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Annexure-A

PIPING CONTRACT AND EXECUTION OF WELDING

WORKS FOR PRINCIPAL TEST STAND (PTS) AND

ADDITIONAL TEST BAY (ATB) OF IPRC,

MAHENDRAGIRI

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ISRO PROPULSION COMPLEX INDIAN SPACE RESEARCH ORGANISATION

DEPARTMENT OF SPACE, GOVERNMENT OF INDIA, MAHENDRAGIRI, TAMILNADU 627133

INDIA 4.0

INSPECTION AND QUALITY CONTROL 16

4.1 General 16

4.2 Welding Procedure and Welder performance 17

4.3 Inspection 18

CONTENTS

NO SECTION PAGE NO

1.0 INTRODUCTION 5

2.0 SITE LOCATION AND CLIMATIC CONDITION 5

3.0 SCOPE OF WORK 6

3.1 General 6

3.1.1 Responsibility Of Contractor 7

3.1.2 Responsibility Of Department 8

3A DETAILED DESCRIPTION OF WORKS

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3A.1 Piping Erection 8

3A.2 Piping Layout & Isometric Drawings 9

3A.3 Fabrication and Welding of Pipe lines 9

3A.4 Purging, Pressure Tests 13

3A.5 Requirements of Painting 13

3A.6 Installation of Pipelines 13

3A.7 Procedure For Pressure Tests 15

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4.4 Norms of Quality Control 19

4.5 Elimination of Weld Defects 21

5.0 GENERAL FABRICATION PROCEDURE 22

5.1 Welding and DP testing 22

5.2 Radiography 24

5.3 Chemical Cleaning 24

5.4 Removing Work done for Re-work or Alteration 26

5.5 Retrieval of Pre-Welded Fittings & Flow components

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5.6 Dismantling of pipeline assemblies 26

5.7 Structural Works 27

5.8 Painting 27

6.0 WORK SITE CONDITIONS 29

6.1. Site establishment 29

6.2. Electricity 30

6.3. Water 31

6.4. Messing & Accommodation 31

6.5. First Aid 31

6.6. Supervision of Work 31

6.7. Employment of labours 31

6.8. Reporting 32

6.9. Working and Safety Regulations 32

6.10. Electrical Safety Regulations 33

7.0 GENERAL TERMS AND CONDITIONS 34

7.1 Contract Price 34

7.2 Variation in Contract Value due to Variation in Quantity.

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7.3 Schedule of Contract and Work Execution 35

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7.4 Sub – Contracting 36

7.5 Confidentiality 37

7.6 Warranty 37

7.7 Cancellation of Contract 37

7.8 Department Furnished (Free Issue Materials) 37

7.9 Insurance coverage for Contractor’s Employees & Labour

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7.10 Documentation 38

7.11 Settlement of Disputes 41

8.0 INSTRUCTIONS TO BIDDERS 41

8.1 Man Power 41

8.2 Site Visit 41

8.3 Availability of Site for erection activities 41

8.4 Insurance 41

8.5 Prices 42

8.6 Pipeline Size and Dimensional standards 42

8.7 Unit of Measure “ Inch Dia” & “Inch Metre” 42

TABLES

Table-6 Requirements to quality evaluation for welded joints of stainless steel structures at visual examination.

Table-7 Requirements to quality evaluation of steel welded joints by radiographic testing method.

Table-8 Requirements to quality evaluation of angle joints, T-joints and lap joints.

Table-9

Requirements to quality evaluation of category I & II weld joints for pores and inclusions using radiography.

A3. 1 Specification of gaseous argon

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SPECIFICATION FOR PIPING CONTRACT WORKS: 1.0 INTRODUCTION:

The proposed pipe line fabrication work is for the augmentation of Fluid systems from the existing test stand to the Additional Test Bay (ATB) of Principal Test Stand (PTS) at ISRO Propulsion Complex (IPRC), Mahendragiri. The main objective is to carryout on-site Fabrication, erection & testing of S.S pipe lines & Flow components, and some Quantity of C.S pipe line erection, support fabrication and Hydro testing. The work nature can be classified into three categories. The fabrication of S.S pipes / carbon steel lines from fresh supply (free issue by department) and can be executed as per the drawing / site requirements (new lines are to be made as fresh). The existing pipe lines are to be extended to the new facility with new pipe lines and flow components which will be issued from our stores. To complete the above work, the existing flow components are to be removed safely and pipe extension are to be fabricated as per the drawing / site requirement. After successful completion of pipe line qualification work, the flow components are to be assembled back and the modified piping system made ready for operation. The existing fuel supply lines (UH25) are to be replaced with new pipe lines. The existing flow components such as EP valves, manual valve, control valve, flow meter, filters are to be used after completion of new pipe line fabrication. The line sizes, routing of pipe line etc need not be modified. [One to one replacement].

2.0 SITE LOCATION AND CLIMATIC CONDITIONS

SITE LOCATION

The works are to be carried out, at Principal Test Stand (PTS) in ISRO Propulsion Complex (IPRC), Mahendragiri, Tirunelveli District, TamilNadu. IPRC, Mahendragiri is situated at about 60 km from Tirunelveli and at about 20 km from Nagercoil, Kanyakumari district, Tamilnadu State. The site is on Madurai - Kanyakumari National Highway (NH7). At Mahendragiri, PTS is located at about 4 km from the National highway and is connected by black topped road of minimum width of 3.5 meters with one meter berm on either side.

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CLIMATIC CONDITION

PTS is in a hilly terrain at an elevation of about 160 meters above MSL. The climatic conditions at Mahendragiri are tropical and windy with occasional gust. The maximum wind speed is 120 km/hr with 3 sec, gust. Normal monsoon period is June – July and October –November. The contractor will have to provide protective arrangement against wind and rain which they may think necessary, to carry out the work continuously.

3.0 SCOPE OF WORK 3.1 GENERAL

The scope of work of this contract in brief, includes the following.

However the details of each work are dealt in the respective sections.

� Transportation of free issue materials from Department’s

storage yard to work site.

� Fabrication, welding (SS & CS), cleaning, Radiography, Installation and testing of pipe lines for ATB as per the General Fabrication Procedure given in the contract document.

� Fabrication of structural (MS) supports, access platforms

and cross over bridges.

� Mounting of prefabricated pipe supports, brackets, etc.

� Providing static electricity earthing for the pipe lines.

� Painting of structures and supports and colour coding of pipe lines.

� Preparation of as built piping layout and Isometric drawings

and necessary documentation.

3.1.1 RESPONSIBILITY OF CONTRACTOR

The responsibility of the contractor includes, but not limited to providing the followings;

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� Deployment of labourers like helper, welder, fitter, rigger, supervisor, works manager, etc in sufficient numbers to complete the works within the stipulated time.

� Transport vehicles for contractor’s labourers, equipments &

materials.

� Construction of temporary shed/room for carrying out fabrication works and storage of tools, welding machine, dark room for radiography, etc.

� Trucks, cranes, fork lift, chain pulley block, slings, hooks,

metal ropes, etc. for transporting the packages & materials from Department’s storage yard to work site.

� Tools and tackles for the installation of pipe lines and flow

components at work site.

� Welding machine (TIG & Arc), drilling machine, grinding machine, pipe bending machine, etc.

� Equipments and materials for radiographic testing such as

X-ray machine / Gamma ray source, penetrameter, X-ray film, etc.

� Consumables such as Argon gas, Oxygen gas, Acetylene gas

and LPG for welding, filler wire, electrodes, and wire brush, hack saw blades, etc.

� Supply of paints, pipe clamps.

� Consumables such as cleaner (acetone), dye, developer,

etc. for Dye-Penetrate (DP) testing.

� Chemicals (ISO Propyl alcohol) for degreasing.

� Chemical required for chemical cleaning Pickling & Passivation.

� Necessary handling equipments shall be arranged by the

contractor. In case, the contractor is requesting to provide handling equipments/machine’s from the department and will be provided on chargeable basis (subject to the availability).

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� Necessary clamps, packing materials (CAF sheet) to be placed between clamps & pipe and pipe & pipe supports, etc.

� Supply of structural materials will be supplied by the

department. The fabrication and erection of structural supports, access platforms, etc are to be carried out by the supplier.

� Painting of support structures, colour coding of pipes

including supply of paints, primer, thinner etc.

3.1.2 RESPONSIBILITY OF DEPARTMENT

� Furnishing of piping layout. � Identifying working space for construction of temporary

shed/room for storage of contractor’s tools machines, etc.

� Supply of free issue materials such as Pipes, Fittings, Flow components, structural material etc.

� Supply of Gaseous Nitrogen (GN2) for pneumatic testing and

portable/ DM water for hydro testing.

� Supply of electricity on chargeable basis.

� Supply of water on free of cost.

� Inspection by Quality Control (QC) division & site supervision of Department.

3A DETAILED DESCRIPTION OF WORKS

3A. 1 PIPING ERECTION

GENERAL

The free issue materials required for piping works such as equipments, components, pipes and fittings are to be taken delivery from STF stores (near the facility) and transported safely to the site by the contractor. Also the replacement of old pipes with new & extension

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of S.S pipes lines, the existing components are to be removed safely and keft in our stores and allowed to take back to site after erection of new pipe lines.

3A.2 PIPING LAYOUT & ISOMETRIC DRAWINGS

The tentative piping layout will be provided to the contractor for the execution of the works. Based on the inputs about the site condition, the contractor has to prepare the detailed isometric drawing for execution of the work. The pipelines can be classified in the following three categories.

1) Replacement of S.S pipe line in Fuel side (The valves, filters, flow meter, control valve etc shall be removed and installation back with all above).

2) Extension of S.S pipe line from the existing test stand. And new lines also to be laid as per piping layout in addition to the above.

3) C.S pipe lines (new lines) from the existing lines to the new facility.

3A.3 FABRICATION AND WELDING OF PIPE LINES

3A.3.1 GENERAL DECONSERVATION OF THE EQUIPMENTS

- Remove the seals used for conservation of the systems during transportation and storage.

- Remove the transportation caps installed in the pipelines and

flow components.

- After removal of the caps, close these openings temporarily using polyethylene sheet till they are welded.

REQUIREMENT FOR CLEANING AND DEGREASING

The cavities of pipelines and equipments which are in contact with operating medium namely GN2, is already cleaned and degreased at the manufacturer’s plant. Then the ends of the flow components and pipelines are closed by caps for preservation. Prior to welding/mounting of pipelines these caps are to be removed and cleanliness check is to be carried out. If required degreasing is to

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be done using Isopropyl alcohol (IPA) till the following result is obtained.

- The oil content of the surfaces checked should not exceed 200

mg/sq.m. - The size of mechanical particles on the surfaces shall not

exceed 40 microns.

3A.3.2 FABRICATION AND PREPARATION OF PIPELINES FOR WELDING

- During edge preparation, drilling or cutting operations, sufficient protective measures must be employed to avoid entry of metal chips, dirts and contaminants into the pipelines.

- Ovality of the pipes at places of bending shall not exceed 15% of the outer diameter of the pipe.

- The welds at bending location are not permitted. The

distance from the weld joint to the beginning of the bend shall not be less than twice the outer diameter of the pipe.

- The minimum distance to be kept between two successive

weld joints shall be more than 40 mm. - Check for the absence of foreign particles inside the pipe.

- Check for oil content inside the pipeline at the ends and if

required degrease the ends of the pipelines using Iso Propyl Alcohol (IPA).

3A.3.3 PREPARATION OF FIT – UP ASSEMBLY

- The weld joint must be prepared to the required configuration

conforming to the dimensions given in the relevant piping layout drawings and documents.

- Uniform clearance of 1.0 to 1.5mm shall be kept all around

the welding edges.

- Each fit – up assembly has to be checked and accepted by the inspection personnel of the Department and the same shall be documented.

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- Proper appliances shall be used to maintain coaxiality of the assembly and welding up of temporary fasteners to the pipelines for this purpose is not permitted.

- The deviation of axes of the joined pipelines for linearity shall

not exceed 10 mm per 10 meter of length and 15 mm for any length more than 10 m.

- Shifting or mismatch of the weld edges of butt joints shall

conform to the specification given in Table 6

- The weld joints shall be well protected to strictly avoid entry of water, dust, oil and any other contamination through it in to the assembly.

- Tack welding shall be performed only by qualified welders and

only qualified welding procedure has to be adopted for tack welding also.

- The quality of tack welding will be visually inspected and tack

welding with defects will not be allowed.

- Tack welds shall be cleaned to remove slags, scale etc.

3A.3.4 REQUIREMENTS FOR WELDING

- All stainless steel welding shall be done only as per ASME SEC

IX-Argon of 99.99% purity shall be used for TIG welding and for carbon steel pipes, structural platform and supports MMAW shall be used.

- Argon gas only shall be used for purging the internal surface of the pipe as well as shielding of arc during welding.

- All mild steel structural welding shall be done by MMAW welding process. The required welding materials and consumables shall be brought by the contractor.

- The welding materials brought by the contractor shall have

certificates conforming their quality. Only materials of reputed manufactures with the approval of the department shall be used.

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- The filler wires and the electrodes are to be kept in dry room.

- Welding shall be done strictly in accordance with the qualified welding procedure and the welding parameters for each joint shall be recorded in the prescribed format. Only welders qualified for the work shall carry out the welding.

- Manual valves, pneumatic valves, control valves, are to be

kept completely open during welding. The contractor shall make all arrangements to provide pneumatic supply to the pneumatic valves for keeping them open temporarily during welding.

- Tack welding or complete welding shall be done only after

acceptance of the fit-up assembly by the inspection personnel.

- It is necessary to over lap the beginning of weld for minimum

15 to 20 mm of weld length.

- When the weld metal is deposited in more than one pass, the starting point of each successive pass shall be shifted relatively by 20 to 25 mm. It is necessary to clean thoroughly the beads to remove slag, oxides etc after performing each pass and such cleaning shall be done until clean and bright weld surface is obtained.

- In the butt welding of pipes, the welding must be performed

without interruptions at uniform rate. In case of any interruption, the continuation of welding shall be done with an over lapping of 15 – 20 mm.

- After completion of welding, the weld joint as well as the

adjacent surface in the parent metal for a width of not less than 20mm on either side shall be cleaned to remove slag scale etc.

- For cleaning of weld joints or the parent metals at weld edges

only stainless steel brushes must be used.

- The contractor shall provide adequate cover at the place of welding in order to protect the equipments / pipelines being welded from wind, rain and contamination.

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3A.4 PURGING, PRESSURE TESTS :

PURGING The pipes are to be purged thoroughly with gaseous nitrogen after welding. Purging of pipe segments containing turbine-type flow meter with gas is not permitted. PRESSURE TESTS The following pressure tests are required to be done with gases at ambient temperature:

3A.4.1 Stainless Steel Pipelines

- Pressure test with water (or) by GN2. - Leak test of pipe lines with snoop solution.

The Department will provide the snoop & gaseous Nitrogen (GN2) to be used for purging and testing. It is the responsibility of the contractor to bring all materials such as hoses, adaptors, soap solution required for leak proof ness etc., required for connecting with the existing fluid circuits available at work site (PTS).

3A.5 REQUIREMENTS FOR PAINTING

The supports/ pedestal of pipe lines are to be painted with 2 Coats of primer.

3A.6 INSTALLATION OF PIPE LINES

3A.6.1 GENERAL

The work covered under this item include all the work required for proper installation and testing (pneumatic / Hydro) of all types of stainless steel pipes/ C.S pipes, including all fittings such as flanges, tees, elbows, bellows and instruments such as pressure gauges, flow meters, etc. The work involves connecting pair of flanges such as the flange between a pipeline and a flanged valve by tightening the fasteners and screwing the threaded fittings like pressure gauges, threaded interface valves, etc, with a mating fitting. However, the weld joints will be paid separately under the heading welding and DP testing. There shall be no limitations on

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the number of flanged or threaded connections per metre length of the pipe line installed. The installation of pipelines at test stand structure shall be carried out at an elevation ranging from test stand pavement level to 30m level at different orientation / positions. It shall be noted that the routing of the pipelines may involve complexities, such as branching / re-routing of existing pipeline segments of un-insulated lines, installation of pipelines in congested locations at different elevation levels in a existing test stand structure. The general procedure is;

- Keep the open end of the pipelines assemblies temporarily

closed during the period between completion of welding and commencement of installation. Ensure the temporary closures are removed just prior to commencement of installation.

- Perform the final welding of supports after mounting of

pipelines and checking of their straightness.

- The minimum distance to be kept between the support and the nearest weld joint shall be 25 mm unless otherwise specified in drawings.

- Maintain clearance between the pipeline and the support

wherever required, in accordance with the drawings. - While mounting, ensure a minimum gap of 10mm between

the pipelines and also between any pipeline and other equipments or civil structures.

- Install the pipelines strictly as per the piping layout.

- For assembly of flanged joints, ensure all the bolts, pins,

screws and nuts are properly tightened and the ends of the bolts/pins shall project from nuts by 1 to 4 turns of the thread.

- Tighten the diametrically opposites fasteners alternately.

- Install the filter elements after completion of mounting,

purging and pressure testing of pipelines.

- After completion of installation works list out the detachable joints with open ends. These ends shall be closed and sealed.

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3A.6.2 INSTALLATION OF FLOW COMPONENTS

Installation of all flow components such as E.P valves, manual valves, filters; flow meters, etc. is based on their weight. The installation charges shall not be paid for flow components weighing less than 10 kg. The following 3 range of weights are given below.

The weight for each flow component will be provided by the Department from the records of sub-vendor from whom the flow components were bought. If the contractor is not agreeing the weight provided by the Department, then it shall be the responsibility of contractor to arrange for weighing the flow component using a standard weighing machine / method agreeable to Department. The work shall include transportation, handling, rigging, scaffolding, lifting and alignment of flow components with pipes and fittings in their respective positions and on to their respective supports. The installation of flow components at test stand structure can be carried out at an elevation ranging from test stand pavement level to 30m level at different orientation / positions. The payment for the work done under this item will be made only when the flow component is properly located and permanently supported in its final position in the field.

3A.7 PROCEDURE FOR PRESSURE TESTING

3A.7.1 GENERAL

The standard procedure for carrying out the pressure testing is given below. However there can be changes in the procedures, hence before commencing each operation the contractor shall

Sl No Weight Range

1 10 to 50kg

2 50 to 75kg

3 Above 75, below 150kg

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prepare the procedure and shall get duly approved by the supervising agency, Quality division of the Department. The approved procedure shall only be used by the contractor.

3A.7.2 TESTS OF S.S PIPE LINES FOR STRENGTH AND LEAK

PROOFNESS

- For measuring the test pressure the pressure sensors and pressure

gauges forming part of the system can not be used as their ranges

will not be adequate. Calibrated pressure gauges of suitable range

shall be brought and mounted by the contractor for the test.

- Pressurize the inner pipe by nitrogen to the specified proof pressure

and keep it for 5 minutes.

- Reduce the pressure to operating pressure and keep it for 1 hr.

Perform leak test of the weld joints, flange joint etc with soap

solution.

- Fall in the pressure value in one hour period is not allowed.

4.0 INSPECTION & QUALITY CONTROL

4.1 GENERAL

All the works under this contract shall be inspected by the QC-ESTF wing of department. Works under this item comprise inspection of mounting of equipments and components, complete piping works. Inspection of mounting works includes checking, measuring and marking of co-ordinates, equipment leveling, leak checking etc. Inspection of piping works include stage by stage inspection of handling, cleaning & degreasing, rigging, all procedures adopted in weld joint preparation, filler wire material, alignment of pipes, fit-up welding, fabrication, fixing of supports, installation and testing of all the pipe lines as per the drawings supplied by the department or supplied by the contractor which are duly approved by the department.

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Also included under this item are checking the procedure, techniques and methodology adopted by the contractor in the DPT and radiographic examination of weld joints, checking the radiography films, checking of weld joints, DPT of the weld joints, etc. All procedures involved in the total piping fabrication, erection, testing and commissioning shall be submitted in the detailed form to QC-ESTF wing of department for checking of compliance with the relevant codes and standards and acceptance. However, the department has the final authority to issue written approval, clearances and certificates of the work in consultation with the supervising organization wherever necessary.

4.2 WELDING PROCEDURE AND WELDER PERFORMANCE Welding procedure & welder performance qualification tests shall be carried out in accordance with section IX of ASME. At least six welders shall be qualified for the work. The procedure qualification & welder qualification tests have to be conducted for welding of the following similar / dissimilar materials. The welder qualification and weld procedure qualification test shall be carried out under the inspection of Quality Assurance (QC-ESTF) wing of department.

Sl

No Material designation Filler wire code

a) ASTM A312 TP, 304 /304L/ 316/ 316L

with ASTM A312 TP, 304 / 304L/316/316L

ER308/ 308L/316 L To be brought by contractor

b) ASTM A53/ A106 Gr B with ASTM A 105/ A234 Gr Wp B

Suitable material brought by contractor

Materials required for the qualification tests namely pipes and filler wires will be supplied by the department for welding of the materials given in Sl.No (a) & (b).

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The size of pipe welds range from 15mm NB to 400mm NB and thickness of the pipes range from 1mm to 16mm. Welding procedure & welder qualification tests have to be carried out with pipes of 6mm (OD) x 1 mm (thickness), 22 x 2.5 & 120 x 6. Test procedure, specimen preparation, NDT testing, tensile test, bend test etc shall be done as per sec IX of ASME and any other requirement specified by the department at the time of execution of the work.

4.3 INSPECTION

Inspection of welding works will be carried out generally in the following manner:

� Preliminary check � Checking of welding procedure � Checking of the quality of weld joints

Preliminary checks

� Checking whether qualified welder is being engaged for the work. Also checking of the qualification or other allied operating personnel.

� Checking the state of the appliances, instruments and devices used for welding and inspection.

� Checking the quality of welding materials, their

correspondence with the certificates and their storage conditions.

� Checking the quality of preparation of the weld joint.

Measuring the weld geometry and checking the fit-up assembly for conformance to the required norms.

Checking of Welding Procedure

� Checking whether qualified procedure is being adopted. � Monitoring and Recording all the essential parameters for

each weld.

Checking the quality of the weld joints

� External inspection of the weld joint. � Dye penetrant test. � Radiography examination.

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4. 4 NORMS OF QUALITY CONTROL

4.4.1 NORMS OF QUALITY CONTROL

� All weld joints shall be subjected to external examination to detect weld defects.

� The quality norms with acceptance limits for external examination of piping are as per ASME.

� All the SS Butt Weld joints shall be subjected to 100% X-

ray examination. CS Butt Weld joints shall be subjected to 10% X-ray examination. Such weld joints will be identified for test by the inspection personnel of the Department.

� Radiography examination of the weld joints shall be done only

after elimination of defects detected by the external inspection.

- The heat affected zone adjacent to the weld joint for a minimum of 20 mm on either side of the weld shall also be subjected to inspection.

- The inspection of the weld joints shall be performed for the complete length using magnifying glass with a minimum of 4 times magnification. The weld joint shall also be inspected internally wherever it is accessible.

- The quality norms with acceptance limits for external

examination of piping is given in Table – 6

- Radiography examination of the weld joints shall be done only after elimination of defects detected by the external inspection.

- There are three categories of weld joints in system as given

below;

� Weld category - I � Weld category – II � Weld category - III

The weld joints of category-I are to meet stringent quality standard because these joints are subjected to service

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conditions such as low temperature, high operating pressure, flammable & explosive fluid media, high dynamic loads etc. The weld joints of category- II are subjected to service conditions such as operating pressure, vacuum, low temperature, dynamic loads etc. The weld joints not included in these two categories are related to the III category. Generally welding of supports, structural welding is falling in the III category.

- The following weld joints shall be subjected to 100% X-ray examination.

� Weld joints of category – I.

� Butt weld joints with operating pressure more than 100 bar.

- All butt welds of category II shall be subjected to 10% X-ray

examination. Such weld joints will be identified for test by the inspection personnel of the Department.

- The detected defects in piping shall conform to the acceptable

quality norms specified in Table – 7

� The cumulative length of allowable defects shall not exceed 30% of total weld length, otherwise the weld joint will be rejected in full and the same joint has to be welded again.

� For those weld joints which are inaccessible for

examination by X-ray, stage wise clearance of each operation shall be obtained. Visual inspection shall be done after completing each pass of welding.

� The presence of two allowable defects within 100 mm

length is not permitted for welds of category – I.

� The combination of two permissible defects within 100mm length may be allowed for welds of category-II in accordance with the norms of QC-ESTF wing of Department / Russian agency.

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� The quality of welds made for pipe supports and welds inaccessible for radiography shall be ensured by means of checking of preparation of edges, weld geometry, welding procedure, and DP testing and external inspection.

4.5 ELIMINATION OF WELD DEFECTS

- Elimination of weld defects shall be carried out operation by operation in the presence or with the concurrence of the inspection personnel and the supervising agency.

- The acceptance norms specified for the weld joints are

applicable for the rectified weld joint also.

- The weld joints which are found to be defective in X-ray examination or strength test or leak test or vacuum leak proofness test shall be subjected to the same type of check/testing repeatedly after rectification work until all the checks / tests are passed successfully.

- The elimination of such defects which are not defined in this

document shall be done as per the norms stipulated by the inspection personnel consultation with the supervising agency at the time of execution of the work.

- Length of the defective segment is to be determined before

preparation of the edges for re-welding and the width of the edge preparation is determined by the nature of the defect.

- Width of the weld after re-welding shall not exceed double

the width of the weld existed earlier.

- Weld sagging, under cuts and hollows between beads shall be eliminated by welding again over the defective place after polishing such spots to get bright metallic surface.

- For repairing joints with incomplete fusion, inclusions, cracks

etc. (internal weld defects) the material shall be removed till the defects are completely eliminated from the job and then re-welding shall be done.

- The repair of weld joints by re-welding at the same place is

allowed only up to 2 times.

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- After elimination of defects, the pipeline shall be purged with GN2.

- During repair works in the defective joints, ensure chips, dust

and other contaminations do not enter into the pipelines.

- Subject the repaired welds to repeated checks as well as tests for strength, leak proofness etc.

5.0 GENERAL FABRICATION PROCEDURE

5.1 WELDING AND DP TESTING

The scope of work for weld joints includes all operations associated with making each joint, including cleaning, marking-out, cutting, profiling, bevelling, grinding, aligning, fitting-up, tack welding, cleaning, chipping, pre-heating (if necessary), placement of wind shields, weather protection, necessary scaffolding if any and final welding together with final cleaning of welds, post-heating and DP testing. The choice, grade and make of the welding electrodes and filler wires shall got approved by the Quality division of the Department. After tack-welding, the alignment of the fit-up shall got approved by Quality division of the Department before proceeding with final welding. DP testing shall be carried out for the root and final passes of the welding in the presence of Quality division of the Department. Welding rods, filler wires, argon purging gas and chemicals required for DP testing, Acetone cleaner, SS wire brush, dye, developer, etc shall be brought by the contractor and be included under this item.

For the longitudinal (L-seam) welds, the length of welds shall be measured in mm and will be divided by a factor of 105 for converting the length to “Inch Dia”.

5.1.1 STAINLESS STEEL BUTT WELDING

The welding shall be carried out by gas-purged Tungsten Arc Welding (GTAW/TIG) process with Argon gas (purity 99.99%) purging both inside and on the weld zone in outside of the pipe. The following welding is typical, but not limited to the work covered by this item:

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a. Pipe to butt weld fittings and flow components b. Butt weld fittings to butt weld fittings and flow components

c. Pipe to pipe and half sleeves of pipes

5.1.2 STAINLESS STEEL SOCKET WELDING

The welding shall be performed by (GTAW/TIG) process with Argon gas purging on the weld zone in outside surface of pipe. This welding involves, but not limited to welding of straight pipe to socket weld fittings, valves and half sleeves of pipes.

5.1.3 STAINLESS STEEL MITRE WELDING

This work involves all the operations including bevel-cutting of pipes to the required number & angle and welding the bevel-cut pieces to form a bend. The final bend angle may be required up to 90o. One “Mitre joint” means making a bend up to 90o by welding together 2 or more bevel-cut pieces, as may be required. The rates quoted per “Joint” shall include the number of bevel-cuttings and the number of welds required to make a bend. The welding shall be performed by (GTAW/TIG) process with Argon gas purging both inside and outside the pipe.

5.1.4 CARBON/MILD STEEL BUTT WELDING AND DPT

The root pass shall be carried out by TIG welding process with complete purging inside the pipe with argon gas. After the DPT clearance of the root subsequent passes of the welding shall be carried out by Shielded Metal Arc Welding (SMAW).The welding Electrodes selection and usage only after clearance from IPRC Inspection team clearance. The following welding is typical, but not limited to the work covered by this item:

a. Pipe to butt weld fittings and flow components.

b. Butt weld fittings to butt weld fittings and flow components.

c. Pipe to pipe.

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5.1.5 CARBON/MILD STEEL SOCKET WELDING AND DPT

The welding shall be performed by SMAW process. The welding involves, but not limited to, welding of straight pipe to socket weld fittings and flow components.

5.1.6 CARBON/MILD STEEL MITRE WELDING AND DPT

The method of making the mitre joints shall be the same as that give in Paragraph 5.1.2, except that the welding is performed by SMAW process without purging.

5.2 RADIOGRAPHY

The rates shall be quoted per weld joint /Inch Dia radio graphed for different range of sizes, but irrespective of schedules and material. The mobilisation charges for the X-ray machine shall be quoted separately. This item is indented to cover all the operations and arrangements such as supply of X-ray machines, penetra-meters, screens, films, necessary scaffoldings if any, etc., required for performing radiography of welds. 100% of the stainless steel butt weld and mitre weld joints along with heat affected zone shall be radio graphed. Radiography shall be conducted as per the relevant procedures and codes. In all radiography films, 2-2T sensitivity level shall be achieved. The quoted rates shall include supply of good quality film and developing charges of film. The developed film shall be handed over to the Department with the joint identification number marked on the film. During the inspection, if any defect is found, it shall be the responsibility of the contractor to rectify the defect or re-execute the work with out additional charge for both welding and radiography. It is required to carry out the radiography of joints using X-ray machines only. The joint(s) which are inaccessible for X-Ray machine shall be carried out by Gamma-Ray source of 2-2T sensitivity level. However the decision (“inaccessible for X-Ray”) shall be taken only by the Department.

5.3 CHEMICAL CLEANING

The rates shall be quoted to `inch-metre’ of the pipeline cleaned. The rates quoted shall include the cost of all chemicals, SS wire

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brushes, pumps etc. After hydrostatic/pneumatic testing, the surfaces of all stainless steel pipelines shall be cleaned as per the following procedure:

5.3.1 MECHANICAL CLEANING:

All the metallic surfaces with scales and newly welded surfaces shall be cleaned by scrubbing with stainless steel metallic wire brush.

5.3.2 PICKLING: (Pump circulation is only allowed for pickling and passivation process)

This is done to remove rust and scale. This is done by cleaning with water, followed by pickling with a solution containing Hydro-fluoric acid (HF) and Nitric acid (HNO3). The composition of the pickling solution and duration are adjusted after trial test on a sample piece to remove uniformly less than 25 micron thick material. Mostly the composition is

HF : 5% (by mass)

HNO3 : 15 to 20 %

Water : Remainder

This is followed by rinsing with water.

5.3.3 PASSIVATION:

It is done with a solution of the following composition

HNO3 : 25% (by volume) Water : 75 % Duration : 2 hours (minimum)

This is followed by rinsing with clean water. The supply of clean water is under the scope of the Department. The litmus paper required for checking the PH of rinsed-out water is also under the scope of Contractor.

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5.4 REMOVING WORK DONE FOR RE-WORK OR ALTERATION

This item is intended to cover alterations or modifications to work actually erected in the field or completely re-fabricated, pre-fabricated spool pieces. Re-work may be necessitated as a result of drawing changes, specification changes, changes in materials, dimensional changes, changes of line size or combinations of any of the above mentioned changes. The contractor shall be responsible for notifying Department immediately when a change arises, which affects work partially or wholly completed. Any re-work performed by contractor without written authorisation from the Department will be done at contractor’s own risk and expense. The mode of payment for this item will be on an open cost and/or unit rate basis. All work involved in salvaging will be paid for at the open cost rate which shall be indicated in the quotation. The fabrication and erection of new replacement materials, which replace the rejected sections, will be paid for at unit rates applicable to the various functions of work.

The contractor shall note that all costs incurred as a result of re-work or alternations to complete work will be paid for under this item and not under any other item. Additional work in the shape of new piping runs extensions to existing lines that do not require any re-work will be paid for at the appropriate unit rates shown under the different headings.

5.5 RETRIEVAL OF PRE-WELDED FITTINGS AND FLOW

COMPONENTS

This work may be a continuation of the works defined in point 5.7. The work shall involve removing the weldment by grinding between the pipes, fittings and flow components from the dismantled segment of the pipeline assembly and retrieving the fittings and flow components to re-usable state. The price to be agreed under this heading shall be per “inch-diameter joint” of the pre-welded fittings and components retrieved, but irrespective of the schedule number.

5.6 DISMANTLING OF PIPELINE ASSEMBLIES

Due to changes brought in the Engineer-in-charge of the facility, it may be required to dismantle pipeline assemblies installed either by the same contractor or by some other contractor. The work shall involve cutting the specified segment of the pipeline

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assembly, removing U-clamps from supports and shifting to the store of the work site. The work shall also include removal of cladding and PUF insulation in case of insulated pipelines. The prices to be agreed upon under this heading shall be per “inch-metre” length of the segment of the pipeline assembly dismantled.

5.7 STRUCTURAL WORKS

5.7.1 Structural Works Excluding Supply Of Structural Materials

(Supply of Structural Materials under the Scope of Department)

The rates shall be quoted per tonne of fabricated structure. The required structural steel materials shall be supplied by Department. The work under this item cover design, fabrication, assembly, installation and painting of all types and sizes of structures like pipe supports, templates and any other type of structure as may be required by the Department. The contractor shall get approval for the design and drawings from the Department. Handling, fabrication, cutting, drilling, machining, welding, assembly, installation and adjustment of the structures according to their specifications and drawings at specified locations are also included in the scope of work. There shall be no limitation on the number of welds or drillings to be carried out per tonne of the structural works.

The payment will be made based on the weight of the fabricated structure painted with 2 coats of zinc chromate primer and 2 coats grey colour chlorinated Rubberised paint over it. The contractor shall obtain necessary approval before selecting the colour shade and brand of the paint. If the painting on the structural members constructed by the department is removed or scratched off due to mounting and installation works carried out by the contractor, then such materials shall be painted properly with the same colour by the contractor. The cost quoted under this item shall take into account the fabrication losses of material. The weight will be calculated based on geometry of the structure and density of the steel used.

5.8 PAINTING

The work shall include supply of reputed brand Chlorinated Rubberised (CR) Paint, Zinc chromate primer and arrangement of necessary scaffolding, spray gun, paint brush, abrasive paper, etc. The painting shall be carried out on flat and curved surface on

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following 4 modes. The rate shall be quoted per Sq.Mtr. of painted surface for each mode of painting.

- Applying only Primer – 2 coats by Brush - Applying only Paint – 2 coats by Brush

� Painting Procedure � The surfaces to be painted shall be thoroughly cleaned (using metal

brush, abrasive paper, etc.) dried and shall be free from oil & grease.

� Painting shall be carried out in compliance with the specifications

given in the drawings.

� Chlorinated Rubberised (CR) Paint and Zinc chromate primer of reputed brand such as “Berger” make shall only be used.

� The primer should be applied within 2 hours after preparation of

the surface.

� Painting shall be done only after the primer has completely dried.

5.8.1 COLOUR CODING

All the pipes shall be colour coded (colour bands) using paint (2 coats). Painting and colour coding of these lines shall be done in accordance with the instruction given in the piping layout drawings.

5.8.2 LETTER WRITING

Marking of all pipelines and flow components with their identification remarks like tag number, name plate details, etc. Stencils shall be used for painting alpha-numeric characters. Prior to painting, the surfaces shall be prepared in compliances with IS 147 Part I and II. The requirements of this standard shall be considered the minimum acceptable criterion. Letter shall be written over the painted surface. The rate shall be quoted “per letter” for a Letter Height ≤ 1 Inch and for letter height more than 1 inch the rate shall be quoted for “inch – height letter ” for diff. range of size (height).

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The scope of work under this item includes surface preparation, supply of primers, paints, painting brushes, thinners, etc and painting (writing of letters). All the surfaces shall be initially painted with 2 coats of Zinc chromate primer. The surfaces shall be finally painted with 2 coats of chlorinated rubber paint over which the letters shall be painted (written). The surface preparation and painting shall be performed to the satisfaction of the Department. The colour scheme will be provided during the execution of work.

6.0 WORK SITE CONDITIONS

6.1 SITE ESTABLISHMENT

The contractor shall provide sheds, stores, tarpaulins and other

covers for the accommodation of his workmen and materials. All materials likely to deteriorate in the open area shall be stored under suitable cover. The contractor shall mention in his bid the site requirements, which shall include the office, covered storage, open storage, fabrication yard, dark room, etc. Space shall be allotted to the contractor for erection of his sheds and storage of materials, but he will not be permitted to make use of any other space without the prior written permission/ approval of the department. The sanitary conditions of the ground in and around such areas shall be maintained by the contractor.

Security of the contractor’s equipments and materials is his own responsibility. The contractor shall ascertain what security arrangements are made available on site by the department and make his own arrangements for additional security as he may think necessary. The department accepts no liability for loss or damage to the contractor’s materials.

The material issued to the contractor by the department will remain under the custody of the contractor. The contractor will be responsible for loss or damage of such materials and shall preserve them in a good working condition as required for the contract and good construction practices till such time that they are erected, aligned, fully installed in position and handed over to the department.

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In case, the department feels that the arrangements made by the contractor are not adequate, department shall so advice the contractor and the contractor promptly take corrective action. In case contractor fails to take corrective steps within reasonable time, then the department will take corrective action, and recover the cost thereof from the contractor’s bills.

The contractor shall provide all necessary equipments, tools, tackles, etc, necessary to complete the works under the contract. Such materials shall not be removed from the site till completion of the work. A gate pass must be obtained from the department in order to remove from site any tools, materials and equipment.

All employees of the contractor shall comply with the rules of conduct, established by the department. Failure to do so will be sufficient cause for removal of such person from the site.

It is the responsibility of the contractor for safe un-loading and storage of his own materials and also for safe transportation of free-issue material from the department’s store and its proper storage at the work area.

6.2 ELECTRICITY

The bidder shall mention in his bid, his electrical power requirement to allow the department for planning the temporary electrical supply. Supply of electricity will be made available at one point, on chargeable basis at prevailing tariff rates to the contractor.

For welding in the test stand area, the department will terminate the electrical power supply near the test stand. The maximum distance between the cable terminal point and any area in the test stand where welding is required will be 200m. For welding the lines which runs over, other than test stand structure, the maximum distance between the cable terminal point and any area where welding is required may be 300m.

The contractor shall arrange for his own power distribution board with switch-cum-fuse unit and calibrated energy meter. Necessary power cabling from the department’s power isolator (terminal point) to the contractor’s utility points shall be provided by the contractor.

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The joints on the cable shall be properly insulated. All temporary cabling must comply with local regulations and subject to the department’s satisfaction before giving power supply.

6.3 WATER

Free supply of water will be made available at one point on the site. Any further distribution will be the responsibility of the contractor.

6.4 MESSING & ACCOMMODATION

The contractor shall make his own arrangements for messing, accommodation and food for his employees.

6.5 FIRST AID

The contractor may have access to the purchasers’ qualified first aid personnel and ambulance in case of accidents, subject to the availability of the same. However, the contractor shall make his own medical and transport arrangements to take care of his employees in case of accident. The contractor shall provide a first aid kit at the work site to meet the requirements of minor injuries.

6.6 SUPERVISION OF WORK

The contractor shall submit to the department a resume of his Site – in – charge / supervisor(s) for approval, prior to commencement of the work. Once approved, contractor shall not remove his Site – in – charge / supervisor(s) without prior concurrence of the contract Manager of department.

6.7 EMPLOYMENT OF LABOURS

The contractor will be expected to employ, on the work, only his

regular skilled employees with experience of this particular work. No female labour shall be employed after normal working hours. No person below the age of 18 years shall be employed.

The contractor shall pay to each person, wages not less than those paid for similar work in the neighbourhood. The employees / labour, for carrying out all the site works shall be identified well in advance by the contractor and necessary approval shall be obtained from the department for entry to the work site. The contractor shall be

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liable to comply with all relevant laws of the land with respect to all the labours deployed for the work either permanently, temporarily or contracted.

The Contractor shall identify the different categories of personnel with their names and designations, who shall be deployed by him for the site work. The Contractor shall indicate against each name of the personnel, the duration for which the presence of the personnel will be required at the site.

The hours of work on the site shall be decided by the department and the contractor shall strictly adhere to it. Normal working time will be 8 hours per day. Monday through Saturday except government holidays, permission to work on other days may be granted at the purchasers’ discretion, on the written request from the contractor.

It is the responsibility of the contractor to meet all the expenses including provision of necessary transport to and from the work site, lodging, allowances and other payments to the contractor’s employees. All the contractor’s employees shall wear identification badges while working on site. All notices displayed on the site and any instructions issued by the department must strictly adhered by the contractor’s employees.

6.8 REPORTING

The manager ESTF/ Dy.Manager, PTS responsible for the execution

of work on the part of Department shall be designated as contract manager. The contractor must report the following information to the contract manager by the end of every week.

a) Number of men employed, by trades b) Progress achieved c) Expected dates for completion of individual works d) Any actual or likely delay in the execution of work

6.9 WORKING AND SAFETY REGULATIONS

The contractor at his own risk shall be responsible for;

1. The safety of his men, materials, etc. 2. Arranging necessary insurance coverage for his employees

and labours.

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The contractor shall carryout the works in strict compliance with the Departments safety norms & Instructions. The safety team of Department is authorised to stop the work found breach of any of the safety norms & Instructions. The contractor shall observe all statutory and legal requirements enforced by Central and State Government applicable to the work as well as any local regulations applying to the site issued by department or any other authority. Particular attention is drawn to the following;

a) In case of accident, the Department shall be informed in

writing forthwith. The contractor shall strictly follow the regulations laid down by the Factory Inspector, Central and State Government authorities in this regard

b) Compliance with all electricity regulations

c) Compliance with statutory requirements for inspection and test of all lifting appliances and auxiliary lifting gear

The Contractor will notify the department of his intention to bring on to the site any equipment such as space heating or welding apparatus, or any container holdings liquid or gaseous fuel or other substance, which might create a hazard. The department will have the right to prohibit the use of such equipment or to prescribe the conditions under which such equipment may be used. The department will have the right to inspect any construction plant and to forbid its use, if in its opinion it is unsuitable or unsafe. No claim arising there from shall be made by the contractor. The contractor or anyone acting on his instructions will not bring on to the site any radio-active substance or any X-ray apparatus until written permission and direction regarding the use of such equipment has been received from the department. The contractor shall be responsible for the safe storage of radiographic sources of those of his sub-contractor. The contractor shall be responsible for the provision of all safety notices and equipments required by the relevant legislation as the department may deem necessary.

6.10 ELECTRICAL SAFETY REGULATIONS

In no circumstances will the contractor interfere with fuses and electrical equipment belonging to the department or other contractors. Before the contractor connects any electrical appliance

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to any plug or socket belonging to other contractor or department, he will

a) Satisfy department that the appliances are in good working condition

b) Inform the department of the maximum current rating, voltage and phase of the appliance.

c) Obtain permission of the department detailing the

sockets, to which the appliance may be connected

The department will not grant permission to plug-in until the department is satisfied that:

a) The appliance is in good condition and is fitted with

suitable plug.

b) The appliance is fitted with suitable cable, having two earth conductors, one of which shall be an earthed metal sheath surrounding the cores.

No electric cable in use by the department/contractor will be disturbed without prior permission. No weight of any description will be imposed on any such cable and no ladder or similar equipment will rest against or be attached to it. The voltage for all portable equipments like drilling machines, temporary lighting etc, shall be 240 ± 10% volts. No work must be carried out on any live equipment. Then equipment must be made safe by the Department and a “permit-to-work” issued before any work is carried out. Contractor shall employ a full time electrician to maintain his temporary electrical installations.

7.0 GENERAL TERMS AND CONDITIONS 7.1

CONTRACT PRICE

The prices quoted shall be firm and fixed and applicable for the

entire duration of contract subject to the work variation given in section 7.2. The bidder shall include in his bid, the cost of the following apart from those elaborated under the heading “Description of work” given in section 3A. No payment will be made under any heading other than the ones mentioned in the contract and there fore the bidder shall include the prices of any

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other material supply, services, etc to be rendered for completion of full scope of the work of the contract in the appropriate headings.

a. Mobilization of contractor’s equipments & materials.

b. Temporary construction of site office, stores, dark room

and work shops.

c. Suitable storage facility for contractor’s equipments & materials including the provision of covered shed for storage of Department supplied materials.

d. Transportation of materials from the department storage yard to the work site, loading & un-loading, etc.

e. Cost of consumables such as Industrial gases, filler wires, welding electrodes, X-ray films, chemicals for DP test, etc. for the effective execution of the work.

f. Statutory Insurance coverage for Contractors work force (labours) and equipments.

g. Mobilisation charges for ‘X’ Ray/ gamma ray source shall be quoted separately.

h.

Documentation.

7.2 VARIATION IN CONTRACT VALUE DUE TO THE VARIATION

IN THE QUANTITY OF EACH WORK COVERED UNDER THE CONTRACT.

Quantity variation shall be allowed up to ± 25%.

7.3 SCHEDULE OF CONTRACT AND WORK EXECUTION

The effective date of contract shall be the date of awarding work

order or any other date mutually agreed upon by the Department and the Contractor. It is to be noted that the commencement of actual work may sometimes be possible only after 4 months from the date of award of contract. The entire works under this Contract shall be completed within 6 months from the effective date of Contract. In the total contract period of 6 months, the work site (PTS/ATB test stand) will be made available only for 3 to 4 months. However, the contractor has to carryout pre-fabrication

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works immediately after the effective date of contract at the place nearer to the work site identified by the department.

The Contractor shall furnish a detailed schedule of work execution within 15 days from the date of award of Contract. The schedule of work execution will be scrutinized and approved by Department and the approved schedule chart will be used as a work progress monitoring tool. The contractor shall employ necessary manpower at least not less than the number given below in the Table; Also carbon steel welding work and S.S welding work shall be identified by the controller.

Separate bath shall be identified for

Sl.No DESIGNATION Ammonia

system

(C.S welding

team)

PTS & ATS

(S.S

welding

team)

1. Supervisor Quality Assurance

1 1

2. Supervisor execution 1 1

3. Fitter 4 4

4. TIG Welder (X-Ray Quality) 2 to 3 2 to 3

5. Structural Welder 1 1

6. Rigger 4 3

7. Helper 4 4

7.4 SUB – CONTRACTING

The contractor shall not assign or subcontract the work or any part of the work without the written approval of the department. The responsibility of the performance of sub-contractor shall lie with the contractor. Any delay in carrying out the work by the subcontractor which affects the overall schedule of the work does not absolve the contractor from payment of compensation for the delays. All terms and conditions applicable to the contractor shall also be applicable to the sub-contractor.

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7.5

CONFIDENTIALITY:

The technical information, drawings, specification, and other related documents forming part of enquiry or contract are the property of the department and shall not be used for any other purpose except for the execution of the contract. The technical information, drawings, and other documents shall not be copied transcribed, traced or reproduced in any other form or otherwise in whole and / or duplicated, modified, divulged and / or disclosed to a third party and / or not misused in any other form whatsoever with out the departments consent in writing except to the extent required for the execution of the contract. These drawings, technical information, specifications and other related documents shall be returned to the department with all approved copies and duplicates, if any immediately after they have been used for the agreed purpose.

7.6 WARRANTY

The Contractor shall provide warranty for the systems fabricated under this contract for work man ship for a minimum period of 18 months from the date of final acceptance of the systems by the Department.

7.7 CANCELLATION OF CONTRACT

The department have the right, at any time, to cancel the contract,

either wholly or in part by giving written notice. The contractor shall under take to observe the instructions of the department as to the winding up of the contract both on his own part and on the part of his sub – contractors. In case of cancellation of contract, all finished / completed work item will be taken over by department at the price specified in the Contract.

7.8 DEPARTMENT–FURNISHED MATERIALS (“FREE ISSUE MATERIALS”)

The required materials such as pipes, pipe fittings & flow

components will be issued by the Department as Free-Issue material and to be erected by the Contractor.

In the event the contractor damages the Department furnished materials (above normal fabrication loss as given below) or if the contractor work is rejected by the Department, the contractor shall furnish, free of cost, replacement material of equal quantity or at

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Departments option, the cost of damaged materials shall be deducted from the contractor’s invoices. Normal fabrication loss to be permitted to the Contractor as stated above shall be as under;

Sl. No

Item Salvageable Un

accountable

a. Pipes 3 % 0.75 %

b. Flow components , pipe fittings, etc

Nil Nil

c. Bolts & Nuts Nil 0.50 %

The Contractor shall take delivery of materials from the storage area of Department in a systematic manner to follow sequence of erection. Indents for materials shall be placed at least 2 days in advance, so that the department can make prior arrangements to deliver the materials. Materials delivered shall be transported to work site, unloaded, and stored properly by the Contractor. The Contractor will set up an intermediate store, where they will store all the materials being issued from the Department’s stock for convenience and proper scheduling of erection work. The Department reserves the right to verify, at any time, the stock of the materials supplied as free issue to the Contractor.

7.9 INSURANCE COVERAGE FOR CONTRACTOR’S EMPLOYEES/ LABOURS

It is the responsibility of the contractor for arranging necessary

insurance coverage for their employees and labours as per statutory requirements. It is compulsory to produce records of insurance details to the Safety division of Department for obtaining “Safety Permit” to commence site work by the Contractor.

7.10 DOCUMENTATION

7.10.1 DEPARTMENT PROVIDED DOCUMENTS:

The technical details and drawings given in this tender document are indicative of work to be performed under this contract and deemed to be sufficient for the bidder to comprehend the scope of work.

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In the event of the contract awarded, approved drawings for construction will be issued to the contractor progressively during the execution of work. Work shall be carried out strictly as per the drawings marked “good for construction” duly signed by the departments’ contract manager.

After completion of work, it shall be the responsibility of the contractor to prepare and submit “as built” piping layout and isometric drawings, taking in to account of actual dimensions after installation

7.10.2 DOCUMENTS TO BE PREPARED & SUBMITTED BY CONTRACTOR:

In the course of execution of the contract the contractor shall

prepare and submit the following document.

� Procedure for welding and welder qualification tests.

� Isometric drawings based on the piping layout supplied by the Department

� Log sheet for welding

� Certificates signed by QC – ESTF of the Department for stage inspection and clearance.

� Certificates signed by QC–ESTF of the Department for testing of pipelines and clearance.

� Records for the free issue materials

� The X-ray films of weld joints.

� As built Isometric and piping layout

The contractor shall be responsible for the preparation of all additional fabrication drawings/sketches, which he may feel necessary to supplement the ‘Good for construction’ documentation supplied by the Department. Before completion of the work, the contractor shall furnish 4 sets of all the drawings prepared by him of the piping actually erected and assembled at site. The documents softcopy shall also be provided in compact diskette (CD), besides the 4 sets of hard copies.

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Any work carried out by the contractor prior to the issue of ‘Good for construction’ drawings shall be at the contractor’s risk. The contractor shall only make change to his drawings with the prior approval of Department, which are necessary to conform to the requirements of the contract. These shall be carried out at no additional cost to the Department. Approval of the contractor’s drawings shall not relieve the contractor of any of his obligations to meet all the requirements of the contract or the responsibility for the correctness of his drawings.

Contractor shall submit for approval his proposed weld procedures, together with procedure qualification and shall obtain written approval from the Department before commencing welding. Procedures shall be submitted in 4 copies. If the procedure has been qualified and the particular electrodes used in the original qualification are not available, then contractor shall re-qualify the procedure in the presence of QC ESTF division of the Department, who shall approve the procedure before it is used on production welding.

The contractor shall ensure that any welder employed on the work shall be qualified on the weld procedures being used before being permitted to weld. If welders qualification on the procedures is more than six months old before the proposed commencement date of this contract, he shall be re-qualified. The contractor shall furnish to the Department 4 copies of all inspection document and test certificates approved by QC-ESTF division of the Department. Further 4 copies of the test certificates shall be submitted for all tests covered in the contract along with the completion and acceptance reports.

7.10.3 ERRORS OR OMISSIONS IN CONTRACTOR’S

DOCUMENTATION

The contractor shall be responsible for and shall bear the cost of any alteration of the work due to discrepancies. Errors or omissions in the drawings or other particulars supplied by him, whether the drawings or particulars have been approved by the Department or not, provided that such discrepancies, errors and omissions are not due to inaccurate information or particulars furnished to the contractor by the Department.

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7.11 SETTLEMENT OF DISPUTES

Except as otherwise specially provided in the contract, the

nature of matter (dispute), arising under the contract shall be determined by the Department. If amicable settlement of occurred disputes can not be reached by the parties, then it shall be referred to the arbitration of sole arbitrator to be appointed by the Director, IPRC in accordance with the Arbitration and Conciliation Act 1996, whose decision shall be final and binding on both parties.

8.0 INSTRUCTION TO BIDDERS

8.1 MAN POWER

The contractor shall employ necessary manpower at least not less than the number given in Serial No.7.3.

8.2 SITE VISIT

The contractor is allowed to visit the Department’s site during working days (Monday to Friday) to have a clear understanding of the site conditions and job nature before submission of quotation. 8.3 AVAILABLITY OF SITE FOR ERECTION ACTIVITIES

Vendors will be allowed to execute the contract work after placement order & clearing the site to take of the erection work. However the work will be intervened due to the occupation of test facility towards hot testing activities, during that period, work will be stopped temporarily.

8.3.A The work package will be assigned to a single contractor (over all Lowest offer) for completing the entire scope of work due to the following facts:

The entire work will be executed by the contractor at multiple subsystems and are interlinked with the main facility.

8.4 INSURANCE

It is the responsibility of the contractor for arranging necessary insurance coverage for their employees and labours as per statutory requirements. It is compulsory to produce records of insurance details

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to the Safety division of Department for obtaining “Safety Permit” to commence site work by the Contractor.

8. 5 PRICES

The bidder shall quote firm and fixed prices valid during the currency of contract till completion and final acceptance of the works.

8.6 PIPELINE SIZE AND DIMENSIONAL STANDARD

Fluid circuits of additional bay SYSTEM

: Stainless Steel pipes as per ANSI B36.19

: Carbon Steel pipes as per ANSI B36.10

8.7 THE UNIT OF MEASURE “INCH-DIA” & “INCH-METRE”

INCH-DIA : 1 inch diameter. For example, if unit cost for welding is given in Inch-dia for a varying size range, then the cost per joint of particular size within the given range is the pipe nominal Size multiplied by the Inch-dia cost. INCH-METRE : 1 Inch size pipe of 1 meter length. For example, if a 4 Inch size pipeline of 1 meter length is hydro tested then the quantity hydro tested is 4 Inch meter.

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