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TECHNICAL SPECIFICATION

FOR

FPS PIPE FABRICATION

FOR SPP FACILITIES

JANUARY, 2019

SDSC SHAR, SRIHARIKOTA

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SPECIFICATION FOR FIRE PROTECTION SYSTEM PIPING FOR SPP FACILITIES 1.0 Introduction

Fire protection system yard and Deluge System or Sprinkler System are to be erected for different facilities in SPP, SDSC-SHAR. Tapping to these shall be taken from the existing available pipe line available near to the facility. In the yard piping fabrication, hydrant and water monitor systems meant for these facilities are to be erected as conceived.

2.0 Scope of work of the Contractor / Vendor: 2.1 Supply and erection of following materials including handling and unloading at work

spot (refer BOQ for quantity and other details):

Ø Fittings like reducers, tees etc Ø Introduction of isolation butterfly valves to facilitate isolation of building as per

annexure Ø Paints- epoxy mastic primer and aliphatic polyurethane finish coat. Ø Preparation of as built diagram, piping schematic and piping layout drawings after

the completion of the work. Ø Civil RCC pedestals are to the required quantity & dimension as per the drawing

shall be constructed wherever specified in the drawings. If not provided for the locations will be issued later while carrying out the work at SPP site. For pedestals grade shall be of RCC grade M35. cement shall be of PPC (Portland Pozzolana Cement). Construction & cube testing requirements shall be as per IS 456:2000.

2.1.1 Mobilization of following work front for completing the total scope of the work Ø Machinery (welding, grinding, cutting, painting, NDT, testing etc) Ø Man power (skilled, semi skilled and helpers / labourers) Ø Tools and tackles and measuring instruments Ø Fabrication fixtures and scaffolding Ø Fabrication and testing consumables Ø Transportation to and from work spot, boarding and lodging of contract staff Ø Receipt of department free issue materials from department stores, loading /

unloading, handling and transportation to work spot. After completion of work excess free issue material shall be returned back to stores before completion of work, SPP.

2.2 Hydrant and Water monitor System: Ø Providing hydrant and water monitor system for the Building by suitably tapping

from the 600/300NB size pipe line as shown in the drawing. Ø Introduction of isolation butterfly valves to facilitate isolation of hydrant system. Ø Preparation of P&I diagram, piping schematic and piping layout drawings. Ø Providing structural steel piping supports for the piping header. Ø Fabrication of piping header spool pieces and hydrant branch headers as per

approved P&I and Piping layout drawings. Ø Fabrication of flanged piping spools meant for road crossings including fabrication

of piping shoes, hydro testing, application of multilayer wrapping tapes of (minimum 100 mm width x 4 mm thick) over the hydro tested spool piece

Ø Providing isolation valves and providing double landing valves and pressure gauges with root valve for the hydrant system.

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Ø Edge preparation, fittup, Fabrication of piping header spool pieces and branch headers consisting of pipe and pipe fittings as per approved P&I and Piping layout drawings.

Ø Dismantling of existing pipeline max of 100m and erecting new pipeline wherever applicable. Cost to be included in the erection cost of pipelines.

Air actuation piping network system: (if required) Ø Air actuation piping network system of Building NO. 1 by suitably tapping from the

Air compressor erected in the deluge/sprinkler Room. Ø Introduction of isolation ball valves to facilitate isolation of air actuation system Ø Providing anchor fasteners for deriving the support from columns / beams and from

roof, wherever embedment plates are not available Ø Erecting with structural steel materials, requisite column / wall brackets for vertical

piping and roof hanging supports for detection piping network laid below the roof, for supporting the above piping network.

Ø Fabrication of piping header spool pieces and branch headers as per approved P&I and Piping layout drawings. Bending of seamless pipe is allowed provided hydraulic bending machines are used by vendor.

2.3 Fabrication Procedure for 2.2 Ø Laying of pre-fabricated piping spool over pedestals / pipe supports, assembly of

flow components, alignment, and field welding by SMAW/TIG process welding with arc electrodes of ER70S2/6 for root pass and electrodes confirming to AWS classification ER 7018 for final pass.

Ø Only qualified welders with proven track record will be permitted to carryout of the welding works. Qualification of welder need to be carried out in the presence of department Engineer suiting to the pipe size / schedule requirements. Fitters/Fabricators/Grinders should be well experienced. Test shall be the party scope. Weld joint test report shall be submitted from the approved TPI agency.

Ø Providing slope, required vent and drain points as per code. Ø Necessary openings in walls of buildings for the pipeline work including making the

wall shall be carried out by the party. Ø Providing Wrapper coating: Wrapper coating of buried MS pipe and MS pipes inside

Hume pipe with 4mm thick multilayer wrapper coating tapes as per AWWA C203. It may be noted that for hydrant stand posts which will project above ground level, shall be protected by wrapper coating for the entire MS portion inside ground and up to 200mm minimum from formed ground level. The application, characteristics of material and testing requirements shall strictly as per IS: 10221. Excavation, back filling of excavated sand shall be considered while estimating.

Ø Carrying out 100% DPT for root pass of butt welds and final pass of socket and branch welds, including consumables like cleaner, dye and developer spray canisters

Ø Carrying out 10% radiography of 2-2T penetrameter sensitivity on total butt weld joints

Ø Above two tests shall be carried out by the TPI agency in the presence of NDT expert available with the department.

Ø Preparation of weld joints and fabrication history sheet and taking clearance for hydro test from department inspector.

Ø Carrying out hydro test of piping spool, followed by integrated hydro testing of overall pipeline for leak tightness as per approved procedure and as per relevant ASTM standards at 1.5 times the maximum operating pressure.

Ø Painting of pipe line and supports as per approved procedure, with epoxy primer (DFT 110microns) and aliphatic polyurethane finish (DFT 40microns) for a total DFT of 150microns.

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Ø Boxing up including fixing of hydrants and water monitors including tag numbering of pipe line and flow components.

Ø Commissioning by way of functional water flow test for yard piping and flood testing for deluge / sprinkler system as per approved procedure.

Ø Necessary covering materials shall be arranged to cover all the electrical and electronics items in the facility.

Ø Handing over the system including as built drawings and documents as per PO terms.

Ø All the requisite test for qualifying the pipeline like DP, Radiography etc shall be cleared/preformed only by a competent third party agency. All requisite authorization document, qualification certificates and relevant documents as asked by the department of Third Party Inspector shall be submitted for getting approval.

3.0 Scope Of Department (Free Issue For Contractor) as per annexure 4

Ø Construction Electrical power and water. (Vendor shall arrange for extending power with necessary junction boxes, fuses, cables etc / water /air supply from the facility to the work spot) Ø Pipes and butterfly valves will be made available at department stores. (1.5km from

work spot) Ø Hydrants valves and water monitors will be given to the party. Ø Required quantity of wrap coat material with primer will be made available to the

party

4.0 Bill of Quantity & Quantity Variations Ø It is to be noted that the BILL OF MATERIALS is only indicative and parties has to

supply all the materials required to complete the work to meet the requirement as stipulated in the tender. The extra materials supplied and erected as per the site requirements shall be paid as per the unit rates.

Ø A quantity variation of 10% in each item as per BOQ shall be allowed to account for variation in routing owing to prevailing site conditions in the field. However, payment will be made for the actual quantity erected and tested.

5.0 General conditions Ø Sriharikota is an island located 18km from Sullurupeta (the nearest railway station).

It is bounded by Bay of Bengal and Pulicat Lake. The work site is located about 14.0 km from main gate of Sriharikota. Vendors have to arrange own transport for his personnel to and from the work spot.

Ø The parties are requested to quote after visiting the site for assessing the requirements and site conditions.

Ø Parties should give compliance/deviation/remarks point wise. Quotations of parties without enclosing this will not be considered.

Ø The parties should be in a position to complete the entire work in 180 days from the date of placing the order.

Ø The representative of the department shall have access and right to inspect the work at all times, during the course of installation and commissioning. The party without delay and without any extra cost shall correct any work, which is found faulty. The department has no obligation to discover defects in the work performed and it shall be the sole responsibility of the party (CONTRACTOR) to ensure such completed work is defect free and meets the technical specifications / requirements.

6.0 Quality assurance plan (QAP):

The vendor has to check and produce all the necessary certificates, procedures and plan, at various stages during progress of work for approval to the purchaser.

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7.0 Warranty

Ø Warranty period shall be for a period of 12 months, commencing from the date of acceptance & taken over by the purchaser or 18 months from the date of supply of items.

8.0 Delivery & Commissioning conditions:

Party shall complete supply, erection, testing and commissioning of all the items with in 180 days from the date issue of order.

9.0 Documents to be given during commissioning of the system Ø After awarding the contactor: Contractor has to submit the following for approval

· Work execution plan / PERT · Procedures for approval (PQR, WPS, Equipment erection, alignment of

pipeline, radiography, hydro/pneumatic test, painting) · Monthly and weekly schedules

Ø During the execution of work: · Preparation of material identification · Preparation of line and weld history sheets · Preparation of test packs · Preparation of as built drawings

Ø After commissioning (3 sets) · Submission of as built drawings. · Submission of final test dossier with neatly bounded condition

10. Liquidated Damages In all cases, delivery schedule indicated in the Purchase Order/Contract is the essence of the contract and if the party fails to deliver the material within the delivery schedule, Liquidated Damages will be levied @ 0.5% per week or part thereof subject to a maximum of 10% of total order value.

11. Performance Bank Guarantee

Performance Bank Guarantee for 10% of the order value should be furnished in the form of Bank Guarantee from nationalized/scheduled bank or by Demand Draft valid till warranty period plus sixty days as claim period.

12. Security deposit

Party shall submit security deposit, within 15 days of Order Acknowledgement, for 10% of the total order value. Security Deposit shall be obtained through Bank Guarantee or fixed deposit receipt from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value and shall be valid for a period of sixty days beyond the date for completion of the Purchase Order.

13. Payment Terms

Payment will be made on pro-rate basis against submission of bill. Centre Level Inspection Panel (CLIP) approval is to be obtained against the bill submitted. Payment will be made only after that. Payment against the work shall inspected by Engineer In-charge and the same shall be cleared by CLIP representative for the work. Wherever advance payment is requested, Bank Guarantee from any Nationalized Bank/Scheduled Bank should be furnished. In case of advance payments, if the party is not supplying the material within the delivery schedule, interest will be levied as per

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the Bank Lending Rate plus 2% penal interest in addition to the LD Clause. 14. Delivery schedule:

Party shall complete supply, erection, testing and commissioning of all the items within 180 days from the date issue of order.

15. Bid Qualification Criteria:

· Bidder shall submit the work order executed preferably to any one of ISRO centers related only to piping. Any other government / non-government fabrication work order is also can be submitted.

· Supply work order to ISRO centers or government organizations will not be considered. As the work involves fire water pipe fabrication, bidder shall have experience in pipeline fabrication, erection and commissioning.

· Minimum executed pipe fabrication work order shall be 20 lacs or more. Party shall submit the copy of the order along with quotation for bid evaluation. Bid, without the copy of work orders will be liable for rejection.

· Recent five years work order executed and its work order value shall be submitted to participate in the tender.

Annexure -1

LIST OF APPROVED VENDORS / MAKES

SL. No. ITEMS MAKE / MANUFACTURER

1 Fittings Rajmani/union/sangvi/bharat (if any) 2 Paint Berger Paints/ Asian Paints/ Goodlass

Nerolac/ Shalimar Paints 3 Welding electrodes ESAB / ADAR / L&T 4 Anchor Fasteners Hilti / Fischer / Powers

Bill of Materials (To be supplied and erected by vendors)

Annexure – 2 Sl. No

Description Standards / codes

Quantity to be erected

PIPING 1. a) Butt welding of pipes, fittings etc, by

SMAW/TIG welding process with filler rod ER70S2/6 for root and SMAW (E7018) Arc welding for subsequent passes with 10% radiography

ASME B 31.3 3200 InDia

2. b) Socket welding of fittings, slip on flanges etc by SMAW/TIG welding process with filler rod ER70S2/6 for root and SMAW (E7018) for subsequent passes

ASME B 31.3 2400 InDia

3. c) MS piping erection, installation of flow ASME B 31.3 18000 Inch.m

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components by providing adequate anchoring, clamping, testing, painting, tag numbering and commissioning

4. Road crossing: Erection of wrap coating as per the specification (with 4 mm thick AWWA C 203 tape, earth excavation, positioning of pipeline inside hume pipe or below ground level)

IS 10221 Wrap with

primer Department

scope

180 m2 of pipe is to wrapped with standard overlapping

CIVIL WORKS 5. Construction of civil pedestals specified as per the

drawing. Pedestal works includes excavation, wood / steel working,

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STURCTURAL STEEL 6. Erection of Structural Steel like rods, channels,

equal leg angle, plate * - Quantity indicated may vary due to site condition

1500

Notes:

1 No separate payment will be made for applying paints on pipe, structural steel. Same is to be included in the erection cost of pipes / channels and U-clamps.

2 No separate erection payment will be made for erection of isolation valves, strainer, fitting, U clamps and gaskets, hose box, QBDs, nozzles etc. Same is to be included in the erection cost per unit length of pipes.

3 The party may be paid as per the actual materials supplied and erected at site. 4 The party may quote unit rates separately for supply and erection of items respectively

wherever asked. 5 A quantity variation of 10% in each item as per BOQ shall be allowed to account for

variation in routing owing to prevailing site conditions in the field. However, payment will be made for the actual quantity erected and tested.

6 Order cannot be splited as it involves fabrication and supply of sub components. Realization is inter dependable. If any delay in one will affect the whole system realization. Hence, splitting not recommended.

Annexure – 3 List of layout drawings: S/No Drawing Description Drawing reference No. 1. Facility layout SPP/SAFETY/FPS/FACILITY LAYOUT/01 &

02.

2. Hydrant and water monitor drawing SPP/SAFETY/FPS/Yard piping/01.

3. Arrangement of underground

pipeline inside the trench

SPP/SAFETY/FPS/HUMEPIPE/01

4. Construction of civil pedestals RCC PEDESTAL FOR SUPPORT FFS

PIPELINES.

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Annexure - 4

Scope of Department (Free Issue Material* for Contractor) * - Quantity is indicative S/No Item description Specification Quantity, nos/m/m2

1. MS ERW & Seamless Pipes · 350 NB X 8.0 mm thick · 200NB X 6.35mm thick · 150 NB Heavy class · 100 NB Heavy class · 50 NB Heavy class · 25NB seamless pipe

IS 3589 Gr-Fe410 IS 3589 Gr-Fe410

IS 1239 IS 1239 IS 1239

ASTM A 106A

120 900 100 200 24

100 2. Butterfly valves

· 350 NB gear operated · 200 NB gear operated · 100 NB lever operated · 50 NB lever operated

Tested and manufactured as per BS 5155 / BS

5146 /

3 4

20 4

3. Single headed hydrant valves

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4. Water monitors 6 5. Wrap coat with primer 200 6. Deluge / Sprinkler valve 1

Annexure - 5 Mandatory Checklist to be filled and submitted for bid evaluation:-

Vendor shall fill the following checklist and submit with the offer. Deviation from point wise confirmation shall be spelt out clearly.

Sl. No Scope of work contractor Reference Sl. No. & Page No.

Confirmation Deviations, if any

1. Scope of work of the Contractor / Vendor 2 YES / NO

2. Mobilization of following work front for completing the total scope of the work

2 YES / NO

3. Hydrant and Water monitor System 2 YES / NO

4. Fabrication Procedure for 2.2 3 YES / NO

5. Scope Of Department (Free Issue For Contractor) as per annexure 4

4 YES / NO

6. Bill of Quantity & Quantity Variations

4 YES / NO

7. General conditions 4 YES / NO

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8. Quality assurance plan (QAP) 4 YES / NO

9. Warranty 4 YES / NO

10. Delivery & Commissioning conditions 5 YES / NO

11. Documents to be given during commissioning of the system

5 YES / NO

12. Liquidated Damages

5 YES / NO

13. Performance Bank Guarantee

5 YES / NO

14. Security deposit 5 YES / NO

15. Payment Terms 5 YES / NO

16. Delivery schedule:

6 YES / NO

17. Bid Qualification Criteria

6 YES / NO

18. Annexure 1 6 YES / NO

19. Annexure 2 6 YES / NO

20. Annexure 3 7 YES / NO

21. Annexure 4 8 YES / NO

TYPICAL ARRANGEMENT FOR WATER MONITOR AND HYDRANTDWG. NO: 2 SPP/SAFETY/FPS/Yardpiping/01