion and shrinkage stresses. After making each run of welding, all slag shall be removed and final run shall be protected by clean boiled lined oil till approved. The weld metal, as deposited shall be free from crack, slag, excessive porosity, cavities and other faults. The weld metal shall be properly fused with the parent metal without overlapping or serious undercutting at the toes of the weld. The surface of the weld shall have a uniform and consistent contour and regular appearance




In welds containing crack, porosity or cavities in which the weld metal tends to overlap on the parent metal without proper fusion, the defective portions of the welds shall be out cut and rewelded. Where serious under cutting occurs, additional weld metal shall be deposited to make good reduction. MODE OF MEASUREMENT : All structural steel shall be measured on weight basis in metric tonnes or quintals or kgs as mentioned in the schedule of quantities. The length or areas of various members including gusset plates shall be measured correct to two places of decimals and the net weight worked out from the standard steel tables published by Bureau of Indian Standards. No separate measurements shall be taken for welding, riveting, bolting, field connections Etc. The rate shall include cost of all labour, materials, scaffolding, transport and also cost of welding, riveting and bolting, field connections if any all to complete the job as per specifications.




TECHNICAL SPECIFICATIONS - CIVIL WORKMANSHIP

EARTH WORK

GENERAL, DEFINITIONS

DEADMEN OR TELL TALES :

Mounds of earth left undisturbed in pits dug out for borrowing earth.

FORMATION :

Final shape or profile of the ground after excavation or filling up.

PROFILE :

The pattern to which the earth is to be out or made up and dressed.

FILL :

Shall mean earth, sand, stabilised aggregate or other material specified to replace earth or rock removed

during construction.

CLASSIFICATION

The earth shall be classified, measured and paid separately for categories as mentioned below :

ORDINARY SOIL

Any soil which can be removed with the ordinary or close application of bicks or jumpers or scarifiers and

rippers.

ORDINARY ROCK

Which may be quarried by crowbars or picks such as limestone, sandstone, hard laterite, hard

conglomerate, and un-reinforced concrete below ground level shall be treated as ordinary rock.

PROTECTION

a) Trenches and foundation pits shall be securely fenced and proper caution sign and night lighting shall

be arranged.

b) Any excavation shall not be carried out below the foundation level of adjoining structure unless proper

precautions like underpinnig shoring etc are taken.

EXACAVATION FOR FOUNDATION

SCOPE

Excavation for normal spread footings, trenches, u/g storage tanks, excavation over large areas, etc.

SITE CLEARENCE

Before the earth work is started the area shall be cleared of shrubs, vegetation, grass brush, wood, trees

and rubbish. The roots of trees shall be removed to a minimum 600mm below ground level or 30 cm

below formation level whichever is lower and the hollows shall be filled up with earth, leveled and

rammed.




SETTING OUT AND MAKING PROFILES

Masonry pillars will be erected at suitable points to serve as benchmark, for execution of work. These

bench marks shall be connected to standard bench mark if required by Engg.-in-charge / Architects. In

addition to these pillars, centre line pillars shall also be erected by the contractor and footing positions

shall be marked with the help of these pillars.

The necessary profile shall be set out. The level shall be taken at an interval as directed by Engg.-in-

charge / Architects but the intervals shall not be more than 5 meters in any case. The levels shall be

recorded in field books and plotted on plan before starting the excavation and the same shall be

countersigned by the Engg.-in-charge / Architects.

CUTTING FOR FOUNDATION:

The cutting shall be done to minimum depths as indicated in the drawings and if required the depth shall

be increased to obtain proper strata for foundations. Any excess excavation carried out by the contractor

without the proper authorisation from etc shall not be paid and the excess depth shall be made good by

the contractor by PCC 1:4:8.

CUTTING TRENCHES: Unless otherwise indicated on the drawings, trench excavation shall be by open

out and the bottom of the trenches for piping shall be accurately graded so that the pipe is uniformly

supported along its entire length. After trench bottom has been graded all holes or depressions for other

type of piping joints shall be cut below the trench to the depth necessary for the particular joint.

BACKFILLING:

Backfilling of the excavated spaces shall be done with the selected material from the excavation.

Backfilling shall be done to the original ground level or the elevation shown on the plan in layers of

150mms to 220mms and well compacted. When the excavated earth is not suitable or adequate for

backfill then approved backfill material shall be brought from outside and the same shall be paid

separately. Backfilling is to be done in such a manner as not to cause undue thrust on the any part of the

structure.

TRENCH BACKFILL:

Backfilling of trenches for pipelines shall be done first over the middle portion of each length of pipe

bringing the cover to a depth of at least 300mm over the top of the pipe while leaving all field joints

exposed. After all required tests on the piping have been carried out and approved by the Engg.-in-

charge / Architects the remaining trench backfill shall be accomplished. Extreme care shall be exercised

during backfilling operations to prevent damages to coated or wrapped pipes.

SIDE PROTECTION FOR DEEP EXCAVATION:

In case of excavation for foundations exceeding 2.0 metres depth from existing ground level, proper

precautions shall be taken to prevent sides from collapse. This can be ensured by adopting any one of

the following methods given below and as directed by EIC.




1. Stepping

2. Side slopes

3. Planking and Strutting

The first two methods can be adopted where the soil is not loose and sloping/stepping is possible. The

sides slopes shall be done to such a degree that the sides are stable. In case of very loose and

trecherous soil, planking and strutting shall be done to avoid collapse. Planking and strutting shall be

done in accordance with IS 3764 (Safety code for excavation works). Sheetings, shorings and bracings

shall be maintained in place until immediately before filling or backfilling and then shall be removed by

stages as the filling or the backfilling progresses. The responsibility of designing, supplying and erecting a

sound and stable shoring system rests with the contractor and shall be approved by EIC before

execution.

DEWATERING :

In case of water being encountered during the excavation for foundation, the contractor shall arrange for

adequate capacity of dewatering system. Pumping shall be controlled to dispose of water to drainage

ditches and shall not be routed to cause inconvenience to the construction operation in general.

MEASUREMENT:

The length, breadth and depth shall be measured to nearest centimetre and the quantity shall be worked

out in cubic metres to two decimal places. The depth shall be taken as per drawing or as excavated under

special conditions under instructions from Engineer-in-Charge/Architects. The width and length shall be

taken as per length and width of PCC as per drawing.

MORTARS :

CEMENT MORTAR :

SCOPE

This shall cover cement mortars used in general building works for masonry work and plastering.

Materials :

Cement, Water and Waterproofing compound : As specified in Materials specifications.

Sand :

sand as specified in clause 3.2.0 of materials section shall be used.

Proportioning:

Proportion of sand and cement shall be as specified. The unit of measurement for cement shall be a bag

of cement weighing 50kgs and this shall be taken as 0.035 cu.m. Sand in specified proportion shall be

measured in boxes of suitable sizes. It shall be measured on the basis of its dry volume. If the sand is

wet, the quantities shall be increased suitably to allow for bulkage.




If the sand as specified for plastering is not available, proper sieving shall be carried out at site to obtain

the required fineness modulus and only such sieved sand shall be used for plastering work.

Mixing :

The mixing of mortars shall be done in mechanical mixers operated manually or by power. The Engg.-in-

Charge / Architects may however relax this condition taking into account the nature and the location of

the work.

Mixing in Mechanical Mixers :

Cement and sand in specified proportion shall be mixed dry thoroughly in a mixer and then water shall be

added gradually and wet mixing shall continue for at least one minute. Water shall be added only in such

proportion to bring the mortar to the consistency of a stiff paste. Only the quantity of mortar which can be

used within 30 minutes of its mixing shall be prepared at a time. The mixer shall be cleaned with water

each time before suspending the work.

Hand Mixing :

The measured quantity of sand shall be leveled on clean masonry platform and cement bags emptied on

top. The cement and sand shall be thoroughly mixed dry by turning over backwards and forwards several

times till the dry mixture is of a uniform colour. The quantity of dry mix which can be used within 30

minutes shall then be mixed in masonry troughs with just sufficient quantity of water to bring the mortar to

the consistency of a stiff paste.

CONCRETE WORKS :-

MATERIALS :

Water, cement, lime, surkhi, coarse aggregates, fine aggregate shall be as specified in above Section.

Cement Concrete :

Scope :

This shall cover plain cement concrete in leveling courses, subgrades, coping, kerbs, steps, sills etc.

Proportion :

Shall be done by volume, Boxes of suitable sizes shall be used for measuring sand and aggregates. The

unit measurement of cement shall be a bag of 50 kgs and this shall be taken as 0.035 cu.m.

While measuring the aggregates, shaking, heaping, ramming shall not be done.

The proportioning of sand shall be on the basis of its dry weight and in case of damp sand allowances for

bulkage shallbe made. Different sizes of boxes are advised to be used while measuring sand with

bulkage allowance.

Mixing shall be done in mechanical mixers. Mixing by hand shall not be permitted unless specific prior

permission of the Engg.-in-Charge/Architects has been obtained in writing.

Machine Mixing :




The mixture drum shall be cleaned with water and half the required quantity of dry coarse aggregates

shall be placed first in the hopper followed by cement and sand and finally the balance quantity of coarse

aggregates shall be put in the hopper. The dry material shall be mixed for at least four turns of the drum

after which the correct quantity of water shall be added gradually while the drum is in motion. The

materials shall be mixed for not less than a period of two minutes and until a uniform colour and

consistency is obtained.

Hand Mixing ;

Shall be done on smooth clean watertight platform. Measured quantity of sand shall be spread and the

required number of bags of cement shall be distributed evenly on top of sand. The sand and cement shall

be mixed intimately by turning the mixture over and over again to get a uniform colour. The sand cement

mixture shall be spread and measured quantity of coarse aggregates shall be distributed on top of it. This

shall be mixed at least three times by shoveling. A hollow shall be made in the middle of the mixed pile

and three quarter of total quantity of water shall be poured into it while the material is turned in towards

the centre with spades. The remaining water shall be added slowly turning the whole mixture over and

again until a uniform colour and consistency is obtained.

CONSISTENCY:

The quantity of water to be used for each mix of 50 kg cement to obtain the required consistency shall not

be more than 34 litres for 1:3:6 mix, 30 litres for 1:2:4 mix, 27 litres for 1:1:5:3 mix.

In case of vibrated concrete, the limits specified shall be suitably reduced to avoid segregation. The

quantity of water shall be regulated by carrying out regular slump cone tests as specified. The following

slumps shall be adopted for different kind of works :

------------------------------------------------------------------------------------------------------------------------------

Description Slump in mm

With Without

Vibrators Vibrators

--------------------------------------------------------------------------------------------------------------------------------

Plain Cement Concrete :

Mass concrete in foundation,

Footings, retaining, walls

And pavements : 10 - 25 50 - 75

Thin sections of flooring less

than 75mm thk 25 - 40 75 - 100

Reinforoed concrete :




Mass concrete in RCC

Foundations, footings

Retaining walls 10 - 25 80

Beams, slabs and columns

Simply reinforced 25 - 40 100 - 125

Thin RCC sections or

Sections with congested steel 40 - 50 125 - 150

LAYING :

The concrete shall be laid gently in layers not exceeding 150mm Mechanical vibrators shall be used for

compaction. Hand compaction may be permitted by Engg.-in-charge / Architects depending upon the

thickness of the member and feasibility of vibrating the same. Hand compaction shall be done with the

help of tamping rods. Next layer of concrete shall be carried out before initial setting starts in the previous

layer i.e. within 30 minutes.

Concreting shall not be carried out if the temperature falls below 4.5C. During hot weather care shall be

taken to see that the temperature of concrete dose not exceed 38C. When the concreting is suspended,

necessary removal of laitance and roughening of surface for jointing shall be done before concrete sets.

On the resumption of work the joint shall be thoroughly cleaned, roughened, watered and a grout of neat

cement slurry (1Kg of cement in 2Lt of water) shall be applied uniformly.

CURING :

Green work shall be protected from rain by suitable covering. After about 1 to 2 hours of concreting, the

surface of concrete shall be protected from drying with the help of moist gunny bag, sand or any other

approved method. After 24 hours the surface shall be flooded with water of min. 25mm depth. The

curing shall continue for minm. 14 days or more if required by Engg.-in-Charge / Architects. The masonry

work can be started after 48 hours of concreting, but the curing shall continue for minm 14 days alongwith

masonry.

FORM WORK :

Shall be as specified in R.C.C. section.

REINFORCED CEMENT CONCRETE :

SCOPE :

This shall cover general reinforced cement concrete work in footings, columns, beams, pardis, slabs,

overhead/underground tanks, retaining walls, etc.




SETTING OUT WORKS :

All the center lines and reference lines shall be permanently marked on brick masonry pillars and these

pillars along with the center line marking shall be preserved till the completion of work. Reference bench

marks wherever required shall also be built and maintained.

MATERIALS :

All materials like cement, sand, aggregates and steel shall conform to the specifications details in the

Materials section.

CEMENT :

Cement supplied in bags (gunny, multiply paper or cloth) shall be stored and stacked in dry and

waterproof sheds. Bags shall be stacked at least 10 to 20 cms clear above the floor. A space of 60 cms

all round shall be left between the exterior walls and the stacks. Cement bags should be placed close

together to reduce circulation of air as much as possible. Bags shall stored one above the other in stacks

not more than 10 bags to avoid lumping under pressure. If more than 7 bags are stacked one above the

other the same should be arranged in header and stretcher fashion to avoid toppling. For extra safety

during monsoon or when cement is to be stored for longer periods, the entire stack shall be enclosed in

polythene sheets or any other suitable water proofing material. When removing the cement bags for use,

first in first out principle should be adhered to. Each consignment of cement when received at site, shall

be stacked separately to permit easy access for inspection and facilitate removal.

Aggregates required for concrete work shall be stored separately as their sizes and grades. All

aggregates shall be stored on a clean hard surface, preferably on a floor of bricks.

FORMWORK

Unless specified the formwork shall be of plywood not less than 10mm thick or steel plates not less than

3mm thick with suitable frames. Plain surfaces shall be adequately strengthened at edges and centre

bracing to prevent buckling, warping or bending. Faces in contact shall be free from adherings, grouts,

projecting nails, splits and other defects.

FIXING AND ERECTING FORMWORK :

PROPS :

Props used for shuttering shall be of steel, timber posts, and ballis. In no case ballis used shall be of

diameter less than 100mm at mid length and 80 m at thin end. Maximum permissible spacing in case of

ballis shall be 1.2 metres centre to centre.




In case of structures with two or more floors, the weight of concrete shuttering and centrering of any

upper floor being cast shall be suitably supported on one floor below the topmost floor already cast.

Formwork and concreting of upper floors shall not be done until concrete of the lower floor has set for at

least 14 days. For all cantilever beams and slabs, the props shall not be removed for 28 days.

The above specification is applicable only for spans upto 4.5 metres and heights upto 3.5 metres. In case

any of the limits are exceeded the formwork shall be properly designed.

BRACINGS :

Upto 3.0 metre height, single stage bracing shall be provided and from 3.0 - 4.5 metre height double

stage bracing shall be provided.

SHUTTERING :

All the joints in shuttering shall be leakproof. Faulty joints shall be caulked to prevent leakage.

Connections shall be constructed to permit easy removal of the shuttering and shall be either nailed,

screwed, bolted, clamped or wired. The connections should be strong enough to retain the correct shape

during consolidation of concrete. The chamfers beveled edges and moulding shall be made in the

formwork itself. Opening for the fan clamps and other fittings for services shall be provided in the

shuttering as directed. Care shall be taken while providing dowel bars so that the holes in the shuttering

are leakproof. Shuttering shall be true to line and level and braced to prevent deformation under the

weight and pressure of wet concrete, constructional load, wind and other pressures.

The shuttering of beams and slabs shall be so erected that the shuttering on the sides of the beams and

of the soffit of the slabs can be removed without disturbing the beam bottoms.

SURFACE TREATMENT FOR SHUTTERING :

Any approved mould oil or other material shall be used. For timber shuttering the surfaces coming in

contact with concrete shall be well wetted and coated with soap solution, raw linseed oil or form oil of

approved manufacturer.

CAMBER

Suitable camber shall be provided in horizontal members especially in long spans to compensate the

effects of deflection. The camber for beams and slabs shall be 4 mm per metre and the camber for

cantilever at the free end shall be 1/50 of the projected length.

REMOVAL OF FORMWORK :




The formwork shall be removed in such a way that no damage is done to the concrete work due to shock

or vibration. In case of horizontal members, formwork should be eased carefully in order to prevent the

load being suddenly transferred to the concrete. The minimum required period before de-shuttering is

given in the table below :-

_____________________________________________________________________________

Part of Structure Minimum period

For removal of formwork

_____________________________________________________________________________

Sides of foundations, columns,

Beams and walls 48 hours

Undersides of slabs upto 4.5 m span 7 days

Undersides of slabs above 4.5 m span

And undersides of beams upto 6.0m span 14 days

Undersides of beams over 6.0 m and

Upto 9.0 m span 21 days

Undersides of beams over 9.0 m span 28 days

Note :

In case of cantilever slabs and beams, the centering shall remain till structures for counteracting or

bearing -down have been erected and have attained adequate strength.

Proper precautions shall be taken to allow for the decrease in the rate of hardening with all cements in

cold weather.

MEASUREMENT :

Wherever specified as a separate item, the formwork shall be paid for separately. The concrete items

mentioned in the tender are inclusive of shuttering and formwork.

REINFORCEMENT :

All the reinforcement used in RCC work shall conform to the specifications as described in Materials

section.

GENERAL :

All reinforcement shall be clean and free from loose mill scales, dust, coats of paint, oil, loose rust or

other coatings which may destroy or reduce bond.




BENIDNG AND OVERLAPPING :

All reinforcement bars shall be made perfectly straight before bending. Bars shall be bent by suitable

machine or manually round by a pin having a diameter not less than four times the diameter of the bar

being bent, producing a gradual and even motion. Bars shall be bent cold. No reinforcement shall be bent

when is position on the works. Bending shall comply with the dimensions given in the approved bending

schedule (tolerances permitted is 0.5%)

In case of mild steel, the ends of rods shall be bent into a semicircular hook having clear diametr equal to

four times the diameter of the bar with a length beyond the bend equal to four times the diameter of the

bar. In case of deformed bars, the hooks are not required.

Overlapping of the bars where necessary, shall be done as directed by the Engg.-in-charge / Architects.

The overlapping bars shall be bound together at interval not exceeding ten times the diameter of the

smaller diameter bar with two strands of annealed steel wires of 18 SWG thickness twisted tight. The

overlap shall be staggered for different bars and located at points, along the span, where neither shear

nor bending movement is maximum. Where facility is available welding of bars shall be restored to in view

of overlap.

PLACING IN POSITION :

Reinforcement bars shall be placed in position as shown in the drawings. The bars crossing one another

shall be tied together at every intersection with two strands of binding wire. Tack welding shall also be

permitted in lieu of binding with steel wire.

The bars shall be kept in position by the following methods :-

a) In case of beam and slab construction, precast cover blocks (cement mortar 1:2 blocks, pieces of

broken mosaic tiles or plastic cover blocks) of thickness equal to the specified cover shall be placed

between the bars and shuttering.

b) In case of cantilever and double reinforced beams or slabs, the vertical distance between horizontal

bars shall be maintained by introducing chair spacers of steel at 1 metre or less spacing to avoid

sagging.

c) In case of columns and walls, the vertical bars shall be kept in position by means of timber templates

with slots accurately cut in them or with cover blocks suitably tied to the reinforcement.

MEASUREMENT :

Reinforcement including authorised spacer bars and laps shall be measured in lengths of different

diameters as actually used in the work nearest to a centimeter and their weight calculated on the basis of

standard tables. Wastages and unauthorised overlaps shall not be paid. Annealed steel wire required for




binding shall not be measured. Wherever welding is restored in lieu of laps such welds shall be measured

separately in numbers for different size of reinforcement.

CONCRETING

The concrete shall be as specified under “Cement Concrete”. Concrete shall be mixed by mechanical

mixer only and no hand mixing shall be allowed for RCC works.

CONSISTENCY :

The consistency of the concrete shall be such that it flows sluggishly into the forms and around the

reinforcement without any segregation of coarse aggregate from mortar. The consistency shall depend on

the mode of compaction viz., vibrated or hand tamped. The slump tests are mandatory and shall be

carried out at regular intervals so that the consistency of concrete can be monitored.

For details see under cement concrete

PLACING OF CONCRETE :

Concreting shall commence only after inspection and approval by Engg.-in-Charge / Architects of

shuttering, centering and reinforcement are placed. The approval for concreting shall be given in writing

by Engg.-in-charge / Architects. Shuttering shall be clean and free from shavings, saw dust, pieces of

wood or other foreign material and proper de-shuttering agent shall be applied to the surface.

Proper arrangements shall be provided for conveying the concrete to the place of deposition without

disturbing the reinforcement. This can be achieved by providing wooden planks or catwalks supported

directly on centering by means of wooden blocks or lugs. The labour shall not be allowed to walk on the

reinforcement.

In case of columns and walls it is desirable to place concrete without construction joints. To achieve this a

concrete pouring window should be provided in one of the sides of formwork approximately 2 to 3 feet

from bottom to facilitate placement of concrete and compaction of the bottom portion and avoid

segregation of the concrete. Rate of concreting in vertical direction shall be restricted to one metre per

hour.

The concrete deposited in its final position shall be in a cohesive mass and no segregation shall be

allowed. In deep trenches and footings, concreting shall be placed through chutes as directed by Engg.-

in-Charge / Architects.




COMPACTION

Concrete shall be compacted into a dense mass immediately after placing by means of mechanical

vibrators. Use of mechanical vibrators for compaction may be relaxed depending on the thickness of the

members and feasibility of vibrating the same. Hand compaction shall be done with the help of tamping

rods. The different layers of concrete shall be placed before the final setting of the previous layer takes

place.

Concrete shall be judged being properly compacted when the mortar fills the spaces between the coarse

aggregates and begins to cream up to form an even surface. If vibrating table and the external vibrators

are being used, they shall be stopped as soon as the compaction is over. In case of needle vibrators the

needle shall be withdrawn slowly to prevent formation of loose pockets. Shaking of the reinforcement for

purpose of compaction shall not be allowed. Compaction shall be completed within thirty minutes from the

time of addition of water to the dry mixture.

CONSTRUCTION JOINTS :

Before starting the concrete, the position and location of the construction joint shall be decided, if not

indicated on the drawings, and proper arrangements like stop board with necessary slots for

reinforcement bars shall be made. No construction joint shall be located in valleys. Preferably the joint

shall be kept at places where the shear force is minimum and the joint shall be straight and at right angles

to the direction of the main reinforcement. In case of columns, the joint shall be horizontal and 10 to 15

cm below the bottom of the beam. Any concrete flowing through the joints of stop board shall be removed

soon after the initial set.

When the work has to be resumed, the joints shall be thoroughly cleaned with wire brush and loose

particles removed. A coat of neat cement slurry at the rate of 2.75 kg of cement per square metre shall be

applied before fresh concrete is laid.

CURING :

Shall be as specified in “Cement Concrete”.

FINISHING :

In case of roof slabs, the top surface shall be finished even and smooth before the concrete begins to set.

In case of RCC slabs which are to be treated with any flooring shall be roughened with wire brushes while

the concrete is green.

STRENGTH OF CONCRETE :

The compressive strength on work tests for different mixes shall be as follows :




_____________________________________________________

Concrete Mix Compressive strength

Kg/cm2

7 days 28 days

_____________________________________________________

1:1:2 210 315

1:1:5:3 175 265

1:2:4 140 210

______________________________________________________

INSPECTION AND RECTIFICATIONOF DEFECTS :

Immediately on removal of forms, the RCC works shall be examined by the Engg. -in-Charge / Architects

before any defects are made good.

The work that has sagged or contains honey combing to an extent detrimental to the structural safety or

architectural concept shall be rejected.

Surface defects on a minor nature may be accepted and the same shall be rectified as follows :

a) Bulges due to movement of forms, ridges at forms, ridges at form joints shall be carefully chipped and

then rubbed with a grinding stone.

b) Honeycombed and other defective areas must be chipped out, the edges being out as straight as

possible and perpendicular to the surface. Shallow patches are first treated with a coat of thin grout (1

cement : 1 sand) and then filled with mortar similar to that used in concrete. Large and deep patches

shall be filled up with concrete held in place by forms and shall be reinforced.

c) Holes left by bolts shall be filled carefully with mortar. Holes extending right through the concrete shall

be filled with mortar with a pressure gun.

d) The same amount of care to cure the material in patches should be taken as with the whole structure.

POST TREATMENT OF SURFACE :

The surface which has to receive plaster or where it has to be joined with brick masonry walls shall be

properly roughened immediately after the shuttering is removed.

ACCEPTANCE CRITERIA OF CONCRETE WORK :

Minimum of six sample cubes shall be taken for all concreting work (periodicity as specified in 9.6 of

section III) and three cubes shall be tested after 7 days curing and balance after 28 days curing.

7 Days Test :

The average strength of the three specimens shall be accepted as the compressive strength of the

concrete provided that the difference between maximum and minimum strength of the three cubes does

not exceed 15% of average strength




In case the 7 days strength is not satisfactory all further work structurally interlinked with the concrete

represented by the samples shall be stopped till the remaining three cubes are tested for 28 days

strength and are found satisfactory.

28 Days Test :

The tests should generally be carried out on 28th day, but in no case, should be delayed beyond 35 days.

The strength of the cubes shall be as specified in table above if they are tested on the 28th day. In case,

the cubes are tested after 28 days, the minimum acceptable compressive strength shall be increased by

1.5 kg/cm2 for each day beyond 28th day.

The acceptance criteria of 28 days test shall be as follows ;

a) If the average compressive strength of three cubes is more or equal to the comp. Strength shown in

table above, the concrete shall be accepted at full rates.

b) If the average comp. Strength of the three cubes is less than specified but not less than 75% of the

specified strength, the concrete shall be accepted at reduced rates at the discretion of EIC. The

reduced rate shall be calculated on proportionate basis, i.e. for every percent decrease in the

specified strength the rate shall be reduced by the same percentage.

c) If the average compressive strength of the three cubes is less than 75% of the specified strength, eic

shall either reject the defective portion or get it dismantled along with the structurally connected work

as considered necessary at the risk and cost of the contractor. Eic may also desire to carry out

additional tests on the defective work and if on the basis of these additional tests, eic is satisfied

about the structural adequacy of the concrete the concrete work may be accepted at the reduced rate

as specified in b) above except, for the reduced strength below 75% for which the reduction shall be

1.5 times for every percent decrease below 75%

Example : Average compressive strength is 70% of specified strength. The rate payable shall be 75 - 1 5

(75-70) = 67.5% of tendered rate.

MEASUREMENT

All measurements shall be as per IS 1200

MASONRY :

BRICK WORK :

SCOPE : Shall cover brick masonry works of 225 thick or more in all buildings, walls, etc.

CLASSIFICATION : Brick work shall be classified according to the class designation of bricks used.

MORTAR : The mortar shall be as specified, Materials, preparation and mixing of mortar shall be as

specified in “MORTAR” section.




SOAKING OF BRICKS : Bricks required for masonry in cement/ lime mortar shall be thoroughly soaked

in clean water for at least one hour in tanks of tanks of sufficient size immediately before use. The soaked

bricks shall be kept on wooden planks or brick platform to avoid earth smearing on them.

LAYING : Bricks shall be laid in English bond unless otherwise specified. Half or cut bricks shall not be

used except where necessary to complete the bond. Closure in such cases shall be cut to the required

size and used near the end of the wall.

A layer of mortar shall be spread on full width over a suitable length of lower course. Each brick shall be

properly bedded and set home in position by gently tapping with handle of trowel or wooden mallet. Its

inside faces shall be buttered with mortar before the next brick is laid and pressed against it. On

completion of a course, all vertical joints shall be fully filled from the top with mortar.

The wall shall be taken truly plumb. All courses shall be laid truly horizontal and all vertical joints shall be

truly vertical. Vertical joints in alternate course shall come directly one over the other. The thickness of the

brick courses shall be kept uniform and for this purpose, wooden edge with graduations giving thickness

of each brick course including shall be used. The height of window sill, bottom of lintels and such other

important points shall be marked on it. A set of tools comprising of a wooden straight edge, mason spirit

level, square, two foot rule, line and pins, strings and plumb shall be kept on the side of the work.

Both the faces of walls of thickness greater than 225 mm shall be kept in proper plane. The connecting

brick work shall be carried out nearly at one level and no portion of work shall be left more than one metre

below the rest of the work. Where this is not possible the work shall be raked back according to bond

(and not left toothed) at an angle not exceeding 45 degrees.

All iron fixtures, pipes outlets of water, holdfasts of doors, windows, etc. which are required to be built in

walls shall be embedded in cement mortar or in cement concrete as specified in their correct position as

the work proceeds.

The work done per day should not be more than one metre in height.

JOINTS ;

Bricks shall so be laid that all joints are full of mortar. The thickness of joints shall not exceed one cm for

brickwork of any class designation. All face joints shall be raked to a minimum depth of 10mm by a raking

tool during the progress of work where the mortar is still green so as to provide proper key for the plaster

or pointing to be done. Where plastering or pointing is not required to be done the joints shall be struck

flush and finished at the time of laying.

The face of brickwork shall be cleaned on the same day on which brickwork is laid and all mortar

dropping shall be removed promptly.




CURING :

Brickwork shall be protected from rain by suitable covering when mortar is green. Masonry work in

cement mortar and lime mortar shall be kept constantly moist on all faces for a minimum period of seven

days. Brickwork carried out during the day shall be suitably marked indicating the date on which the work

is done to keep a control on the curing period.

SCAFFOLDING :

For all exposed brickwork or tile work, double scaffolding having two sets of vertical supports shall be

provided. For all other brickwork single scaffolding shall be permitted. Where single scaffolding is

provided, the horizontal scaffolding pole shall rest in a hole provided only in the header course. No holes

for scaffolding shall be provided in pillars, columns and immediately near the skewback of arches.

MEASUREMENT :

Unless otherwise specified, all brick masonry works shall be measured correct to a centlmetre and the

area shall be calculated in square metres to the nearest two decimal places.

STONE WORK :

SCOPE

Shall include all stone masonry work in general and erection of stone walls.

MATERIALS :

Cement, sand shall conform to the specifications detailed in Materials section. Mortars of specified mix

shall conform to “Cement Mortars”.

RANDOM RUBBLE MASONRY :

Stone : Stones used for this purpose shall be hard, sound, free from decay, weathering and defects like

cavities, cracks, flaws, sand holes, veins, patches of soft or loose materials, etc. Stone shall be sharp,

angular and round stones shall not be used.

Generally, blue basalt or granite shall be used for masonry works.

The length of the stone shall not exceed three times the height and the breadth on base shall not be

greater than 3/4th of the thickness of wall. The height of stone may be upto 30 cm.

Stones shall be hammer dressed on the face, sides and the beds to enable it to come into close proximity

with adjacent stones. The bushing in the face shall not project more than 20 mm. For exposed masonry

and 10 mm for masonry which is to be plastered.




LAYING

Stones shall be wetted before use. The wall shall be carried up truly plumb. Every stone shall be fitted

carefully with the adjacent stones to form neat and close joints. The bond shall be obtained by using bond

stones. Face stones shall extend well into the backing and these shall be arranged to break joints as

much as possible and avoid long vertical lines of joints. The interior filling of the wall shall consist of

rubble stones of any shape but shall not pass through a circular ring of 15 cm dia. Thickness of these

inner stones shall not be less than 10 cm. The inner stones shall be carefully laid hammered down with a

wooden mallet into position and solidly bedded into mortar. Use of chips and spalls shall be limited and

should be used only to avoid thick mortar joints.

Bond Stones : Bond stones or through stones running right through the thickness of walls shall be

provided in walls upto 60 cm thick and in case of walls more than 60 cm thick, a set of two or more bond

stones overlapping each other by 15 cm shall be provided in a line from face to back. At least one bond

stone shall be provided for every 1.0 sqm. of wall surface.

Joints : Stones shall be so laid that all joints are full of mortar. Face joints shall not be more than 25mm

thick. When plastering and pointing is not required to be done, the joints shall be struck flush or raised

pointed as per requirement and finished at the time of laying.

SCAFFOLDING, CURING AND MEASUREMENT :

Shall be as per Brick Masonry.

PLASTERING :

SCOPE :

This covers cement plaster finishes to column, ceilings, walls and similar surfaces on backgrounds met

with such as brick, stone or concrete.

MATERIALS :

All materials like sand and cement shall conform to specifications detailed in ‘materials section”.

MORTAR :

The mortar of the specified mix using the type of sand described in the item shall be used. It shall be as

specified in “Cement Mortars”. For external and undercoat work, the fine aggregate conforming to

Grading IV and for finishing coat work the fine aggregate conforming to Grading V shall be used.

SCAFFOLDING :

Scaffolding shall be done in line with details specified under “BRICK WORK”.




PREPARATIN OF SURFACE

Dust and loose mortar shall be brushed out. Efflorescence if any shall be removed by brushing and

scraping. The surface shall then be thoroughly washed with water, cleaned and kept wet before plastering

is commenced.

In case of concrete surface if chemical retarder has been applied to the formwork, the surface shall be

roughened by wire brushing and all the resulting dust and loose particles cleaned off and care shall be

taken that none of the retarders is left on the surface.

APPLICATION :

Ceiling plaster shall be first completed before commencement of wall plaster.

Plastering shall be started from the top and worked down towards the floor. All putlog holes shall be

properly filled in advance of the plastering as the scaffolding is being taken down. To ensure even

thickness and a true surface, plaster of about 15 x 15 cm shall be first applied horizontally and vertically,

at 3 metres intervals over the entire surface to serve as gauges. The surfaces of these gauged areas

shall be truly in the plane of the finished plaster surface. The mortar shall then be laid on the wall,

between the gauges with trowel. The mortar shall be applied in a uniform manner slightly more than the

specified thickness and brought to true surface by working a wooden straight edge reaching across the

gauges with small upward and sideways movements at a time. Finally the surface shall be finished off

true with trowel or wooden float according to whether a smooth or a sandy granular texture is required.

Excessive trowelling or overworking the float shall be avoided.

All corners, arises, angles and junctions shall be truly vertical or horizontal as the case may be and shall

be carefully finished. Rounding or chamfering corners, arrises, junctions, etc, where required shall be

done without any extra payment. Such rounding or chamfering shall be carried out with proper templates

to the sizes required.

Plastering and finishing shall be completed within half an hour of adding water to the dry mortar. In

suspending work at the end of the day the plaster shall be left out clean to line both horizontally and

vertically and while recommencing the edge of the old work shall be scraped, cleaned and wetted to

enable proper jointing.

Notes :

Plastering work shall be closed at the end of the day on the body of the wall and nearer than 15 cm to any

corners or arrises.

Horizontal joints in plaster shall not occur on parapet tops and copings as these invariably lead to

leakages.

No portion of the surface shall be left out initially to patch up later on.




CURING :

Curing shall be commenced as soon as the plaster has hardened sufficiently. Plaster shall be kept wet for

a period of seven days.

20mm THICK CEMENT PLASTER (TWO COAT WORK) :

MORTAR :

This shall be done at detailed under cement mortars. Generally coarse sand shall be used for the

undercoat (first coat) and fine sand for the finishing coat (second coat) unless otherwise specified.

APPLICATION

The plaster shall be applied in two coats, i.e. 12mm thick under coat and 8 mm. Thick finishing coat and

shall have an average total thickness of not less than 20mm.

12mm thick undercoat :

This shall be applied as detailed above. However, when the plaster has been brought to true surface with

a wooden straight edge, the surface shall be left rough and 2mm deep furrows shall be made with a

scratching tool to form key for the finishing coat. The surface shall be kept wet till the finishing coat is

applied.

8mm thick finishing coat :

The finishing coat shall be applied as detailed above after the undercoat has sufficiently set but not dried

and in any case within 48 hours of laying the undercoat. The surface shall be finished with special rubbing

by sponge pads and other tools recommended for cement plaster work to obtain a uniform textured

surface.

Curing shall be as detailed above.

CEILING CEMENT PLASTER :

SCAFFOLDING :

Shall be as detailed under “Brick Masonry” and stage scaffolding shall be provided independent of the

walls.

PREPARATION OF SURFACE : Projecting burrs of mortar formed due to gaps at joints in shuttering

shall be removed, the surface shall be scrubbed with wire brushes. Concrete surfaces shall be hacked at

spacings not more than 5cm centres and depth shall not be less than 3mm. Surface shall be well wetted

before applying the plaster.




MORTAR

Mortar of specified mix shall be used and shall conform to the specifications detailed under “Cement

Mortars”.

APPLICATION :

Ceiling plaster shall not be commenced until the slab above has been finished and centering has been

removed. In the case of ceilings of roof slabs, plaster shall not commence until the terrace work has been

completed. This is to ensure that ceiling plaster is not disturbed by the vibrations set or in the above

operations. To ensure even thickness and true surface, gauges of plaster 15 x 15 cm shall be first applied

at not more than 1.5 metre centres in both directions true in the plane of finished surface.

The plaster shall be then applied in a uniform manner to a thickness little more than the specified

thickness and shall be then brought to true and even surface by working with a wooden straight edge

reaching across the gauges. Finally the surface shall be finished true with a trowel to obtain a smooth

surface. The work shall be checked frequently with a true straight edge not less than 2.5 metre long.

THICKNESS

The average thickness of plaster shall not be less than 6mm. The minimum thickness over a portion of

the surface shall not be less than 4mm.

POINTING :

SCOPE : This shall include cement mortar pointing on brickwork and stone work.

MATERIALS :

Cement and sand for plastering shall conform to specifications detailed in Materials section.

SCAFFOLDING :

For exposed brickwork or stonework, scaffolding having two sets of vertical supports shall be provided.

MORTAR :

Shall be of specified mix and as specified in Cement Mortars.

PREPARATION OF SURFACE :

The joints shall be raked out properly while the mortar is green. Efflorescence if any, shall be removed by

brushing and scraping. The surface shall be washed with water and kept wet before pointing is

commenced. The joints shall be raked in such a fashion that the minimum depth of new mortar measured

from either the sunk surface of the finished pointing or from the edge of the brick/stone shall not be less

than 12mm.




APPLICATION AND FINISHING :

The mortar shall be pressed into the raked out joints with a pointing trowel according to the type of

pointing required. Care shall be taken that mortar does not spread over the corner, edges and surface of

the masonry. The pointing lines shall be truly horizontal and vertical except where the joints are slanting

as in RR masonry. Lines of joints from different directions shall meet neatly at the junctions. The pointing

shall be finished with proper tool as follows :

1. Flush Pointing :The mortar shall be pressed into the joints and shall be finished off flush and level

with the edges of bricks/stones. The edges shall be neatly trimmed with a trowel and a straight edge.

2. Raised Pointing :Raised pointing shall project from the wall facing with its edges cut parallel so as to

have a uniformly raised band with about 6mm projection and 10mm width.

3. Sunk Pointing :The mortar shall be pressed into joints and the top of the horizontal joint shall then be

neatly pressed back about 3mm or as directed with the pointing tool.

CURING :

The pointing shall be kept wet for about 7 days and during this period it shall be protected from all

damages.

MEASUREMENTS :

Length and breadth shall be measured correct to a cm and area shall be calculated in square metres upto

two decimal places. The measurement of plaster shall be taken before the plastering is done. No

deductions shall be made or extra paid for openings less than 0.5 sqm. Openings more than 0.5 sqm

shall be deducted but additional measurements shall than 0.5 sqm shall be deducted but additional

measurements shall be taken for jambs, sills and soffits. Skirting of the wall shall not be measured (if the

skirting is of different finish)




TESTING OF BUILDING MATERIALS

The contractor shall carryout the following tests at his own expense and as directed by the Engg.-in-

charge / Architects. Engg.-in-charge / Architects reserves their right to ask the contractor to carry out any

further tests on any material which is being used in the project.

WATER: Suitability for construction/ concreting purposes as per IS 456-2000

Periodicity: One test at the beginning of the project and once in every change of source

SANDS

Tests to be conducted

a. Particle size - Lab

b. Silt content - Field

c. Bulking of sand-Field

d. Percentage of Deleterious material / Organic impurities - lab

Is code for material - IS-383-1970

IS code for testing - IS-2386 (Part I) to IS-2386 (Part VIII)

Periodicity of testing

Whenever there is a change in source of supply or as directed by the Engineer-in-Charge.

Remarks

1. Silt content should not exceed 8%.

2. For sand pad foundation no need of particle size distribution. Only silt & bulk content to be carried

out.

Sand (for plastering)


a) Particle size - Lab

b) Silt content - Field

c) Percentage of Deleterious /organic impurities - Lab.

IS code for material - IS-1542

IS code for testing - IS-1727

Periodicity of testing

Same as above, Test shall be repeated for Minimum qty. 500 sq. m of plastering.

Remarks

1. Silt content not to exceed 5%

2. Sand to be sieved in sieve size 4.75 mm




COARSE AGGREGATE


a. Percentage of Soft deleterious materials- Field (Visual)

b. Particle size distribution

c. Aggregate value :

1. Crushing - Lab

2. Impact - Lab

3. Abrasion - Lab (Only for Roads)

IS code for material - IS-383-1970

IS code for testing - IS-2386 (Part I) to IS 2386 (Part VIII)

Periodicity of Testing

Minimum 45 cum. Tests to be repeated for every 45 cum of coarse aggregate or part thereof.

Remarks

Percentage of soft deleterious materials. Usually visual inspection shall be carried out. If Engg.-in-Charge

/ Architects has doubts, the same may be tested in Lab.

CEMENT


a. fineness - Lab

b. Soundness - Lab

c. Setting Time - Lab

d. Compressive strength – Lab


Minimum qty. 20 MT, Tests to be repeated for every 50 MT or part thereof or change of supplier.

Remarks

Cement to be tested if supplied by the contractor. Cement to be tested if stored for more than 3 months.

CEMENT CONCRETE Tests to be conducted

a. Slump test - Field

b. Cube strength - Lab/field


a. Once for minimum 5 cum.

b. Minimum 15 cum of part thereof.




Remarks

Cube strength to be taken for both 7 days as well as 28 days. Cubes of critical members (decided by

Engg.-in-Charge) shall be tested at lab.

REINFORCEMENT STEEL


a. Free from defects - Field (Visual)

b. Weight - Lab

c. Size - Lab

d. Ultimate tensile stress - Lab

e. Yield stress - Lab

f. Elongation percentage - Lab

g. Bend Re-bend test - Lab

IS code for material

• IS-432 for mild steel

• IS-1786 for Tor steel

IS code for testing - IS-1608


Minimum qty. 10 MT, tests shall be repeated for every 10 MT of each size (dia) or part thereof.

Remarks

a. Steel shall be tested if supplied by contractor.

b. Steel shall be tested if stored in open yard for more than one year.

BRICKS


a. Compressive Test - Lab

b. Water absorption - Lab

c. Efflorescence - Lab

d. Percentage of Deleterious material - Lab.

e. Dimension test-Lab

IS code for material - IS-1077-1986

IS code for Testing - IS-3495 (Part I) to IS-3495 (Part III)





Minimum 20000 bricks but tests shall be repeated for every 40000 or part thereof depending on the

volume of work.

THEORITICAL CONSUMPTION OF CEMENT IN VARIOUS ITEMS OF WORK

ITEM / WORK UNIT CONSUMPTION / UNIT IN 50 KG BAGS

MORTARS 1:3 CUM 10.2 1:4 CUM 7.6 1:5 CUM 6.2 1:6 CUM 5.0

CONCRETE 1:1:2 CUM 12.2 1:1.5:3 CUM 8.0 1:2:4 CUM 6.4 1:3:6 CUM 4.4 1:4:8 CUM 3.4 BRICK MASONARY 1:4 CUM 1.8 1:5 CUM 1.56 1:6 CUM 1.24 HALF BRICK MASONARY 1:3 SQM 0.29 1:4 SQM 0.21 STONE MASONARY 1:6 CUM 1.7 PLASTERING - 12 MM THICK 1:6 SQM 0.072 1:5 SQM 0.084 1:4 SQM 0.102 PLASTERING - 20 MM THICK 1:3 SQM 0.23 1:4 SQM 0.17 For all other works, which are not covered in the above list, the actual cement consumed during the execution shall be recorded i.e., for water proofing works, etc.,




LIST OF APPROVED BRAND / MANUFACTURERS

Sl. No. MATERIAL BRAND / MANUFACTURER 1 Cement ACC, Birla, L & T, Gujarat Siddhi,Gujarat Ambuja, Rajashri. 2 Reinforcement steel SAIL, TISCO, RIN 3 Water proofing compound CICO, IMPERMO, ACCOPROOF, ROFFE, CHEMISOL 4 Plastic emulsion ICI Dulux, Berger, Asian, J & N, Goodlass nerolac

4 Synthetic enamel paint Berger, Asain, J&N, Goodlass nerolac. 6 Cement Paint Snowcem, Nitcocem,Terracem. 7 Ceramic tiles Kajaria, Johnson, Somani, Bell, Naveen. 8 Hardware for doors/ CIEF or Approved equivalent windows 9 Aluminium sections Jindal, INDAL. HINDALCO 10 Glazing Modi float, Asahi float 11 Kitchen sink Nirali, AMC, 12 Sanitary ware Parry, Hindustan, Neycer, 13 CP fittings Jaquar or equivalent 14 GI pipes Tata, Zenith or approved equivalent 15 GI Fittings R Brand Kirti or approved equivalent 16 CI pipes and fittings NECO 17 Gate valves Leader , Sant 18 Watermeter Capstan or approved equivalent 19 Flush doors Anchor, Kitply, Alpro 20 CI covers NECO 21 RCC hume pipe Indian Hume Pipe or approved equivalent 22 PVC pipes Finolex, Supreme, Garware




STANDARD

SPECIFICATION

FOR

WELDING




CONTENTS

1. GENERAL

2. WELDING REQUIREMENTS

3. WELDING PROCEDURE QUALIFICATION

4. WELDER’S QUALIFICATION

5. WELDER’S IDENTIFICATION CARD

6. WEATHER CONDITIONS

7. BASE MATERIALS

8. FILLER MATERIALS

9. WELDING PROCESS

10. PREPARATION OF PIECES TO BE WELDED

11. WELDING TECHNIQUE FOR ROOT PASS

12. JOINT COMPLETION




1. GENERAL This specification covers field and shop welding for carbon steel piping system. In particular, following types of joints are considered:

• Butt welds between pipes, flanges, bends, branch connection valves. etc. • Fillet welds for junction of slip on flanges; butt and socket weld fittings, reinforcing pads,

etc The following accepted standard and procedures shall be applicable:

• Standard for welding pipes and related facilities – ANSI – B 31.3. – latest edition. • Code of practice for manual for welding of mild steel – IS: 823 latest edition (for

structural work only) In case of any variation between the provisions of the codes and the specifications given below the later shall prevail. 2. WELDING REQUIREMENTS All welds joining two sections of pipe, a section of pipe to a fittings or fittings shall be performed employing qualified welding procedure and welders in accordance with Clauses 3 to 12 of this specification. 3. WELDING PROCEDURE QUALIFICATION Welding procedure qualifications for all piping except those under the purview of IBR, shall be as per the latest edition of Standard for welding pipelines and related facilities, ASME section IX. The contractor shall submit the welding procedure after receipt of work order. Owner inspector shall review, check and approve welding procedure after conducting such tests as are necessary. It shall be the responsibility of contractor to arrange and carry out such tests at his own costs. 4. WELDER’S QUALIFICATION Welder’s qualification for all piping except those coming under the purview of IBR, shall be in accordance with ASME Sec IX. Owner’s Inspector shall witness the test and certify the qualification of each welder. Welders approved by the owners’ Inspector only shall be employed. Contractor shall submit the welder qualification reports before the commencement of work. It shall be the responsibility of the Contractor to carry out the qualification test of the welders at his own cost at the job site all the tools, tackles and auxiliaries required for carrying out Welder’s test shall be supplied by contractor at his own cost. 5. WELDER’S IDENTIFICATION CARD The welder shall carry on his person identification card as per Exhibit C and shall produce it wherever demanded by Owner’s Inspector. It shall be the responsibility of the Contractor to issue the identification card after it is duly certified by Owners inspector. No welder shall be permitted to work without the possession of identification card. If a welder is found to perform a type of welding or in a position or on a material for which he is not qualified,




he shall be debarred from doing further work. All such welds shall be cut and redone by the contractor at his own cost. 6. WEATHER CONDITIONS If the welding is to be performed during rain or strong wind, suitable protection shall be provided for the parts to be welded and the welder. 7. BASE MATERIALS In general this specification shall be used in welding the carbon steel materials having a specified tensile strength of 60,000 psi or less. Backing rings, if required, shall be similar in chemical composition to the base material. 8. FILLER MATERIALS Electrodes: Electrodes used for welding shall conform to IS 814 and IS 815 latest editions. The electrodes to be used by the Contractor shall be approved by the Engineer in charge after conducting tests as per IS: 814 testing procedure. These tests shall be carried out by the contractor at his own cost. The contractor shall submit manufacturer’s certificates for each batch of electrodes supplied by him. Electrodes shall be stored in unopened original containers. They shall be stored adequately to prevent moisture loss or moisture absorption and shall be handled in such a manner so as to avoid the damage of coating. Electrodes when used shall be free of rust, oil, grease, earth or any other matter which could be harmful for the quality of welding. The electrodes used shall be suitably to the welding process and the base metal and the weld properties shall not be lower than those of base metal. 9. WELDING PROCESS Welding under this specification shall be done with the manual shielded metal arc process. Automatic or semi automatic welding shall be done only after the procedure and materials have been specifically approved by the Engineer in charge. The welding shall conform to the standard codes of welding practice. Welding of carbon steel in general shall be in accordance with IS: 823 - Code of practice for use of metal arc welding in mild steel (for structural work only). The welding of pipes shall conform to ANSI B 31.3 (latest edition) the compliance with this specification does not relieve fully or partially the contractor, responsible for piping fabrication and erection of his own responsibilities as well as on any contractual obligations.




10. PREPARATION OF PIECES TO BE WELDED End Preparation Preparation of ends to be welded will be preferably made by machining. However, preparation of the ends may be made by flame cutting, providing all grooves and irregularities are ground off and all the oxidation is removed.] Cleaning The ends to be welded shall be properly cleaned. All paint, oil, grease, rust and oxide in general shall be removed, as well as all earth, sand or any other material which could be harmful to the welding. Ends shall be totally dry when welded. No dirt or debris will be permitted in the pipeline. Prior to alignment, the inside of each joint shall be adequately swabbed, either by use of leather of canvas belt disc of proper diameter or other improved method. Alignment and Spacing Pieces to be welded shall be aligned and spaced in a suitable manner, so as to hold the ends during welding at a distance to ensure full penetration. Root opening shall not be more than as specified. Internal misalignment shall not exceed 1.5 mm. For pipe with thickness 4 mm or larger, the pieces to be butt welded shall be coupled by means of pipe couplers or by yokes or bridge “C” clamps. Owner’s inspector shall check and approve the joint fit up and alignment prior to the commencement of welding. 11. WELDING TECHNIQE FOR ROOT PASS For Butt Joints: The maximum electrode size shall be 3.25 mm or 1/8 (10 SWG) and the electrode holder shall be connected, having due regard for the polarity requirements of the electrode approved for the use for pipe in horizontal position. Upward technique shall be used with the recommended values of current. The root pass of butt joints, regardless of the technique used, shall be such as to achieve full penetration. However, projection of weld metal into the pipe bore shall not exceed more than 3 mm. Root grooves and defective restart of the welding shall be carefully avoided. The weld shall be back chipped from inside by grinding or chiselling and a sealing run shall be given. At each interruption of welding and on completion of each run, craters, weld irregularities and slag shall be removed by grinding or chiselling.




After the welding is started and until the joint has been completed, displacements, shocks, vibrations or stresses shall be avoided in order to prevent cracks or breaks in the weld. For fillet welds The maximum electrode size shall be 4 mm or (5/32) (8 SWG) On completion of the root pass, any visual defect or irregularities shall be ground off to avoid defects or irregularities in the new pass. 12. JOINT COMPLETION 12.1 Electrode size of more than 8 SWG (4mm or 5/32) shall not be allowed for filling of the weld. Upward technique shall generally be used for pipe in horizontal and vertical position. 12.2 At each interruption of welding, and after each run of welding is completed, chipping and slag removal shall be done. 12.3 When the welding is complete, but joints shall have a cover pass. It shall be slightly convey and fuse into the surface to the base metal in such a manner as to have a gradual notch free finish a good fusion at the joint edges. It shall not be chipped after completion. Welds shall have a regular appearance and shall be free from defects. 12.4 Welder number shall be stamped along side each weld. Whenever required by the Engineer in charge. 12.5 When welding is completed, the butt joints of piping regardless of welding methods used, shall have a weld reinforcement referred to the outside of the pipe, not more than 2 mm for pipes not thicker than 12.




GENERAL

SPECIFICATIONS

FOR FABRICATION OF

ABOVE GROUND

PIPELINE




WELDING SPECIFICATION FOR THE FABRICATION OF PIPING

(Above Ground Portion) 1. GENERAL

This specification shall be followed for the fabrication of all types of welded joints of MS / carbon steel and alloy steel piping system within the battery limits of the plant. The welded pipe joints shall include the following:

a) All pipe joints of the longitudinal and circumferential butt welded and socket welded types. Attachments of forgings, flanges and other supports to pipes. Welded manifold headers and other sub-assemblies Welded branch connections with or without reinforcing pads. Joints in welded / fabricated piping components. The attachments of smaller connections for vents, drain drips and other instrument tappings.

b) Any approval granted by the Engineer-in-charge or Owner’s inspector, shall not relieve the

Contractor of his responsibilities and guarantee. c) This specification shall not be applicable for welding of pipelines for transportation of liquid

petroleum and other similar products. 2. APPLICATION CODES &STANDARDS : All welding work, equipments for welding, heat treatment, other auxiliary functions and the

welding personnel shall meet the requirements of the latest editions of the following expected standards and procedures unless otherwise specified in the Welding specification chart and the technical notes attached. In the case of conflicting requirements, the requirements mentioned in welding specification chart / Technical Notes shall be applicable.

i) Chemical Plant and Petroleum Refinery Piping - ANSI:B31.3 ii) The Indian Boiler Regulations - I.B.R.

relevant code of fabrication shall be followed for the welding procedures.

i. Welding and Brazing Qualifications ASME Sec IX. ii. Non destructive examination ASME Sec. V iii. Material Specifications : welding rods, Electrodes and filler metals ASME Sec II

Part C

In the event of any differences due to the additional requirements mentioned in this specification, over and above those obligatory as per codes, this specification shall be binding.

3. BASE METAL:

3.1 In general, use of carbon steel, alloy steel and stainless steel are envisaged. The details of the material specifications are given in the welding specification chart.




3.2 The contractor shall provide the manufacturer’s test certificates for every heat of the materials supplied by him.

4. WELDING CONSUMABLES

4.1 The contractor shall provide, at his own expense, all the welding consumables necessary for the execution of the job such as electrodes, filler wires, oxygen, acetylene, argon etc, and these should bear the approval of the Engineer-in-charge.

4.2 The welding electrodes and filler wires supplied by the Contractor shall conform to the class specified in the welding specifications chart. The materials shall be of the make approved by the Engineer-in-charge.

4.3 Electrode qualification test records should be submitted as per the Exhibit –A (attached) in respect of the electrodes tested by the Contractor, for obtaining the approval of the engineer-in-charge.

4.4 The contractor shall submit batch test certificates, from the electrode manufacturers, giving details of physical and chemical tests carried out by them, for each batch of electrode to be used.

4.5 All electrodes shall be purchased in sealed containers and stores properly to prevent deterioration. The electrodes removed from the containers shall be kept in holding ovens at temperatures recommended by the electrode manufacturer. ‘Out of the oven time’ on electrodes, before they are consumed shall not exceed the limits recommended by the electrode manufacturer. The electrodes shall be handled with care to avoid any damage to the flux covering.

4.6 All low hydrogen tupe of electrodes shall be rebarked at 3500 C for 1 hour minimum and stored in ovens kept at 80-1000C before use. Recommendations of the electrode manufacturer shall be followed if available.

4.7 The electrodes, filler wires and flux used shall be free from rust, oil, grease, earth and other foreign matter which affect the quality of welding.

4.8 Tungsten electrodes used shall conform to SPA 5.12 specification. 5. SHIELDING & PURGING GAS :

5.1 Argon gas used in GTA welding for shielding purpose shall be 99.995% pure. The purity of the gas shall be certified by the manufacturer. The rate of flow shielding purpose shall be established through procedure qualification tests. Normally this rate may be 12-20 CFH.

5.2 Argon gas with a purity level of 99.995% shall be used for purging. 5.3 When GTAW process alone or a combination of GTAW processes is recommended

for the production of a particular joint, the purging shall be maintained during the root pass and for the first filling pass to minimize oxidation on the inner side of the pipe, unless otherwise specified in welding specification chart.

5.4 Initial purging shall be maintained for sufficient period of time so that at least 4-5 time the volume between the dams is displaced, in order to completely remove the entrapped air. In no case should the initial purging period be less than 10 minutes. High gas pressure should be avoided.

5.5 After initial purging, the flow of the backing gas should be reduced to a point where only a slight positive pressure prevails. For systems which have a small volume ( upto ½ cubic foot) to be purged, a gas flow rate of 6-CFH is usually adequate. Systems of larger volume may require higher flow rates and these should be established procedure qualification tests.

5.6 Gas backing (purging) is not required for socket type of welded joints.




5.7 Dams, used for conserving inert gas during purging, shall be removed after completion of the welding, and shall be accounted for. Wherever, removal of dams is not possible after welding, use of water soluble dams should be made.

6.0 EQUIPMENTS & ACCESSORIES : 6.1 The contractor should have the arrangement of sufficient number of welding and

cutting equipments, auxiliaries, and accessories of sufficient capacities so as to meet the target/ schedule.

6.2 All the equipments for performing the heat treatment, including transformers, thermo-couples, pyro-meters, automatic temperature recorders with suitable calibration arrangements etc. shall be provided by the Contractor at his own expense and these should bear the approval of the Engineer-in-charge.

6.3 Contractor shall make necessary arrangements at his own expense for providing the radiographic equipments, radiographic films, and all the equipments / materials required for carrying out the dye-penetrant/ magnetic particle test for satisfactory and time completion of the job.

6.4 Redoing of any work necessitated by faulty equipments or operaion used by the Contractor, will be done at his own expense.

7.0 WELDING PROCESSES : 7.1 Welding of various materials under this specification shall be carried out using one or

more of the following processes with the approval of the Engineer-in-charge. - Shielded Metal Arc Welding Process (SMAW) - Gas Tungsten Arc Welding Process (GTAW).

7.2 The welding processes to be employed are given in the welding specifications chart. Any deviation desired by the contractor shall be obtained through the express consent of the Engineer-in-charge.

7.3 Automatic and semi-automatic welding processes shall be employed only with the express approval of the Engineer-in-charge. The welding procedure adopted and consumables used shall be specifically approved.

7.4 A combination of different welding processes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-in-charge.

8.0 EDGE PREPARATION : 8.1 The edges to be welded shall be prepared to meet the joint design requirements by

any of the following methods recommended. a. Carbon Steel

Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides shall be removed by chipping or grinding.

b. Low Alloy Steels (containing upto 2 ½ chromium): Gas cutting, machining or grinding methods shall be used. After cutting, machining or grinding shall be carried out on the cut surface.

c. High alloy steels, cupro-nickel, nickel alloys, and aluminium alloys: Plasma cutting, machining or grinding methods shall be used. After plasma cutting, cut surfaces shall be machined or ground smooth.

8.2 Cleaning-




a. The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth and other foreign matter. The ends shall be complete dry before the welding commences.

b. On completion of each run, craters, welding irregularities, slag etc., shall be removed by grinding and chiseling. Wire brushes used for cleaning stainless steel joints shall have stainless steel wires and the grinding wheels used for grinding stainless steel shall be of suitable type. Separate grinding wheels and wire brushes should be used for carbon steels and stainless steel.

9.0 ALIGNMENT & SPACING : 9.1 Components to be welded shall be aligned and spaced as per the requirements laid

down in applicable code. Special care must be taken to ensure proper fitting and alignment when the welding is performed by GTAW process. Flame heating for adjustment and correction of end is not permitted unless specifically approved by the engineer-in-charge.

9.2 A wire spacer of suitable diameter may be used for maintaining the weld root

opening while tacking, but it must be removed after tack welding and before laying the root bead.

9.3 For pipes of wall thickness 5mm and above, the ends to be welded shall be secured in position with the aid of couplers; yokes and ‘C’ clamp to maintain perfect alignment. Yokes shall be detached after the completion of weld, without causing any surface irregularity. Any irregularity caused on the pipe surface must be suitably repaired to satisfaction of the engineer-in-charge.

9.4 Tack welds, for maintaining the alignment, of pipe joints shall be executed carefully

and shall be free from defects. Defective tack welds must be removed prior to the actual welding of the joints.

9.5 Tacks should be equally spaced. Minimum number of tacks shall be 2 tacks – for 2 ½ “ and smaller dia pipes 4 tacks - for 3” to 12” dia. pipes 6” tacks – for 14” and larger dia pipes 9.6 Engineer-in-charge shall check and approve the fit-up and alignment pipe joint prior

to the commencement of welding.

10.0 WEATHER CONDITIONS :

10.1 The parts being welded and the welding personnel should be adequately protected from rain and strong wings. In the absence of such a protection no welding shall be carried out.

10.2 During field welding using GTAW process, particular care shall be exercised to prevent any air current affecting the welding process.

11.0 WELDING TECHNIQUE:

11.1 Root Pass




• Root pass shall be made with electrodes/ filler wires recommended in the welding specification chart. For fillet welding root welding shall be done with consumables recommended for filler passes. The preferable size of the electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.25 mm (10 SWG)

• Upward technique shall be adopted for welding pipe held fixed with its axis horizontal.

• The root pass of butt joints should be executed so as to achieve full penetration with

complete fusion of the root edges. Weld projection inside the pipe shall not exceed 3 mm, wherever, ___ specified by the applicable code.

• Any deviation desired from the recommended welding technique and electrodes

indicated in the welding specification chart should be adopted only after obtaining express approval of the Engineer-in-charge.

• Welding shall be uninterrupted.

• While the welding is in progress care should be taken to avoid any klind of movement

of the components, shocks, vibrations and stresses to prevent occurrence of weld cracks.

• Peening shall not be used

11.2 Joint Completion

a) Joint shall be completed using the class of electrodes, recommended in the Welding Specification Chart. Size of the electrode shall not exceed 4 mm in diameter for stainless steel and alloy steels used for low temperature applications.

b) Two welds beads shall not be started at the same point in. c) Butt joints shall be completed with a cover layer that would affect good fusion at the

joint edges and a gradual notch free surface. d) Each weld joint should have a workman like finish. e) Weld identification work shall be stamped clearly at each joint just adjacent to the

weld. Metal stamping shall not be used as standard. Suitable paint shall be used on thin wall pipes for identification.

f) No painting shall be done until the weld joint has been approved.

11.3 Dissimilar welds

Where welds are to be produced between carbon steels and alloy steels, preheat and postweld Heat Treatment requirement shall be those specified for corresponding alloy steels and electrodes shall correspond to AWS E-7016/7018 type. For welds between two dissimilar Cr-Mo low alloy steels, preheat and post weld heat treatment shall be those specified for higher alloy steel and electrodes used shall correspond to those specified for steel of lower alloy content. For carbon steel or alloy steel to stainless welds, use of electrodes E-309 / E-310/ E NiCr Fe-2 shall be made. The welding procedure, electrodes/ filler wires to be used, approved by the Engineer-in-charge. 12. HEAT TREATMENT :

12.1 Preheating




a) No welding shall be performed without preheating the joint to 10º (50ºF) when the ambient temperature is 10º and below.

b) Preheating requirements for the various materials shall be as per the welding specification chart attaches.

c) Preheating shall be performed using resistance or induction heating methods. Preheating by gas burners, utilizing oxy-acetylene or oxy-propane gas mixtures, with neutral flame may also be carried when permitted by the Engineer-in-charge.

d) Preheating shall extend ununiformly to at least three times the thickness of the joint, but not less than 50 mm, on both sides of the weld.

e) Preheating temperature shall be maintained over the whole length of the joint during welding. Temperature indicating caryons of other temperature indicating devices shall be provided by the contractor to check the temperature.

12.2 Post Heating

In case of alloy steel materials such as Cr-Mc steels, if the Post We Heat Temperature is not performed immediately after welding, the weld joint and adjacent of pipe, at least 150mm on either side of weld, shall be uniformly heated to 300ºC. This temperature shall be maintained for 2 hours minimum, then wrapped in asbestos or insulating before allowing it to cool to room temperature, postweld Heat Treatment as specified in the Welding Specification Chart shall be carried out later on.

12.3 Postweld Heat Treatment

a) Post weld Heat Treatment, wherever required for joints between pipes, pipes and fittings, pipe body and supports shall be carried out as per the welding specification chart, applicable codes standards and the instructions of the Engineer-in-charge.

b) The contractor shall submit for the approval of the Engineer-in-charge, well before carrying out actual Heat Treatment, the details of the post weld Heat Treatment procedure as per Exhib B attached, that he proposes to adopt for each of the material assembly/ part involved.

c) Post weld Heat Treatment shall be done ina furnace or by using and electric resistance or induction heating equipment, as decided by the Engineer-in-charge.

d) While carrying out local post weld Heat Treatment, technique of application of heat must ensure uniform temperature attainment at all points of the portion being heat treated. Care shall be taken to ensure that width of heated band over which specified post weld Heat Treatment temperature attained is at least that specified in the relevant applicable standards/codes.

e) Throughout the cycle of heat treatment, the portion outside the heated band shall be suitably wrapped under insulation so as to avoid any harmful temperature gradient at the exposed surface of pipe. For this purpose temperature at the exposed surface of pipe should not be allowed to exceed 400ºC.

f) The temperature attained by the portion under heat treatment shall be recorded by means of thermocouple pyrometers. Adequate number of thermocouples should be attached to the pipe directly at equally spaced locations along the periphery of the pipe joint. The minimum number of thermocouples attached per joint shall be 1 upto 6” dia, 2 upto 10” dia and 3 for 12” dia and above. However, the Engineer-in-charge can increase the required minimum number of thermocouples to be attached if found necessary.

g) Automatic temperature recorders which have been suitably calibrated should be employed. The calibration chart of each record should be submitted to the Engineer-




in-charge prior to starting the Heat Treatment operations and his approval should be obtained.

h) Immediately on completion of the Heat Treatment, the post weld Heat Treatment charts/records along with the hardness test resulted on the weld joints, wherever required as per the Welding Specification chart, shall be submitted to Engineer-in-charge for his approval.

i) Each joint shall bear an identification number which shall be maintained in the piping sketch to be prepared by the Contractor. The joint identification number should appear on the corresponding post weld Heat Treatment charts. The chart containing the identification numbers and piping sketch shall be submitted to the Engineer-in-charge in suitable folders.

13. CLEANING OF THE WELD JOINT

All weld joints shall be free from adherent weld spatters slag, swarf, dirt or foreign matter. This can be achieved by brushing. For stainless steel, brushes with only stainless steel bristles should be used.

14. INSPECTION AND TESTING

14.1 General a) The owner’s inspector shall have free access to all concerned areas,

where the actual work is being performed. The contractor shall also afford the Owner’s Inspector all means and facilities necessary to carry out inspection.

b) The owner is entitled to depute his own inspector to the shop or field

where prefabrication and erection of pipe lines are being done with (but not limited to) the following objectives. i. To check the conformance to relevant standards and suitability of

various welding equipments and the welding performance. ii. To witness the welding procedure qualification iii. To witness the welder performance qualification iv. To check whether shop/field welding being executed is in

conformity with the relevant specifications and codes of practice followed in piping construction.

c) Contractor shall intimate sufficiently in advance the commencement of qualification tests, welding works and acceptance tests to enable the Owner’s inspector to be present to supervise them.

14.2 Welding Procedure Qualification Welding procedure qualification shall be carried out in accordance with the relevant requirement of ASME Sec. IX latest edition or other applicable codes and the job requirements. The contractor shall submit the latest welding procedure specifications in format as per Exhibit-C (attached) immediately after the receipt of the order. Owner’s inspector will review, check and approve the welding procedure submitted and shall release the procedure for qualification tests. The procedure qualification test shall be carried out by the Contractor at his own expense. A complete set of test results in format as per Exhibition attached shall be submitted to the owner’s




inspector for his approval immediately after completing the procedure qualification test and at least 2 weeks before the commencement of actual work. Standard tests as specified in the code shall be carried out in all cases. In addition to these tests, other tests like macro/micro examination, hardness tests, dye penetrant examination, charpy V-notch and U-notch impact test etc shall be carried out on specimens depending upon the ytpe of base matter operating conditions and requirements laid down in the detailed drawings and specifications. It shall be the responsibility of the Contractor to carry out all the tests required to the satisfaction of the Owner’s inspector. 14.3 Welder’s Qualificaton a) Welders shall be qualified in accordance with the ASME Section –IX or

other applicable codes. The owner’s inspector shall witness the test and certify the qualification of each welder. Separately only those welders who have been approved by the owner’s Inspector shall be employed for welding. Contractor shall submit the welder qualification test report in the format as per Exhibit –E (attached) and obtain express approval before commencement of the work. It shall be the responsibility of Contractor to carry out qualification tests of welders. For welding of the only those welders with IBR Certifications, qualified by Boiler Inspectorate, and acceptable to the local Boiler Inspector authority shall be employed.

b) The welders shall always have in their possession the identification card

as shown in Exhibit –G and shall produce it on demand by the Owner’s inspector. It shall be the responsibility of the Contractor to issue the identity cards after it has been duly certified by the Inspector.

c) No welder shall be submitted to work without the possession of identity card.

d) If the welder is found to perform a type of welding in a position for which

he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder at the expense of the Contractor.

14.4 Visual Inspection

Inspection of all welds shall be carried out as per the latest editions of the applicable codes and specifications. All finished welds shall be visually inspected for parallel and axial alignment of the work, excessive reinforcement, concavity of welds, shrinkages cracks, inadequate penetration, unrepaired burn-through, under cuts, dimentions of the weld, surface porosity and other surface defects. Undercutting adjacement to the completed weld shall not exceed the limits specified in the applicable standard/code. 14.5 Radiographic Examination a) The Radiographic Examination procedure to be adopted shall be submitted by

the Contractor as per Exhibit-P and shall be got approved by the Owner’s Inspector prior to employment. The radiographic technique and procedure




adopted shall conform to the requirements mentioned in Article 2, as well Article (SE94, SE 142) of ASME Sec V. The IQI sensitivity obtained shall be equal to or better than the requirements mentioned in table 262.2 and table 272 of Article 2 of ASME Sec V for single wall and double wall radiography respectively. Source side procedure/technique. The acceptable limits of defects and removal of defects shall be as per the relevant codes of fabrication. The contractor shall be responsible for carrying out Radiography, rectification of defects and re-radiography of welds repaired/rectified.

b) The extent of Radiography shall be as per specifications to be supplied to the

Contractor. For welds between dissimilar materials, the extent of Radiographic Examination for the materials being welded. Wherever random Radiography is called for in a particular piping class, the dissimilar materials weld joint shall essentially be included.

c) Radiographic Examination shall be carried out using X-Radiation, Gamma ray

sources may be used in place of X-ray with the approval of the Owner’s inspector.

d) The contractor shall fulfill all the statutory safety requirement while handling X-ray and Gamma-ray equipments.

e) The joints for Radiography shall be selected by the Owner’s Inspector and the

Radiography shall be performed in his presence. The contractor shall furnish all the radiographs to the owner’s Inspector immediately after processing. The details of the radiographs along with the joint identification number shall be duly entered in a register and signed by the Contractor and shall be submitted to the Owner’s Inspector for approval.

f) The contractor shall provide the Inspector all the necessary facilities at site

such as a dark room with controlled temperature, film viewer etc. to enable him to examine the radiographs.

g) Where random radiography is specified, the first weld of each welder shall be

completely radiographed. In the case of pipe of sizes 6” and below, the first two welds shall be completely radiographed.

h) For each weld performed by a welder, found unacceptable two additional

checks should be carried out on welds performed by the same welder. This operation is iterative and the procedure of radiographing two additional welds for each weld deemed unsatisfactory shall be continued till such time that the two consecutive welds of satisfactory are found for every defective weld.

14.6 Liquid Penetrant and Magnetic Particle Examination a) Whenever such tests are specified, the tests shall be carried out on joints

chosen by the Owner’s inspector, as per ASME Section V article 6 and 7 respectively.

b) For austentic stainless steels and other nonmagnetic materials, liquid (dye)

penetrant test shall be carried out. For carrying out this test, the materials shall be brought within a temperature limit of 15º to 50ºC.




14.7 Hardness Test

Hardness required for welds shall be as per the welding specification chart (attached). Hardness testing shall be carried out by Vickers Hardness Tester during welding procedure qualification. In all other cases hardness testing may be carried out by Vickers, Brinnel, or Poldy hardness tester as agreed by the Owner’s Inspector. 14.8 Proof Tests Hydrostatic and pneumatic tests shall be performed as per the requirement laid down by respective flushing and Testing specification/applicable codes to demonstrate the soundness of the welds. The tests shall be conducted after fulfilling the requirement of visual examinations radiography etc., and after the entire work has been certified by the Owner’s inspector to be fit for being subjected to such tests.

15.0 REPAIRS OF WELDS a) Defects ascertained, through the inspection methods, which are beyond acceptable

limits shall be removed after the joint is completely radiographed by the process of chipping and grinding.

b) When the entire joint is judged unacceptable, the welding shall be completely cut and the edges be suitably prepared as per required alignment tolerances. The rewelded joint shall again be examined following standard practices.

c) No repair shall be carried out without prior permission of the Owner’s inspector. d) Repairs and / or work of defective welds shall be done in time to avoid difficulties in

meeting the construction schedules. 16.0 DOCUMENTS TO SUBMITTED BY CONTRACTOR (4 COPIES EACH) a) Electrode and Welding Consumable Qualification Records as per Exhibit-A, for the

Welding Consumables tested and approved for the work. b) Batch test Certificates, for the Electrodes used, obtained from the Electrode

Manufacturer. c) Proposed Heat Treatment Procedure as per Exhibit-B d) Heat Treatment Charts e) Weld joint hardness test results f) Welding Procedure Specifications as per Exhibit-C immediately after receipt of the order. g) Welding Procedure Qualification records as per Exhibit-D h) Welder Performance Qualification records as per Exhibit-E immediately after conducting

welder qualification tests. i) Radiography Procedure as per Exhibit-F j) Radiographic test Report alongwith Radiographs. k) Pipeline Sketch (Isometric) giving all the details regarding the pipe specifications, welded

joints, joints radiographed, joints heat treated, electrodes used, welders identification number etc.




TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION INSPECTION CLASS : 1 INSPECTION CLASS

SERVICE

MATERIAL(NOTE 3)

P.NO. TEMP DEG. C.

PRESSURE CLASS B16.5 B16.34

APPLICABLE PIPING CLASS

TYPES OF EXAMINATION

TYPES OF WELD EXAMINATION

REMARK

1

2

3

4

5

6

7

8

9

10

11

12

13

14

I

CATEGORY ‘D‘

CARBON STEEL

1 0 TO186

150 UPTO10.55KG/CM2

A3A,A3Y, A) VISUAL

B) LP (NOTE4 )

S

AUSTENTIC S.S

8 29 TO 186

A3K

AIZ,MZ,A5Z HDPE 20 TO 50

CURPONICKEL

29 TO60




STANDARD

SPECIFICATION

FOR

TANK PADS




STANDARD SPECIFICATION FOR TANK PADS

SCOPE

The specification describes the technical requirements for the materials and construction of tank pads of murrum / Sand fill construction, materials and processes for providing anti corrosive layer and materials and processes for providing RCC Apron and RCC Toe Beam.

1.0 REFERENCE STANDARDS

IS:383 IS: 2720, PART-4,PART-7,PART-8 AND PART-14 IS:1498

2.0 SUB-GRADE PREPARATION

The surface of natural soil exposed at the bottom of excavated pit shall be thoroughly compacted by rolling or other means as directed by HPCL to obtain 95% of Standard Proctor Max. Lab dry density of the virgin soil.

3.0 TANK PAD CONSTRUCTION

The tank pad shall be constructed with murrum or sand or combination of murrum and sand pad.

3.1 MURRUM /SAND FILL It shall consist of coarse and granular murrum / sand containing not more than 20% cohesive

fines i.e., clay. The murrum / sand shall be 20mm and down size grading and shall be brought from approved quarries from outside plant premises. The Maximum dry density of material shall be not less than 1.80 grams/cc. The Plasticity Index shall be in the range of 7-18 (Medium Plastic).

The murrum / sand shall be spread in layers not exceeding 200mm loose depth over the area.

Each layer shall be uniform in density, quality of materials and moisture content before compaction. Each layer shall be copiously watered so that the required standard proctor MDD is attained and also the required mass of the compacted standard proctor sample is attained. However, puddles should be avoided.

Compaction of each layer shall be done by a vibratory roller. Only inaccessible reaches shall

be done manually. Each layer shall be uniformly compacted to obtain 95% of standard proctor maximum laboratory dry density of the material as per IS: 2720. If the material fails to achieve the required density, the layer shall be reworked so that the necessary compaction is achieved.

Further layers shall be placed only after the layer already laid has been compacted to the

required density. The finished surface should be dressed to required slope and grade. Excess material must be removed from compaction site.

3.2 PAYMENT Payment for murrum / sand filling shall be made on the basis of volume of fill, after placement and

compaction and achieving the grade and slope as per drawings. Any additional filling carried out or required as per site conditions/ specification requirements for attaining the MDD/OMC requirements on slopes, etc will be carried out by Contractor and same are deemed to be included in quoted rates. No payment will be made by HPCL for such additional filling which is to be subsequently stripped.

4.0 ANTI-CORROSIVE LAYER(75 MM COMPACTED THICKNESS)




4.1 Anti-corrosive layer shall consist of screened coarse sand mixed with 80/100 bitumen or

equivalent 8 to 10% by volume. 4.2 Materials

SAND Sand shall be clean, dry, coarse, hard, angular, and free from coatings of clay, dust and mix of

vegetable and organic matters and shall conform to IS: 383 Grade III.

BITUMEN Bitumen required shall be 80/100 grade or equivalent

4.3 Bitumen shall be heated to a temperature of 175 to 190 deg.C with 3% kerosene if required and

sand shall be mixed thoroughly with it in a mixing drum to give uniform mixture and shall be laid over the compacted surface of pad in line, grade and levels as shown in the drawings and as directed by HPCL. The area of pad to be provided with Anti-Corrosive layer shall be thoroughly cleaned of all dust and loose materials. On the clean surface, a tack coat at the rate of 1 kg/sq.m of hot bitumen shall be uniformly applied by sprayers. The applied binder shall be evenly brushed. Bitumen shall not be heated beyond the limits shown above. The layer shall be tamped to form a hard mass of uniform compacted thickness of 75mm as per drawings and specifications.

4.4 PAYMENT The payment shall be made on sq.m basis of the area of the layer laid on top of tank pads. The

quoted rate shall include cost of materials, transportation, mixing, laying, tamping, finishing, curing, etc.

5.0 RCC APRON Materials

5.1 Water Water used for all civil and structural works shall be clean and free from injurious amount of oil,

acids, alkalies, organic matters or other harmful substances which may be deleterious to Concrete or Steel. The pH value of water sample shall not be less than 6.

Tests on water samples shall be carried out in accordance with IS: 3025 and they shall fulfill all

the guidelines and requirements given in IS: 456-latest edition. Contractor shall collect water samples prior to start of Work. HPCL Engineer-in- Charge will

issue Covering letter for getting the same tested at a lab approved by HPCL. Based on the test results and after reviewing same with respect to IS Standards and acceptance thereof, HPCL Engineer-in –Charge may permit use in the works. In case there is any change in source of water, water samples shall be tested again.

Water shall be stored in tin Barrels, steel tanks or water tight reservoirs made with bricks/

stone or RCC. These storages shall be of sufficient capacity to meet the water requirement at any stage of construction.

Water for curing shall be of the same quality as used for concreting works. Borewell water may be permitted to be used if the same is found meeting the IS Standards

requirements. 5.2 Aggregates




Coarse and Fine aggregates for Civil and Structural works shall conform in all respects to IS: 383(Specification for coarse and fine aggregates from natural sources for concrete). Aggregates shall be obtained from an approved source known to produce the same satisfactorily. Aggregates shall consist of naturally occurring (crushed or uncrushed) stones and sand. These shall be chemically inert, hard, strong, durable, dense, clean and free from veins, adherent coatings, injurious amount of alkalies, vegetable matter and other deleterious substances such as iron pyrites, coal, lignite, mica, shale, sea shells, etc.

Source and type of aggregates shall be got approved by the Engineer-in-Charge prior to

procurement. Change in source and type of aggregates at a later stage may be permitted by the Engineer-in-Charge based on satisfactory lab test results of samples of changed sources (proposed). Design mix wherever warranted may be revised by the Contractor as per instructions of HPCL Engineer-in-Charge.

Aggregates which may chemically react with alkalies of cement or might cause corrosion of

reinforcement steel shall not be used. Tests for deleterious materials as per IS: 2386-Part II shall be carried out in an approved

laboratory and based on satisfactory test results, the aggregates may be accepted by HPCL Engineer-in-Charge.

The Concrete shall be placed by volume batching only and the mix design, wherever applicable

shall be carried out for volume batching only. Coarse and Fine aggregates shall be batched separately.

Whenever required by HPCL Engineer-in-Charge, the aggregates shall be sieved and /or washed

by the Contractor prior to use in the works without any extra cost to HPCL. Whenever a particular lot/ load of aggregates is rejected by HPCL Engineer, same shall be

forthwith removed by the Contractor from the Site. Coarse aggregates shall have a sp.gr. not less than 2.6( Saturated surface dry basis) and

retained on 4.75 mm IS Sieve. They may be supplied as single sized or graded. The grading shall be as per IS:383 or as required by the Mix design to obtain densest possible concrete. For this purpose, the Contractor shall submit at least three sets of mix design and test results each with different gradings of coarse aggregates, proposed to be used. HPCL engineer-in-Charge may permit All-in Aggregates conforming to IS: 383 requirements to be used in the works.

Fine aggregates (Sand) are the aggregate which pass through 4.75 mm IS Sieve but no more

than 10% pass through 150 micron IS Sieve. Fine aggregates conforming to grading requirements of Zones I, II and III of IS: 383 only shall be used for RCC Works.

The Contractor shall carry out all the tests including Mix design at his own expense at the

start of work as well as during any stage of construction as required by HPCL Engineer-in-Charge. Testing shall be carried out in HPCL approved laboratories. However, HPCL engineer-in-Charge may permit Silt Content test and Sieve Analysis to be conducted by the Contractor at Site and review and accept the same.

Storage of all types of aggregates shall be at Contractor’s own expense and risk. Proper drainage

shall be ensured by the Contractor around the storage heaps to avoid water logging. 5.3 Cement

Cement to be used for Civil and structural works shall be one of the following: Ordinary Portland Cement(OPC) 43 Grade as per IS: 8112 OPC 53 Grade as per IS: 12269




Portland slag Cement(PSC) as per IS: 455 Portland Pozzolana Cement-Fly ash based as per IS: 1489 (Part-1) Specific requirement of cement from among those listed above shall be decided by HPCL Engineer-in-Charge. The storage of cement at the site of work shall be at Contractor’s expense and risk.The cement shall be stored above ground in a suitable weather tight godown/ shed to prevent deterioration due to moisture. Any damage to cement quality due to improper storage or force majeure shall be borne by the Contractor only. Cement bags shall be stacked in such a manner that inspection by HPCL engineers is unobstructed. Approved Brands of Cement are Ultratech (Formerly L&T) cement, ACC, Birla Cements, Gujarat Ambuja, Ramco Cement and India Cements. However, prior to commencement of CC/RCC work, Contractor shall submit technical details of the Brand and type of cement proposed to be used in the works and samples shall be tested in HPCL approved laboratory for conformance to relevant IS Standards/ specifications. Only the approved type and brand shall be used by the Contractor in Design of Mix. Stack of cement bags shall not exceed 8 bags arranged one over another. The Contractor shall ensure that Cement is consumed on FIFO (First In First Out) Basis. The Contractor shall maintain a Cement Consumption Register in HPCL approved proforma containing details of Receipt of Cement and daily theoretical and actual consumption and daily balance. The Register shall be signed on a regular basis by the Contractor and HPCL Engineer. Each consignment of cement shall be tested by the Contractor at his own expense for conformance to relevant IS Standards’ requirements at HPCL approved laboratory. Additionally, each batch of cement shall be accompanied by the Manufacturer’s Test Certificate for conformance to relevant IS Standards’ requirements. Any lot / batch of cement rejected by HPCL Engineer due to any reason whatsoever shall be removed forthwith by the Contractor and details of the same shall be incorporated in the Cement register.

5.4 Reinforcement Steel Reinforcement steel shall be sourced from SAIL, TISCO or VIZAG STEEL/ RINL only.

Reinforcement steel shall be High Yield Strength Deformed (HYSD) bars conforming to IS: 1786. Each batch/Lot of reinforcement steel shall be accompanied by the relevant Batch test certificate issued by the relevant Manufacturer. After receipt at site, samples shall be drawn by HPCL engineer and same shall be tested by Contractor at his own expense for Yield strength, Ultimate tensile Strength, elongation, Bend & Rebend and chemical Composition. Laboratory testing shall be carried out by the Contractor @ One Full set of tests as mentioned above for every 40 MT quantity or part thereof.

Reinforcement Steel Consumption Register shall be maintained by the Contractor. This shall

contain details of Receipt of steel rods, details of daily consumption with bar bending schedules duly approved by HPCL Engineer. The Register shall be signed on a regular basis by HPCL engineer and Contractor.

The reinforcement shall normally be held in position by tying the bars at every intersection with 20

G Black annealed steel binding wires. The quoted rates for Reinforcement steel shall include the cost of supplying and tying these binding wires.




5.5 Curing shall be carried out for a minimum period of 7/10 days as per IS: 456 by the Contractor. Curing shall normally commence after completion of Final set of Concrete has completed. The Concrete shall be kept continuously wet during the entire duration of the day by using pitchers, gunny bags/ hay / hessain and dedicated manpower.




SPECIFICATIONS

FOR

TANK

FABRICATION




CONTENTS

1.0 SCOPE

2.0 REFERENCE

3.0 SELECTION OF MATERIALS

4.0 DRAWINGS AND DOCUMENTS

5.0 FABRICATION AND ERECTION

6.0 APPURTENANCES

7.0 INSPECTION AND TESTING

8.0 CALIBRATION

9.0 PAINTING

10.0 TOLERANCES

11.0 IDENTIFICATION, PACKING AND TRANSPORTATION

12.0 GUARANTEE




STANDARD SPECIFICATIONS FOR FABRICATION, ERECTION AND TESTING OF ABOVE GROUND STORAGE TANKS

1.0 SCOPE

1.1 This specification covers the minimum requirements for design, selection of materials, fabrication, erection, inspection, testing, fitting of other attachments and appurtenances, cleaning, calibration and painting of A/G CONE ROOF PETROLEUM PRODUCTS storage tanks and is intended to supplement the minimum requirements of the applicable codes.

1.2 Engineering drawings shall take precedence over specifications/standards.

1.3 The Review / approval of design by HPCL shall not absolve Contractor from the

responsibility of successful performance of Self supporting cone roof. It shall be the sole responsibility of the Contractor to ensure successful performance of Cone Roof design.

1.4 The Shell and Wind Girders have been designed by HPCL as per API

650(latest Edition). However the Contractor shall independently verify the above design and confirm his verification of adequacy of the steel plates (Free issue materials) to be supplied by HPCL immediately after award of the contract.

2.0 REFERENCE

2.1 Design Codes

The following codes in their latest edition shall form the basis for design, fabrication, inspection, testing and acceptance of storage tanks :

IS 803 (Latest edition) : Vertical Mild Steel Cylindrical welded Oil Storage tanks API Standard 650 : Welded steel tanks for oil storage. (Latest edition)

IS : 875 (Part 3) : Code of practice for design loads Wind Loads (other than earthquake) for

Building and structures. IS: 1893 : Criteria for earthquake resistant

design of Structures. API : 2000 : Venting atmospheric and low Pressure storage tanks. IS : 2007 : Method for calibration of Vertical




Oil Storage tanks. IS : 2008 : Method for computation of

Capacity tables for Vertical Oil Storage Tanks.

API : RP 2003 : Protection against ignitions arising out of static, lightning and stray currents. OISD-129 : Inspection of storage tanks. OISD-11 : Fire Protection facilities for Petroleum

depots and Terminals.

OISD-118 : Layouts for Oil & Gas installations. OISD-105 : Work permit system.

2.2 Materials Codes

Material to be used shall conform to: Indian Standard Specifications or ASTM standards as applicable.

2.3 Regulations National laws and regulations together with local bye-laws for the country or state wherever the tanks are to be erected must be compiled with.

3.0 SELECTION OF MATERIALS

3.1 All materials shall be as per applicable Codes.

3.2 Manhole necks, nozzle necks 350 mm NB and above may be fabricated from same plate material as used for shell.

3.3 Plate material used for ring flanges shall have a minimum UTS of 4200 Kg./cm2 .

For Flange thickness over 38 mm, plate material shall be boiler quality, fine-grained, killed, and normalized and impact tested as per the requirements of API Standard 650.

3.4 All clips and attachments shall be fabricated from carbon steel plates of weldable quality.

3.5 Gaskets for manholes and nozzles fitted with blind flanges shall conform to IS:

2712. Thickness of gasket shall be 1.5 mm for nozzles up to 450 mm NB and 3.0 mm for nozzles above 450 mm NB.




3.6 Stud Bolts and nuts for all nozzles fitted with blind flanges shall conform to ASTM A-307 Gr. B, A-193 Gr. B-7, or A-194 Gr. 2H. Bolts and nuts for all structural shall conform to IS: 1363.

3.7 Floating roof pipe supports and pipe sleeves shall be of carbon steel conforming

to ASTM A-53 /IS: 1978.

3.8 Following classifications of electrodes are recommended for welding. However, minimum requirements of applicable codes and appendices should be adhered to: 1. Low hydrogen electrodes namely, E-7018 shall be used for all manual

metal-arc welds of shall courses having a thickness of 12mm or more and for attachment of shell courses to bottom or annular plates.

2. High cellulose/rutile type electrodes namely, E-6013 as per the AWS classification SFA 5.1 is acceptable for all other welding.

ESAB, ADVANI OERLIKON & D&H SECHERON make electrodes /approved equivalent will only be permitted to be used in the works. Based on above, fabricator shall furnish samples of welding electrodes to Engineer-in-Charge for approval.

4.0 DRAWINGS AND DOCUMENTS 4.1 All individual tank data sheets shall have dimensional/design as well as material

specification. Final drawing with revisions, if any, shall be issued after award of contract/purchase order.

4.2 Contractor shall prepare all design calculations and fabrication drawings based on

the drawings issued on award of contract/purchase order and shall include the following:

1. Drawing index and Schedule of Submission.

2. Design calculation for cone roof wherever called for in the tender document

for HPCL review. 3. GA drawing covering all details shown in HPCL data sheets like list of

appurtenances, lists of standards and specifications, materials of construction, Tank design data, General Notes including details of test to be conducted on tank, specification and brand-name of welding electrodes to be used etc.

4. Plate layout, details of welding and bill of material for bottom sketch and

annular plates. 5. Development details of welding and Bill of Materials for shell including shell

extensions showing location of nozzles and stairway on developed shell.




6. Plate layout, details of welding and Bill of Material for Self supporting cone roof.

7. Details of spiral stairway and extension stairway to still well platform / LT

platform, landings and handrails with bill of materials. 8. Details of wind girders with Bill of Material. 9 Details of Roof Supporting Structure. 10 Details of shell nozzles and Inlet / Outlet Troughs and shell earthing cleats

with Bill of Material. 11 Details of still-wells, Gauge hatch and Bill of Material. 12 Details of mounting of Rim vents. 13 Details of Emergency Roof Drains. 14 Details of Foam Cooling System along with Foam makers and orifice plates. 15 Details of Fixed water spray cooling System along with along with structural

supports mounted atop secondary and tertiary wind girders and spray nozzles and orifice plates.

16 Plate cutting diagrams for all free issue material. 17 Plate reconciliation statement for free issue material. In case the contractor intends to make some modification for accommodating

his fabrication facilities or available materials, the same shall be submitted to HPCL for approval with supplementary design calculations. The approved modifications shall be incorporated in fabrication drawing and submitted to HPCL for approval.

4.3 Requisite number (as per the Time schedule of this Work/Tender document) of

prints of detailed fabrication drawings prepared by contractor shall be sent to HPCL for approval and one copy shall be returned to the contractor after comments/approval. No fabrication / erection shall be carried out without approved drawings.

5.0 FABRICATION AND ERECTION 5.1 Plates a) Plates edges shall preferably be sheared or machine cut as per code. All

machined parts shall be suitably protected before assembly. b) Gas cut plates shall be grounded to the satisfaction of the Engineer-in-

Charge.




c) All formed plates shall be match marked with paint on the concave side with numbers as shown on erection drawings.

5.2 Structural steel and Roof a] Structural steel fabrication shall be carried out to the required shapes for

making the structure. b] A pre-assembly of a sufficient part of roof structure may be called for by

the Engineer-in-Charge to assess the correct workmanship. 5.3 Bottom a] Bottom slope shall be as indicated in the respective tank drawings. b] Overlaps shall be properly cleaned with steel wire brush before welding. c] Single pass welds are not permitted.

d] Arrange the laps to shade the water towards the Bottom drain Nozzle/ shell.

e] Annular plates shall be assembled by butt welding with backing strips and

the sketch plates shall be lap welded to the Annular plates. f] Three plates lap joints shall be suitably joggled to a length of 150 mm

minimum to facilitate welding. Joggling shall be to the satisfaction of Engineer-in-Charge.

g] Contractor shall provide a Welding sequence which shall be adopted so

as to give minimum shrinkage and distortion and it shall be indicated on fabrication drawings. This shall be approved by Engineer-in-Charge.

5.4 Shell a) Shell erection shall be carried out by Jack – up method only. Calculations

for deployment of number of jacks and their placement / location shall be submitted by the Contractor for HPCL’s approval.

b) All vertical and horizontal shell joints shall be full penetration and full

fusion welds using any one of the edge preparations permitted by the Code. Single side butt welds are not permitted.

c] Top curb angle shall be lap or butt welded to the top course with flange

turned outside. d) Drain holes of 20 mm diameter suitably staggered shall be provided on

the horizontal plates of the stiffening ring (wind girder).




e) Hand railing shall be provided all around when stiffening ring is used as walkway for floating roof rank.

f) Curb angle and stiffening ring joints shall not coincide with the vertical

shell plate welds. g) Vertical joints should preferably be offset by at least 1000mm. h) First shell course plates shall be so arranged that the vertical joints clear

the annular ring welds or sketch plates welds by at least 300 mm. Vertical joints of the shell courses shall also clear the nozzle attachment welds or reinforcement pad welds as per code and applicable appendices.

i) Holes shall not be made in shell plates for erection purpose. j) Shell plate alignment shall be within the limits specified in code and as

approved by HPCL. 6.0 APPURTENANCES

6.1 Nozzles & Accessories

a) All appurtenances and accessories as shown in the respective tank drawings shall be supplied by the Contractor.

b) Manhole and nozzles with blind flanges shall be provided with gaskets

and bolting.

c) Nozzle and manholes may be shop assembled.

d) Flange faces shall be varnished and protected by wooden discs using at least three bolts.

e) All nozzles and accessories shall be prefabricated and attached to the

shell plate. The prefabricated assembly shall be stress relieved prior to installation, wherever required as per code and applicable appendices.

6.2 Stairways, Roof Access and Handrailing.

Each tank shall be provided with stairway and roof access. Handrailing if not indicated otherwise on tank drawings shall be provided all around.

6.3 Settling Marker:

Marker shall be provided on the shell, 500mm from the bottom to check tank settlement. Size shall be 50x50x5mm angle and 100mm long. The distance between setting market is approximately 5 meter. (Minimum 4 numbers).

Shell settlement measurement shall be made after tank erection, prior to hydro testing and during water filling.




While taking measurement on settling markers, rim space (distance between shell and outer rim) shall also be measured at location corresponding to settling markers for floating roof tanks.

Bottom internal measurements shall be made after hydro testing; such measurement shall be made at all pipe support location. Additional measurements shall be made in annular plate region at 5 meter intervals around the tank shell.

7.0 INSPECTION AND TESTING

Inspection shall be co-coordinated by Engineer-in-Charge at all stages.

7.1 Inspection

a) All tanks shall be offered for inspection at all stages as desired by Engineer-in-Charge.

b) HPCL’S representatives shall have free access to the entire contractor’s

as well as to worksite.

c) The contractor shall provided all facilities, such as access ladder, lighting, tools and tackles, instruments etc. and personnel to inspectors, for proper execution of their inspection.

d) All the inspection shall be carried out in accordance with the relevant

codes and requirements of drawings and specifications. e) Approval of the HPCL’S Engineer-in-Charge shall in no way relieve the

contractor of his responsibilities for proper execution of work.

7.1.2 Welding Procedure a) Welding procedure qualification shall be carried out as per ASME

Boiler and Pressure vessel Code Section IX.

b) No welding shall be undertaken without approval of the welding procedure and welder qualification test by the Engineer-in-charge.

7.1.3 Radiography and Inspection of Welds

a) All welds shall be inspected and tested as per Section 6.1 of API 650, Tenth edition and this specification.

b) All long seams of fabricated nozzles shall be fully radio graphed.

c) Weld areas to be radio graphed shall be designated by the Engineer-in-

charge.




d) Radiographs shall be taken as soon as welding of the Joint is completed. If repairs are required, these shall be carried out before starting other welds. New radiography examination of such repairs shall also be carried out by the Contractor at his own cost.

e) Radiograph film length shall be 250 mm min. except if the weld is less

than 250 mm long. In such cases, film length shall be full length of weld.

f) Radiographic film shall be of approved quality.

g) The radiography films and reports shall be reviewed and approved by a HPCL approved Third Party Agency. The quoted rates are deemed to include same.

7.1.4 Liquid penetrant examination:

Wherever specified in drawing/code, liquid penetrant examination shall be carried out as per specifications and codes. Additionally, all Horizontal and vertical Shell joints including extensions above the Maximum Design Liquid Level shall be Dye Penetrant Tested after Root Run and necessary repairs carried out.

7.2 Testing All equipment required for testing shall be supplied by the contractor. Opening other than those used for hydrostatic test or any other test shall be closed by plugs and blind flanges supplied by the contractors.

7.2.1 Bottom test

a) A detailed description of the proposed test method shall be first submitted for approval to the Engineer-in-Charge.

b) Vacuum box testing shall be carried out for detection of leaks in the

bottom.

c) The weld joints under the shell periphery shall be tested before erection and welding of first shell course.

d) Contractor shall test the tank bottom for the entire weld length in the

presence of the Engineer-in-Charge and test reports shall be issued accordingly.

7.2.2 Shell Test

a) Bottom to shell joints shall be tested as follows: i) Inner fillet weld shall be inspected and tested prior to welding the

outside fillet weld. Leak test shall be performed with penetrating oil after removal of slag. Oil shall be removed before, welding the outer fillet.

ii) Examination for inner fillet to detect cracks shall be performed

using either the liquid penetrant method.




b) All welded lugs and brackets used for erection purpose shall be carefully removed from inside and outside surface of the tank to the satisfaction of the Engineer-in-Charge.

c) The shell joints above the Design Liquid level and not subjected to

Hydrotest shall be radio graphed in accordance with API and all such joints shall be Dye penetrant tested for entire length after Root run.

d) Contractor shall perform the hydrostatic test in the presence of Engineer-

in-Charge on each tank after complete erection. Any defects observed during the test shall be repaired by the contractor. No Hot work shall be permitted after Hydrotest.

e) Filling of the tank may be restricted by HPCL Engineer-in-Charge for

preloading of foundation and hydrostatic test may be extended over a period of 4 weeks or more to ensure proper settlement of the tanks.

f) On completion of tank ad after cleaning, the tank shall be filled with water

as follows, unless otherwise specified in the tender documents. Filling shall be in 4 stages - 25%, 50%, 75% and 100%. After each stage

a load stabilization period shall be observed: - 24 hrs between each stage for tanks with a capacity under 10,000 cum. Filling rate shall not exceed 1 metre per day till 50% of the tank capacity

and therafter 0.75 m per day. If the settlement reading after 24 hours of filling exceeds 2 mm, the tank may be observed for another 24 hours to ensure that the settlement comes to a halt. Further filling will be carried out only after ascertaining that there is no settlement of the tank at this stage.

g) When the tank is full all the weld joints shall be hammered by the

Contractor in the presence of Engineer-in-Charge. In case of any defect it shall be repaired and retested by the Contractor as per instructions of Engineer-in-charge.

h) Tank shall be emptied at a maximum water level variation rate of 5

metres per day or as per instructions of Engineer-in-Charge.

i) All weld repairs shall be done with water level minimum 300 mm below the joint being repaired.

7.2.3 Nozzle Reinforcing Plates

Nozzle reinforcing plates shall be pneumatically tested at 1.05 kg/cm2g with soap solution. This test shall be carried out before filling the tank for hydrostatic testing.

8.0 CALIBRATION

Strapping and Calibration of all tanks shall be done in accordance with IS:2007 & 2008 (Latest editions).




9.0 PAINTING For details of primer and painting, Painting specification shall be referred to.

10.0 IDENTIFICATION, PACKING AND TRANSPORTATION

11.1 Identification

Each plate and structural member shall be clearly marked with the specification number, drawing number and assembly number.

11.2 Packing and Transportation a. All plates shall be transported in tractor or trailor and shall not be

dragged. b. All rolled shell plates shall be packed properly to retain the shape and

shall be handled carefully to avoid damage during transit. c. Contractor shall be responsible for transportation of material fabricated in

his workshop or worksite.

12.0 GUARANTEE Guarantee, if not covered by the General Conditions of contract, shall be as following 12.1 The entire Work shall be guaranteed in accordance with conditions given in the

“General terms and Conditions of Contract” 12.2 Any part of tank found detective within 12 months from the date of Completion of

work as per Completion Certificate and not having been subjected to faulty operations or incorrect service conditions shall be promptly replaced/repaired and reassembled by the contractor at his own cost, failing which owner has the right to get the same replaced/repaired by others and charge the cost incurred to the contractor.

SPECIFICATION FOR PRESSURE RELIEF VENTS MATERIAL OF CONSTRUCTION BODY - ALUMINIUM PALLET - ALUMINIUM PALLET SEAT - ALUMINIUM SCREEN - ALUMINIUM SCREEN MESN - BRASS TOP COVER - ALUMINIUM BOLTS AND - ZINC PLATED STEEL HARDWARE CONSTRUCTION TYPE - DEAD WEIGHT TYPE NATURE OF SERVICE - PRESSURE RELIEF BASE FLANGE - 150 NB WITH BAYS AS PER ANSTUB 16.5 PRESSURE SETTING - 75MM WATER GAUGE CONFORMING TO CODE - API 2000




STANDARD

INSPECTION

TEST PLAN

FOR

TANK FABRICATION �




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STANDARD

SPECIFICATION

FOR

SHOP AND

FIELD PAINTING




TECHNICAL SPECIFICATIONS FOR COPPER SLAG BLASTING AND PAINTING OF ABOVE GROUND TANKS

1.0 SCOPE This specifications cover the minimum requirements of all material, paint, equipment,

consumables, requisite scaffolding, spray equipment, Compressors, applicators, brushes, utilities, application including all labour, supervision, inspection and tests of performance of all operations and incidentals necessary for painting of vertical storage tanks, steel structures as per detailed specifications given below.

2.0 SURFACE PREPARATION Surface preparation of the external and internal surface of the tank shall be done by

copper slag Blasting as per Attachment-1. 3.0 PAINTS: All primer/paints shall be strictly in accordance with those given in the tender

specifications for painting & general specifications for painting (Attachment-II) and no deviations shall be accepted.

4.0 SCAFFOLDING Scaffolding has to be arranged by the contractor. Material has to be erected as per safe

methods. Ropes and guy wires shall be used for tying etc. The scaffolding shall be of good material and shall not endanger the painter/blaster. Scaffolding shall be sufficiently away from the tank shell so as to enable the painter/blaster to work with ease. It shall have a screen to avoid blasting abrasive flying onto the adjacent existing product tanks there by affecting the quality of the product. It is the responsibility of the Contractor to take all the necessary safety precautions like providing safety belts to all labour working on the heights and any other safety requirements which is mandatory to complete the job safely. HPCL is not responsible for any accidents to labour due to non-compliance of safety precautions.

5.0 Reference Standards: IS:5 , IS: 101 and ASTM Satandards 6.0 APPROVED MAKES OF PAINTS/PRIMER 1. M/s Berger Paints 2. M/s Asian Paints 3. M/s Goodlass Nerolac 4. M/s Jenson & Nicholson 5. M/s Shalimar Paints




ATTACHMENT-I SPECIFICATIONS FOR COPPER SLAG BLASTING :

1) The surface shall be cleaned of all dust and heavier layers of rust by copper slag blasting the entire internal surface to photographic standard SIS: 055900-1967.

2) The consumption rate of copper slag is 1.6 Kg/Sqm of the blasted area. This has to be

ensured strictly. 3) All tools, equipments, base material, hand and power tools for cleaning, including

scaffolding material, copper slag blasting equipment, air compressor etc. shall be arranged by the contractor at site in sufficient quantity.

4) The compressor used shall be of size enough to produce displacement of 5.6 to 7.0

Cum/Min of air at a pressure of 7 Kg/sqcm. Standard blasting equipment, hoppers, hoses nozzles and attachments shall be used to obtain best test results and to maintain safety standards. The rate of cleaning shall be about 15 sq.mt. per hour at a pressure of 7 kg/sq.cm.

5) The abrasive used shall be of the physical properties as mentioned below and shall be

free from oil, loan and mud etc.

6) The blast cleaned surface shall be blasted with dry compressed air before applying primer. This should be done even if the surface appears very clean and white in colour. The white colour may be due to deposition of silicon and reflection of light on the surface.

7) Proper earthing and bonding arrangements shall be made to prevent any damage by

sparks produced by static electricity. Bonding shall be done between tank and blast nozzles and hopper and air compressor also. The bonding conductor should not be less than 16 SWG single strand copper cable.

8) The time gap between blast cleaning and application of primer shall not be more than

THREE hours. Blast cleaning work shall, commence from top to bottom. 9) The blast cleaning operation shall be carried out keeping the nozzle at an angle of 30

degree to the vertical in order to prevent rebounding abrasive from showing down the abrasives emerging from nozzle and from under cutting the material to be removed.

10) A blast cleaning, the percentage of bare metal obtained shall be between 95% to 100%

of each of sq.cm.of the blasted area corresponding to photographic visual standards of SA 2 ½ of the Swedish standard referred above. (Pictora) surface preparation standards for painting steel surfaces).




11) Arrangements for inspection of various stages of the job shall be made available by the Contractor so that the entire Copper Slag blasted area is available for inspection. Any defective work noticed shall be immediately rectified and even reblasting shall be done if necessary.

12) Physical properties of Copper Slag: a) Colour : Black b) Grain Shape : Granulated, Angular multifaceted c) Hardness : 5 to 7 Moh’s scale d) Sp. Gravity : 3.2 to 3.7 e) Bulk Density : 1.87 kg/ltr. f) Moisture Content : less than 1 %

13) Sieve Analysis of Copper Slag Sieve Size (mm) Range -4.0 to + 3.0 2 to 4 -3 to +2.36 3 to 12 -2.36 to +1 40 to 55 -1 to +0.5 15 to 30 -0.5 to + 0.212 6 to 12 -0.212 below 0.2 to 1.0




ATTACHMENT-II

SPECIFICATIONS FOR PAINTING PRODUCT TANKS 1. Staircase, railing, steps, landing platforms shall be painted with black as

Specified by the site-in-charge. 2. All the tank appurtenances viz. delivery, receipt water drain off etc. will be identified

witn 4” long x 1.5” thick size lettering. The tank No., product, capacity in litres, size etc. will be identified using approved shade.

3. The water pipeline shall be painted signal red and foam lines yellow of Berger enamel

or equivalent as approved by HPCL. 4. When ever necessary, the paints may be tested according to IS specifications (latest

edition) for various chemical properties like consistency, spreading rate, time colour fasteners to light hardness, flexibility, adhesion, water resistance etc. at approved laboratory and as per the directions of the site engineer regarding the frequency of the test etc. Even if the party provides manufacturing test certificates of each batch showing all the above details, the Engineer in charge may advise the party get the paints test at his discretion.

5. The contractor shall adhere to paint manufacturers instruction strictly and all coats shall be of uniform thickness as specified. 6. All paints shall be of Asian / Berger/Shalimar/Goodlass Nerolac/Jenson & Nicholson

protective coatings make only. However, final discretion to use a particular brand of paints shall remain with HPCL depending upon performance, past experience and availability of the same.

7. The overall dry film thickness shall be minimum as specified in sequence of painting.

Contractor shall arrange necessary instrument (Elcometer) to measure the film thickness at various stages of painting. If the contractor fails to provide the elcometer, HPCL, at their own discretion may procure the same at the contractor’s risk and expense so as to expedite the job.

8. PRECAUTION AGAINST FIRE

Paints and thinners leave vapors which are inflammable; hence, adequate precautions shall be taken in the form of screens covers etc against fire while painting, mixing of paint in work is in progress.

9. DRYING TIME




The time gap of 24 hours for each coat of paint is the minimum and if any deviation becomes necessary due to any reason, paint manufacturers shall be consulted and their instructions followed only with the approval of the site-in-charge.

10. USE OF THINNER PAINTS

The addition of thinners shall be limited strictly to the paint manufacturer’s instructions. Each coat of primer and finishing coats shall be applied only after ensuring that the paint is free from dew or moisture and the surface is hard dry and free from dust.

11. APPLICATION OF PAINT BY AIR LESS SPRAY OR BRUSH

The contractor shall engage only skilled workmen for painting work. The brushes used shall be of best quality suitable for painting. The paint brush shall not be dipped deep into the paint as the bristles get overloaded and the heels gets filled up with paint and thereby loses flexibility. The brushes shall be dipped to only ¾ of the total length of the bristles. After the brush is initially dipped, the end shall be wiped against the walls of the painting. The brush shall be held at an angle of 45 degree to the vertical surface and several light strokes applied in the area to be painted so as to first transfer the paint on both turned 180 degrees in order to ensure that the paint on both the faces of the bristles is utilized completely. The paint is then to be spread with gentle pressure so as to be ensured that the ends and not the sides of the bristles come into contact with the surface during painting. The paint shall be applied first using vertical strokes until the surface is covered and then brushed crosswise for complete coverage with light strokes so as to smooth out laps and brush marks and finally laid off with vertical strokes.

12. During painting, every time after the paint has been worked out of the brush bristles

or after the brush is unloaded, the bristles of the brush (which are drawn together due to high surface tension of the small quantity of paint left in between the bristles) shall be opened up by stroking the brush against a portion of the unpainted surface with the end of the bristles held at right angles to the surface so that the bristles thereafter will collect the correct amount of paint when dipped again into the container.

13. A new bristle brush shall be properly conditioned by suspending it in raw linseed oil for

a period of 24 hours. The oil soaks into the bristles which make it further impervious to paint pigments. Before use, the linseed oil shall be removed from the brush by washing it in a thinner compatible with the paint and subsequently used. After each day’s work the brush shall be cleaned in mineral turpentine oil or any other thinner compatible with paint to remove all paint and pigments from the bristles and the heel of the brush. If the brushes are to be re-used the next day, they shall be hung in a thinner or linseed oil in a container. The brushes shall not be allowed to stand on bristles.

14. GENERAL INSTRUCTIONS

Painting shall follow immediately after satisfactory shot blasting/manual cleaning.




15. No painting shall be carried out when there is a danger of dew or moisture or high

humid conditions on the surface to be painted. 16. Tools used shall be clean and not worn out. 17. The paint in drum shall be mixed thoroughly and proper mixing shall be done in case

of two pack systems as per manufacturer’s specifications before application. The drum shall be inspected for the correct grade and to see that no sediments is left in it.

18. In case paint is thickened because of evaporation of solvents, its viscosity shall

be adjusted as recommended by the paint manufacturer. 19. Each coat shall be inspected and allowed sufficient drying time to make the surface

hard dry but not excessive before applying the next coat. Manufacturer’s specifications for drying time shall be adhered to strictly.

20. Each individual coat shall be properly applied and shall be free from dust

etc. 21. BASIS OF MEASUREMENT AND PAYMENT As given in job schedule. 22. INSPECTION AND APPROVAL OF SURFACE 22.1 All painting materials including primers and thinners brought to site by the Contractor for

application shall be directly procured from Approved manufacturers as per specifications and shall be accompanied by Manufacturer Test Certificates.

22.2 HPCL may call for tests for the primers and paints including verification of batch wise tests for physical and chemical analysis. The Contractor shall carry out the same at his own cost and provide the results to HPCL.

22.3 The painting work shall be subjected to inspection by HPCL at all times. Stages of

inspection are as follows: 1) Surface preparation 2) Primer application 3) Each coat of paint All records of inspection shall be maintained in Registers and jointly signed by HPCL and Contractor. Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the satisfaction of HPCL before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, Contractor shall be fully responsible for making good any defects found during Final inspection or during the




Defect Liability period. DFT shall be checked and wherever shot same shall be made up with additional coats.

22.4 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats in consultation with manufacturer.

22.5 Calibrated Digital Elcometers, surface profile gauges and any other inspection

instrument required by HPCL shall be provided by the contractor at site. 22.6 The contractor shall arrange expert technical support at site by paint Manufacturer who

will cross verify independently regarding surface preparation and DFT and quality and provide a report to HPCL.

23. DOCUMENTATION:

1. A written quality Plan with procedure for qualification trials and for actual work. 2. Daily progress Report with details of humidity, surface preparation, surface

profile, Dry film thickness particulars of applications, number of coats applied, type of materials used, methodology-Air or Airless or Brush, progress of work vs programme.

3. Code and Batch numbers of primers and paint materials used. 4. Type of testing equipments and their calibration. 5. Elcometer readings for the various components jointly recorded with HPCL. 6. Paint consumption statement along with the Theoretical consumption

requirements.

24.0 HPCL LOGO AND LETTERING HPCL will provide their LOGO with sizing, Flow, coloring and same is to be provided to

the Tanks. HPCL will also convey to the Contractor in writing details of the lettering for product and

tank details along with the desired color-coding and same has to be arranged by the Contractor.

The DFT measurements shall be taken after each coat as following- TANK SHELL : On each plate of strake at least 5 readings. ROOF : On each plate of strake at least 5 readings. STRUCTURES : As per the discretion of HPCL Engineer PIPELINES : As per the discretion of HPCL Engineer VALVES : As per the discretion of HPCL Engineer.




The DFT for particular surface / pipeline length / structural / pipeline fittings / tank appurtenances would be calculated by taking the average of readings as per the sole discretion of HPCL Engineer. If during inspection, DFT specified is not found on painted surface, the contractor shall provide additional coat to make up the deficit in DFT, at no extra cost. 25.0 COLOUR SCHEME FOR STORAGE TANKS

PRODUCT ROOF / SHELL IS NO. BOTTOM BAND IS NO. ATF As per HPCL-EIC As per HPCL-EIC

Note: The colour scheme for the Tank will be advised by HPCL-EIC. 26.0 PRIMERS AND FINISH COATS DESIGNATIONS

PRIMERS P-1 : ZINC PHOSPHATE PRIMER P-2 : COAL TAR EPOXY FINSIH COATS/ PAINTS F-1 : SYNTHETIC ENAMEL COATING

PAINTING FOR, CONE ROOF AND FIREWATER TANKS: EXTERNAL

SL. NO.

COMPONENT SURFACE PREPARATION

PAINT SYSTEM TOTAL DFT IN MICRONS FIELD

PRIMER FINISH PAINT

1 Soil side of bottom plates

SA 2 1/2 1 COAT OF P2 @ 100 MICRONS DFT/ COAT

1 COAT OF P2 @ 100 MICRONS DFT/ COAT

Total=200 microns

2 External shell, wind girders, WG supports, associated structural, roof supports above roof, spiral stairway incldg. Gratings, chequered plates, kerb angle, hatches, covers and roof top

SA 2 1/2 2 COATS OF P-1 @ 25 MICRONS DFT/ COAT (ie.50 MICRONS)

2 COATS OF F-1 @ 25 MICRONS DFT/COAT(APPRVD SHADE (ie.50 MICRONS)

100 MICRONS)

3 Internal Tank Bottom and All Shell Course, Internal roof surface, roof supporting structures, supports, guage well pipes, &

SA 2 1/2 One Coat of 75 Micron Epilux FRX Anti Corrosive primer of Berger or equivalent

2 Coats of 100 Microns each with Epilux 78 HB TL of Berger or Equivalent Make

275 MICRONS




all fittings inside the tank

Make

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP FINISH COAT




TECHNICAL SPECIFICATIONS FOR SAND BLASTING AND PAINTING OF PIPELINES

1.0 SCOPE This specifications cover the minimum requirements of all material, paint, equipment,

consumables, requisite scaffolding, spray equipment, Compressors, applicators, brushes, utilities, application including all labour, supervision, inspection and tests of performance of all operations and incidentals necessary for painting of vertical storage tanks, steel structures and pipelines as per detailed specifications given below.

2.0 SURFACE PREPARATION Surface preparation of the PIPELINE shall be done by SAND Blasting. 3.0 PAINTS: All primer/paints shall be strictly in accordance with those given in the tender

specifications for painting & general specifications for painting and no deviations shall be accepted.

4.0 SCAFFOLDING Scaffolding has to be arranged by the contractor wherever required. Material has to be

erected as per safe methods. Ropes and guy wires shall be used for tying etc. The scaffolding shall be of good material and shall not endanger the painter/blaster. Scaffolding shall be sufficiently away from the surfaces to be blasted so as to enable the painter/blaster to work with ease. It shall have a screen to avoid blasting abrasive flying onto the adjacent existing product tanks there by affecting the quality of the product. It is the responsibility of the Contractor to take all the necessary safety precautions like providing safety belts to all labour working on the heights and any other safety requirements which is mandatory to complete the job safely. HPCL is not responsible for any accidents to labour due to non-compliance of safety precautions.

5.0 Reference Standards: IS:5 , IS: 101 and ASTM Standards 6.0 APPROVED MAKES OF PAINTS / PRIMER 1. M/s Berger Paints 2. M/s Asian Paints 3. M/s Goodlass Nerolac 4. M/s Jenson & Nicholson 5. M/s Shalimar Paints

SPECIFICATIONS FOR SAND BLASTING :

1. The surface shall be cleaned of all dust and heavier layers of rust by sand blasting the entire internal surface to photographic SIS:055900-1967.




2. All tools, equipments, base material, hand and power tools for cleaning, including scaffolding material, sand blasting equipment, air compressor etc. shall be arranged by the contractor at site in sufficient quantity.

3. The compressor used shall be of size enough to produce displacement of 5.6 to 7.0 Cum/Min of air at a pressure of 7 Kg/sqcm. Standard blasting equipment, hoppers, hoses nozzles and attachments shall be used to obtain best test results and to maintain safety standards. The rate of cleaning shall be about 15 sq.mt.per hour at a pressure of 7 kg/sq.cm.

4. The abrasive used shall be hard, sharp river silicon (sand) of max. particle size not larger than 1.00 mm, 15 seaves specifications no. IS: 400-1962 (for test seaves) and shall be free from loam and mud, for blast cleaning of small inaccessible spots, special care shall be taken.

5. The blast-cleaned surface shall be blasted with dry compressed air before applying primer. This should be done even if the surface appears very clean and white in colour. The white colour may be due to deposition of silicon and reflection of light on the surface.

6. Proper earthing and bonding arrangements shall be made to prevent any damage by sparks produced by static electricity. Bonding shall be done between pipeline and blast nozzles and hopper and air compressor also. The bonding conductor should not be less than 16 SWG single strand copper cable.

7. The time gap between blast cleaning and application of primer shall not be more than THREE hours.

8. The blast cleaning operation shall be carried out keeping the nozzle at an angle of 30 degree to the vertical in order to prevent rebounding abrasive from showing down the abrasives emerging from nozzle and from under cutting the material to be removed.

9. A blast cleaning, the percentage of bare metal obtained shall be between 95% to 100% of each of sq.cm.of the blasted area corresponding to photographic visual standards of SA 2 ½ of the Swedish standard referred above. (Pictora) surface preparation standards for painting steel surfaces).




STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

1.0 GENERAL 1.1 These technical specifications shall be applicable for the work covered by the Contract.

It is understood that Contractor shall complete the work in all respects with best quality materials and workmanship, best engineering practice, Manufacturer recommendations and instructions of HPCL.

1.2 All the items covered in this specification are required to be supplied by the Contractor

only. 2.0 SCOPE

Scope of work covered in this specification shall include but not limited to the following:

1. Surface preparation for all components of pipelines covered in this Contract. 2. Selection, procurement and application of primers, paints and other materials on various

metallic surfaces including providing all requisite scaffolding, spray equipment, compressors, applicators, brushes, etc.

3. Lettering, marking as per HPCL requirements. 3.0 CODES AND STANDARDS 3.1 REFERENCE STANDARDS IS : 5 IS : 101 ASTM STANDARDS 3.2 SURFACE PREPARATION STANDARDS SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988 THIS STANDARD CONTAINS PHOTOGRAPHS OF THE VARIOUS STANDARDS ON

FOUR DIFFERENT DEGREES OF RUSTED STEEL. MANUFACTURER’S BROCHURES AND INSTRUCTIONS WITH RESPECT TO

STORAGE, SURFACE PREPARATION, MIXING AND THINNING, APPLICATION AND CURING INTERVALS.

4.0 EQUIPMENT

All tools, brushes, rollers, spray guns, abrasive materials, sand, hand/ power tools for cleaning, scaffolding materials, air compressors, instrument for measuring humidity, etc required for the works shall be supplied by the Contractor.

5.0 SURFACE PREPARATION, COATING APPLICATION AND DOCUMENTATION

5.1 GENERAL




5.1.1 In order to achieve the maximum durability, sand blast cleaning shall be followed. 5.1.2 Mill scale, rust, rust scale, etc. shall be fully removed by sand blast cleaning to SA 2 ½

or equivalent as per SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988.

5.1.3 Sand Blast cleaning shall not be performed where dust can contaminate surfaces

undergoing such cleaning or in conditions where the humidity exceeds 85%. 5.1.4 The first coat of primer must be applied on dry surface immediately and in any case

within 4 hrs of cleaning of surface. 5.1.5 Blasting and painting shall in general be avoided during unfavorable weather conditions. 5.2 PROCEDURE FOR SURFACE PREPARATION 5.2.1 SAND BLAST CLEANING

The surface shall be sand blasted with Sand at a pressure of about 7 kg/sqcm at appropriate distance and angle using compressed air and Grit to give a white metallic luster. Surface profile shall be uniform to provide good key for paint adhesion. Ferrous Grit will normally be available in round shape.

5.3 COATING PROCEDURE AND APPLICATION 5.3.1 Sand blasted surface upon inspection and clearance by HPCL shall be coated with one

complete application of primer as soon as practicable and in no case later than 4 hrs on the same day. Applied paint shall have the required Dry Film Thickness (DFT) after drying.

5.3.2 Each coat shall be in a proper state of cure or dryness before the application of

succeeding coat. Manufacturer’s instructions shall be followed for time interval. 5.3.3 The type of application may be Air spray or Airless spray or Brush application as per

manufacturer recommendation and HPCL instructions for getting satisfactory results. 5.3.4 For each coat, the painter should know the WFT corresponding to the specified DFT and

standardize the paint application technique accordingly. This has to be ensured in a qualification trial by Contractor.

5.4 SCAFFOLDING

Approved type of scaffolding shall be used and all the painters shall be provided with Safety belts for ensuring accident free working wherever required.

5.5 DOCUMENTATION




1. A written quality Plan with procedure for qualification trials and for actual work. 2. Daily progress Report with details of humidity, surface preparation, surface profile, Dry film

thickness particulars of applications, number of coats applied, type of materials used, methodology-Air or Airless or Brush, progress of work vs programme.

3. Code and Batch numbers of primers and paint materials used. 4. Type of testing equipments and their calibration. 5. Elcometer readings for the various components jointly recorded with HPCL. 6. Paint consumption statement along with the Theoretical consumption requirements. 7. LETTERING

HPCL will provide their Flow, coloring and size and same is to be provided to the pipelines.

HPCL will also convey to the Contractor in writing details of the lettering for product along with the desired color-coding and same has to be arranged by the Contractor.

8. INSPECTION AND TESTING 8.1 All painting materials including primers and thinners brought to site by the Contractor for

application shall be directly procured from Approved manufacturers as per specifications and shall be accompanied by Manufacturer Test Certificates.

8.2 HPCL may call for tests for the primers and paints including verification of batch wise

tests for physical and chemical analysis. The Contractor shall carry out the same at his own cost and provide the results to HPCL.

8.3 The painting work shall be subjected to inspection by HPCL at all times. Stages of

inspection are as follows:

1) Surface preparation 2) Primer application 3) Each coat of paint All records of inspection shall be maintained in Registers and jointly signed by HPCL and Contractor. Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the satisfaction of HPCL before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, Contractor shall be fully responsible for making good any defects found during Final inspection or during the




Defect Liability period. DFT shall be checked and wherever shot same shall be made up with additional coats.

8.4 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats in consultation with manufacturer.

8.5 Calibrated Digital Elcometers, surface profile gauges and any other inspection

instrument required by HPCL shall be provided by the contractor at site. 8.6 The contractor shall arrange expert technical support at site by paint Manufacturer who

will cross verify independently regarding surface preparation and DFT and quality and provide a report to HPCL.

9.0 PRIMERS AND FINISH COATS DESIGNATIONS PRIMERS P-1 : ZINC PHOSPHATE PRIMER P-2 : COAL TAR EPOXY FINSIH COATS/ PAINTS F-1 : SYNTHETIC ENAMEL COATING

PAINTING FOR PIPING

SL.NO. TYPE OF PIPING

SURFACE PREPARATION

PAINT SYSTEM TOTAL DFT IN MICRONS FIELD

PRIMER FINISH PAINT

1 FIRE WATER


2 COATS OF F-1 @ 25 MICRONS DFT/COAT(FIRE RED; IS:536) (ie.50 MICRONS)

100 MICRONS

2 PRODUCT LINE


2 COATS OF F-1 @ 25 MICRONS DFT/COAT(APPRVD SHADE (ie.50 MICRONS)

100 MICRONS

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP FINISH COAT Colour Coding shall have one band of 100mm on each side with a gap of 300mm in between. The band

shall be painted near both sides of the valves and thereafter at every 20 metres of length of the pipeline.

Extra band shall be provided wherever there is 90 deg bend in the pipeline adjacent to the bend on one




side for easy identification. The product carried shall be written in the gap of 300mm in black letters in

the flow direction and the size of the letters shall be half the diameter of the pipelines. A 45-50mm thick

x 300mm long arrow shall be painted after each band on the pipeline in the flow direction.

Note : The finish shades of the external paints shall be as directed by HPCL Engineer-in-charge.




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TECHNICAL SPECIFICATION FOR MEDIUM VELOCITY

WATER SPRAY NOZZLES The spray nozzles should be designed for cooling of above ground tanks, which are exposed to radiant heat. Material of construction : Body : Copper Alloy Grade-II as per IS: 318 Deflector : Brass sheet as per IS: 410 Insert : Brass rod as per IS: 319 Standard finish : Powder coated , Chrome plated Design requirement : a) The nozzle shall produce a 120 degree angle uniform full cone spray pattern

covering a circular area of about 3 meter diameter when located about 1.0 meter away from the tank surface.

b) The water shall strike the vessel with low impact and minimum rebound. c) Vendor shall furnish the performance test data for nozzle regarding variation in

discharge rate and spray angle at different pressure varying from 1.5 kg/ sq. cm to 6.0 kg/sq. cm.

d) The nozzle shall be non clogging type. e) Inlet side of nozzle shall have tapered threads conforming to IS:554. f) M.S. half coupling shall be of 3000 lbs. rating as per ANSI B 16.11 g) Nozzle shall have a hexagonal or square shape on the out side to facilitate screwing

of the nozzle to female half coupling welded to the water ring. h) Nozzle shall be fitted on the circumferential ring around vessels. i) Water pressure available at the nozzle shall be varying 4.0 kg/sq. cm to 6.0 kg /

sqcm j) Marking : All nozzles shall have ISI marking or approval as acceptable to TAC.

Vendor shall furnish the required documents / certificates in this regard. k) Accessories : Vendor shall supply forged steel spanners for fixing the nozzles to the

half couplings. l) Workmanship and finish : All nozzles shall have good workmanship and finish. All

basic and other irregularities shall be neatly removed. Inspection : Material shall be inspected by HPCL representative before dispatch.




TECHNICAL SPECIFICATIONS FOR

FORGED BENDS. SCOPE : Supply of forged 1.5 D 90 deg., 1.5 D 45 deg. Bends conforming to ASTM A-234 Grade WPB with bevelled ends conforming to ANSI B 16.9. Note: Scope of supply includes manufacturing, inspection, packing and delivery of fittings at Project site. CONSTRUCTION : 1) All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm. Welds shall be ground smooth at least 25 mm from the ends. 2) Thickness / Schedule lower or higher than specified shall not be accepted. INSPECTION AGENCY: Third party inspection is Mandatory and shall be carried out by any of the following agencies at no extra cost. 1. LLOYDS 2. DNV 3. EIL 4. IRS. 5. BV 6. Baux Council 7. ICS SCOPE OF INSPECTION: All the Fittings shall be 100 % checked for: 1. Fittings shall be inspected for dimensional accuracy , uniform surface, edge preparation, bevel angle etc. They shall be within permissible limits specified in the applicable standards. 2. Hydrostatic test certificate of the Bends to be witnessed and recorded by the third party inspection agency. 3. Thickness / schedule of the fittings shall be checked and recorded. Third party inspection report shall be submitted to HPCL before despatch of the fittings. In addition Vendor will submit 4 copies of all the test certificates as follows: 2 Copies - Material Despatch Location 1 Copy - To HPCL E&P Department, 1st Floor, Hindustan Bhawan. 1 Copy - To be submitted to Commercial department, Hindustan Bhawan along with Bills PACKING AND FORWARDING : All the fittings shall be cleaned and protected from rust, corrossion and mechanical damage during shipment / transit especially to the bevelled ends. Each end of the fittings shall be protected with a wood, metal or plastic cover.




TECHNICAL SPECIFICATIONS FOR SORF FLANGES -------------------------------------------------- DIMENSIONAL DETAILS : ------------------------------------------------- ITEM SIZE (MM) THICKNESS NO. (DIA) (MM) ----------------------------------------------- SLIP ON FLANGE ------------------------------------------------ 1. 150 25.4 2. 100 23.9 TECHNICAL SPECIFICATION ----------------------- ------------------------------------------------------------------------------------------------------- HPC requirement Vendor's confirmation Deviation , if any ------------------------------------------------------------------------------------------------------- 1.Specification : Conforming to ASA Class 150 raised face without neck. 2.Material : MS plates conforming to IS:2062 Gr A 3.Dimensions & : As per ANSI B.16.5 Holes drilled 4.Working Pressure : 10 Kg/cm2 5.Face : Raised with serrations. Both faces shall be turned smooth before fabrication. 6.Bolt holes : All bolt holes shall saddle the centre line. 3RD PARTY INSPECTION The third party inspection is mandatory and shall be arranged by the vendor at their own cost. The third party inspection shall be carried out by anyone of the following parties :




a) M/s. Lloyds b) M/s. DNV

c) M/s. EIL

d) M/s. Indian Register of Shipping

e) M/s. BV f) M/s Baux Council

e) M/s ICS The Scope of inspection of 3rd Party shall be as follows : a) Plates to be used for fabrication of Flanges shall be tested at any approved Laboratory for confirmation to IS 2062 Gr. A. The plate samples sent to the laboratory shall have to be stamped & witnessed by the 3rd Party. The laboratory test certificate shall have to be reviewed and approved by the 3rd party before start of fabrication of Flanges. b) Visual Inspection c) Dimension check All (100%) Flanges shall be inspected by the 3rd party, except for 80 mm dia and 10 % flanges shall be inspected for 80 mm dia. NOTE : After the third Party provides clearance for despatch all the original test Certificates shall be submitted to HPCL before despatch of the Flanges. In addition Vendor will submit 4 copies of all the test certificates as follows: 2 Copies - Material Despatch Location 1 Copy - To HPCL E&P Department, 1st Floor, Hindustan Bhawan. 1 Copy - To be submitted to Commercial department, Hindustan Bhawan along with Bills PACKING AND FORWARDING : All the fittings shall be cleaned and protected from rust, corrossion and mechanical damage during shipment / transit.




HEALTH, SAFETY

AND ENVIRONMENT

REQUIREMENTS




SAFETY , HEALTH & ENVIRONMENT POLICY SPECIFICATION FOR HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT CONTENTS ________________________________________________________________ CLAUSE NO. TITLE PAGE NO. 1.0 SCOPE 2.0 REFERENCES 3.0 REQUIREMENT OF HEALTH, SAFETY AND

ENVIRONMENT (HSE) 3.1 MANAGEMENT RESPONSIBILITY 3.2 HOUSE KEEPING 3.3 SAFETY, HEALTH & ENVIRONMENT 4.0 DETAILS OF HSE MANAGEMENT SYSTEM

BY CONTRACTOR

4.1 ON AWARD OF CONTRACT

4.2 DURING JOB EXECUTION ANNEXURES 1 ANNEX – I RELEVANT I.S. CODES




] 1.0 SCOPE

This specification establishes the Health, Safety and Environment (HSE) management requirement to be complied with by the Contractors during construction.

Requirements stipulated in this specification shall supplement the

requirements of HSE Management given in relevant Act (s) / legislations. General Conditions of Contract (GCC), Special Conditions of Contract (SCC) and Job Specifications. Where different documents stipulate different requirements, the most stringent shall be adopted.

2.0 REFERENCES This document should be read in conjunction with following:

- General Conditions of Contract (GCC) - Special Conditions of Contract (SCC) - Job Specifications - Relevant IS Codes (refer Annexure – I)

3.0 REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1 MANAGEMENT RESPONSIBILITY

3.1.1 The Contractor should have a documented HSE policy to cover

commitment of their organization to ensure health, safety and environment aspects in their line of operations.

3.1.2 The HSE management system of the Contractor shall cover the HSE

requirements including but not limited to what is specified under Para 1.0 and para 2.0 above.

3.1.3 Contractor shall be fully responsible for planning and implementing HSE

requirements. Contractor as a minimum requirement shall designate / deploy the following to co-ordinate the above : No. of workers deployed Up to 250 - Designate one safety supervisor




Above 250 & upto 500 - Deploy one qualified and Experienced safety Engineer / officer

Above 500 - One additional safety engineer/officer as above. (for every 500 or less)

Contractor shall indemnify & hold harmless Owner / HPCL & either

representatives free from any and all liabilities arising out of non – fulfillment of HSE requirements.

3.1.4 The Contractor shall ensure that the Health, Safety and Environment (HSE)

requirements are clearly understood & faithfully implemented at all levels at site.

3.1.5 The Contractor shall promote and develop consciousness for Health, Safety and Environment among all personnel working for the Contractor. Regular awareness, programme and fabrication shop / work site meetings shall be arranged on HSE activities to cover hazards involved in various operations during construction.

3.1.6 Arrange suitable first aid measures such as First Aid Box, trained personnel to give First Aid, Stand by Ambulance or Vehicle and install fire protection measures such as : adequate number of steel buckets with sand and water and adequate fire extinguishers to the satisfaction of HPCL/Owner.

3.1.7 The Contractor shall evolve a comprehensive planned and documented system for implementation and monitoring of the HSE requirements. This shall be submitted to HPCL/Owner for approval. The monitoring for implementation shall be done by regular inspections and compliance to the observations thereof. The Contractor shall get similar HSE requirements implemented at his sub-contractor(s) work site/office. However, compliance of HSE requirements shall be the sole responsibility of the Contractor. Any review / approval by HPCL/Owner shall not absolve contractor of his responsibility / liability in relation to all HSE requirements.

3.1.8 Non-Conformance on HSE by Contractor (including his Sub-contractors) as brought out during review/audit by HPCL/Owner representatives shall be resolved forthwith by Contractor. Compliance report shall be provided to HPCL/Owner.

3.1.9 The Contractor shall ensure participation of his Resident Engineer / Site-in-Charge in the Safety Committee / HSE Committees meetings arranged by HPCL/Owner. The compliance of any observations shall be arranged urgently.




He shall assist HPCL/Owner to achieve the targets set by them on HSE during the project implementation.

3.1.10 The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non-compliance or continuous failure in implementation of any of HSE provisions; HPCL/Owner may impose stoppage of work without any Cost & Time implication to Owner and/or impose a suitable penalty for non-compliance with a notice of suitable period, upto a cumulative limit of 1.0% (one percent) of Contract Value with a maximum limit of Rs. 10 lakhs. This penalty shall be in addition to all other penalties specified else where in the contract. The decision of imposing stoppage work, its extent & monitory penalty shall rest with HPCL/Owner & binding on the Contractor.

3.1.11 All fatal accidents and other personnel accidents shall be investigated by a team of Contractor’s senior personnel for root cause & recommend corrective and preventive actions. Findings shall be documented and suitable actions taken to avoid recurrences shall be communicated to HPCL/Owner. Owner / HPCL shall have the liberty to independently investigate such occurrences and Contractor shall extend all necessary help and co-operation in this regard. 3.2 HOUSE KEEPING

3.2.1 Contractor shall ensure that a high degree of house keeping is maintained and shall ensure inter-alia the followings:

a. All surplus earth and debris are removed/disposed off from the working areas to identified location(s).

b. Unused/Surplus Cables, Steel items and steel scrap lying

scattered at different places within the working areas are removed to identified location(s).

c. All wooden scrap, empty wooden cable drums and

other combustible packing materials, shall be removed from work place to identified location(s).

d. Roads shall be kept clear and materials like: pipes, steel,

sand boulders, concrete, chips and bricks etc. shall not be allowed on the roads to obstruct free movement of men & machineries.




e. Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.

f. Water logging on roads shall not be allowed. g. No parking of trucks / trolleys, cranes and trailers etc. shall

be allowed on roads which may obstruct the traffic movement.

h. Utmost care shall be taken to ensure over all cleanliness

and proper upkeep of the working areas. i. Trucks carrying sand, earth and pulverized materials etc. shall

be covered while moving within the plane area.

3.3 HEALTH, SAFETY AND ENVIRONMENT

3.3.1 The Contractor shall provide safe means of access to any working place including provisions of suitable and sufficient scaffolding at various stages during all operations of the work for the safety of his workmen, and, HPCL/Owner. Contractor shall ensure deployment of appropriate equipment and appliances for adequate safety and health of the workmen and protection of surrounding areas.

3.3.2 The Contractor shall ensure that all their staff and workers including their sub-contractor(s) shall wear Safety Helmet and Safety shoes. Contractor shall also ensure use of safety belt, protective goggles, gloves etc. by the personnel as per job requirements. All these gadgets shall conform to relevant IS specifications or equivalent.

3.3.3 Contractor shall ensure that a proper Safety Net System shall be used at appropriate locations. The safety net shall be located not more than 30 feet (9.0 metres) below the working surface at site to arrest or to reduce the consequences of a possible fall of persons working at different heights.

3.3.4 Contractor shall ensure that flash back arrester shall be used while using Gas Cylinders at site. Cylinders shall be mounted on trolleys.

3.3.5 The Contractor shall assign to his workmen, tasks commensurate with their qualification, experience and state of health for driving of vehicles, handling and erection of materials and equipments. All lifting equipments shall be tested certified for its capacity before use. Adequate and suitable lighting at every work place and approach there to, shall be provided by the Contractor before starting the actual operations at night.




3.3.6 Hazardous and/or toxic materials such as solvent coating, or thinners shall

be stored in appropriate containers.

3.3.7 All hazardous materials shall be labeled with the name of the materials, the hazards associated with its use and necessary precautions to be taken.

3.3.8 Contractor shall ensure that during the performance of the work, all hazards to be health of personnel, have been identified, assessed and eliminated.

3.3.9 Chemical spills shall be contained & cleaned up immediately to prevent further contamination.

3.3.10 All personnel exposed to physical agents such as ionizing radiation, ultraviolet rays or similar other physical agents shall be provided with adequate shielding or protection commensurate with the type of exposure involved.

3.3.11 Where contact or exposure of hazardous materials could exceed limits or could otherwise have harmful affects, appropriate personal protective equipments such as gloves, goggles, aprons, chemical resistant clothing and respirator shall be used. - A Crèche where 10 or more female workers are having

children below the age of 6 years. - Reasonable Canteen facilities are made available at

appropriate location depending upon site conditions.

3.3.13 Suitable facilities for toilet, drinking water, proper lighting shall be provided at site and labour camps, commensurate with applicable Laws / Legislation.

3.3.14 Contractor shall ensure storage and utilization methodology of materials that are not detrimental to t he environment. Where required Contractor shall ensure that only the environment friendly materials are selected.

3.3.15 All persons deployed at site shall be knowledgeable of and comply with the environmental laws, rules & regulations relating to the hazardous materials substances and wastes. Contractor shall not dump, release or otherwise discharge or dispose off any such materials without the express authorization of HPCL/Owner.




4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR 4.1 On Award of Contract The Contractor shall prior to start of work submit his Health, Safety

and Environment Manual or procedure and HSE Plans for approval by HPCL/Owner. The Contractor shall participate in the pre-start meeting with HPCL/Owner to finalise HSE Plans including the following :

- Job procedure to be followed by Contractor for activities

covering. Handling of equipment, Scaffolding, Electric Installation, describing the risks involved, actions to be taken and methodology for monitoring each activity.

- HPCL/Owner review / audit requirement. - Organization structure along with responsibility and authority

records / reports etc. on HSE activities. 4.2 During job execution

4.2.1 Implement approved Health, Safety and Environment management procedure including but not limited to as brought out under para 3.0. Contractor shall also ensure to: - arrange workmen compensation insurance, registration under ESI Act, third party liability insurance etc., as applicable. - arrange all HSE permits before start of activities (as applicable) like hot work, confined space, work at heights, storage of chemical / explosive materials and its use and implement all precautions mentioned therein. - submit timely the completed checklist on HSE activities,

Monthly HSE report, accident reports, investigation reports etc. as per HPCL/Owner requirements. Compliance of instructions on HSE shall be done by Contractor and informed urgently to HPCL/Owner.

- ensure that Resident Engineer / Site-in-Charge of the

Contractor shall attend all the Safety Committee / HSE meetings arranged by HPCL/Owner. Only in case of his absence from site that a second senior most person




shall be nominated by him in advance and communicated to HPCL/Owner.

- display at site office and work locations caution boards, list

of hospitals, emergency services available. - provide posters, banners for safe working to promote safety

consciousness. - carryout audits / inspection at sub contractor works as per

approved HSE document and submit the reports for HPCL/Owner review.

- assist in HSE audits by HPCL/Owner, and submit compliance

report. - generate & submit HSE records / report as per HSE Plan. - appraise HPCL/Owner on HSE activities at site.




EMD FORMAT




GENERAL TERMS & CONDITIONS OF WORKS CONTRACT

1 PRELIMINARY 1.1 This is a Contract for execution of __________________ work at

_______________________. (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.




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 authorised 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.

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.

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 Owners 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 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 alongwith 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:

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 upto Rs. 50,000/- and in the form of Demand draft / Bank guarantee beyond Rs. 50,000/-.




Composite PBG for 10% of PO value towards Security Deposit and Performance bank guarantee shall be accepted; which shall be valid upto 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.

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."

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”.

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).

2) If such a request for extension is received with a Bank

Guarantee for the full 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 in any case not later than 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 uspended 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 havethe option to terminate the Contract as provided under the clause fortermination. 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 the provisions of this contract, may instead of Contract and undertaking charge 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.

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 commencenent 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.

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 upto +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.

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.

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 work or the Contract until the work is completed in full in accordance with the provisions of this Contract.

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. Notwithstanding 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.

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 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.

6.d.6. he 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.

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.

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 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 certified bill by the Disbursement Section of the Owner.

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 45 days from the date of

receipt of the certified bill by the Disbursement Section of the owner. 7.a. MEASUREMENT OF WORKS 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 authorised 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 :

• 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.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.

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.

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 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).

iii) 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.

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 nationalized 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 judgment 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.

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 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 realized. 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. One 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 he 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.

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 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. 60,000/- per case 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 stage wise 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.

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 Mumbai for all purposes. The Arbitration shall be held at Mumbai 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 exceeds Rs.1 crores. Failure to sign the Integrity Pact shall lead to outright rejection of bid.