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HINDUSTAN PETROLEUM CORPORATION LTD.

HINDUSTAN PETROLEUM CORPORATION LIMITED,6th Floor, Scope Minar, Luxmi Nagar, Delhi

TENDER DOCUMENTFOR

CONVERSION OF 1x3500KL HSD TANK TO MTO,2x90 KL FROM ETHANOL TO HEXANE FOOD GRADE &

2x90KL FROM ETHANOL TO SOLVENT1425

AT BIJWASAN DEPOT, DELHI.

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INDEX

Sr.No.DESCRIPTION

PAGESFROM TO

1. TENDER COVER PAGE 1 12. INDEX 2 2

3. PROJECT DESCRIPTION & SCOPE OF WORK 3 6

4. TIME SCHEDULE 7 85. SCHEDULE OF QUANTITIES 9 236. TECHNICAL SPECIFICATIONS 24 158

a) CONCRETE & REINFORCEMENT WORKS 26 41

b) CIVIL WORKS 42 81

c) SPECIFICATION FOR WELDING 82 88

d) FABRICATION OF PIPELINE 89 111

e) FIELD PAINTING 112 117

f) SPECIFICATION OF SHOP AND FIELD PAINTING 118 123

g) STRUCTURAL STEEL WORKS 124 158

7. TECHNICALSPECIFICATION FOR SUPPLY ITEMS 159 182

8. QUALITY ASSURANCE PROGRAM FOR SUPPLY ITEMS 183 186

9. SPECIAL CONDITIONS OF CONTRACT 187 209

10. SAFETY, HEALTH & ENVIRONMENT 210 219

9. DRAWINGS 220 223

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PROJECT DESCRIPTION&

SCOPE OF WORK

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SCOPE OF THE JOB

1.0 PROJECT DESCRIPTIONThe project envisages conversion of tanks to different products, laying of

product pipelines along with construction of mechanical structures like Trestle Bridge and Product pump house at Bijwasan IRD, Delhi. The site addresses is as below:

Hindustan Petroleum CorporationBijwasan IRD,Near IOCL Terminal,New Delhi – 110045.

Phone:- (011) 28061496/ 3149/ 3802/ 3061.

The scope of the current tender involves but not limited to the following:

(i) Conversion of 1 x 3500 KL HSD tank to MTO Tank.(ii) Conversion of 2 x 90 KL Underground Ethanol Tank to Hexane Food

Grade.(iii) Conversion of 2 x 90 KL Underground Ethanol Tank to Solvent. (iv) Laying of product pipelines(v) Construction of Product Pump House and pump manifolding jobs(vi) Various allied civil jobs including pedestals etc.(vii) Supply, fixing of all pipeline fittings as SORF flanges, blind flanges,

nut bolts, gaskets, consumables, Equal Tees, forged eccentric reducers/ expanders, forged concentric reducers/expanders, forged LR bends( 45 degree, 90 degree) ( short radius, long radius), companion flanges etc.

(viii) Supply & installation of the pipeline, gate valves, check valves and strainers as per the datasheet.

The prospective bidders are requested to thoroughly read and comprehend the various sections of this tender document and visit the sites before quoting for the tender.

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SITE CONDITION:

The job needs to be carried out in the Depot /Terminal premises (during working hours of the depot i.e. 0900 Hrs to 1730 Hrs, excluding Sunday/Holidays). However, during hot work, precaution has to be taken to prevent any incidents due to presence of any petroleum vapors. Also since the Terminal is in operation, hot work permission has to be obtained for working on a daily basis. The explosive meter readings and check for presence of flammable vapor shall be checked by contractor’s supervisor along with HPCL’s representative before undertaking hot work. Full time supervisor to be provided at work spot and job shall be carried out only after complying with all safety norms of the depot. A full Time Qualified Engineer who is technically competent and having sufficient Site experience to be posted for supervising and carrying out all the Jobs as per the Scope.

All safety precautions to be taken for carrying out the above jobs like local fire screen etc., as per requirement and safe working practices in a working petroleum installation.

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 tenderers 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 Shri. Satish Kumar, Manager-Depot, HPCL Bijwasan IRD, Bijwasan, New Delhi- 110061 on 011-28063149 / 28061496 regarding any queries.

The contractor shall arrange all equipment, tools, power and water required for execution, testing & completion of the job.

All the safety precautions including supplying & providing localised fire screens for welding of pipe lines etc shall be arranged by the Contractors as per the directions of Engineer in charge at no extra cost to HPCL.

Design / Drawings required to be submitted by the Party:

1. Design & Drawing of foundations and structures of Product Pump House and Trestle Bridge as required and directed by Engineer In Charge.

2. Preparation of all detailed and working drawing

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3. Design of Pipe Line Pedestals and sectional / Construction drawing to be submitted for HPCL approval before commencing the work.

4. All the fabrication drawings showing the welding details including structural supports for laying of pipe line along with grouting details to be submitted.

5. Isometric and cross sectional drawings of P&I diagram to be submitted prior to construction.

After the job is completed, 4 copies of all the above drawings (As built) shall be submitted along with CD containing soft copy in Auto-CAD latest version.

NOTES: 1. Any cables / piping encountered during excavation and other any

construction activities as specified above, the same shall be separated using Sand Bed and Tiles or to be re-routed, if necessary as directed by the Engineer incharge at no extra cost to HPCL.

2. 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.

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

Scope also includes shifting of any scrap materials lying at the constructional area 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 and make the site free for construction at no extra cost.

The contractor shall arrange for all materials, equipment, tools, power and water required for execution & completion of the job.

The bidders are required to go through the tender document thoroughly and carefully and offer their most competitive rates for the job. They are also advised to visit the site before offering their quotation.

2.0 SITE VISIT

2.1 The bidder is advised to visit and examine the site of works at all locations and their surrounding and obtain for himself on his own responsibility all information that may be necessary for preparing of the bid and entering into the contract. The cost of visiting the sites shall be at bidder’s own expenses. No extra claim on account of non-familiarity of site conditions shall be entertained during execution of works.

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2.2 The bidder and any of his personnel or agents will be granted permission by the Owner to enter upon his premises and lands for the purpose of such inspection, but only upon the explicit condition that the bidder, his personnel or agents will release and indemnify the Owner and his personnel and agents from and against all liability in respect thereof and will be responsible for personnel injury (whether fatal or otherwise), loss of or damage and expenses incurred as a result hereof.

TIME SCHEDULE

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DESCRIPTION OF WORK:

CONVERSION OF 1x3500KL HSD TANK TO MTO,2x90KL FROM ETHANOL TO HEXANE FOOD GRADE &

2x90KL FROM ETHANOL TO SOLVENT1425 AT BIJWASAN DEPOT, DELHI

PART LOCATION COMPLETION PERIOD FROM DATE OF BIJWASAN DEPOT ISSUE OF FOI /LOI/PO DELHI

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FOUR (4) MONTHS

NOTE:

1) Time for completion shall be reckoned from the date of issue of Fax/ Letter of Intent/Purchase Order 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.3) The job scope is as defined in tender.

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SCHEDULE OF QUANTITIES

ITEM NO DESCRIPTION OF ITEM UNIT QTY

1 EXCAVATION UPTO 2.0 Mt. FOR FOUNDATION OF GANTRY, PIPE PEDESTALS, TRESTLE BRIDGE, PUMP HOUSE ETC

Cubic Meter

100

Excavation in all type of soil including WBM surface upto a maximum depth of 2.0 meters including removal of stems and roots to full extent, removal of all vegetation including bushes and grass, bailing out of water/ oil mixed water if encountered, shoring, back filling and compacting the excavated earth in the sides of foundations.Rate to include carting away surplus excavated earth, spreading, leveling and compacting, inside/outside the terminal in approved dump yard as directed by EIC (Engineer In Charge).

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2 DISMANTLING OF RCC

Dismantling of the existing RCC driveway including reinforcement found during excavation of the soil strata upto a maximum depth of 2.0 meters as per the direction of EIC. The excavation of earth shall be paid separately under item no 1. Rate to includes separation of reinforced Steel from dismantled RCC and kept at designated place as directed by EIC.Rate to include carting away surplus excavated earth, spreading, leveling and compacting, inside/outside the terminal in approved dump yard as directed by EIC (Engineer In Charge).

Cubic Meter

6

3 SAND FILLING

Supplying and filling locally available best quality coarse river sand duly approved by EIC in foundations in layers of compacted thickness 150 mm. Rate to include, loading, transportation, unloading, removal of debris, organic matter etc, spreading in layers, watering, and compacting each layer till maximum compaction is achieved.

Cubic Meter

25

4 RUBBLE SOLING

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

Cubic Meter

35

5 PCC 1:2:4

Providing and laying PCC 1:2:4, using 20 mm and down size crushed aggregate including providing shuttering for formwork, mixing, compacting by Vibrators, curing etc. complete for foundation beds of rafts, columns, pedestals and driveways etc as per attached technical specification and as per direction of Engineer In Charge. Cement shall conform to IS 8112 – 43 grade/ IS 12269- 53 grade OPC or IS 1489- PPC. Cement shall be either of the following make Ultratech, ACC, Ambuja, Birla or L&T duly approved by the EIC

Cubic Meter

12

6 REINFORCED CEMENT CONCRETE (RCC: M-25)[Raft / Footing / Column / Pedestals / Pump Foundation] Providing and laying RCC with M-25 design mix as per IS456-2000 with latest amendments for raft, footing, columns, pedestals, cable trenches etc at all heights and depths using 20 mm and down size graded crushed aggregate including providing and fixing shuttering for

Cubic Meter

25

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form work with approved quality supports, scaffolding, machine mixing, compacting by mechanical vibrators, curing, etc complete as per attached technical specification and as per direction of Engineer In Charge. Concrete ingredients shall conform to IS 456- 2000 with latest amendments. The cement content shall be governed by Design mix.Rate also to include necessary Polythene sheets of approved quality to be placed before laying the concrete. Rate shall be exclusive of the cost of supplying and providing steel reinforcement, which will be paid under a separate item. Cement shall conform to IS 8112 – 43 grade/ IS 12269- 53 grade OPC or IS 1489- PPC. Cement shall be either of the following make Ultratech, ACC, Ambuja, Birla or L&T duly approved by the EIC.

7 REINFORCED CEMENT CONCRETE (RCC: M-25)[For Floor] Providing and laying RCC with M-25 design mix as per IS456-2000 for driveway flooring of required thickness using 20mm and downsize graded crushed stone aggregates including providing and fixing MS channel shuttering, machine mixing, vibrating, compacting , curing etc. complete as per attached technical specification and as per direction of Engineer In Charge. The cement content shall be governed by Design mix.Rate to include the following: Repairing of the edges and grouting the concrete for the same. Providing shuttering with provision for fixing reinforcement bars in position including proper vibrating. Providing broom finish to the top surface when concrete is green. Pond curing for 15 days. Rate also to include necessary Polythene sheets of approved quality to be placed before laying the concrete.Concrete shall conform to IS 456-2000 with latest amendments. Rate shall be exclusive of steel reinforcement, which shall be paid under a separate item. Cement shall conform to IS 8112 – 43 grade/ IS 12269- 53 grade OPC or IS 1489- PPC. Cement shall be either of the following make Ultratech, ACC, Ambuja, Birla or L&T duly approved by the EIC.

Cubic Meter

14

8 STEEL REINFORCEMENTS

Supply, fabrication, bending, tying and laying in position steel reinforcement conforming to IS 1786, Fe-500 (latest edition) . Job includes, cutting, cold bending, tying with 22 SWG black annealed binding wire and placing the reinforcement in position at all heights/line/levels etc., complete in all respects as per standard

Metric Ton

3

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specification and as per direction of EIC. Payment shall be made as per reinforcement drawings and at theoretical weights only. Laps, chairs and spacer bars shall not be considered for measurement and payment purposes. Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC.

9 BRICK MASONARY

Providing and fixing locally available brick masonry using bricks of minimum comp. Strength 35 kg / sqcm for pump house & miscellaneous jobs in C.M. (1:4) including racking out of joints, making provision for opening in walls, watering, curing etc. complete. The item includes construction of masonry and to complete as per instructions by EIC.

CubicMeter

10

10 PLASTERING

Providing and fixing in position external sand faced cement plaster to concrete surfaces, brick work, curved surfaces, etc. 20mm thick applied in 2 coats. First coat in 1:3 cement mortar 12mm thick including making the surface ready for receiving coat and second coat in 1:4 cement mortar 8 mm thick sand faced including watering, curing, cleaning etc. complete. Rate to include providing, laying & making drip mould for all projected parts all complete as advised by EIC. Cement shall conform to IS 8112 – 43 grade/ IS 12269- 53 grade OPC or IS 1489- PPC. Cement shall be either of the following make Ultratech, ACC, Ambuja, Birla or L&T duly approved by the EIC. The item also includes providing GI wire mesh 12 mm x 12 mm x 24 G at junction of masonry and concrete.

SquareMeter

40

11 STRUCTURAL STEEL:Pipe support/Columns/Girders/Trusses/Walkways etc.

Supply, fabrication, erection and welding of structural steel Conforming to IS: 2062/IS: 226 latest edition for Pipe supports/ Walkways /columns/girders and as directed by EIC. Rate also includes Copper Slag blasting the members thoroughly to S.A 2.5 of Swedish Ivonsk Standard SIS 055900-Latest edition before applying the primer . Rate also to include applying Two coats of approved first quality synthetic enamel paint over two coats of Zinc Phosphate primer of approved quality on all exposed surfaces of the member. The Nut & Bolts of the Structural members will not be paid separately. Only theoretical structural weights of the

Metric Ton

4

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structural member will only be taken for measurement and payment .The rate shall include execution of the job at all heights and to be done to the correct line and level etc Complete. Foundation Bolts shall also be paid under this item itself.

12 CHEQUERED PLATES

Supply, fabricating, fixing and welding of 6mm thick chequered plate to the floor for covering of the cable trench. Rate to include painting with three coats of polyurethane paint (each 40 microns) of approved make and shade over two coat of zinc silicate primer (75 microns) after copper slag blasting. Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC.

Square Meter

15

13 GALVANUME SHEETING - ROOF/CLADDING/RIDGE PIECE/CORNER PIECE

Supplying and fixing of klippon AZ 150 Bare Galvanume sheet approved equivalent for roof and cladding of size in 0.55 mm Total Coating Thickness (TCT) including Screws & Clips conforming to IS 9933-1995. The fixing of sheets shall be carried out as per standard code of practice and as per manufacturer specification. The manufacturer shall give a minimum guarantee of 5 years for the product and the same shall be extended to HPCL. The roof design and colour combination needs to be carried out as per Visual Identity standards of HPCL. Job to be completed in all respect as per direction of EIC. The rates includes supply and fixing of flashing in 0.55 mm TCT of 301-500 mm girth & 0-300 mm girth to the gantry roofing as corner piece and ridge pieceNOTE: Roof area shall be measured along the incline and no payments shall be made for overlaps provided on sheets.

Square Meter

100

Supply of the following materials (Item No 14 to 20) as per the Specifications attached in the tender. Rate to include the Third Party Inspection and as per the direction of EIC.

14 Supply of 150 mm NB product pipe as per IS 1978 Each 690



17 Supply of 150 mm T-type Strainers Each 4

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18 Supply of 150 mm NB Gate Valves as per API 600 Each 18

19 Supply of 100 mm NB Gate Valves as per API 600 Each 4

20 Supply of 150 mm Swing Check Valves Each 4

COPPER SLAG BLASTING AND SUPPLY & PRIMER COATING(Item No. 21 to 23 )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. Rate to include loading, hauling, handling, transportation of the pipes. Rate also to include painting of the copper Slag blasted pipes with one coat (min DFT – 60 Microns) of zinc anode (zinc silicate) primer of Berger or approved equivalent of as directed by EIC.Note: If the coating is damaged while handling the pipes the same need to be redone by the Contractor as per above and make good surface.

21 150 MM NB Running Meter

370


320


20

INTERMEDIATE COAT & FINAL COAT PAINTING(Note: For Item No 24 to 26)

Intermediate Coat:-

Supply and painting one coat of 100 micron of Epilux 155 HB MIO of Berger or approved make in one coat to pipelines of following sizes including all fittings like valves, strainers, bends, tees etc. complete .

Final Coat:-Supply and application of 100 micron DFT (to be achieved in minimum two coats) of Bergerthane Enamel Paint (1st Quality) of Berger or Shalimaar by HPCL with appropriate shades in two or more no. of coats to pipelines of following sizes including all fittings like valves, strainers, bends, tees etc. complete.

Rate to include wastages, mixing the paint properly as per manufacturer’s specifications, applying coat with conventional spray /

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brush till 100 micron DFT of paint thickness is achieved, testing for thickness etc. complete. The Job includes providing & applying additional coats (free of cost) to the satisfaction of HPCL Engineer-In-Charge in case desired thickness (100 micron) or proper surface finish is not achieved after applying the coat. The decision of HPCL Engineer-In-Charge will be final in this regard & shall have binding on the contractor. The payment shall be made on the basis of running meter of pipeline painted, measured only once.

Note: If the coating is damaged while handling the pipes the same need to be redone by the Contractor as per above and make good surface.


370


320


20

LAYING & INSTALLATION OF ABOVEGROUND PRODUCT PIPELINES – IS: 1978(Note: For Item No. 27 to 29 )

Laying, Installation, fabrication, welding (With 100% Dry Penetration Test), 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., DPT test of 100% joints, carrying out repairs if any & re-radiography, 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 of the job includes but not limited to the following: Receiving owner supplied materials, including handling, hauling/loading and 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.The rate to include fabrication of any fittings viz bends, tees

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eccentric or concentric reducers etc. to the pipeline. ---The rate also to include fabrication and welding of spud points, fixing of owner supplied tees, bends, flanges where ever they are necessary.


370


320


20

NOTE FOR ITEM NO 27 TO 29

• If leakage through the pipe seam joint is observed, contractor shall remove the defective portion of the pipeline and replace with a new pipe and retest it.

• Length of all pipelines shall be measured upto the neck of the flange only. Length of the flange shall not be measured as they are paid separately.

COATING AND WRAPPING

Supply, coating and wrapping, the pipelines and flanges to be laid underground with PYPKOTE (IWL MAKE) or equivalent with two layers of 2mm thick wrapping material as per IS: 10211 and as per manufacturer's standard. Contractor should strictly follow Manufacturer's application procedure. Rate to include supply of all the raw materials (coal tar primer, wrapping tape etc) as specified in above Manufacture's specification. Note: Contractor shall give test certificates for the above mentioned materials.


320


20

LAYING & INSTALLATION OF UNDER GROUND PRODUCT PIPELINES – IS: 1978

Laying, Installation, fabrication, welding (With 100% Dry Penetration Test), 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., DPT test of 100% joints,

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carrying out repairs if any & re-radiography, 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 of the job includes but not limited to the following: Receiving owner supplied materials, including handling, hauling/loading and 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.The rate to include fabrication of any fittings viz bends, tees eccentric or concentric reducers etc. to the pipeline. ---The rate also to include fabrication and welding of spud points, fixing of owner supplied tees, bends, flanges where ever they are necessary.Rate also to include excavation work required for the laying of pipeline.

32 150 mm NB Running Meter

320

33 100 mm NB Running Meter

20

FIXING OF VALVES – GV/GOV/NRV/STRAINER/PLUG VALVE(Note: For Item No 34 to 36)

Loading, transportation, handling, erection and fixing of the HPCL supplied CS or CI Gate Valves/ Ball Valves/ Gear Operating Valve/ Plug Valve/ Non-Return Valve/ Thermal Relief Valves/ Strainer/ NRV of following sizes from owners store, including alignment, supplying & fixing of 2 mm thick CAF oil permeable 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, supply & fixing 2 nos.10 SWG copper wire(on each flange joint) on both sides of valve (connected to flange). Rate to include supply & welding flanges on both sides for

fixing of valves/ strainer/ NRV etc complete.

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34 200 mm NB Each 3

35 150 mm NB Each 26

36 100 mm NB Each 6

S&I SORF TO BLIND FLANGE JOINT(Note: For Item No 37 to 39)

Supplying and Providing SORF to Blind Flange joints of following sizes including fixing and welding. Rate shall also include supply and fixing 2 mm thick CAF oil permeable gasket conforming to IS: 2712 of approved make and rating, supply & fixing all stud & nuts (conforming to ASTM A 193 B7 & A194 2H) of approved make, size & NB with washers etc, complete. The job also includes supply & fixing 10 SWG copper wires on stud & bolts (2 nos. wire on each flange joint) on either side for electrical continuity.

Two flanges shall constitute one flange point. Rate to include supply of the flange.

37 200 mm NB Each 6


39 100 mm NB Each 6

S&I SORF TO SORF FLANGE JOINTS(Note: For Item No. 40 to 41 )

Providing SORF to SORF joints of following sizes from HPCL supplied flanges including fixing and welding. Rate shall also include supply and fixing 2 mm thick CAF oil permeable gasket conforming to IS: 2712 of approved make and rating, supply & fixing all stud & bolts (conforming to ASTM A 193 B7 & 194 2H) of approved make, size & NB with washers etc, complete. The job also includes supply & fixing 10 SWG copper wires on stud & bolts (2 nos. wire on each flange joint) on either side for electrical continuity.

Two flanges shall constitute one flange point. Rate to include supply of the flange.


41 100 mm NB Each 6

INSTALLATION OF PRODUCT PUMP SETS TTL and TTD INCLUDING SUPPLY & INSTALLATION OF PRESSURE GAUGE

A. INSTALLATION:

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Installation of HPCL supplied TTD & TTL Product Pump sets of capacities along with the coupled motors and base plate on the RCC foundations. The type of grouting shall be either non shrink cementitious grout or epoxy grout as per the specifications attached. The entire base frame needs to be grouted with the same epoxy grout. Job also includes finishing smooth the top surface with cement slurry, making necessary changes in the base plate if required, handling, lifting the pump sets, installing them on the RCC foundation, tightening the foundation nut bolts after aligning the pump set, checking the coupling alignment, decoupling and recoupling the same if necessary with dial gauges etc. and placing the owner supplied coupling guard in place complete as per specifications.

B. SUPPLY & INSTALLATION OF PRESSURE GAUGES:Supply and fixing 150 mm NB pressure gauges of approved makes including supply & welding. Necessary 1500 class half coupling to the pipeline, supply and fixing suitable 1500 class SS ball valve of LEADER make or equivalent with all necessary fittings like pressure dampeners etc. as per drawing/ specifications of HPCL while execution of job and making the entire arrangement leak proof. The following type of pressure gauge can be used as per instruction of EIC (Engineer In Charge) and also as per site requirement:a) 0-20 Kgf/cm2

b) 0-5 Kgf/cm2

C. SUPPLY & INSTALLATION OF VACCUUM GAUGES:Same as above but vacuum gauges of range 0 to (-5) Kg/sq.cm. Job to include providing facility so that differential pressure across strainer can be measured at pump house.Note:Necessary tools & tackles for installation, like cranes / tripods chain blocks, dial gauges, foundation bolts of specified size labour etc shall be arranged by the contractor.The foundation bolts, if supplied by contractor, shall be paid through separate item.

42 Installation of Product Pump Each 4

43 PIPELINE ROLLER SUPPORT

The job includes fabrication of the pipe roller support and the grouting of the same in the pedestals. The support to be made up of 200mm width 6mm thick plate having T-supports of 300mm long 12mm torr

Metric Tonne

0.6

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rod welded at the base. The plate is also provided with a 32mm dia rod provided with a free rotation mechanism as per the drawing attached. The rod needs to painted with a corrosion protective coating.

44 VENT POINT

Supply, fabrication and welding of high point vent with SCH 80 MS pipe of 80 mm NB including welding necessary 1500 class half coupling to pipeline, supply and fixing 1500 class forged steel ball valve of approved make with all other necessary fitting as directed by EIC.

Each 4

45 PIPE EARTHING

Supply and constructing Pipe electrode type earthing pits with all GI parts and B class GI Pipe of 65 mm NB dia x 3 mtr long as per IS 3043 (latest edition) in line attached drawing. Rate to include supply of all material, BM chamber & CI cover etc necessary for earthing pit, supply and welding of MS earthing boss to structures etc. Rate to include testing with megger and submitting test certificates from licensed electrical contractors. GI flat require for earthing connection shall be paid separately. All the bolt used shall be Cadmium alloys.

Each 10

46 GI FLAT

Supply, fabrication and fixing 50 mm x 6 mm size GI Flat for connecting earth pit with various structures as directed by Engineer In charge. Rate to include supply and welding of MS boss to structures, bolts, washer etc complete.

Running Meter

150

47 GI PIPE

Supply, fabrication and fixing of 50mm dia GI Pipe for cable connection to pumps from control room and all other necessary cables in pump house with necessary Cement Concrete grouting.

Running Meter

20

SUPPLY OF FITTINGS (Note: For Item No 48 to 51)

Supply of flanges. 90 degree bends, 45 degree bends, BLFR, SORF, WNRF, Tee, and Reducers of various sizes as given below.Party has to submit manufacturers test certificate for the fittings.

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Supply of Blind Flanges ASA Class 150 raised face, made out of MS plate conforming to IS2062 GrA,/B, dimension & holes drilled as per ANSI B.16.5,

Supply of SORF conforming to ASA Class 150 raised face, made out of MS plate conforming to IS 226/IS2062 GrA, Dimension & Holes Drilled as per ANSI B.16.5

Supply of WNRF confirming to ASA class 150 holes as per ANSI B 16.

48 Supply of 150mm NB, SCH 40, 90DEG ELBOW Each 24



51 Supply of 150mm NB, SCH 40 EQUAL TEE Each 6

52 HUME PIPES

Supplying, laying, joining and aligning 250mm NB NP3 class RCC Hume pipes conforming to IS-458 Latest Edition below approach road wherever directed. Rate to include joining with cement mortar, excavation to required depth and providing and laying 150 mm thick sand cushion all around the pipes. Test certificates from manufacture shall be submitted and approved by EIC before use.

Running Meter

80

53 PAVER BLOCKS

Providing & laying hydraulically pressed machine made interlocking pre-cast cement concrete paving blocks (mat finish) with a compressive strength not less than 350 Kg/Cm2 & 80 mm thickness of approved makes, shade & colour as directed by the Engineer In Charge/ Architect/ Consultant laid over WBM of 100mm thick with 50 mm thick sand cushion to match the shade of tile, including curing, finishing, labour, materials complete.

Square Meter

75

54 DISMANTLING OF EXISTING PIPES

Dismantling of existing old product lines by hacksaw /gas cutting as required after locating and isolating the lines. Extreme care and all the

Inch Meter

500

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safety precautions to be taken while carrying out the job. The product shall have to be decanted in barrels and transported to a designated place as directed by EIC. The dismantled lines shall be transported to a designated place and stacked properly at no extra cost. Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC Inch meter means NB sze of pipe in inch multiplied by length of piping including fitting, flanges etc eg: If 4 meter length of pipeline is dismantled of 4 inch NB then measurement will be for 16 inch meter. Vendor to quote rate for inchmeter units

55 CONVERSION OF 1 x 3500KL HSD TO MTO

De-gased and cleaned tank will be handed over to the Contractor for miscellaneous jobs i.e..Rate to include supply and replacing of the existing gasket at the manhole nozzle with the metallic gasket. Rate also includes flushing, de-gasing and hook up of the existing pipeline to the new pipeline and closing the existing pipeline by cutting and fixing blind flange out side the dyke wall. The job also includes to ensure collection of any residual product remaining in the pipeline in the drums provided by HPCL.

LS 1

56 CONVERSION OF 90KL ETHANOL U/G TANK TO HEXANE FOOD GRADE

De-gased and cleaned tank will be handed over to the Contractor for following jobs.Rate to include supply and replacing of the existing gasket at the manhole nozzle with the metallic gasket. The job also includes the following activities to be done:-Copper Slag Blasting:- Preparation of surface of tank bottom, shell, roof, roof structurals and tank nozzles, tank body valves etc. Copper Slag Blasting thoroughly to SA 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. Rate to include for cleaning of tank farm area after completing copper slag blasting.Note:-

1. Contractor to arrange and keep at site relevant Swedish photographic standards for inspection by HPCL.

LS 2

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Primer Coat (Internal):-Supply and application of one coat 75 micron Epilux FRX Anticorrosive Primer of Berger or approved equivalent make all internals of tank. 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 thicknesss is obtained, tested for thickness, providing scaffolding etc. complete.

Finish Coat (Internal):-Supply and application of two coats 100 micron DFT each Epilux 78 HB TL of Berger or approved equivalent make to all internals of tank. Rate to include wastages, mixing the paint properly as per manufacturer’s specification s, applying in line with manufacturer’s recommendation till 200 micron DFT of paint thickness is obtained, testing for thickness, providing scaffolding etc.

Rate to include flushing, degassing and hook up of the existing pipeline to the new pipeline.

57 CONVERSION OF 90KL ETHANOL U/G TANK TO SOLVENT

De-gased and cleaned tank will be handed over to the Contractor for following jobs.Rate to include supply and replacing of the existing gasket at the manhole nozzle with the metallic gasket. Rate to include flushing, de-gasing and hook up of the existing pipeline to the new pipeline and installation of pressure relief valve at the tank end. Rate to include supply of pressure relief valve. The job also includes to ensure collection of any residual product remaining in the pipeline in the drums provided by HPCL.

LS 2

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TECHNICALSPECIFICATION

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INDEX OF TECHNICAL SPECIFICATION

SR NO

DESCRIPTION

1 CONCRETE AND REINFORCEMENT WORKS

2 CIVIL JOBS

3 STANDARD SPECIFICATION FOR WELDING

4 SPECIFICATION FOR FABRICATION OF PIPELINE

5 STANDARD SPECIFICATION FOR FIELD PAINTING

6 STANDARD SPECIFICATION FOR SHOP & FIELD PAINTING

7 STRUCTURAL STEEL JOBS

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TECHNICAL SPECIFICATIONFOR CONCRETE AND

REINFORCEMENT

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WORKS

1. CONCRETE AND STEEL REINFORCEMENT

1.1 GENERAL:This section describes and specifies work required for plain and reinforced cement concrete including reinforcement and form work. Unless otherwise specified or agreed in writing by the EIC, all materials and methods used in the production, testing and handling of concrete shall comply with the latest editions or amendments of the relevant Indian Standards.

1.2 MATERIALS: All materials shall be obtained from sources approved by the EIC. The agreed source or quality of any material shall not be changed during the course of the contract except with the approval of the EIC.

Whenever requested by the EIC, the Contractor shall provide a certificate from the manufacturer, for each and every delivery of material, showing the source, quantity delivered and confirming that the material has been tested and conforms to the required Indian Standard.

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1.3 TESTING OF CONCRETE MATERIALS:Prior to the commencement of concrete work, the contractor shall get all cement aggregates and water tested in the laboratories approved by the EIC and shall keep the approved samples in the site office for inspection at any time of the concreting operation. The test certificates shall be submitted to EIC for review & approval before concreting. During construction also, the materials shall be sampled and tested as often as deemed necessary and also as per the “Periodicity of Testing” by the EIC. Samples shall be taken and tested in accordance with the latest revision of relevant Indian Standard Specifications and the cost thereto shall be borne by the Contractor.

1.4 CEMENT:The cement used throughout the work shall be IS:269/ 8112 – 43/53 grade or PPC. A certificate shall be obtained from the manufacturers and produced to EIC for each delivery of cement and it shall comply with the requirements of as mentioned in the “Technical Specification – Materials” . The Contractor shall store the cement in storage sheds to be provided by him for this purpose at site. The cement shall be delivered to the site in bags sealed with the manufacturer's seal and different types of cement shall be stored separately. The storage sheds with watertight walls and roof, shall be maintained in a perfectly dry and wall ventilated condition, 12" above ground level and the cement shall be stored a per instructions issued by EIC. It shall be turned over from the bottom as and when required by the EIC. Any cement which has been deteriorated caked or which has been damaged due to any reason whatsoever shall not be used. No cement shall be used for the works that has been stored at site for more than three months. Test samples of cement may be drawn from each consignment as delivered and tested by the EIC. Should the results of such test show that any samples does not comply with the specified requirement, the whole consignment from which the sample was taken, shall be rejected and forthwith removed entirely from the site and replaced with cement of satisfactory quality.

1.5 SAND : Sand to be used for concrete shall be well graded mixture from coarse to fine grains, complying with the requirements of IS 383 Latest edition. It shall be clean, hard and free from salt, earth, clay and other impurities. Fine sand confirming to Zone – iv shall not be used. It will comply with sieve analysis in accordance with IS 2386 Part I & II.Unless initially clean, all sand shall be thoroughly and carefully cleaned by screening and washing in fresh and clean water. The screened and washed sand shall not contain more than 8% by volume of clay, dust and silt immediately after allowing it to settle for 3 hours in water.

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Field tests shall be carried out regularly to ensure the suitability of sand.

Sample loads shall be available at site for inspection of the EIC and if approved by him all sand in the work shall be of quality at least equal thereto.In case of sand containing moisture the proportions of concrete materials shall be adjusted to give the correct mixture.

1.6 COARSE AGGREGATE:The coarse aggregate for the reinforced concrete work shall consist of crushed gravel, black trap, granite or other stone to the approval of the EIC and shall be free from dust confirming to IS – 383 latest edition. If considered necessary by the EIC, the aggregate shall be washed especially until an approved cleanliness is obtained. The use of laminated stone, flat or flaky material will not be permitted. The combined coarse aggregate shall in all respects be so graded as to allow 95% to 100% by weight to pass a 20mm I.S. sieve 25% to 55% by weight to pass a 5mm I.S. sieve and 0% by weight to pass a 5mm I.S. sieve. The aggregates of different sizes shall be stored in separate stacks in clean state and free from all dirt.

The coarse aggregate where absorption of water after 24 hours immersion is more than 5% by weight shall not be used.

When required by the EIC the tests indicated in I.S. 383 or IS-2386 ( all parts ) shall be got carried out by the Contractor at his cost to show the acceptability of the materials.

Stowage piles of aggregate shall have good drainage, preclude inclusion of foreign matter and preserve the gradation.

1.7 WATER:Water used for all purpose in this contract shall be free from oil, acid, vegetable matter, salts or dirt of any kind which will have adverse effect on cement or steel in the case of reinforced concrete. Whenever called for, the Contractor shall produce test results for water being used on work. The water quality shall confirm to IS-456-2000.

1.8 ADMIXTURES:Admixtures or Cement containing additives (such as accelerators, retarders, water proofing agents etc.) shall not be used unless specified or otherwise directed or approved by the EICs). The Admixtures shall confirm to IS-9103 latest edition.

1.9 FORM WORK:

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The form work shall be designed and constructed in such a manner that all concrete work shall be true to line, level and size, and free from honeycombing, pinholes, surface irregularities and every other defect whatsoever.All form work shall be adequately propped, braced and framed to prevent deformation under weight and pressure of wet concrete, constructional loads, wind, vibrations and other forces. All joints in shuttering shall be close fitting to prevent the loss of cement paste or mortar from the concrete.

All form work shall be carefully cleaned and coated with an approved proprietary mould oil before use, care being taken to keep all reinforcement away from contact with such oil. All moulds shall be free from sawdust, shavings, dirt, mud or other debris by hosing with water or oil free compressed air.

The shuttering for beams and slabs shall be erected so that the shuttering on the sides of the beams and of the soffits of the slabs can be removed without disturbing the beam bottoms. For beams having spans greater than 6 meters and for cantilevers, the form work shall be given adequate upward camber as directed by the EIC.

Details of all temporary work (timbering, staging etc.) are to be submitted for the approval of the EIC and the form work shall be inspected and approved by the EIC before concrete is placed within it. Notwithstanding such approval, any damage or consequences arising there from shall be the Contractor's entire responsibility.

1.10 PROPORTIONS FOR CONCRETE:The contractor shall design concrete mixes (by Ready Mix Concrete Plants) to produce concrete of the required strengths. The contractor must submit full designs done from RMC plants of the mixes for approval of EIC and trial mixes will be prepared by the contractor in the presence of the EIC, having workability, strength, minimum cement content and surface finish as criteria. Notwithstanding the acceptance by the EIC of any mix design and series of trial mixes, variations may be made to the proportions when considered necessary by the EIC. Such variations may be made also to normal mixes if used, but variations of this nature will not be allowed to affect the unit price of concrete.

For both Nominal as well as Design mix concrete, the quantity of cement shall be determined by weight. Where standard bags of cement are used, their weight shall be checked at frequent intervals and any loss in weight due to leakage etc. shall be made good.

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In the case of Nominal Mix concrete, aggregates shall be measured by volume, cement by weight and mixing water in graduated cans. In the case of controlled concrete all aggregates and cement shall be measured by weight in approved weigh batching equipment. Mixing water shall be measured in graduated cans.

While calculating the amount of mixing water, the moisture content of the aggregates shall be taken into account.

The grades of concrete shall be in accordance with Table below the cement content of the mixes specified shall not exceed the minimum content specified in Table by more than 20%.

READY MIX CONCRETE:

The provision in this section shall apply to all concrete grades and is to be considered as a supplementary to general provisions for Plain Cement Concrete & Reinforced Cement Concrete works.

Ready mix concrete (RMC) may be manufactured in a central automatic weigh batching plant and transported to the job by agitating Transit mixers. The RMC is to be sourced from reputed & approved batching plants as mentioned in the approved list of manufacturers or suppliers only. The design mix has to be submitted to HPCL before concreting and the same has to be approved by HPCL before concreting is done.

The design mix is to be carried out as per IS-10262. The cement content shall be governed by Design mix or soil characteristics as per soil investigation report (report shall be forwarded to the successful bidder), which ever is higher.

The standard deviation for concrete mix design will be considered as per Table 8 of IS-456-2000.

The proportion of fine aggregates to coarse aggregates should be adjusted so as to keep them within the specified limits as mentioned in IS-383.

The Bidders have to submit the Quality Assurance Plan of theirs as well as the RMC plant for approval and shall strictly adhere to the same.

The admixtures used shall confirm to IS-9103.

APPLICABLE CODES AND SPECIFICATIONS:

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The following specifications, standards and codes are made a part of this specification. All standards, tentative specifications, codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions.

In case of discrepancy between this specification and those referred to herein, this specification shall govern.

APPLICABLE IS SPECIFICATIONS AND CODES OF PRACTICE:

IS 269:- Specification for ordinary, rapid hardening and low heat portland cement.

IS-10262: Recommended guidelines for concrete mix design.

IS 8112:- Specification for high strength ordinary, portland cement.

IS 1489 - Specification for portland - pozzolona cement.

IS 383:- Specification for coarse and find aggregates from natural source for concrete.

IS 2386:- Methods of test for aggregates for concrete. (Part I to VIII)

IS 516:- Method of test for strength of concrete.

IS 1199:- Method of sampling and analysis of concrete.

IS 3025:- Methods of sampling and test (Physical and chemical) water used in industry.

IS 432:- Specification for mild steel and medium tensile steel (parts I & II) bars and hard drawn steel wire for concrete reinforcement.

IS 1139:- Specification for hot rolled mild steel and medium tensile steel deformed bars for concrete reinforcement.

IS 4926: Ready Mix Concrete – Code Of Practice

IS 1566:- Specification for plain hard drawn steel wire fabric (Part I) for concrete reinforcement.

IS 1786:- Specification for cold twisted steel bars for concrete reinforcement.

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IS 2645:- Specification for integral cement waterproofing compound.

IS 456:- Code of practice for plain and reinforced concrete.

IS 3370:- Code of practice for concrete structures for storage of liquids (Part I to IV)

IS 2502:- Code of practice for bending and fixing of bars for concrete reinforcement.

IS 2571:- Code of practice for laying in situ cement concrete flooring.

IS 3596:- Safety code for scaffolds and ladders. (Part I & II)

IS 1200:- Method of measurement of building works.

In the event that state, city or other Government bodies have requirements, more stringent than those set forth in this specification, such requirements shall be considered part of this specification and shall supersede this specification where applicable.The quality of materials , method and control of manufacture and transportation of all concrete works irrespective of the mix , whether reinforced or otherwise, shall conform to the applicable portion of this specification.Engineer shall have the right to inspect the source/s of material/s , the layout of operations of procurement and storage of materials, the concrete batching and mixing equipment and quality control system. Such an inspection shall be arranged and approval of Engineer-In-Charge shall be obtained prior to starting of concrete work. Concrete shall be mixed by mechanical mixer only and no hand mixing shall be allowed for RCC works.

GENERAL:

The quality of materials and method and control of manufacture and transportation of all concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portions of this specification. Engineer shall have the right to inspect the source/s of material/s, the layout and operation of procurement and storage of materials, the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and Engineer’s approval obtained, prior to starting of concrete work.

MATERIALS FOR STANDARD CONCRETE:The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard type portland cement, clean sand, natural coarse aggregate, clean water and admixtures, if specially called for on drawings or specifications.

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CONSISTENCY:The consistency of the concrete shall be such that it flows sluggish during pumping of concrete into the forms and around the reinforcement without any segregation coarse aggregate from mortar. The slump tests are mandatory and shall be carried out at regular intervals so that the consistency concrete can be monitored.

PLACING OF CONCRETE:Concreting shall commence only after inspection and written approval by EIC.Shuttering shall be clean and free from deposits of foreign materials and proper deshuttering agent shall be applied to the surface.Proper arrangements shall be provided for conveying the concrete the place of deposition without disturbing the reinforcement.

COMPACTION:Concrete shall be compacted immediately after placing by means of mechanical vibrators.All RCC works shall be cured for a minimum period of 14 days or more as advised by EIC.

INSPECTION AND RECTIFICATION OF 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.

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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.

REINFORCED CEMENT CONCRETE DRIVEWAY:

The RCC drive way will be cast in panels. The concreting sequence will be discussed and got approved by EIC.

Ready Mix Concrete (RMC) will only be used for concreting. The Mix design from the RMC plant will be submitted to HPCL for approval and concreting job is to be taken up only after the design mix is approved. The cement content shall be governed by Design mix or soil characteristics as per soil investigation report (report shall be forwarded to the successful bidder), which ever is higher.

Casting of slab in alternate panels of size 6M X 3M (or as instructed by engineer in charge) including vibrating with screed vibrators. The shuttering material should be sufficient for concreting a minimum of 6 Cum ( minimum qty of a RMC Transit mixer)

Providing broom finish to the top surface when concrete is green.

Pond curing for 15 days.Concrete shall conform to IS 456-2000 and also to the specifications discussed

above under the Ready Mix Concrete section. Rate shall be exclusive of steel

reinforcement, which shall be paid under a separate item.

ACCEPTANCE CRITERIA OF CONCRETE WORK: will be as per IS-456-2000.MEASUREMENT All measurements shall be as per IS 1200

1.11 MIXING OF CONCRETE:

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Mixing of concrete shall continue until there is a uniform distribution of material and the concrete is uniform in colour and consistency and for at least two minutes.

Mixes and weigh batches shall be maintained in first class condition throughout the contract and any mixer or plant which is faulty shall not be used. The drums on all mixers shall revolve at the speed recommended by the maker. A mixer of any type which has been out of use for more than 20 minutes shall be thoroughly cleaned out before any fresh concrete is mixed. All equipment shall be maintained in a clean serviceable condition and their accuracy periodically checked.

1.12 SLUMP TEST:The Contractor shall keep at the site of the works for the EIC’s use or his representative a standard slump test mould and shall provide facilities throughout the construction for tests to be made as and when the EIC may require.

1.13 COMPRESSIVE STRENGTH: Concrete shall confirm to IS: 456-2000.

The Contractor shall keep on site minimum 12 nos standard 15 cm test cube moulds and ancillary equipment for preparing test cubes. Before the Contractor commences any concrete construction he shall make six cubes of mix concrete with the cement sand, aggregate and water which he proposes using on the contract and shall have them tested at a Laboratory approved by the EIC/EIC. Three cubes shall be tested at 7 days and three cubes at 28 days after casting and curing. In all cases the cubes shall give the minimum compressive strength. No concrete construction shall be commenced until Preliminary Tests on the six cubes referred above have been completed and results show the concrete to have the minimum compressive strength. As construction proceeds samples from fresh concrete shall be taken as per IS 1199 - 1959 and cubes shall be made, cured and tested in accordance with IS 516 1959.

Three test specimens shall be made from each sample for testing at 28 days. Additional cubes may be required for various purposes as to determine the strength of concrete at 7 days or at the time of striking form work, or to determine the duration of curing, or to check the testing error.

The test strength of the sample shall be the average of the strength of three specimens. The individual variation should not be more than 15 percent of the average.

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Any part of the work from which the cubes fail to give the required minimum compressive strength shall be dealt with by the Contractor as directed by the EIC and at the expenses of the Contractor.

The concrete is also liable to be rejected or repaired as per the instructions of the EIC/EIC if it is porous or honeycombed, its placing has been interrupted without providing a construction joint or the reinforcement has been disproportionately displaced. The rejected concrete has to be demolished and redone to the satisfaction of the EIC free of cost.

The Contractor shall keep a daily record (Concrete Pour Card ) showing the date when each portion of concrete is poured in slab, beam, column etc., curing, removal of form work and test cube results at 7 days and 28 days period. They shall be sent immediately to the EIC/EIC.

1.14 TRANSPORTING, PLACING AND COMPACTING OF CONCRETE:The concrete shall be transported maintaining required workability in a manner such as to avoid the segregation of the constituent materials, and loss of any of the ingredients. It shall be deposited as nearly as practicable in its final position to avoid re handling. It shall be placed and compacted before setting commences and should not be subsequently disturbed. Methods of pouring should be such as to preclude segregation, and to avoid displacement of reinforcement and movement of form work. Concrete Pumping needs to be arranged for conveying the concrete from transit mixers to work spot.

The concrete should be thoroughly compacted and fully worked around the reinforcement, around embedded fixtures and into the corner of the form work without formation of honeycombing, pinholes or surface irregularities and any other defects whatsoever.

The use of mechanical vibrators having capacity of producing vibrations at a rate not less than 5000 cycles per minute is recommended. Over vibration or vibration of very wet concrete is harmful. In addition to mechanical vibration, sufficient hand tools must be used to assure full consolidation around reinforcement and at edges and corners.

The deposition of concrete shall be carried out as continuously as possible to reduce to minimum joints between new concrete and concrete which has set. Where construction joints are necessary they shall be formed at right angles to the axis of the member concerned by the insertion of rigid stopping off forms, against which concrete can be properly rammed or as per the advice of Structural EIC..

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No unset concrete shall be brought into contact with unset concrete containing cement of different type. Special permission and instructions shall be obtained when concrete has to be deposited under water.

Accumulation of set concrete on the reinforcement shall be avoided. Before fresh concrete is deposited upon or against any concrete which has already hardened, the surface of hardened concrete shall be well roughened if necessary by chipping and laitance remove. The surface shall then be swept clean with wire brushes, thoroughly wetted and covered with a thin layer of cement mortar.

1.15 PROTECTION OF CONCRETE: Newly placed concrete shall be protected by approved means from rain, sun and drying winds. Concrete placed below the ground shall be protected from falling earth during and after placing. Approved means shall be taken to protect immature concrete from damage by debris, excessive loading, vibration, abrasion, deleterious ground-water, mixing with earth or other materials that may impair the strength and durability of concrete.

1.16 CONSTRUCTION JOINTS: Before construction commences the Contractor shall submit to the EIC, for his approval, sketches showing proposed positions of construction joints.

Each section of concrete shall be poured continuously between construction joints. Shuttering to all construction joints should be so made that it produces on the face of joints a suitable grooved or indented surface to act as a sheer key or bond for the subsequent concrete. Inclined joints shall not be permitted.

If the concrete has been allowed to harden excessively, the surface shall be chipped over its whole surface to a depth of at least 3/8"and thereafter thoroughly washed. If the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet surface with wire brushes to avoid dislodgement of particles of aggregate. Before fresh concrete is added to the other site of a construction joint the surface of the old concrete will be thoroughly wetted and then covered with a thin layer of cement mortar of the same quality as that in the concrete.

No distortion or displacement of reinforcement from the positions shown on the drawings shall be permitted at construction joints.

Water stoppers shall be provided to the construction joints of terrace slabs, kitchen and bathroom slabs, and water retaining structures where water leakage poses serious problems.

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1.17 STRUCTURAL JOINTS :Expansion joints or other permanent structural joints shall be provided in the positions and of the form described in the drawings or elsewhere. In no case shall the reinforcement, corner protecting angles or other fixed metal items, embedded or bonded into concrete run continuously through as expansion joint. The placing of concrete on either side of the expansion joint shall be done separately after an interval of at least 7 days.

1.18 CUTTING INTO CONCRETE:No concrete shall be cut into, nor shall it be interfered with in any way, without the prior approval in writing of the EIC. Necessary holes shall be provided as required for plumbing work and for electrical pipes etc. at the time of execution.

1.19 CURING OF CONCRETE :Exposed surfaces of concrete shall be kept continuously in a damp or wet condition for at least seven days from the date of placing of concrete.

Approved curing compounds may be used in lieu of moist curing with the permission of the EIC. Such compounds shall be applied to all exposed surfaces of the concrete as soon as possible after the concrete has set.

1.20 SUPERVISION :Constant and strict supervision of all the items of the construction is necessary during the progress of the work, including the proportioning and mixing of the concrete. Supervision is also of extreme importance to check the reinforcement and its placing before being covered.

Before any important operation, such as concreting or striking off the form work is started, adequate notice shall be given to the EIC.

1.21 CONTRACTOR'S RATES TO INCLUDE :The rates of contractor for providing and laying cement concrete in various grades or proportions in the Schedule of Quantities shall, apart from any other factors specified elsewhere in the tender documents, include for the following:

(a) For all factors and method of work described in these specifications.

(b) For all materials, labour, tools and plants, scaffolding, etc. mixing, conveying and placing concrete in position, ramming, vibrating, trawling, curing,

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providing necessary scaffolding and removing the same after the work is complete.

(c) Unless otherwise specified in the Schedule of Quantities the cost for concrete items shall include for providing and fixing form work as described inclusive of erecting, propping to required heights, bracing, providing stays, struts, bolts, nuts and everything necessary to keep the forms rigid, smoothening the surface to receive concrete as per detailed drawing, striking and stripping form work after the concrete is cured, hacking the concrete surface required to receive plaster etc.

(d) The reinforcement in case of Reinforced Concrete work will be paid for separately unless otherwise stated in the particular items, but rate shall include for pouring concrete and packing around reinforcement.

(e) The measurement of concrete will be as per detailed drawings, shapes and size based on net structural sizes as per drawings i.e. exclusive of plaster.

(f) Rates for concrete items shall cover for any shape of structural members like columns, beams, facias, fins, louvers etc. and for cantilevered beams slabs etc.

(g) Formation and treatment of contraction and expansion joints (where water bars like copper strips or joint fillers like 'Shalitex' are specified, such materials shall be paid for separately.

(h) Design of mixes where so required by specification in an approved Laboratory and on tests of materials and work required in the opinion of the EIC and described in these specifications.

(i) Fixing all inserts like pipes, plugs, forming holes etc. as described.

(j) Weigh-batching using a Mechanical weigh-batcher or a batching plant or where so specified for volumetric batching.

(k) For taking out dowel bars, fan hooks etc. through shuttering.

(l) In case where at the junctions of beams, columns, slabs, the composition of concrete mix or specified strength be different for columns, beams and slabs, then in such cases only the richer concrete among those specified for in all these members shall be used at the junctions and rate quoted for columns, beams and slabs or any member entering such junctions shall allow for the same. Rate shall also cover for spill over of richer concrete in beams to

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natural angle of repose of wet concrete required from practical considerations, while concreting the junctions.

(m) For forming drip moulds in Chajjas, sills, etc. and where shown in the drawings or as directed.

(n) For work at all levels.

2 STEEL REINFORCEMENT:

2.1 THERMO MECHANICALLY TREATED (TMT) BARS :Wherever TMT reinforcement bars are specified, the contractor shall use one of the following, accompanied by a certificate from the Manufacturer like TATA/SAIL/VIZAG only confirming to IS-1786 latest edition.

2.2 CLEANING OF REINFORCEMENT :Before steel reinforcement is placed in position, the surface of the reinforcement shall be cleaned of rust, dust, grease and other objectionable substances.

2.3 CUTTING OF REINFORCEMENT :Before the reinforcement bars are cut, the contractor shall study the lengths of bars required as per drawings and shall carry out cutting only to suit the sizes required as per drawings.

2.4 PLACING AND SECURING :Reinforcement bars shall be accurately placed and secured in position and firmly supported or wedged by precast concrete blocks of suitable thickness, at sufficiently close intervals, so that they will not sag between the supports or get displaced during the placing of concrete or any other operation of the work. It is most important to maintain reinforcement in its correct position without displacement and to maintain the correct specified cover. Contractor shall be responsible for all costs for rectification required in case the bars are displaced out of their correct position.

2.5 BINDING WIRE :The reinforcement shall be securely bound wherever bars cross or wherever required with 18 gauge soft annealed steel wire.

2.6 WELDING :Welding of bars shall not be carried out unless specially authorised in writing by Structural EIC.

2.7 BENDS ETC :

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Bends, cranks etc. on steel reinforcement shall be carefully formed, care being taken to keep bends out of winding. Otherwise, all rods shall be truly straight. If any bend shows signs of brittleness or cracking, the rod shall be removed immediately from the site. Minimum radius of 9 times diameter of the bar shall be used unless otherwise specified in the drawings. However, in respect of standard hooks the radius of bend shall be 2 times of diameter of bar. Heating of reinforcement of bar to facilitate bending will not be permitted. The bars shall always be bent cold.

In case of mild steel reinforcement bars of larger sizes, where cold bending is not possible, they may be bent by heating with written permission of the Project Engineer. Bars when bent hot shall not be heated beyond cherry red colour and after bending, shall be allowed to cool slowly without quenching. The bars damaged or weakened in any way in bending shall not be used on the work. High strength deformed bars shall in no case be heated to facilitate bending or cranking.

2.8 INSPECTION OF REINFORCEMENT :No concreting shall be commenced until the Structural EIC has inspected the reinforcement in position and until his approval has been obtained.

A notice of at least 24 hours shall be given to the Project Engineer by the Contractor for inspection of reinforcement.

If in the opinion of the Project Engineer any material is not in accordance with the specification or the reinforcement is incorrectly spaced, bent or otherwise defective, the contractor shall immediately remove such materials from the site and replace the same and rectify any other defects in accordance with the instruction of the Project Engineer to his entire satisfaction.

2.9 NET MEASUREMENTS :Reinforcement shall be placed as shown on the structural drawings and payment will be made on the net measurements from drawings. No laps, dowels, chairs and pins in reinforcement shall be paid for. The Contractor shall allow in his quoted rate for all wastage which will not be paid for.

2.10 RATES QUOTED FOR REINFORCEMENT SHALL IN ADDITION TO ANY FACTORS MENTIONED ELSEWHERE SHALL ALSO INCLUDE FOR :

(a) All cutting to lengths, labour in bending and cranking, forming hooked ends, handling, hoisting and everything necessary to fix reinforcement in work as per drawings.

(b) Cost of binding wire required as described.

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(c) Cost of PVC blocks to maintain cover and holding reinforcement in position.

(d) For fabricating and fixing reinforcement in any structural member irrespective of its location, dimensions and level.

(e) Removal of rust and every other undesirable substances, using wire brush etc. as described.

(f) Stock piling of reinforcement as described.

(g) Work at all levels.

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TECHNICAL SPECIFICATIONFOR

CIVIL JOBS

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TECHNICAL SPECIFICATIONS: CIVIL – MATERIALS

1.0WATER

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.

2.0CEMENT

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 Pozzolana cement conforming to IS:1489-1976.

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

e) Ordinary Portland Cement conforming to IS:8112 (43/53-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.

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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

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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).

3.0AGGREGATES :

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

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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 quantity 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

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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 NOMINAL 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

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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).

4.0BRICKS :-

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

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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.

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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).

5.0STEEL REINFORCEMENT :-

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

a) TMT bars IS 1786-latest version.

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5.1.2 TMT 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.

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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

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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.

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 :

Arc 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.

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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

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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 WORKGENERAL, DEFINITIONSDEADMEN 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 :

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

earth or rock removed during construction.

CLASSIFICATIONThe earth shall be classified, measured and paid separately for categories as

mentioned below :

ORDINARY SOILAny soil which can be removed with the ordinary or close application of bicks or

jumpers or scarifiers and rippers.

ORDINARY ROCKWhich 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.

PROTECTIONa) 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 FOUNDATIONSCOPEExcavation for normal spread footings, trenches, u/g storage tanks, excavation over

large areas, etc.

SITE CLEARENCEBefore 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.

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SETTING OUT AND MAKING PROFILESMasonry 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

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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 treacherous 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

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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 :SCOPEThis 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

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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 levelled 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:

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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 levelling courses, sub grades, 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 shall be 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 (Weigh batching only):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.

No hand mixing is allowed.

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CONSISTENCY:The quantity of water to be used for each mix of 50 kg cement is governed by IS

456 -2000.

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

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------

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

Reinforced 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

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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 :

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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.

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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.

FORMWORKUnless 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 :

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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.

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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 :

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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.

REINFORCED CEMENT CONCRETE DRIVEWAY:

The RCC drive way will be cast in panels. The concreting sequence will be discussed and got approved by EIC. Ready Mix Concrete (RMC) shall only be used for concreting. The Mix design from the RMC plant will be submitted to HPCL for approval and concreting job is to be taken up only after the design mix is approved.

Casting of slab in alternate panels of size 6M X 3M (or as instructed by engineer in charge) including vibrating with screed vibrators. The shuttering material should be sufficient for concreting a minimum of 6 Cum ( minimum qty of a RMC Transit mixer)

Providing broom finish to the top surface when concrete is green.

Pond curing for 15 days.Concrete shall conform to IS 456-2000 and also to the specifications discussed

above under the Ready Mix Concrete section. Rate shall be exclusive of steel

reinforcement, which shall be paid under a separate item

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

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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 diameter 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.

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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

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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.

COMPACTIONConcrete 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:

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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 per IS 456 -

2000.

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.

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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

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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.

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MEASUREMENT: All measurements shall be as per IS: 1200

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”.

PREPARATION 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

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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 :

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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.

APPLICATIONThe 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.

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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.

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

SANDSTests to be conducted

a. Particle size - Lab

b. Silt content - Field

c. Bulking of sand-Field

d. Percentage of Deleterious material / Organic impurities - lab

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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)Tests to be conducted

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 testingSame 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 AGGREGATETests to be conducted

a. Percentage of Soft deleterious materials- Field (Visual)

b. Particle size distribution

c. Aggregate value :

1. Crushing - Lab

2. Impact - Lab

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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 TestingMinimum 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.

CEMENTTests to be conducted

a. fineness - Lab

b. Soundness - Lab

c. Setting Time - Lab

d. Compressive strength - Lab

Periodicity of TestingMinimum 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 CONCRETETests to be conducted

a. Slump test - Field

b. Cube strength - Lab/field

Periodicity of Testinga. Once for minimum 5 cum.

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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 STEELTests to be conducted

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-1786 for TMT bars

IS code for testing - IS-1608

Periodicity of Testing

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.

BRICKSTests to be conducted

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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)

Periodicity of TestingMinimum 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

MORTARS1:3 CUM 10.21:4 CUM 7.61:5 CUM 6.21:6 CUM 5.0

CONCRETE AS PER DESIGN MIX PROVISIONS OF IS 456 2000

BRICK MASONARY1:4 CUM 1.81:5 CUM 1.561:6 CUM 1.24

HALF BRICK MASONARY1:3 SQM 0.291:4 SQM 0.21

STONE MASONARY1:6 CUM 1.7

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PLASTERING - 12 MM THICK1:6 SQM 0.0721:5 SQM 0.0841:4 SQM 0.102

PLASTERING - 20 MM THICK1:3 SQM 0.231:4 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.,

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STANDARD SPECIFICATION

FOR WELDING

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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

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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

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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

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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. PREPARATINO 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

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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

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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.

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GENERAL SPECIFICATION

FOR FABRICATION OF PIPELINE

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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:B31.3ii) 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

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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.

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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

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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

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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 pipes4 tacks - for 3” to 12” dia. pipes6” 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. WELDING TECHNIQUE :

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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.

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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, post weld 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

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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 Exhibit 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

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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 Generala) 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 qualificationiii. To witness the welder performance qualificationiv. 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 specified 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

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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 specified 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 specified 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

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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 specified 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.

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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 TestsHydrostatic 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

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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 specifiedd) Heat Treatment Chartse) Weld joint hardness test resultsf) Welding Procedure Specifications as per Exhibit-C immediately after receipt of

the order.g) Welding Procedure Qualification records as per Exhibit-Dh) Welder Performance Qualification records as per Exhibit-E immediately after

conducting welder qualification tests.i) Radiography Procedure as per Exhibit-Fj) 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 : 1INSPECTIONCLASS

SERVICE MATERIAL(NOTE 3)

P.NO.

TEMPDEG. C.

PRESSURECLASS B16.5B16.34

APPLICABLE PIPING CLASS

TYPES OFEXAMINATION

TYPES OF WELDD EXAMINATION

REMARK

1 2 3 4 5 6 7 8 9 10 11 12 13 14

ICATEGORY ‘D‘

CARBON STEEL

1 0 TO186 A3A,A3Y, A) VISUAL S

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150 UPTO10.55KG/CM2

B) LP (NOTE4 )

AUSTENTIC S.S

8 29 TO 186

A3K

AIZ,MZ,A5Z

HDPE 20 TO 50

CURPONICKEL

29 TO60

SPECIFICATIONS FOR PIPELINE WORK

MATERIALS:

ELECTRODES

Electrodes for welding of pipelines shall strictly conform to AWS SPECIFICATION AWS-1.5.1.69-E 6013 and be of the following make/brandESABINDIAN OXYGENADVANI ORLIKOND&H SECHERONPHILIPSWELDCRAFTGEE LTD

PIPING

Pipe and pipe fittings, wherever required to be supplied by the contractor, shall conform to IS: 1978/1239/3598-latest edition.

FLANGES

MS plate ring flanges wherever required to be supplied by the contractor shall conform to ASA class 150, ANSI B-16.5 Specification, unless otherwise mentioned.

BOLTS AND NUTS

Bolts and nuts shall conform to the requirement of turned gauge botls of symbol 4D, 5D and 5S, specifications in IS:1367-1962 technical supply conditions for threaded fasteners. The screw thread shall conform to coarse series medium class referred in IS:1367-1962. All stu & bolts shall conform to ASTM A 193 B 7 & A194 2H.

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JOINTING MATERIALS (GASKETS)

The details of the gaskets to be used shall be as given below:

QUALITY : As mentioned in Job schedule.

Manufacturer : Champion or Equivalent approved by Engineer In Charge

SERVICE : For use on all pipeline, flange joints, etc.

PREPARATION OF PIPE END

The fabrication of pipeline shall conform to IS:10234

The pipes supplied will be in random lengths of 5-7 meters generally with bevelled ends. However, in case any ends are damaged cutting/bevelling shall be done by the contractor at no extra cost. Cutting/bevelling will also be required to be done before welding my cut piece of pipeline.

For pipes that are intended to be in axial alignment the place of the pipe ends shall be square with the axis of the pipe.

The pipes which are intentionally out of axial alignment, the plane of the joint shall bisect the angle between adjacent pipes.

All tack welded but joint assemblies shall be inspected to ensure rootgap, alignment, quality of tackwelds, their root penetration section, cleaning and free fromcracks. Any substandard tack weld shall be cut and remade upto the standard befor estaring the welding.

Contractor shall arrange to maintain register for stagewise inspection and clearance by site incharge for above and any other checks as desired by site in charge.

LAYING OF PIPELINES:

Above ground pipeline:

Above ground pipelines shall laid on RCC pedestals. Pipelines shall follow the general alignment of the ground. The height of the pedestal shall be adjusted in such a way that clearance from the ground to the bottom of the pipeline shall not be more than 400 mm. No flange or valve joint shall fall on support.

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UNDERGROUND PIPES

A) The trench shall be excavated to proper width as decided by site in charge.

b) It should be ensured that while laying the pipes, no foreign material like stones, sand, gunny bags, bits of welding rods, weld materials etc. are left inside the laid pipes. At the end of each day’s work the free end of the laid pipes must be kept properly closed with dry gunny bags.

C) The trenches shall not be backfilled till the final inspection by radiography/hydrostatic tests are completed, and all the defects pointed out by the Engineer-in-charge are rectified to the satisfaction of the Engineer-in-charge.

WELDING:

A) Only welders proficient in the vertical and overhead positions as per the stipulations of ISI-817 shall be allowed to weld these pipelines. Preferably welders with proficiency certificates from Govt. test house or equivalent recognized authority should be deployed for the job. Optionally welders will be tested at site and the test pieces shall be tested by radiography in an approved laboratory. All expenses for this shall be borne by the contractor.

If a welder is found to perform a type of welding or in a position for which he is not qualified he shall be debarred from doing further work. All welds performed by an unqualified welder shall be cut and rewelded by a qualified welder at the expense of the contractor.

It shall be contractor’s responsibility to arrange for and bear all costs towards testing of welders for prequalification.

Welding shall be manual shielded metal arc process. Standard quality line up jigs and fixtures which will ensure sound welds shall be used. The cutting of pipes and welding shall conform to IS specifications and to the satisfaction of Engineer-in-charge. The pipe shall be butt welded with three or more runs of weld.

Welding shall not be performed when surfaces to be welded are wet, when rain is falling on which such surface or during the period of high winds unless the welder and the works are shielded in an approved manner.

Joint preparation for welding shall be so as to leave a smooth finished profile free of cavities and conforming to standard practice. Edges shall be cleaned of paint, rust, scale, slag, dirt and other foreign materials before welding.

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The thickness of the tack welds shall be similar to that of the initial root run to be deposited in the groove and where necessary, the extremities of the tack welds shall be dressed by grinding, chipping and flame gauged to facilitate proper fusion when they are incorporated in the initial root run.

All slag and scales etc.shall be removed from the surface of each completed bead before depositing the next bead.

The finished weld shall present a smooth bright and shiny surface of constant width and uniformly spaced ripples. The welds shall be free from slag pockets, porosity, undercutting, incomplete penetration and fusion and other weld defects.

The weld shall not project beyond the plain surface in butt weld by more than 2 mm.

All welds protrusions spatter etc.on the weld surface and adjacent area shall be removed so as to leave the surface smooth and clean.

All valves, flanges risers, bends and other fittings shall be in perfect plumb and plane. Care shall be taken to align the pipelines and bends properly to keep the symmetry of the pipeline layout.

To maintain the specified alignment and gap during welding the pipes shall be securely held in position by mechanical means and not by tack welding or by welding on bridge place. Electrode or filler rods used for tack welding shall be of the same quality as those used for the first run of the weld.

INSPECTION OF WELDS

The methods of inspection shall be as under:

Visual inspection shall be done for all weld joints of pipelines as well as flanges.

Dimensions of weld deposits:

The dimensions of weld shallbe checked. The size of weld shallbe as specified and it may be slightly over but not undersize.

Shape of Profile:

The profile of the weld is affected by position of the joint but shall be uniform. In the case of butt and corner welds the profile shall be slightly convex and in the case of fillet weld it is usually slighlty concave.

Uniformity of Surface:

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The height and spacing of the ripples shall be uniform these being indicative of quality of workmanship.

Degree of Undercuts:

The welded joints shall be free from undercuts, but slight intermittent occurrences may be disregarded provided that such undercuts is not in the form of sharp notch.

Smoothness of joints where welding is recommended:

The joints in the weld run shall be as smooth as possible and shallshow no pronounced lump or crater in the weld surface.

Freedom from surface defects:The surface of the weld shallbe free from porosity, cavities and burnts or scale.

Penetration bead in butt welds:

A slight penetration bead shall be present and it shall be reasonably uniform in width and appearance. Intermittent occurrences of lack of penetration bead may be disregarded.

HYDROSTATIC TESTING

A) On completion of laying of entire pipeline, all open flanges except one on the line shall be blanked of with blind flanges.

B) The trench shall be kept free of water and the pipeline surface dry. The pipeline shall be filled with water and the pressure built up by means of test pump with a pressure gauge to the specified pressure i.e. 10.5 Kgs/Sq.cm.

C) The pressure shall be maintained for a minimum period of 12 hours unless otherwise specified by the Engineer-in-charge. The hydrostatic test shall ge considered positive only if there is no drop in the built up pressure at the end of the specified period.

D) All weldedb and flange joints and the seam welds on the ERW pipes shall be inspected for leak by passing a dry hand.

E) Leaky joints shall be repaired by methods as approved by site incharge. After repairing the leaky joints, the joint shall be re-radiographed and entire pipeline section shall be hydrotested to prescribed pressure. No claims for such expenditure

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incurred by the contractor towards such repairs of defective work and retesting shall be entertained.

F) After hydrotesting, pipeline shall be completely emptied out and the line shall be made free fo water.

RADIOGRAPHIC INSPECTIONSCOPEThis specification covers the radiographic inspection of all types of welded joints of the main pipeline and piping system.The welded joints shall include the following:i. Full girth welds on the main line construction including double jointing of pipe, if adopted.ii. Welds for installation of block valves, insulating joints, other appurtenances and tie-ins

APPLICABLE STANDARDSThis specification shall apply in conjunction with the following (latest edition):i.) DNV Rules for Submarine Pipeline Systems.ii.) ASME Section V, Nondestructive Examinationiii.) ASTM E 94, Standard Practice for Radiographic Testing.iv.) ASTM E 142,Method for Controlling Quality of Radiographic Testing.v.) SNT-TC-IA - Recommended Practice for Nondestructive Testing Personnel Qualification and Certification.VI) API-1104 Standard for Welding Pipelines and Related Facilities.

PROCEDUREThe radiographic examination procedure to be adopted shall be submitted by the Contractor.

The procedure of radiographic examination shall be qualified to the entire satisfaction of Company/Company’s authorised Inspection agency. It shall include but not be limited to the following requirements.i. Manual or automatic film processing shall be done, so that they are interpretable for atleast three years after they are produced.

ii. A single- wall exposure technique shall be used for radiography whenever practical. When it is not practical to use a single wall technique, a double wall technique shall be used. An adequate number of exposures shall be made to demonstrate that the required coverage has been obtained.

iii. The quality level required for radiography shall be atleast 2% (2-2T)iv. A densitometer shall be used to determine film density. The transmitted film

density shall be 1.8 - 2.5 throughout the weld.

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The Contractor shall qualify each procedure in the presence of the Company prior to use. The radiographic procedures are to be made of a weld joint using pipe of same diameter, wall thickness and of material same as that used in the pipeline system.

The procedure of radiographic examination shall produce radiographs of sufficient density, clarity and contrast so that defects in the weld or in the pipe adjacent to the weld, and the outline and hole wires and identification no. of the penetrameter wires are clearly discernible.

All the girth, welds of mainline shall be subjected to 10% radiographic examination The Contractor shall furnish all the radiographs to Company/Company’s authorised representative, immediately after processing and drying for review and approval, together with the corresponding interpretation reports on approved formats. The details of the radiographs along with the joint identification number shall be duly entered in a register and signed by the Contractor and submitted to the Company/ Company’s authorised representative for approval.

When the radiation source and the film are both on the outside of the weld and located diametrically opposite to each other, the maximum acceptable length of film for exposure shall not exceed the values given as per acceptable procedure. The minimum film overlap, in each cases, shall be 40 mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch and smaller provided that the source to film distance used is a minimum of 12 inch.

Three copies of each acceptable radiographic procedure (as specified) and three copies of radiographic qualification records shall be supplied to Company. One set of the qualifying radiographs on the job, shall be kept by the Contractor’s authorised representative, to be used as a standard for the quality of production radiographs during the job. The other two sets shall be retained by Company for its permanent record.

Three copies of the exposure charts relating to material thickness, kilo voltage, source to film distance and exposure time shall also be made available to company by the Contractor.

The Contractor on daily basis, record for each radiograph (i) Radiograph’s number (ii) Welder/s number (iii) Approximate chainage of weld location, (iv) Whether or not the welds meet the specified acceptance standards and (v) the nature and approximate location of unacceptable defects observed. It must be possible to relate back to a particular butt weld and welder on piping drawing and pipeline alignment drawing.

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Each batch production of processed radiographs shall be properly packaged separately identified by atleast the week No. and job location.

The contractor shall provide all the necessary facilities at site such as a dark room with controlled temperature, film viewer etc. to enable the Company/Company’s authorised representative to examine the radiographs.

The contractor, if found necessary, may modify the procedure of radiographic examination suiting to the local conditions prevailing. This shall, however, be subject to the approval of the Company/Company’s authorised agency.

Company/Company’s authorised representative shall have free access to all the Contractor’s work facilities in the field.

Any approval granted by the Company/Company’s authorised representative shall not relieve the Contractor of his responsibilities and guarantees.

RADIATION SOURCE Radiographic examination shall be carried out using Gamma radiations at the discretion of the Company.

LEVEL OF QUALITYThe quality level required for radiography shall be atleast 2% (2-2T)

PENTRAMETERThe image quality indication shall be used for the qualification of the welding procedure and during examination shall produce radiographs to suit the requirement of the codes. For radiographs made with the source on the outside a penetrameter shall be placed on each side of the film with the smaller wire of penetrameter turned towards the end of the film itself. When a complete weld is radiographed in a single exposure using a source inside the pipe minimum three penetrameters approximately equally spaced around the circumference shall be used. During the procedure qualification IQI shall be placed both on the source side and on the film side.

The sensitivity limit may be considered to have been reached when the outline of the IQI, its identification number and the wire if the required diameter show up clearly on the radiograph.

The Company/Company’s authorized representative may authorize use of types of IQI other than those planned, provided that they confirm with recognized standards and only if the contractor is able to demonstrate that the minimum

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sensitivity level required is obtained. For this demonstration, a test shall be carried out comparing the IQI, scheduled and the Contractor’s to show up the identification number and other details of the proposed IQI, which must be visible in the test radiograph. Material of the penetrameter shall be of equivalent radiographic density to that of the material under examination.

FILM IDENTIFICATION MARKERSAll films shall be clearly identified by lead numbers, letters and/or markers. The image of the markers shall appear on the films, without interfering with the interpretation. These markers positions shall also be marked on the part to be radiographed and shall be maintained during radiography.

PROTECTION AND CARE OF FILMAll exposed and unexposed film shall be protected and stored properly as per the requirements of ASTM E94 and DNV rules.The exposed and unexposed film shall be protected from light, heat, dust and moisture. Sufficient shielding shall be supplied to prevent exposure of film to damaging radiation prior to and following the use of the film for radiographic exposure.

RE –RADIOGRAPHYThe weld joints shall be re-radiographed in case of unsatisfactory quality of radiographs.All the repaired weld joints shall be re-radiographed at repaired position in the same manner at that followed for the original welds. In addition, the repaired weld areas shall be identified with the original identification number plus the letter R to indicate the repair.When evaluating repair film radiographers shall compare each section (exposure) of the weld with the original film to assume repair was correctly marked and original defect removed. The Company/Company’s authorized representative will review prior to any repair of welds, all the radiographs of welds that contain, according to the Contractor’s interpretation, unacceptable defects. The Company/Company’s authorized representative will decide the final deposition of all unacceptable welds.

QUALIFICATION OF RADIOGRAPHERSAs a minimum, all personnel conducting radiographic examination shall be certified to Level- I in accordance with ASNT document SNT-TC-IA.All qualification certification should have current validity. Radiography will be performed under jurisdiction of a certified ASNT Level-II Supervisor.Interpretation of radiographs shall be carried out only by certified ASNT-Level II Personnel.

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All the records of NDT Personnel such as background and experience records, training course records, certification records and fitness records shall be submitted to the Company for review and approval before the NDT personnel are permitted to perform production radiography and interpret films.

PRESERVATION OF RADIOGRAPHSThe radiographs shall be processed to allow storage of films without any discoloration for atleast three years. All the radiographs shall be presented in suitable folders for preservation along with necessary documentation.All radiographs shall become property of the Company.

EQUIPMENT AND ACCESSORIESContractor shall make necessary arrangement at his own expense, for providing the radiographic equipment, radiographic films and all the accessories for carrying out the radiographic examinations for satisfactory and timely completion of the job.For carrying out the radiographic examination contractor shall be equipped with film processing units, film viewer, density meter etc.

RADIATION PROTECTION Contractor shall be responsible for the protection and personal monitoring of every man with or near radiation sources.The protection and monitoring shall comply with local regulations.

In view of visual hazards, in the handling of Radioactive source of material, Contractor shall be solely responsible for complying with all rules and regulations set forth by Atomic Energy Commission or any other Government agencies of India in this regard and Company shall not be responsible and shall be kept indemnified by the Company for all necessary personnel shall be made available for use and maintained for immediate and proper use by the Contractor.

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STANDARD SPECIFICATION

FORFIELD PAINTING

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TECHNICAL SPECIFICATIONS FOR COPPER SLAG BLASTING AND PAINTING

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 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 SCAFFOLDINGScaffolding 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 Standards

6.0 APPROVED MAKES OF PAINTS / PRIMER1. M/s Berger Paints

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2. M/s Asian Paints3. M/s Goodlass Nerolac4. M/s Jenson & Nicholson5. 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.

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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% for each of the square meter 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 re-blasting shall be done if necessary.

12)Physical properties of Copper Slag:a) Colour : Blackb) Grain Shape : Granulated, Angular multifacetedc) Hardness : 5 to 7 Moh’s scaled) Sp. Gravity : 3.2 to 3.7e) 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

GENERAL INSTRUCTIONS FOR PAINTING

1. Painting shall follow immediately after satisfactory shot blasting/manual cleaning.

2. 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.

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3. Tools used shall be clean and not worn out.

4. 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.

5. In case paint is thickened because of evaporation of solvents, its viscosity shall be adjusted as recommended by the paint manufacturer.

6. 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.

7. Each individual coat shall be properly applied and shall be free from dust etc.

8. BASIS OF MEASUREMENT AND PAYMENTAs given in job schedule.

9. INSPECTION AND APPROVAL OF SURFACE

9.1All 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.

9.2HPCL 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.

9.3The painting work shall be subjected to inspection by HPCL at all times. Stages of inspection are as follows:

1) Surface Preparation2) Primer application3) 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.

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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.

9.4 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats in consultation with manufacturer.

9.5Calibrated Digital Elcometers, surface profile gauges and any other inspection instrument required by HPCL shall be provided by the contractor at site.

9.6The 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.

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.

11.0 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.

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The DFT measurements shall be taken after each coat as following-

STRUCTURES : 5 readings on each lengthPIPELINES : 5 readings on each length VALVES : 5 readings on each valve .

The DFT for a particular surface/pipeline length/structural/pipeline fittings/ 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.

STANDARD SPECIFICATION FOR

SHOP AND FIELD PAINTING

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1.0GENERAL

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.

2.0SCOPEScope of work covered in this specification shall include but not limited to the following:

1. Surface preparation for all components of A/G product tank, structural steel, and 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 STANDARDSIS : 5IS : 101ASTM STANDARDS

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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.

4.0EQUIPMENT

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.

5.0SURFACE PREPARATION, COATING APPLICATION AND DOCUMENTATION

5.1 GENERAL

5.1.1 In order to achieve the maximum durability, grit blast cleaning shall be followed.

5.1.2 Mill scale, rust, rust scale, etc. shall be fully removed by Grit blast cleaning to SA 2 ½ or equivalent as per SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988.

5.1.3 Grit 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 GRIT BLAST CLEANINGThe surface shall be Grit blasted with Copper Slag grit at a pressure of about 7 kg/sqcm at appropriate distance and angle using compressed air and Grit

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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 Grit 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 intercoat 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.

5.5 DOCUMENTATION

A written quality Plan with procedure for qualification trials and for actual work.

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.

Code and Batch numbers of primers and paint materials used.

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Type of testing equipments and their calibration.

Elcometer readings for the various components jointly recorded with HPCL.

Paint consumption statement along with the Theoretical consumption requirements.

6.0 RECOMMENDED MANUFACTURERS

ASIAN PAINTS BERGER PAINTS GOODLASS NEROLAC JENSON AND NICHOLSON SHALIMAR PAINTS BOMBAY PAINTS

7.0 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.

8.0 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:4) Surface preparation5) Primer application6) Each coat of paint

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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.

Calibrated Digital Elcometers, surface profile gauges and any other inspection

8.5 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 DESIGNATIONSPRIMERS

P-1 :HIGH BUILD EPOXY MASTIC COATING ( ONLY AT WELD JOINTS)

P-2 : INORGANIC ZINC SILICATE COATING

FINSIH COATS/ PAINTS

F-1 : HIGH BUILD MIO

F-2 : ACRYLIC POLYURETHANE FINISH

PAINTING FOR PIPING

SL.NO. TYPE OF PIPING

SURFACE PREPARATION

PAINT SYSTEM TOTAL DFT IN MICRONSFIELD

PRIMER FINISH PAINT

1 PRODUCT LINE

SA 2 1/2 1 COAT OF P-2 @ 65 MICRONS DFT/COAT

1 COAT OF F-1 @ 100 MICRONS DFT/COAT + 2 COATS OF F-2 @ 40

245 MICRONS

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MICRONS DFT/COAT(TOTAL = 100 + 2 X 40 = 180 MIRCONS)

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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STRUCTURAL STEEL WORKS

STRUCTURAL WORK

1.0 The Specification shall apply to Steel work in GANTRY and general Structural work

2.0 FABRICATION OF STEEL STRUCTURES

2.1 SCOPE OF WORK

2.1.1 The scope of work under fabrication-includes, but not limited to, the following:

a) Preparation and supply of material indents, bolt lists bought out items list.

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b) Procurement and collection of all steel materials from stockyards/stores, including loading, transportation, unloading and slacking and storing on skids or supports.

c) Procurement and collection of all consumables like bolls nuts, hook bolts, washers, electrodes, paints, shims, packs, etc., including allowance for spares and wastage.

d) Preparation and submission of fabrication drawings, modification /rectification sketches, as made drawings, erection drawings, bill of materials, bolts lists and shipping documents for approval of purchaser.

e) Preparation of design calculations for non-standard connections, temporary bracings etc_ for approval of purchaser.

f) Cold straightening of section and plates, whenever they are bent and kinked.

g) Fabrication of all steel structural components covered under tender drawings, design drawings and generally described under the scope of the project including MS gratings, MS tube Hand rails. Gutter, down corner, portal frame etc, complete.

h) Making arrangements for and conducting tests, such as chemical analysis, physical and mechanical tests on raw materials 'here specified/as directed by the purchaser,

i) Making arrangements for providing all facilities for conducting ultrasonic, Radiographic tests of welds; gelling the tests conducted by reputed testing laboratories making available test films 1 graphs, reports and interpretation.

I) Control Assembly of steel structural components at shop, wherever required.

k) Preparation of steel structural surfaces for painting as provided in the specifications / drawings.

I) Application for painting at shop, as specified in the design drawing/specifications.

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m) Loading, transportation from fabrication workshop to site of erection and unloading of all steel structural components 1 units / assemblies, roofing sheets, gratings, gutter, down corner etc,.

n) Rectification of damaged structures including fixing, aligning, levelling, balling & welding etc,

o) Preparation of "As-built" drawings.

2.2 PREPARATION OF FABRICATION AND ERECTION DRAWINGS

2.2.1 Fabrication drawings shall be prepared based on design drawings of steel structures.

2.2.2 Drawing shall be prepared in metric system as per IS:696-1972 and IS: 813-1986. The fabrication drawings shall specify the following details:-

a) Type, size and length of welds in case of welded connections (specifying clearly shop or site weld). Length of weld specified shall be effective length (excluding end crates)

b) In case of bolted joints, arrangement of bolts and specification of bolts, nuts etc (specifying clearly shop and site bolls).

c) Specification of electrode/wire flux.

d) If required special provision to be mentioned in the drawings for handling of structures during and after fabrication.

e) Specification of paint and corresponding surface preparation for painting.

f) General arrangement / marking plan.g) Reference to design drawings.

h) Material list indicating mark number-wise material requirement giving size, weight, material specification, identification number of each items, number of pieces required etc.

i) Layout with all connecting members with blown up joint details wherever required, in order to specify clearly various fabrication and erection requirements as per design drawings.

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j) Specification of preparation of mating surfaces in case of connection by HSFG boils.

k) Appropriate edge preparation in case of butt/groove welds in accordance with 1S:9595-1980, for all plates and sections having thickness greater than 8 mm.

1) Erection clearances in order to facilitate smooth erection at site (ref clause no.11.2.2.of IS: 800- 1984).

m) Each erection piece shall be clearly identified by an erection mark in these drawings. All loose members shall be given part mark, which shall be 'wired on' the main erection piece for dispatch.

2.2.3 Fabrication drawings shall be prepared in such a manner that Structures can be dispatched from fabrication shop to erection site with maximum economic transportable size, so as to reduce work involved at site to a minimum.

2.2.4 Bracings shall be connected for 50% of the capacity of the member or the force specified in the design drawing, whichever is more (for single angle bracing member, consider lull area as effective for this purpose).

2.2.5 Standard simple beam connections, unless otherwise stated in the drawings, shall be designed and detailed for 60% beam shear 1 moment carrying capacity.

2.2.6 Wherever there is risk of nuts becoming loose due to vibration, lock nuts shall be provided, or nuts shall be welded alter alignment and lightening.

2.2.7 For all connections by permanent bolts, two nos. of washers shall be used. One washer bearing against the head and the other bearing against the nut.

2.2.8 Detailing of structural steel members subject to dynamic loading shall be such as to ensure smooth transition of load, as well as best behavior under stress due to fatigue. Welding across tension flange of crane girders is not permitted.

2.2.9 For detailing connection, the allowable stress for materials, welds, bolls etc, shall be as per IS: 800- 1984 and IS: 816-1969, or as specified in the drawing.

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2.2.10 The contractor shall be responsible for design and detailing all connections. The design of connection shall provide adequate strength for transfer of force in the structural elements, as indicated on design drawings. Detailing shall be such that erection shall be convenient and free from all interfaces, drilling and cutting at site.

2.3 MATERIALS

2.3-1 Structural Steel

2.3.1.1 Structural steel and other related materials for construction shall

conform to Annexure-VI and relevant IS standards and BOQ.2.3.1.2 Due to non-availability of specified materials, suitable substitutions

may be provided with the consent of the purchaser. Such substitution shall be incorporated in the 'As-built' drawings.

2.3.1.3 All the items are to be cut as per requirements of the drawing. If joints are to be provided in any item, in order to meet requirements of size and shape, cutting plan showing locations of joints shall be prepared for consideration of purchaser. Joints provided shall be incorporated in "As-built" drawings.

2.3.1.4 Rolling and cutting tolerances shall be as per IS:1852. 1985.2.3.1.5 Only tested materials shall be used unless use of untested materials

for certain secondary structural members is permitted by purchaser- If test certificate for the material is not available from the main producer, the following tests shall be carried out at the discretion of the purchaser.

a) Chemical Compositionb) Mechanical PropertiesC) Weld ability Test

2.3.1.6 Where steel castings are to be used the same shall conform to IS:

1030:1989.

2.3,2 Bolts and Nuts2.3.2.1 Black hexagonal bolts, nuts and lock-nuts shall conform to

IS:1363:1992.2.3.2.2 Precision and semi-precision hexagonal bolls, screws, nuts and

lock-nuts shall conform to IS: 1364:1992.2.3.2.3 High tensile friction grip bolls shall conform to IS:3757:1985 and

high strength structural nuts shall conform to IS:6623:1985, and hardened steel washers to IS: 6649:1985.

2.3.3 Electrodes

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1. Mild steel electrodes and high tensile steel electrodes shall conform to IS:814:1991. Electrode to be used for submerged are welding shall conform to specification IS:7280:1974.

2.4 STORING OF MATERIALS2.4.1 Materials shall be stored and stacked properly ensuring that place

is properly drained and is free from dirt. It shall be ensured that no damage is caused due to improper stacking. -

2.5 MATERIAL PREPARATION2.5.1 Cut edges shall be finished smooth by grinding or machining

wherever necessary. Sufficient allowance (3 mm to 5 mm ) should be kept in the items in case machining is necessary.

2.5.2 Cutting may be affected by gas culling, shearing, cropping or sawing. In gas cutting of high tensile steel, special care is to be taken to leave sufficient metal to be removed by machining so that all metal that has been hardened by flame is removed.

2.5.3 Sufficient shrinkage allowance (@1mm/M) shall be kept wherever heavy welding is involved.

2.5.4 Straightening and bending shall be done in cold condition as tar as practicable.

2.5.5 If required straightening and bending may be done by application of heat between 900°C and 1100°C. Cooling down of the heated item shall be done slowly.

2.6 DRILLING AND PUNCHING OF HOLES2.6.1 Drilling and Punching of holes for bolts shall be done as per clause

no.11.2.4 of IS: 800-1984, unless otherwise specified by the purchaser.

2.6.2 Drilling of holes for bolls during assembly shall not cause enlargement of holes beyond permissible limit or damage the metal.

2.6.3 Holes for bolted connection should match well to permit easy entry of bolts. Gross mismatch of holes shall be avoided.

2.6.4 Permissible deviation in holes for mild steel bolts of normal accuracy and high strength bolts are given in the ANNEXURE-I.

2.7 ASSEMBLY FOR FABRICATION2.7.1 Fabrication of all structural steelwork shall be in accordance with

1S:800-1984 and in conformity with various clauses of this specification, unless otherwise specified in the drawings.

2.7.2 Fabrication of structures shall preferably be taken up as per the sequence of erection.

2.7.3 All erection units shall bear erection mark no. and reference drg no. at a prominent location on the structures for easy identification at site.

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2.7.4 Fabricated structures shall conform to tolerance as specified in this standard and in 1S:7215-1974_ In case of contradiction, tolerances specified in this standard shall prevail.

2.7.5 All the components of structures shall be free from twist, bend, damage etc,

2.7.6 Assembly of structures shall be carried out by using suitable jigs and fixtures in order to obviate distortion during welding.

2.7.7 Cutting of items specially for truss, bracing, bunker, hopper, galleries surge girder, portal etc, shall be done only after checking of sizes as per Layout.

2.7.8 Surface, wherever machining is specified, shall be either planed or milled to ground to ensure maximum contact.

2.7.9 If end-milling or machining is planned after the assembly i s o v e r , s u f f i c i e n t allowance (5 mm to 15 mm) shall be kept in the items where milling/machining is to be done.

2.7.10 If pre-bending of the plate is required to avoid welding distortion; it shall be done in cold condition.

2.7.11 If extra joints are required to be provided in column, crane girder etc, and approval should be obtained from the purchaser. However, as general guidance following is suggested. Splice joints of column and crane girder shall of full strength bull weld and wherever possible shall be located al zones of minimum or substantially lesser stress.

2.7.12 Splice joints of flange and web should preferably be staggered.

2.7.13 Sufficient trial assembly of fabricated components (despatch elements) shall be carried out in the fabrication works to control the accuracy of workmanship.

2.7.14 Where necessary, washers shall be tapered or otherwise suitably shaped to give the heads of nuts and bolts satisfactory bearing.

2.7-15 The threaded portion of each bolt shall project through the nut at least by one thread.

2.7.16 Tolerance of assembled components of structures are given in ANNEXURE-II

2.7.17Permissible deviations from designed (true) geometrical form of the despatch elements shall be in accordance with IS: 7215-1974.

2.8 WELDING2.8.1.1.1 The Contractor shall work out welding procedure for Purchasers

approval, considering the following factors

i) Specification and thickness of steel.

ii) Specification of electrode or land base wire.

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iii} Welding process (manual arc welding, submerged arc

welding).

iv} Type of structures to be welded (thickness of components meeting at a joint).

V) Pre and post heating requirement.

vi) Preparation of fusion faces.

vii) Sequence of welding.

viii) Weather condition.

ix) Use of jigs and fixtures etc.

X) Type of non-destructive testing to be carried out.

Xi) Inspection procedure to be followed

xii) Design requirements of the joints-

2.8.2 Welding of any load bearing structure shall be carried out only by the person who has passed welder's qualification as per IS:7318 (Part-I)-1974.

2.8.3 All metal arc welding shall be carried out as per IS:9595-1984.2.8.4 Submerged arc welding of mild steel and low alloy steel shall

be as per IS:4353-1967.2.8.5 Electrode shall conform to clause no.2.3.3 of this standard.2.8.6 Electrodes shall be stored in a dry place. - Electrodes whose coatings

are damaged due to absorption of moisture or due any other reason shall not be used.

2.8.7 Low Hydrogen electrodes and flux for submerged welding shall be dried at 250°-300° C for one hour in drying -even before use.

2.8.8 For suitability of wire flux combination, procedure test shall be carried out as per IS: 3613-1974 if so required.

2.8.9 Welding shall be done by electric arc process. Generally submerged arc, automatic & Semi-automatic welding shall be employed. Only where it is not practicable, manual arc welding may be resorted to. In case of manual arc welding, recommendations of electrode manufacturer is to be strictly followed.

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2.8.10 Welding surface shall be smooth, uniform, and free from tins, tears notches or any other defect which may adversely affect welding.

2.8.11 For multi-run weld deposit, the next run should be done only after thorough removal of slag and proper cleaning of surface.

2.8.12 Fillet weld shall have the correct profile with smooth transition into parent metal. Dressing of welds, if specified, shall be done by such method which does not cause grooving and other surface defects on the weld or on the parent metal.

2.8.13 All butt welds shall start and end with run-on and run- off plates. All such plates shall .be carefully trimmed off by gas cutting alter welding is over.

2.8.14 Fillet welds shall not be stopped at corners but shall be returned round them.

2.8.15 If butt weld is to be ground flush with the surface of the member as per drawing_ Adequate reinforcement shall be built up and then the same shall be chipped off and ground flush: The grinding is to done in the direction of stress flow till the transverse marks are eliminated.

2.8.16 Welding shall not be done under such weather conditions, which might adversely affect the efficiency of the welding.

2.8.17 Manipulators shall be used wherever necessary and shall be designed to facilitate welding and ensure that all welds are easily accessible to the operators.

2.8.18 Stress relieving after welding shall be done if especially called for in the drawing or specification. Ends of structural members and portions of gussets receiving welding at site, shall be left unpainted.

2.8.19 Permissible deviation in assembly of weld joints shall be in accordance with ANNEXURE-III.

2.9 INSPECTION & TESTING2.9.1 The HPCL/Consultant shall have free access at all times to those

parts of Contractor's or his Sub- Contractor's works which are concerned with the fabrication of steel works and shall be afforded all reasonable facilities at all stages of preparation, fabrication and trial assemblies far satisfying himself that the fabrication is being undertaken in accordance with the provisions of relevant specification.

2.9.2 All gauges and templates, tools, apparatus, labour and assistance for checking shall be supplied by the contractor free of charge. The purchaser /inspector may at his discretion, check the test results obtained at the Contractor's works, by independent test at the Government Test House or elsewhere, and should the sample so tested be found to be unsatisfactory, the cost of such test shall be borne by the Contractor.

2.9.3 Contractor shall make all necessary arrangements for stage inspection by purchaser/inspector during the fabrication at shop and incorporate

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all on-the-spot instructions / changes conveyed in writing to the Contractor-

2.9.4 Material improperly detailed or wrongly fabricated shall be reported to the Purchaser/Inspector and shall be made good as directed. Minor misfits which can be remedied by moderate use of drift pins, and moderate amount of reaming and slight chipping may be corrected in that manner; if in the opinion of the Purchaser/Inspector the strength or appearance of the structure will not be adversely affected. In the event the Purchaser/inspector directs otherwise, the items will be rejected and a completely new piece shall be fabricated- The cost of correcting errors shall be to the account of the Contractor.

2.9.52.9.5.1 The Purchaser/Engineer shall have the power;

a) To certify, before any structure is submitted for inspection, that the same is not in accordance with the contract, owing to the adoption of any unsatisfactory method of fabrication.

b) To reject any structure as"-not being in accordance with specifications & drawings-

c) To insist that no structure or parts of the structure once rejected is resubmitted for inspection./test, except in cases where the Purchaser 1 Inspector authorized representative considers the defects as rectifiable.

2.9.5.2 If. on rejection of structure by the Purchaser/Inspector the Contractor fails to make satisfactory progress within the stipulated period, the Purchaser/Inspector shall. be at liberty to cancel the contract and fabricate or authorize the fabrication of the structures at any other place he chooses, at the risk and cost of the Contractor, without prejudice to any action being taken in addition to terms of General Conditions of Contract.

2.9.5.3 The Purchaser / inspector's decision regarding rejection shall be final and binding on the Contractor.

2.9.5.4 The specifications prescribe various tests at specified intervals for ascertaining the quality of the work done. if the tests prove unsatisfactory, Purchaser/Inspector shall have liberty to order the Contractor to re-do the work, done in that period and/ or to -order such alterations and strengthening that may be necessary at the cost of the Contractor and the contractor shall be bound to carryout such orders failing which the rectification/redoing will be done by the Purchaser through other agencies and the cost recovered from the Contractor.

2.9.5.5 Notwithstanding any inspection at the workshop the Purchaser/Inspector shall have the liberty to reject, without being liable for compensation any fabricated members or materials brought to site that do not conform to specifications / drawings.

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2.9.5.6 All rejected materials shall be removed from the site of fabrication by the Contractor at his own cost and within the time stipulated by the Purchaser/Inspector.

2.10 CONTROL IN WELDING2.10.1 The extent of quality control in respect of welds for structural

elements for both statically and dynamically loaded structures shall be as follows and shall be conducted by the contractor at his own cost:-

2.10.1.1 Visual Examination - All welds shall be 100% visually inspected to check the following:

i) Presence of undercutsii) Visually identifiable surface cracks in both welds and base metals. iii) Unfilled cratersiv) Improper weld profile and sizev) Excessive reinforcement in weldvi) Surface porosity

Before inspection, the surface of weld metal shall be cleaned of all slag, spatter matter scales etc. by using wire brush or chisel.

2.10.12 Dye Penetration Test (DPI) for pipeline jobs - This shall be carried out for all important fillet welds and groove welds for both statically and dynamically loaded structures to check the following :i) Surface cracksii) Surface porosities

Dye Penetration Test shall be carried out in accordance with American National Standard ASTM B 165.

2.10.1.3 deleted2.10.1.4 deleted

2.11 ACCEPTABLE LIMITS OF DEFECTS IN WELD

2.11.1 Limits of Acceptability of welding defects shall be as follows: -

a) Visual inspection & Dye Penetration Test • The limits of acceptability of defects detected during visual inspection and Dye Penetration Test shall be in accordance with clauses 5.9 & clause 6.10 of American National Standard ANSIIAWS D1.1-96 for statically as well as dynamically loaded structures respectively.

b) Ultrasonic Testing - The limits of acceptability of defects detected during ultrasonic testing shall be in accordance with clause 6.13.1 & clause 6.13.2 of American National Standard ANSIIAWS 01.1-96 Chapter 6: Part C for statically and dynamically loaded structures respectively.

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c) Radiographic testing - The limits of acceptability of defects detected during Radiographic testing shall be in accordance with clauses 6.12.1 & 6.12.2 of American National Standard ANSIIAWS D1.1.96 Chapter 6 : Part C for statically and dynamically loaded structures respectively.

2.12 RECTIFICATION OF DEFECTS IN WELDS2.12.1 In case of detection of defects in welds , the rectification of the same shall be

done as follows : i) All craters in the weld and breaks in the weld run shall be thoroughly

filled with weld.

ii) Undercuts, beyond acceptable limits, shall be repaired with dressing so as to provide smooth transition of weld to parent metal.

iii) Welds with cracks and also welds with incomplete penetration, porosity, slag inclusion etc. exceeding permissible limits shall be rectified by removing the length of weld at the location of such defects plus 10 mm from both ends of defective weld, and shall be re-welded. Defective weld shall be removed by chipping hammer, gouging torch or grinding wheel. Care shall be taken not to damage to the adjacent material.

2.13 ACCEPTANCE CRITERIA OF MACHINING SURFACE2.13.1 Standard of acceptance for machined surfaces, wherever specified

by designer (eg_ in column cap plates, base plates and column shafts etc.) shall be as given as per clause 2.13.2 & 2.13.3.

2.13.2 Maximum surface unevenness on bearing surface of -cap/ base plate shall not exceed 0.5 mm.

2.13.3 When assembled, there must be physical contact for at least 75% of the contact surface_(The checking shall be carried out with 0.2mm gauge .Care should be taken that these connecting members are fixed with such accuracy that they are not reduced in thickness during machining by more than 1.0 mm.

2.14 DESPATCH INSTRUCTIONS

2.14.1 Each despatchable structure shall bear mark no. along with reference drawing number at two prominent locations (e.g. on flange and bottom of base plate of a column).

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2.14.2 As built' drawing shall be prepared after fabrication is completed to indicate additions / alterations made during the process of fabrication. (Refer clause 2.3.1.2 & 2.3.1.3.)

2.14.3 Control assembly of important structures shall be done in the shop floor before despatch to avoid mismatching. For all such important structures.match marking shall be given at the control assembly stage in the shop floor and such match markings shall be made dearly visible while assembling the structures at site.

2.14.4 Centre lines or column flanges and both sides of web shall be punched, preferably at top and bottom to facilitate alignment after erection.

2.15 COMPLETION DOCUMENTS

2.1 5.1 On completion of work, the Contractor shall submit to the Purchaser the following documents:-

a) The technical documents according to which the work was carried out.

b) Copies of the 'As built" drawings showing thereon all additions and alterations made during the fabrication.

c) Manufacturer's test certificates

d) Certificates/documents on control checking

e) Test of welds

2.15.2 Inspection Certificates shall be issued to the contractor for the structures found acceptable in all respects by the Purchaser/Inspector.

2.16 In addition to provision of erection and transport equipments, the scope of work includes supply of tools and tackles, consumables, materials, labour and supervision and shall cover the following:-

a) Storing and slacking of all fabricatedb) structural components/units/assemblies atc) site storage yards till the time of erection.

d) Transportation of structures from storage yard to site of erection including multiple handling, if required.

e) All minor rectification / modifications such as :-

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i) Removal of bends, kinks, twists etc. for parts damaged during transportation and handling.

ii) Reaming of holes which do not register or which are damaged, for use of next higher size bolt.

3.2 Erection Drawings3.2.1 The approved erection drawings and any approved arrangement drg,

specification or instruction accompanying them shall be followed in erecting structures.

3.3 Erection of Structures3.3.1 Erection work shall be taken up after receipt of clearance from the

purchaser.3.3.2 For safety requirements during erection, provisions in IS:7205:1974,

IS.7969:1975 and other relevant Indian standards shall be followed.3.3.3 Erection shall be carried out with the help of maximum

mechanisation possible.3.3.4 Prior to commencement of erection, all the erection

equipment ,tools, tackles, ropes etc. shall be tested for their load carrying capacity. Such tests may be repeated al intermediate stages also it considered necessary and frequent visual inspection shall be done of all vulnerable areas and components to detect damages or distress in the erection equipment, if any.

3.3.5 Following shall be taken care of during erection, whenever necessary:-3.3.5.1 Temporary bracing, whenever required, shall be provided to sustain

forces due to erection loads and equipment etc. Erected parts of the structures shall remain stable during all stages of erection when subjected to the action of wind, dead weight and erection forces etc. Specified sequence of erection of vertical and horizontal structural members shall be followed.

3.3.5.2 Elected members shall be held securely in place by bolts to take care of dead load, wind load and erection load.

3.3.5.3 All connections shall achieve free expansion and contraction of structures wherever provided.

3.3.5.4 No final bolting or welding of joints shall be done until the structure has been properly aligned.

3.3.5.5 For positioning beams, columns and other steel members, the use of steel sledges is not permitted.

3.3.5.6 Instrumental checking of correctness of initial setting out of structures and adjustment of alignment shall be carried out in sequence and at different stages as required. The final leveling and alignment shall be carried out immediately after completion of each section of a building.

3.3.5.7 All structural members shall be erected with erection marks in the same relative position as shown in the appropriate erection and shop drawings.

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3.3.5.8 The contractor shall design, manufacture, erect and provide false-work, staging temporary support etc. required for safe and accurate erection of structural steelwork and shall be fully responsible for the adequacy of the same.

3.3.5.9 The Contractor shall also provide facilities such as adequate temporary access ladders, gangways, tools & tackles, instruments etc., to purchaser for his inspection at any stage during erection.

3.4 Field Connections3.4.1 Assembly by permanent bolts.

3.4.1.1 The numbers of washers on permanent bolts shall not be more than two (and not less than one) for the nuts and one for the bolt head.

3.4.1.2 Wooden rams or mallet shall be used in forcing members into position in order to protect the metal from injury or shock.

3.4.1.3 Where bolting is specified on the drawing, the bolts shall be tightened to the maximum limit. The threaded portion of the each boll shall be project through the nut by al-least one thread. Tapered washers shall be provided for all heads and nuts to achieve uniform bearing on sloping surface.

3.4.1.4 To prevent loosening of nuts, spring washers or lock- nuts shall be provided as specified in the design/shop drawings.

3.4.1.5 All machine-fitted bolts shall be perfectly tight and the ends shall be checked to prevent nuts from becoming loose. No unfilled holes shall be left in any part of the structures.

3.4.2 Assembly by welding3.4.2.1 All field assembly by welding shall be executed in accordance with

the requirements for shop fabrication. Where the steel has been delivered painted, the paint shall be removed before field welding for a distance of at least 50 mm on either side of the joints to be welded.

3.4.2.2 All other requirements in welding shall be in accordance with clauses specified under Section-1 of this specification.

3.4.3 Assembly by High Strength Friction Grip Bolls (HSFG)3.4.3.1 Assembly of structures with HSFG bolts shall conform to IS: 4000-1992.3.4.3.2 The mating surfaces shall be prepared in accordance with the

requirements of design in order to achieve required properties to develop adequate friction between the surfaces.

3.4.3.3 The mating surfaces shall be absolutely free from grease, lubricant, and dust. Rust etc and shall be thoroughly cleaned before assembly.

3.4.3.4 The nuts shall be tightened up-to the specified torque with the help of torque -wrench or by half- turn method with the help of pneumatic wrench lever.

3.4.3.5 The direction of tightening of the nuts shall be from the middle toward the periphery of assembly.

3.4.3.6 After desired tightening the bolt heads, nuts and edges of the mat, i.e. surfaces shall be sealed with a coat of paint to obviate entry of moisture

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3.5 ACCEPTANCE STANDARD OF-MELDING3.5.1 Acceptance standard of welding shall be as specified in SECTION-2

of this specification.

3.6 BEDDING AND GROUTING3.6.1 Base plates shall be set to elevations shown on the drawings,

supported aligned and levelled using steel wedges and shims or by other approved methods. Plates shall be levelled properly, positioned and the anchor boss tightened.

3.6.2 Bedding/grouting shall be carried out until sufficient number of columns have been properly aligned, levelled and plumbed and sufficient number of girders, beams, trusses and bracings have been put in position to the satisfaction of purchaser. The bedding shall be carried out by the use of structural grade grout of approved manufacturer.

3.7 PAINTING AFTER ERECTION3.7.1 The painting shall be as per painting specification (SECTION-5) of this

standard) and instruction given on drawings.3.7.2 Site painting shall not be done in frosty or foggy weather or when humidity

is such as to cause condensation on the surface to be painted.

3.8 ERECTION TOLERANCESMaximum permissible tolerances in erected steel structures shall be as given in ANNEXURE-IV.

3.9 ACCEPTANCE OF WORK3.9.1 Acceptance of erected steel structures shall be either after

completion of erection of the whole building or in blocks.3.9.2 Preliminary acceptance certificates will be given in the following

cases:-i) Any steelwork or part thereof embedded in concrete.ii) Steel structures which are to be covered in the process

of carrying out further work.

3.10 DOCUMENTATION3.10.1 The following documents shall be prepared at the time of

acceptance of erected structures.i) Documents showing actual deviations made during

execution of erection work and approval of competent authority.

ii) Documents showing acceptance of embedded structures.

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ii) Certificate of documents on control checking and test of materials (if any) and weld,

iii) Data and result of geodetic measurements obtained while checking the erection of the structures.

3.10.2 Copies of "As-Built" drawing showing thereon all additions and alternations which took place between approval of drawing and erection of structures.

4.0 FABRICATION AND ERECTION OF MISCELLANEOUS STRUCTURES

4.1 ROOF AND SIDE CLADDING WITH .55 mm SINGLE SKIN CLIP ON ROOFING SYSTEM WITH GALVALUME SHEETS

4.1.1 The scope of work shall cover:a) Preparation of drawings showing layout and size of fibre

sheets- used details of connections and flashings, bill materials.

b) Procurement and supply sheets of .55 MM TCT Galvalume sheets all sizes (Interarch/ Make or equivalent) flashings and fittings like corner pieces. Apron pieces, ridges, cutting and bending of sheets wherever required; drilling of holes all as per specification and drawings.

c) Procurement and supply of GI hook bolts, clips, and nuts, GI switch bolts and nuts, clips, bitumen washers, GI diamond or limpet washers.

d) Loading, transportation, unloading and delivery of sheeting material from place of procurement to erection site.

e) Provision of all tools, tackles, equipment. labour supervision and services required for the satisfactory completion of the work specified herein and on the drawings.

e) Erection in position of t sheets for rooting, walling, louvres; erection of all (lashings, fittings like ridges, valleys, gutters, corners, apron etc. at all locations all work as per drawings and specifications.

4.1.2 The fixing of the sheet shall be done by the approved manufacturer including the design of the clip on system. The

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entire sheet system shall be guaranteed for a minimum of 5 years and shall be replaced if damaged free of cost.

4.1.3 to 4.1.5 Deleted

4.1.6 ERECTION4.1-6.1 Erection is to be carried out with the lay of the side laps such that

under the prevailing wind, rain. is not driven into the lap. The sheers shall be laid so that side laps in any two consecutive rows are staggered.

4.1.6.2 Broken or otherwise damaged sheeting shall not be erected.4.1.6.3 Cutting, framing and trimming of all openings required shall be carried

out al site.

4.3. Grated Walkways/Grilled Flooring:

4.3.1 Unless otherwise stated all grill flooring shall be designed for in addition to its self weight. for a superimposed load of 500 kglm 2 or the alternative minimum load specified in IS:875 or the incidental load, due to erection, operation or maintenance or as specified in the drawing whichever is more critical. The maximum deflection due to dead load and live load should not be more than 1/200 span.

4.3.2 Material used for fabrication shall conform to IS:2062-1999.

4.3.3 Grill flooring shall be fabricated f rom flats of size not less than 30x5 mm. Located at a spacing of not less than 40 mm and shall be provided with suitable transverse members to provide rigidity. Fabrication shall make provision to connect the flooring panels by bolls or by bolls and clips or welding to supporting members as per drawings. Provision shall also be made to interconnect the adjacent panels by bolts or by bolts and clips to prevent movement of floor panels. Top surface of all bars/members shall be flush giving a neat appearance. Welding of different members shall be by electroforge, electric resistance or similar type of welding so that there are no crude weld deposits or lumps.

4.3.4 If permitted, grated walkways may be fabricated by manual arc welding. However, the welding shall be finished smoothly by proper grinding/filing.

4.3.5 The fabricated floor panels shall be cleaned of all rust, dust grease, oil, mill scale, weld flux etc., by wire brushing or by suitable other means and made ready for painting. Painting shall be by cold dip process. First dip shall be in anti-saline metallic primer. After the primer paint has completely dried, the grill flooring shall be dipped for the second time in heavy duty anti-corrosive and wear resistant bituminous black paint. Minimum DFT of anti-saline primer shall be 25 microns and minimum OFT of finishing paint shall be 75 microns or as specified in the BOQ.

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4.3.6 For cold dip painting a thinner recommended by the manufacturer in suitable quantities shall be added. During cold dip painting care shall be taken to guard against sagging or flow-down of paint.

4.3.7 The gratings when erected around opening, shall have circular bands.4.3.8 Sample grating shall be got approved before taking up full scale

manufacture.

5 PAINTING OF STEEL STRUCTURES

5.1 SURFACE PREPARATION FOR PAINTING

5.1.1 GENERAL

The steel surface which is to be prepared shall be cleaned of dirt and grease and the heavier layers of rust shall be removed by grinding prior to Actual surface preparation to a specified grade.

Surface preparation to be followed prior to painting shall be based on the requirement of a particular painting system as per clause 5.3. One of the following specifications for surface preparation is to be followed as per requirement.

5.1.2 MECHANICAL CLEANING

5.1.2.1 (a) Manual/Power tool cleaning.

Manual/power tool cleaning shall be done as per grade St-2 or. St-3,d Swedish Standard Institution SIS 055900.

i) Grade 5t-2: Thorough scraping and wire brushing, machine brushing, grinding etc. This grade of preparation shall remove loose 'mill scale, rust and foreign matter. Finally the surface is to be cleaned with a vacuum cleaner or with clean compressed air or with clean brush. After preparation, the surface should have a faint metallic sheen. The appearance shall correspond to the prints designated 5t-2.

ii) Grade St-3: very thorough scraping and wire brushing, machine brushing, grinding etc. The surface preparation is same as for grade St-2 but to be done much more thoroughly. After preparing the surface, it should have a pronounced metallic sheen and correspond to the prints designated St-3.

5.1.2.1(b) Blast cleaningThe surface shall be blast cleaned using one of the abrasives: chilled cast iron or malleable iron and steel at a pressure of 7 kgrcm2 at appropriate distance and angle depending on nozzle size maintaining constant velocity and pressure. Chilled cast iron,

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malleable iron and sleet shall be in the form of shot or grit of size not greater than 0.055' maximum in case of steel and malleable iron and 0.04" max in case of chilled iron. Compressed air shall be free from moisture and oil. This method will remove loosely adherent materials as well as adherent scales and mill scales. Prior to application of blast, heavy deposit of oil and grease are removed by, solyent cleaning and excessive surface scales are removed by hand tools or power tool-cleaning. The surface shall be cleaned to Sa - 2 ' /2 or SSPC-SP6 quality i.e. 95 % of surface area is free from all rust, mill scales and visible residues, foreign -materials, etc. The blast cleaning is not recommended for sheet metal work. On completion of blast cleaning operation the blasted surface shall be clean and free from any scale or rust and must show a grey white metallic lusture. Primer or first coat of paint shall be applied witthn_4 hours of surface preparation. II oxidation has occurred between blasting and application of primer, the surface should be re-blasted to specified visual standards. The surface profile should be.AiLto_75_Micr.ons.

5.2 PAINTS AND PAINTING5.2.1 For use of specific painting system, the paint manufacturer's

specification shall prevail.5.2.2 General compatibility between primer and finishing paints shall b e

established through the paint manufacturer supplying the paints.5.2.3 Before buying the paint in bulk, it is recommended to obtain sample

of paint and establish "Control Area of Painting". On control area surface preparation and painting shall be carried out in the presence of manufacturer of paint.

5.2.4 In order to ensure that the supplied paint meets the stipulation in design drawing! specification, if required, samples of paint shall be tested in Laboratories to establish quality of paint with respect to' (i) Viscosity (ii) adhesion! bond of paint in steel surfaces (iii) adhesion/simulated salt spray test (iv) chemical analysis (percentage of solids by weight) (v) normal wear resistance as encountered during handling & erection (vi) resistance against exposure to acid fumes etc.

5.2.5 Whole quantity of paint for a particular system of paint (shall be obtained from the same manufacturer).

5.2.6 Thinners, wherever used, shall be as per recommendation of the paint manufacturer.

5.2.7 Areas which became inaccessible after assembly of structures shall be painted before assembly, after cleaning the surfaces as specified.

5.2.8 Wherever shop primer painting is scratched, abraded or damaged, the surfaces shall be thoroughly cleaned using emery paper and power driven wire brush wherever warranted, and touched up with corresponding primer. Touching up paint shall be matched and blended to eliminate conspicuous marks.

5.2.9 If more than 50% of the painted surface of an item requires repair, the entire item shall be mechanically cleaned and new primer coats

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shall be applied followed by finishing coats as per painting specification.

All field welded areas on shop painted item shall be mechanically cleaned (including the weld area proper, adjacent areas contaminated by weld spatter or fumes and areas where existing primer. Intermediate finishing paint is burnt). Subsequently, new primer and finishing coals of paint shall be applied as per painting specification.

5.2.10 Application of paint shall be by air less spraying or brushing as per IS:487-1985 and in uniform layers of 50% overlapping strokes. Painting shall not be done when the temperature is less than 5°C or relative humidity more than 85%, unless manufacturer’s recommendations permit. Also painting shall not be done in frosty or foggy weather. During application, paint agitation must be provided wherever such agitation is recommended by the manufacturer.

5.2.11 Paint shall be applied at manufacturers recommended rates. The number of coals shall be such that the minimum dry film thickness (OFT) specified is achieved. The dry film thickness of painted surfaces shall be checked with ELCOMETER or measuring gauges to ensure application of specified OFT.

5.2.12 All structures shall receive appropriate number of primer and finishing coats in order to achieve overall DFT as per design drawings) specifications. First coat of primer paint shall be applied not later than 2-3 hours after preparation of surface, unless specified otherwise.

5.2.13 The finishing paint as specified shall be of approved colour and quality. The under coal shall have different tint to distinguish the same from the finishing coat.

5.2.1 4 Edges, corners, crevices, depressions, joints and welds shall receive special attention to ensure that they receive painting coats of the required thickness.

5.2.15 Machine-finished surface shall be coated with white lead and tallow before shipment or before being put into the open air.

5.2.16 Parts of surfaces embedded in concrete shall be thoroughly cleaned of grease, rust, mill scale etc. and shall be given a protective coat of Portland cement slurry immediately after fabrication. No paint shall be applied on this part.

5.2-17 Zinc-rich primer paints, which have been exposed several months before finishing coat is applied, shall be washed down thoroughly to remove soluble zinc salt deposits. In similar circumstances, the surfaces of paint cased on epoxy resin should be abraded or lightly blast cleaned to ensure adhesion of next coat.

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5.2.18 Surfaces which cannot be painted but require protection shall be given a: coat of rust inhibitive grease according to IS.958-1975 or equivalent -International standard.

5.3 PAINTING SYSTEM

The recommended painting system for general service requirement of steel structures covering surface preparation, application of primer coats, intermediate coats (if necessary) and final coats to develop the required minimum dry film thickness on steel surface is indicated in ANNEXURE – V

6.0 SALIENT POINTS

6.1 QUOTATION

6.1.1 The bidder should ascertain himself, by- a visit to the site if necessary, the actual site conditions, local factors etc. The Contractor shall bear full responsibility for deductions and conclusions as to the nature and conditions under which the work is to be executed, including effect of climate, rainfall etc. Failure to do so will not absolve the Contractor of his responsibilities about the proper execution of the job. No claims for extra payments due to any special site conditions and ignorance of site conditions will be considered after the acceptance of his quotation.

6.1.2 Deleted.

6.1.3 The cost of MS bolts (permanent and erection), washers, electrodes. putty. gases, cost of straightening the raw materials (hot bending not permitted), cutting of flats from plates and providing splices, paints, tool, plants, etc. as required for the work shall be deemed to be included in the quoted price.

6.1.4 All handling and transport charges of raw materials and fabricated structures, including double handling if required, for completion of the work in accordance with time schedule are deemed to be included in the quoted price.

6.1.5 Cost of NOT of welds as per specification shall be borne by the Contractor. For the welds found defective, the cost of retest shall be borne by the contractor in addition to the cost of rectification or replacement of the defective part.

6.2 Deleted

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6.3 PROGRAMME6.3.1 A monthly time bar chart for various activities like procurement of

steel, preparation and approval of fabrication drawings, fabrication, despatch to site, erection and alignment, sheeting and painting etc. giving starting and completion dates of all activities, shall be submitted along with the bid without which the bid may not be considered for evaluation.

6.3.2 The contractor shall also furnish his overall planning of construction program, the capacity of equipment he proposes to deploy on various components of work etc. for prior approval of purchaser.

6.3.3 All programs on procurement of raw steel and other materials, preparation of drawings, fabrication and despatch shall match with the sequence of erection of different structural components and different building/units, of the project as per network planning.

6.3.4 The purchaser may change or alter the detailed working program for the sequence of work and for the fabrication of components of structures, within the frame work of the agreed schedule, which will be binding on the Contractor.

6.3.5 If due to design or other stipulations in the bid or requirements at site, a particular sequence of overall construction has to be followed due to which certain interruptions to any one or more items of work are inherent, no claims for such interruption will be admissible.

6.4 DRAWINGS

6.4.1 The Contractor will be supplied with design drawings by the Purchaser-

6.4.2 Based on the design drawings, the Contractor shall prepare general arrangement/marking drawings, fabrication drawings, erection drawings, bill of materials, shipping documents and nut and bolt lists. Bill of materials shall form part of fabrication drawings and shall be included in the body of the drawing or prepared separately. Two copies of drawings and documents shall be submitted to the Purchaser for their scrutiny and approval. One set of the Fabrication drawings will be returned to the Contractor with a stamp signifying 'Approved', "Approved as noted" or Not Approved" on the drawing. After the final approval by the Purchaser the Contractor shall furnish to the Purchaser within 2 weeks.... six copies of the approved Fabrication drawings, and erection drawings.

6.4.3 Despite approval of purchaser, Contractor shall riot be relieved of his responsibilities for the accuracy of the detailed dimensions

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shown thereon and the safety of all structural connections as per forces indicated in the design drawings.

6.4.4 Soon after the fabrication of steel work pertaining to a particular drawing is completed, immediate steps shall be taken by Contractor to incorporate in the approved fabrication drawings, all the authorised corrections, additions and alterations made during the course of fabrications and 2 sets of the same shall be submitted to purchaser for his record.

6.4.5 Notes on-specifications shown on design drawings shall be considered as superseding or overriding the specifications given elsewhere, with which they conflict. On all drawings, dimensions shown in figures shall be acted upon.

6.4.6 Two sets of erection drawings shall be submitted to the„Purchaser showing thereon all authorised additions and alterations during the process of erection. These drawings together with drg under clause 6.4.4 shall be treated as “ As Built" drawings.

6.4.7 Supply and distribution of fabrication drawings and other documents like bolt list, etc. for the Contractor's own use or for the use of his Sub-contractors shall be the responsibility of the Contractor

6.4.8 The fabrication work shall be taken up only after the drawing is approved.

6.4.9 The detailer shall ensure the fabrication / erection drawings are prepared in Iola! discussion with the purchaser / Consultant/HPCL , if necessary the detailer should send his engineer to purchaser 1 Consultant/HPCL time to time for discussion during the course of preparation of drawings.

6.5 MATERIAL

6.5.1 The Contractor shall arrange and procure all steel sections, plates, roof Sheets, glazings, flashings, fixtures and fittings required for sheeting and glazing, aluminium or MS astragals and frames for glazing , clips, all the consumables like bolts, turned and fitted bolts, nuts including spares- and service bolts, washers of different types, electrodes, gas, shims, packs, paints, etc. for completing the work satisfactorily and the cost of the same shall be deemed to have been covered in his quoted price.

6.5.2 If assistance is required by the Contractor in obtaining permits/proprieties in allotment of controlled/scarce materials, if any, the same may be extended by the Purchaser by way of issue of recommendation letter, essentiality it certificate etc. to Government Authorities_ Delay, if any, in obtaining the materials will not constitute a ground for claiming any compensation or extension of time.

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6.5.3 Where any raw materials required for the execution of the contract is procured with the assistance of the Purchaser or permit /licence /quota certificate or release order issued by or on behalf of or under authority of Purchaser or by any officer empowered on their behalf by law, or where advance payments are made to the Contractor to enable him to purchase such raw material for execution of work, the Contractor:

i) Shall hold such materials as trustee for the Purchaser.

ii) Shall use such materials economically and solely for the purpose of the contract.

iii)Shall not dispose of the same without prior permission in writing from the Purchaser.

iv)Shall maintain and produce due documents indicating stock position / consumption of such materials from time to time, as required by purchaser.

6.14 BASIS OF PAYMENT6.14.1 The tenderer shall agree to the payment terms given in the tender. As

the quantities mentioned are estimated quantities, payment will be made on the actuals as per the agreed rates.

6.15 MEASUREMENTS6.15.1 Structural Steel

Structural steelwork will be measured by the metric tonne and as per IS:1200 (part-8)- 1993 and 15:1200 (part-9)-1973 subject to provisions outlined below:-

a) The calculation of quantities shall be based on unit on weights for structural sections as given in 1S:808-1989 in the case of mild steel/SAIL-MA Steel plates, the calculated weights shall be based on 78.5 kg per square metre per centimetre thick plate. The payments will be made on the basis of weights of members given in the approved fabrication drawings. However, any changes on the above weights during fabrication erection, payment shall be based on sketches Approved by the purchaser.

b) In the event the LS_ does not specify any mode of measurement for a particular item of work, the same shall be measured as per any other relevant international standard or as directed by the Purchaser.

c) The weight of all plates and sections shall tae calculated from the approved drawing using the minimum overall square or rectangular dimensions and theoretical weight, no deduction being made for skew cuts, holes etc. In the case of plates, other than gussets, the actual dimensions shown on approved

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drawings will apply unless approved otherwise by the purchaser based on cutting diagram of mother plates.

c) The weight of all welding runs, bolt, stanchion base packing, cuttings to waste and rolling margins, and coatings of paint, will be excluded from the measured weight and shall be deemed to have been allowed for in the rates for structural steelworks quoted by the Contractor.

d) Temporary works and all other materials not included in the permanent works shall Uri excluded from any measurement for payment.

6.16 Roofing shee t s (Galvalume) & Colour Coated Toughed Sheets

6.16.1 Sheeting for roof slopes, louvers of big size and side cladding shall be measured by the square metre of net laid area, as specified and shown on the drawings.

6.16.2 No allowance shall be made for wastage, cut outs, overlaps etc. in the measurement.

6.16.3 The unit of measurement as specified in clause 6.16.1 shall include all fasteners, (lashings and fittings such as ridges, corners, aprons and other accessories. . .

6.16.4 No deductions shall be made for openings for area less than a single sheet. Also no extra payment will be made for making opening and installing ventilation chimneys on roof.

6.17 PRELIMINARY ACCEPTANCE

6.17.1 After completing the erection of a unit or portion thereof, the Contractor shall give a notice in writing slating that the job is complete in all respects and ready for preliminary acceptance .The job shall be jointly inspected visually by representatives of Contractor and Purchaser. All observed defects and omissions as per drawing and specification shall be noted down. If the defects are not major in - the opinion of the purchaser/Purchaser's representative, the Contractor will be issued a preliminary acceptance certificate mentioning the defects, deficiencies and omissions which shall be made good by the Contractor within a period of 4 weeks.

6.18. FINAL ACCEPTANCE

6.18.1 Before commencement of inspection for-final acceptance of the building or unit, the Contractor shall make available two complete sets of all drawings, representing "AS BUILT" drawing, (Le. all

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additions and alterations done during fabrication arid erection shall be incorporated in the drgs, Refer clause 6.4.4 & 6.4.6.

6.18.2The Contractor shall make good all defects deficiencies and omissions noted down during preliminary acceptance (Refer clause 6.17.1) and shall inform in advance the Purchased his representative for conducting inspection, for final acceptance. Final acceptance certificate will be issued by the Purchaser / his representative only after all defects deficiencies / omissions noted under Preliminary Acceptance have been rectified.

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ANNEXURE-I

Permissible deviations in pitch and gauge of holes for bolts of normal accuracy (high strength balls included

Description Hole dia(mm) Permissible deviation Per. Dev in groupIn spacing(mm) (mm)

CS Low al.stl

a. Deviation up to 17 +1 No limitIn hole Above 17 +1.5Diameter

b. Ovality up to 17 +1 No limit above 17 +1.5

c. Curves ex Not permissibleone mm & crackson holes

d. Non coincidence up to 50%of holes in separate Details of assembled unitup to 1 m

e. above 1 m up to 10%

f. Slope Up to 30% No limit No limitof axis of Tk of unit

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ANNEXURE-IITOLERANACE OF ASSEMBLED COMPONENTS OF STRUCTURESDescription of Deviation (+) in mm for the Elements of StructuresComponents of Length in MetresStructures Up to 1 1 to 5 5 to 10 10 to 15 15 to 20 20 to 25 Over 25

1 2 3 4 5 6 7 8I.DeviationsFrom the DimensionsAssembledLength & widthOf the details

Cut:a) Manual gasCutting as per 3 3.5 4 4.5 5 - -Markingb) with shears orwith a saw as 2 2.5 3 3.5 4 - -per markingc) with shears orwith a saw 1.5 2 2.5 3 3.5-

-with a stopd) Machine GasCutting 2 2.5 3 3.5 4 - -

i) Length and Width of planedEnds processed 1 1.5 2 2.5 3 - -On Edge planningMachine1 2 3 4 5 6 7 8

IIi) Distance

between theCentres ofthe endholes.

a) Drilledaccording to 2 2.5 3 3.5 4 - -

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a gauge withbushing

b) Drilledaccording to 1 1.5 2 2.5 3 - -a gauge withbushing

ii) Distancebetween the centres ofadjacentholes

a) Drilledaccording to 1.5 - - - - - -marking orto a gauge

b) Drilledaccording to 0.5 - - - - - -a gauge with bushings.

1 2 3 4 5 6 7 8III

Deviation in theDimensions of

Dispatch clementsAfter completion ofFabrication. Assembled inPositioners or in otherDevices with clampsIn fixed positionersAnd also

a) According to guide 2 3 5 7 8 9 10Blocks with pins.

b) assembled with bolts 3 5 8 11 12 14 15c) Size (length & width)

between milled surface 1 1.5 2 2.5 3 3.5 4(for all cases of Assembly).

d) the same made inSeparate details duringmachining & fixed 2 3 5 7 8 9 10during the assemblingwork with clamps

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e) The same drilledaccording to positioners in finished 1 1.5 2 2.5 3 3.5 4structures

ANNEXURE- IIIPERMISSII LE DEVIATION IN ASSEMBLY OF WELDED JOINTS

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ANNEXURE-IVCOLUMNS1 Deviation of column axis at foundation top

Level with respect to true axisIn longitudinal dir +/- 5 mmn Lateral dir +/- 5 mm2. Deviation in the level of bearing surface of

Columns at foundation top wrp to true level +/- 5 mm3. Out of plumb ness of column axis from true

Vertical axis and measured at column topFor columns with out any special requirementUp to and including 30 m +/- H/1000 or +/-25 mm which

Ever is lessOver 30 m ht +/-H/1200 or +/- 35 mm(less)For columns with special reg like cranesOr such similar requirementUp to and including 30 m +/- H/1000 or +/-20 mm which

Ever is lessOver 30 m ht +/-H/1500 or +/- 25 mm(less)4. Deviation in straightness in Long & +/- H/1000 or +/-10mm (less)

Traverse direction of columns at any pointAlong the height

5. Diff in the erected position of adjacent pairs +/-5mm Of columns along length or across width of Building prior to connecting trusses/beamsWith respect to true distance.

6. Deviation in any bearing or seating level +/-5 mmWith respect to true level

NOTE: i) Tolerance specified under 3(a) and 3(b) should be read in conjunction with 4 and 5

ii) “H” above is the column height in mm.

13. TRUSSES1. Shift. At the centre of top chord member + 1/250 of

height span in mm or Truss with Respect to the centre of span or + 15 mm whichever is lessVertical plane passing through the centreOf Bottom chord.

2. Lateral shift of top chord at the centre of ofTruss span from the vertical + 1/1500 of span of truss in plane passing through the centre of mm or + 10mm whicheverSupports of the truss. is less

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.3. Lateral shift in location of truss from its true

Vertical position + 10

4. Lateral shift in location of purlins from + 5True position

5. Deviation in difference of bearing levels L/1200 or 20 mm whichever of trusses or beam from the true is less(L = span) difference.

NOTES:-

1. The tolerances specified do not apply to steel structures where deviation from true positions are intimately linked with or directly influence the technological process. In such cases. The tolerances on erected steel structures shall be as per recommendations of process technologists / equipment suppliers.

2. The observed or calculated values of deviations of steel structures from their true positions shall be rounded off in accordance with IS: 2-1960 for comparison with permissible tolerances specified in this table. The number of significant places retained in the rounded-off value should be same as that specified in this table.

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ANNEXURE-V

PAINTING SYSTEM

A. Surface preparation: Sa 2 ½ according to Swedish standard SIS 055900

1. First Coat (Primer) : Epilux FRX anti corrosive primer75 microns DFT

2. Second coat (Intermediate) : Epilux 950 Super High Build 150Microns DFT

3. Finish Coat (Finishing) : Epilux 950 Super High Build 150microns DFT

Total Thickness : 375 Microns

Painting system for walkways

1 Primer : One coat of Epilux FRX primer – 75 microns DFT.

2. Finish : One coat of 1x150-Epilux 555 CTE HB

ANNEXURE -VI

MATERIAL OF CONSTRUCTION (AS APPLICABLE)

1. Unless otherwise specified in the drawing:

a) All rolled sections and plates shall conform to Grade-A as per IS:2062.1992.

b) Plated structures subjected to dynamic loading shall conform to Grade-B as per 15:2062-1992.

c) High strength micro-alloyed steel shall conform to SAIL-MA 350 HYA/HYB (SAIL product).

2. Steel sheets shall conform to IS:1079-1988.

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3. Steel tubes for structural purposes shall conform to 15:1161 1979 (Grade YST- 240).

4 deleted

5. Gutter and down Corner shall be of copper bearing steel conforming to IS : 2062 – 1992.

6. Crane rails shall conform to IS : 3443 – 1980.

7. Glazing shall be 6 mm thick rough cast wired glass as per IS: 3548 .1988.

8. All black hexagonal bolls, nuts and locknuts shall conform to 1S:1363-1984 and IS: 1364-1983 (for precision and semi-precision hexagonal bolts). Washers shall conform to IS: 1148 .1982:

9. All HSFG bolts shall conform to 15:3757-1985.

10. Covered electrodes for arc welding shall conform to IS: 814- 1991. Coding of electrodes shall be as follows: -

a) ER 421 'C' x for mild steel of Grade A and Grade-Bas per 1S:2062-1992-

b) EB 542 'C' x H3Xfor

i) Mild Steel of Grade B as per 15:2062-1992 for dynamically loaded structures (arising out of crane, vibratory screen, equipment etc.)

ii) For SAIL-MA micro alloyed steel 350 HYAIHYB.

iii) When combined thickness (CT) for steel conforming to 15:2062-1992 exceeds 40mm as per Fig.1

"C" is the value of current as recommended by the electrode manufacturer.

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STANDARD SPECIFICATIONS

OF

SUPPLY ITEMS

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A)STANDARD SPECIFICATIONS FOR PRODUCT PIPES (IS 1978)

CONTENTS

1.1 SCOPE

1.2 DETAILED SPECIFICATION OF PRODUCT PIPELINES

1.3 DIMENSIONS & WEIGHT

1.4 PROCESS OF MANUFACTURE AND MATERIAL

1.5 CHEMICAL PROPERTIES

1.6 WALL THICKNESS

1.7 WEIGHT

1.8 STRAIGHTNESS

1.9 PIPE ENDS, WORKSMANSHIP & FINISH

1.10 VISUAL INSPECTIONS

2.0 MECHANICAL PROPERTIES AND TESTS

3.0 PURCHASER’S INSPECTOR (THIRD PARTY INSPECTING AGENCY) & SCOPE OF THIRD PARTY INSPECTION

STANDARD SPECIFICATION FOR WELDED STEEL LINE PIPES FOR PETROLEUM PRODUCTS SERVICE

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1.1) SCOPE OF BIDDER:

The bidder shall be a manufacturer of the line pipes and shall possess a valid BIS license.The bidder shall furnish the results of all the tests and analyses as set out in IS Code.Line pipes not meeting the requirements of IS Code as observed by the manufacturer during Internal Quality inspection and/or TPI shall not be despatched to HPCL Site.

Within 1 week of issue of PO by HPCL and prior to manufacturing, the Supplier shall submit QAP/ITP in accordance to the specifications set out herein and obtain approval from HPCL. The QAP/ITP shall detail the scope of Internal Inspection by Supplier and Third Party Inspection.

1.2) Details:

Supply of WELDED STEEL LINE PIPES of various sizes conforming to following specifications/details.

Item : WELDED STEEL LINE PIPES namely, EW or SAW conforming & stamped with IS: 1978-1982 marking.

Code : All clause Nos. Referred herein shall be to IS 1978 – 1982(Re- affirmed: 2002).In case of discrepancy, IS Code shall prevail.

Alternatively, bidders may offer line pipes conforming to API 5L –PSL1- Grade A or higher duly satisfying the requirements set out in this document & IS 1978 – 1982(Re-affirmed 2002)

Dimensional standard : IS 1978 – 1982(Re-affirmed 2002) Length of each pipe : Single random length of 6-7 M for all sizes

Ends : Bevelled with end protection caps

Marking : As per Clause no.13.3. of IS Code

1.3) Dimensions & weight:

PLEASE REFER TABLE 2 OF IS CODE FOR FULL DETAILS

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Nominal size( NB In mm )

Thickness Grade OD, mm ID, mm Wt.Kg/m

500 7.1 YST 210 508.0 493.8 87.70450 7.1 YST 210 457.0 442.8 78.77400 7.1 YST 210 406.4 392.2 69.91350 6.4 YST 210 355.6 342.8 55.11300 6.4 YST 210 323.9 311.1 50.11250 6.4 YST 210 273.1 260.3 42.09200 6.4 YST 210 219.1 206.3 33.57150 6.4 YST 210 168.3 155.5 25.5580 6.4 YST 210 88.9 74.7 13.02

In case of any discrepancy in details given herein above, IS Code shall prevail.

Positive Tolerance on mass (Wt-Kg/M) & Wall thickness shall be as per IS :1978, however no negative tolerance shall be permitted.

1.4) Process of Manufacture:

The EW or SAW pipes shall be manufactured by any of the processes given in IS Code.

1.5) Chemical requirements:

Ladle analysis shall be carried out for each heat as per IS Code.Product analysis shall be carried out for each heat as per IS Code.

1.6) Wall thickness:

Each length of pipe shall be checked for wall thickness & same shall be recorded in accordance to IS Code.

Positive tolerance(+) on wall thickness for Pipes conforming to IS: 1978 shall be as per IS: 1978. However, Negative tolerance (-) shall be zero.

1.7) Weight:

Each length of pipe shall be weighed separately & same shall be recorded in accordance to IS Code.

1.8) Straightness:

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Random check to be carried out as per IS Code.

1.9) Pipe ends, Workmanship & finish:

The pipe ends shall be bevel ends and provided with suitable end protectors.

The line pipes shall be provided with a suitable mill coating to prevent rusting during transit as per IS Code.

1.10) Visual Inspection:

All finished pipes shall be visually examined in accordance to IS Code.

2. TESTS:

All the physical tests as detailed in Cl. 11 of IS Code as relevant for the subject pipes shall be carried out by the Manufacturer and results furnished in accordance with IS Code. The tests shall include the following:

1) Longitudinal Tensile2) Transvere tensile3) Weld tensile4) Bend test5) Flattening test6) Hydrostatic test7) Non-destructive tests8) Dimensional Inspection of diameter, wall thickness and bevel ends etc

3.0 PURCHASER’S INSPECTOR (THIRD PARTY INSPECTING AGENCY)

Third party inspection is mandatory and shall be arranged by the supplier. Pipes shall be inspected by one of the following agencies only:

1. Lloyds 2. Det Norkse Veritas 3. CEIL4. IRS5. BV6. SGS

The vendor can select any one of the following agencies for witnessing the Testing, Inspections and Repairs as per relevant clause of this specification and IS 1978:

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(i) EIL (ii) DNV (iii) Lloyds (iv) SGS (v) BV (vi) CEIL

Pipes manufactured as per this specification shall be subjected to all the mandatory tests and checks called for as per this specification and IS 1978. For this purpose Quality Assurance Plan is required to be submitted by the manufacturer after award of Purchase Order. Though the extent of inspection by purchaser or his authorized representative shall be as per this specifications and IS 1978 but the exact extent of hold points shall be mutually decided by the Purchaser and Manufacturer and recorded in the inspection test plan (to be submitted by the manufacturer after award of PO).

3.1.1 SCOPE OF INSPECTION :

TPI shall be carried out in accordance to QAP/ITP approved by HPCL and shall include the following:

TEST/CHECK TPI SCOPE REMARKSWITNESS REVIEW APPROVAL

Ladle analysis Yes Yes TPI shall correlate all the three analyses for chemical & certify if they are within variations permitted by IS Code.

Product analysis

Yes Yes

Mill Control Product analysis

Yes Yes

Wall thickness 10% 100% YesWeight 10% 100% YesStraightness 10% Random as

per I S CodeYes

Pipe ends 10% ------------ Yes Check for end protectors

Finish 100% ------------- Yes Check for mill coatingVisual inspection

100% ------------- Yes

Physical testsLongitudinal tensile

100% ------------ Yes

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Transverse tensile

100% ------------ Yes

Weld tensile 100% ------------ YesBend 100% ------------ YesFlattening 100% ----------- YesHydrostatic 10% 100% YesNDT 100% ------------ Samples as per IS codeMarking 10% YesIn case the tests are required to be carried out in an external lab, then the cost of such tests shall be borne by the Supplier only.

3.2 All pipes shall be stamped/marked by the 3rd party inspection agency. All test reports in original shall be submitted to HPCL despatch location and no pipe shall be despatched without obtaining approval from third party inspection agency.

B. SPECIFICATIONS FOR T- TYPE STRAINER

MATERIAL:

BODY : CS WITH TRIM INTERNALS OF SS 304

BOLTS & NUTS : SA 193 GRADE B7/A194 GRADE 2H

RATING : 150 CLASS

DIMENSIONS : AS PER ENCLOSED DRAWINGS

ENDS : FLANGED TO ANSI B 16.5 RAISED FACE WITH SERRATIONS

SCREEN : SS304, MESH SIZE AS PER ENCLOSED DRAWINGS.

GASKET : SPIRAL WOUND SS 304

TESTING : 150# WORKING PRESURE 10 KG/SQCMHYDRAULIC TEST PRESSURE 20 KG/SQCM

DETAILS OF LIQUID TO BE HANDLED & OTHER DETAILS:

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LIQUID TO BE HANDLED : MTO/ HEXANE/ SOLVENT

DESIGN FLOW RATE (MAX) : 144 KL/HR FOR 150 MM DIA STRAINER- 2 NOS (MTO SERVICE), 72 KL/HR FOR 150 MM DIA STRAINER-1 NOS (HEXANE SERVICE), 72 KL/HR FOR 150 MM DIA STRAINER- 1 NOS (SOLVENT STRAINER)

DESIGN PRESSURE : 10 KG/SQCM

DESIGN TEMPERATURE : AMBIENT

ALLOWABLE PRESSURE DROP : 0.10 KG / CM2.

FILTER LOCATION : SUCTION SIDE.

% IMPURITIES : NIL FOR ABOVE SPECIFIED MESH SIZE.

THIRD PARTY INSPECTION:

1. VENDOR SHALL INDICATE THIRD PARTY INSPECTION CHARGES IN HIS BID AS A PERCENTAGE OF SUPPLY COST.

2. APPROVED THIRD PARTY INSPECTION AGENCIES AREA) M/S. LLOYDS B) M/S. ELLC) M/S SGS D) MIS. DNV E) M/S BV F) M/S BAUX COUNCIL

3. SCOPE OF THIRD PARTY INSPECTION:

(a) TO CHECK DIMENSIONS AS PER ENCLOSED DRAWINGS(b) TO CHECK MATERIAL CERTIFICATES(c) TO WITNESS HYDRO TESTING OF ALL STRINERS AS PER RELEVANT

CODE.

QAP APPROVAL

THE SUCCESSFUL BIDDER TO SUBMIT THEIR QAP AND GET IT APPROVED BY HPCL BEFORE COMMENCING ANY MANUFACTURING.

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TECHNICAL NOTES FOR T TYPE STRAINER:

1. TEST REPORTS FOR ALL MANDATORY TESTS ON MATERIAL AS PER MATERIAL STANDARD SPECIFIED AND HYDROSTATIC TEST SHALL BE SUPPLIED.

2. FLANGED ENDS OF THE STRAINER SHALL BE AS PER ASME B 16.5

3. SMOOTH FINISH WHERE SPECIFIED SHALL BE OF 125 TO 250 MICRO INCHES AARH AND SERRATED FINISH 250 - 500 AARH.

4. ALL THE STRAINERS SHALL BE HYDROSTATICALLY TESTED AT TWICE THE DESIGN PRESSURE.

5. VENDOR SHALL SECURELY ATTACH WITH THE BODY OF STRAINER A METAL TAG STAMPED WITH APPLICABLE TAG NO. OR REQUISITION NO. / ITEM NO. IF TAG NO. IS NOT MENTIONED. WHEREVER NAME PLATE IS PROVIDED MARKING CAN BE MADE ON THE SAME.

6. ALL THE STRAINERS SHALL BE PROVIDE WITH 3/4" SW COUPLING FOR DRAIN CONNECTION.

7. FOR STRAINER SUPPLIED AS PER MANUFACTURER'S STANDARD, VENDOR SHALL FURNISH CERTIFIED DIMENSIONAL DRAWINGS WITH MATERIAL SPECIFICATIONS.

8. THE STAGE WISE INSPECTION OF STRAINERS SHALL BE DONE BY THIRD PARTY INSPECTOR BEFORE DESPATCH.

9. PRESSURE DROP CALCULATIONS SHALL BE FURNISHED BY VENDOR ALONG WITH THE OFFER.

C. TECHNICAL SPECIFICATIONS FOR GATE VALVES

1.0 GENERAL

1.1 VENDOR SHALL SUPPLY VALVES MEETING THE TECHNICAL SPECIFICATIONS GIVEN IN ANNEXURE-I, IF ANY SUCH AS GEAR OPERATOR, DRAINS, ETC. WHEREVER SPECIFIED IN THE TECHNICAL

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SPECIFICATIONS, SUBJECT NOTES AND OTHER ENCLOSURE TO THE REQUISITION.

1.2 VENDOR SHALL QUOTE IN STRICT ACCORDANCE WITH THE VALVE DATA SHEETS, TECHNICAL SPECIFICATIONS AND ALL OTHER ENCLOSURES TO THE REQUISITIONS. DEVIATIONS TO THE SPECIFICATIONS/DATA SHEETS AND OTHER ENCLOSURES OF THE REQUISITIONS, IF ANY, SHALL BE SOUGHT BY THE VENDOR AS EXPLAINED IN CLAUSE 2.0.

1.3 ALL CODES AND STANDARDS FOR MANUFACTURE, TESTING, INSPECTION ETC. SHALL BE OF LATEST EDITIONS.

2.0 DOCUMENTATION

2.1.1 VENDOR SHALL POSSESS A VALID API 600 ACCREDITATION/ MONOGRAM/ LICENSE.

2.1.2 VENDOR SHALL SUBMIT WITH THE OFFER THE FOLLOWING:

COPY OF VALID API 600 ACCREDITATION/MONOGRAM/ LICENSE.

MANUFACTURER’S COMPLETE DESCRIPTIVE AND ILLUSTRATIVE CATALOGUE/ LITERATURE.

DETAILED DIMENSIONED, CROSS SECTION DRAWING WITH PARTS/MATERIAL LIST, WEIGHT ETC. FOR THE VALVES TO MANUFACTURER’S STANDARD.

DRAWINGS FOR VALVES WITH ACCESSORIES LIKE GEAR OPERATOR, EXTENSION BONNET, EXTENDED STEMS WITH STANDS BYPASS ETC. GIVING MAJOR SALIENT DIMENSIONS.

2.1.3 FOR SUBJECT SPECIFICATIONS, IF THERE IS ANY DEVIATION THE SAME SHALL BE QUALIFIED CLAUSE WISE, EVEN CLAUSES WHICH ARE ACCEPTABLE SHALL BE CATEGORICALLY CONFIRMED AS “ACCEPTED”.

2.1.4 UPON FAILURE TO SUBMIT DOCUMENT AS SPECIFIED UNDER CLAUSE 2.1.2, THE OFFER IS LIKELY TO BE REJECTED.

2.1.5 SUBMISSION OF QAP/ITP AS INDICATED IN CL.9.0 (CL. 9.1 TO 9.14).

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2.2 UPON PLACEMENT OF FOI/ LOI/ PURCHASE ORDER, WHICHEVER IS EARLIER, VENDOR SHALL SUBMIT DRAWINGS FOR APPROVAL MENTIONED ABOVE BEFORE START OF MANUFACTURE.

2.3.1 TEST REPORTS SHALL BE SUPPLIED FOR ALL MANDATORY TESTS AS PER THE APPLICABLE CODE AND AS PER QAP/ITP DULY APPROVED BY HPCL.

2.3.2 MATERIAL TEST CERTIFICATES (PHYSICAL PROPERTIES, CHEMICAL COMPOSITION & HEAT TREATMENT REPORT) OF THE PRESSURE CONTAINING PARTS SHALL BE FURNISHED IN ADHERENCE TO APPLICABLE CODES/ STANDARDS AND QAP/ITP DULY APPROVED BY HPCL FOR THE VALVES SUPPLIED. MATERIAL TEST CERTIFICATES FOR THE OTHER PARTS SHALL ALSO BE FURNISHED FOR VERIFICATION IN ACCORDANCE WITH HPCL APPROVED QAP/ITP DURING THIRD PARTY INSPECTION.

3.0 DESIGN AND CONSTRUCTION

3.1 VALVES SHALL BE DESIGNED, MANUFACTURED, TESTED INSPECTED AND MARKED AS PER THE MANUFACTURING STANDARD, DESIGN CODE AND STANDARDS (LATEST EDITION) INDICATED IN THE RESPECTIVE VALVE SPECIFICATION SHEETS. ANY CONFLICT BETWEEN THE REQUISITION, ENCLOSURE, SPECIFICATION SHEETS AND REFERRED STANDARD CODES SHALL BE BROUGHT TO THE NOTICE OF THE PURCHASER FOR CLARIFICATION, BUT GENERALLY SPEC SHEETS AND ENCLOSURES OF THE REQUISITION INCLUDING SUBJECT NOTES SHALL GOVERN. NO DEVIATION TO SPECIFICATION / STDS SHALL BE PERMITTED THROUGH VENDOR DRAWING APPROVAL. APPROVAL OF DRAWING SHALL BE VALID ONLY FOR DESIGN FEATURES.

3.2 ALL FLANGED VALVES SHALL HAVE FLANGES INTEGRAL (EXCEPT FORGED VALVES) WITH THE VALVE BODY. FLANGE FINISH SHALL BE SERRATED FINISH 125 AARH (125 AARH TO 250 AARH) OR (32 AARH TO 63 AARH) AS PER VALVE DATA SHEET.

3.3 IF AN OVERLAY WELD-DEPOSIT IS USED FOR THE BODY SEAT RING, SEATING SURFACE, THE SEAT RING BASE MATERIAL SHALL BE AT LEAST EQUAL TO THE CORROSION RESISTANCE OF THE MATERIAL OF THE SHELL.

3.4 BY-PASS DETAILS:-

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3.4.1 BY-PASS REQUIREMENT FOR GATE VALVES IS INDICATED IN THE RESPECTIVE DATA SHEETS. BY PASS VALVE SHALL BE GLOBE VALVE OF SIZE ¾”. THE BYPASS PIPING AND FITTINGS SHALL BE AS SHOWN IN ENCLOSED SKETCH. BY-PASS ARRANGEMENT IS APPLICABLE FOR SIZE 18” AND ABOVE.

3.4.2 VALVE BODY/BONNET SHALL BE FORGED/ CAST AS SPECIFIED. FORGING ARE ACCEPTABLE IN PLACE OF CASTING BUT NOT VICE-VERSA.

3.4.3 VENDOR SHALL SUPPLY THE BY-PASS VALVE DULY TESTED AND FITTED TO THE MAIN VALVE. VALVES WITH BYPASS, SHALL HAVE THE DIRECTION OF FLOW MARKED ON THE MAIN BODY VALVE. BY PASS ARRANGEMENT TO THE MAIN BODY VALVES SHALL NOT BE SCREWED. ALL FILLET WELDS FOR BY PASS INSTALLATION SHALL BE EXAMINED BY DP/MP TEST.

3.4.4 THE BY PASS PIPING ARRANGEMENT SHALL BE SUCH THAT CLEARANCE BETWEEN MAIN BODY VALVE & BY PASS ASSEMBLY SHALL BE MINIMUM POSSIBLE FOR LAY OUT REASONS. VENDOR SHALL FOLLOW THE ENCLOSED SKETCH.

3.5 VALVE BODY/BONNET SHALL BE FORGED/ CAST AS SPECIFIED IN DATA SHEET. FORGED VALVES ARE ACCEPTABLE IN PLACE OF CASTING BUT NOT VICE-VERSA.

3.6 MATERIAL OF CONSTRUCTION OF YOKE SHALL BE MINIMUM EQUIVALENT TO BODY/BONNET MATERIAL.

3.7 STEM SHALL BE FORGED OR MACHINED FROM FORGED / ROLLED BAR. NO CASTING IS PERMITTED.

3.8 STELLITING / HARD FACING BY DEPOSITION, SHALL BE MINIMUM 1.6 MM. RENEWABLE SEAT RING MAY BE SEAL WELDED.

3.9 SPIRAL WOUND BONNET GASKET ARE TO BE PROVIDED WITH INNER / OUTER RING EXCEPT WHEN ENCAPSULATED GASKET TYPE BODY-BONNET JOINTS ARE EMPLOYED. OUTER RING MAY BE AVOIDED IN CASE OF NON-CIRCULAR SPILAR WOUND GASKET USED IN 150# VALVE PROVIDED THE OUTERMOST LAYER OF SPIRAL TOUCHES THE BOLTS ASCERTAINING THE CENTERING.

4.0 OPERATION

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4.1 GENERALLY THE VALVES OF SIZE 12” AND LARGER SHALL BE PROVIDED WITH GEAR OPERATION. ALL OTHER VALVES ARE TO BE HAND WHEEL OPERATED.

4.2 GEAR OPERATOR SHALL BE TOTALLY ENCLOSED BEVEL GEAR IN GREASE CASE WITH GREASE NIPPLES / PLUGS WITH POSITION INDICATORS FOR OPEN / CLOSE POSITIONS.

4.3 WHERE GEAR OPERATOR IS NOT CALLED FOR AS PER CLAUSE 4.2 BUT VENDOR RECOMMENDS A GEAR OPERATOR, HE SHALL HIGHLIGHT SUCH CASE(S).

4.4 GEAR OPERATORS SHALL BE SO DESIGNED TO OPERATE EFFECTIVELY WITH THE DIFFERENTIAL PPRESSURE ACROSS THE CLOSED VALVE EQUAL TO THE COLD NON-SHOCK PRESSURE RATING.

4.5 HAND WHEEL DIAMETER SHALL NOT EXCEED 750 MM. EFFORT TO OPERATE SHALL NOT EXCEED 35 KGS. AT HANDWHEEL PERIPHERY. HOWEVER FAILING TO MEET THE ABOVE REQUIREMENTS VENDOR SHALL OFFER GEAR OPERATED VALVE AND QUOTE AS PER CLAUSE 4.2

5.0 INSPECTION AND TESTING

5.1 EVERY VALVE, ITS COMPONENTS AND AUXILIARIES SHALL BE SUBJECTED BY THE MANUFACTURER TO ALL THE MANDATORY TESTS AND CHECKS CALLED FOR IN THE RESPECTIVE CODES/DATA SHEETS/ SPECIFICATIONS AND HPCL APPROVED QUALITY ASSURANCE PLAN (TO BE SUBMITTED BY THE MANUFACTURER AFTER AWARD OF PO). THOUGH THE EXTENT OF INSPECTION BY PURCHASER OR HIS AUTHORISED REPRESENTATIVE SHALL BE AS UNDER BUT THE EXACT EXTENT OF HOLD POINTS SHALL BE MUTUALLY DECIDED BY THE PURCHASER OR MANUFACTURER AND RECORDED IN THE INSPECTION TEST PLAN (TO BE SUBMITTED BY THE MANUFACTURER AFTER AWARD OF PO):

THE LIST OF SUCH TESTS SHALL INCLUDE THE FOLLOWING AS A MINIMUM:

5.1.1 VISUAL INSPECTION OF ALL THE VALVES

5.1.2 DIMENSIONAL CHECK ON ALL VALVES.

5.1.3 ANY MANDATORY OR SUPPLEMENTRY TESTS

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5.1.4 REVIEW (WITH TRACEABILITY/ CORELATION) OF CHEMICAL COMPOSITION FOR EACH HEAT OF STEEL USED AS PER RELEVANT MATERIAL STANDARDS AND THIS SPECIFICATION/ DATA SHEET

5.1.5 REVIEW (WITH TRACEABILITY/ CORELATION) OF MECHANICAL PROPERTIES FOR EACH HEAT OF STEEL USED AS PER RELEVANT MATERIAL STANDARDS AND THIS SPECIFICATION/ DATA SHEET

51.6 REVIEW OF RADIOGRAPHS/ RADIOGRAPH REPORT IR ANY OTHER NON-DESTRUCTIVE EXAMINATION OF INDIVIDUAL VALVE MATERIAL/ COMPONENT WHEREEVER APPLICABLE AS PER DATA SHEET.

5.1.7 HYDROSTATIC TEST – 100% FOR BODY AND SEAT

5.1.8 PNEUMATIC TEST – 100% FOR SEAT

5.1.9 ALL VALVES SHALL BE TESTED IN ACCORDANCE WITH API 598 AND AS PER DATA SHEET.

51.10 STRIP TEST IS REQUIRED FOR 1% OF THE TOTAL ORDERED QUANTITY WITH ROUNDED OFF TO THE NEAREEST WHOLE NUMBER. SAMPLES FOR STRIP CHECK SHALL BE SELECTED AT RANDOM (GENERALLY IN HIGHER SIZES IN THE LOT) BY THE PURCHASER OR HIS AUTHORISED REPRESENTATIVE.

5.1.11 IN CASE OF MOTOR OPERATED OR ACTUATOR OPERATED VALVES FUNCTIONAL/ OPERATIONAL CHECKS AS PER THE REQUIREMENT OF THE SPECIFICATION SHALL BE MADE ON EACH VALVE.

6.0 PURCHASER’S AUTHORISED REPRESENTATIVE (THIRD PARTY INSPECTION AGENCY)

6.1 ANY ONE OF THE FOLLOWING AGENCIES CAN BE SELECTED AND SHALL BE EITHER OF THE FOLLOWING:

(I) DNV(II) SGS(III) BAX COUNCIL(IV) CEIL(V) BV(VI) IRS

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7.0 RADIOGRAPHY OF CAST VALVES

7.1 VALVES SHALL BE RADIOGRAPHED AS SPECIFIED IN RESPECTIVE DATA SHEET. WHEN SPECIFICALLY NOT MENTIONED IN INDIVIDUAL DATA SHEETS, VALVE CASTING SHALL UNDERGO RADIOGRAPHIC EXAMINATION AS SPECIFIED HERE UNDER :

____________________________________________________MATERIAL RATING SIZE RANGE RADIOGRAPHY

ALL 150 # 24” AND BELOW NIL

7.2 RADIOGRAPHY PROCEDURE, AREAS OF CASTING TO BE RAIOGRAPHED SHALL BE AS PER ANSI B16.34 AND ACCEPTANCE SHALL BE AS PER ANSI B16.34 ANNEXURE B. HOWEVER FOR AREA OF CASTING TO BE RAIOGRAPHED FOR TYPES OF VALVES NOT COVERED IN ANSI B 16.34, THE VENDOR SHALL ENCLOSE DETAILS OF AREAS TO BE RAIOGRAPHED IN LINE WITH ANSI B 16.34

7.3 RANDON RADIOGRAPHY WHEREEVER SPECIFIED IN THE DATA SHEETS, THE SAMPLING SHALL BE AS PER SIZE OF QUANTITY ORDERED FOR EACH FOUNDRY.

7.4 RADIOGRAPHY WHEREVER SPECIFIED IN DATA SHEET OR AS PER CLAUSE 12.1 SHALL BE DONE BY X-RAY TO GET THE DESIRED SENSITIVITY.

7.5 OVER AND ABOVE THE STIPULATION LAID DOWN IN CLAUSE 12.1, 12.2, 12.3 & 12.4 ALL VALVE CASTINGS SHALL ONLY BE PROCURED FROM APPROVED FOUNDRIES.

8.0 MARKING

8.1 VALVE MARKINGS, SYMBOLS, ABBREVIATIONS ETC. SHALL BE IN ACCORDANCE WITH MSS-SP-25 OR THE STANDARD REFERRED IN SPECIFICATION SHEET AS APPLICABLE. VENDOR NAME, VALVE RATING, MATERIAL DESIGNATION, NOMINAL SIZE, DIRECTION OF FLOW, (IF ANY) ETC. SHALL BE INTEGRAL ON THE BODY.

8.2 EACH VALVE SHALL HAVE A CORROSION RESISTANT TAG GIVING SIZE,

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VALVE TAG/CODDE NO, SECURITY ATTACHED ON THE VALVE.

8.3 PAINT OR INK FOR MARKING SHALL NOT CONTAIN ANY HARMFUL METAL

OR METAL SALTS SUCH AS ZINC, LEAD OR COPPER WHICH CAUSES CORROSIVE ATTACK ON HEATING.

8.4 CARBON STEEL VALVES SHALL BE BLASTED BLAST CLEANED WITH GRIT TO

SSPC SA 2 ½ COATED WITH TWO COATS OF ZINC RICH PRIMER

9.0 DESPATCH

9.1 VALVES SHALL BE DRY, CLEAN AND FREE FROM MOISTURE, DIRT AND LOOSE FOREIGN MATERIALS OF ANY KIND.

9.2 VALVES SHALL BE PROTECTED FROM RUST, CORROSION AND ANY MECHANICAL DAMAGE DURING TRANSORTATION, SHIPMENT AND STORAGE.

9.3 RUST PREVENTIVE ON MACHINED SURFACE TO BE WELDED SHALL BE EASILY REMOVABLE WITH PETROLEUM SOLVENT OR NOT HARMFUL TO WELDING.

9.4 EACH END OF FLANGE FACE OF VALVES SHALL BE PROTECTED WITH WOOD, METAL OR PLASTIC COVER. END PROTECTORS TO BE USED ON FLANGE FACES SHALL BE ATTACHED BY AT LEAST THREE BOLTS OR WIRING THROUGH BOLT HOLES AND SHALL NOT BE SMALLER THAN THE OUTSIDE DIAMETER OF THE FLANGE.

GATE VALVE SPECIFICATION DATA SHEET

Valve Tag No. Piping Class: A10A Corrosion Allowance 1.50 mm

Standard: API 600 Rating: 150 # ServiceMTO/HEXANE/SOLVENT

Size Range: 3 inch to 20 inch Ends: Flanged to B16.5 RF serr.Fin.

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MANUFACTURER'S OFFER

VALVE DESCRIPTION CONSTRUCTION MATERIAL CONSTRUCTIO

N MATERIAL

BODY CAST ASTM A 216 GR. WCB BONNET BOLTED ASTM A 216 GR. WCB STEM RISING ASTM A 182 F 6 A

WEDGE DISC SOLID/FLEXIBLE

13% CR. STEEL FACING/13% CR.STEEL

BODY SEAT RING & GLAND RENEWABLE ASTM A 105 plus stelliting

STEM PACKING

RENEWABLE WITH VALVE ONLINE

GRAPHITE WITH BRAIDED END RINGS

HAND WHEEL NON-RISING MALLEABLE IRON/CAST STEEL BONNET BOLTS ASTM A 193 GR. B 7

BONNET NUTS ASTM A 194 GR. 2 H

BONNET GASKET

SPIRAL WOUND SS316-GRAPHITE FILLER/CORRUGATED SOFT IRON

REQMT.OF GEAR OPERATOR AS PER SPECIFICATIONS SPECIAL SERVICE CONDITIONS

BACK SEAT & SHOULDER 13% CR. STEEL OTHERS OS & Y HYDROSTATIC TEST PRESSURE BODY:450 PSI SEAT:315 PSI

TEST PRESSURE WITH AIR 80 PSI NOTES:1, 2, 3, 4 & 5 BELOW1.This valve specification sheet shall be read in conjunction with specification for valves.

2.Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided .

3.Testing shall be as per API 598

4. Hardness test shall be carried out on each heat of base material for all pressure containing parts of the valve. A full thickness cross-section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV(for non stellited parts).

5. Body Seat Ring & Back Seat & Shoulder to be stellited 1.5 mm.

D. TECHNICAL SPECIFICATIONS FOR CS SWING CHECK VALVES

1.0 GENERAL

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1.1 VENDOR SHALL SUPPLY VALVES IN ACCORDANCE WITH THE VALVE SPECIFICATION SHEETS ALONG WITH AUXILIARIES, IF ANY SUCH AS GEAR OPERATOR, DRAINS, ETC. WHEREVER SPECIFIED IN THE SPECIFICATION SHEETS, SUBJECT TECHNICAL SPECIFICATIONS AND OTHER ENCLOSURES TO THIS TENDER DOCUMENT.

1.2 VENDOR SHALL QUOTE IN STRICT ACCORDANCE WITH THE VALVE DATA/SPECIFICATION SHEETS, SUBJECT TECHNICAL SPECIFICATIONS AND ALL OTHER ENCLOSURES TO THE REQUISITIONS. DEVIATIONS TO THE SPECIFICATIONS/DATA SHEETS, SUBJECT TECHNICAL SPECIFICATIONS AND OTHER ENCLOSURES OF THE REQUISITIONS, IF ANY, SHALL BE SOUGHT BY THE VENDOR AS EXPLAINED IN CLAUSE 2.0.

1.3 THE APPLICABLE CODES AND STANDARDS FOR MANUFACTURE SHALL BE BS:1868/ANSI B16.34 AND TESTING, INSPECTION SHALL BE AS PER BS:6755 PART-1 LATEST EDITION

1.4 CARBON STEEL USED FOR THE MANUFACTURE OF VALVES SHALL BE FULLY KILLED.

2 DOCUMENTATION

2.1.1 VENDOR SHALL SUBMIT ALONG WITH THE OFFER THE FOLLOWING :

2.1.1.1 MANUFACTURER’S COMPLETE DESCRIPTIVE AND ILLUSTRATIVE CATALOGUE/LITERATURE.

2.1.1.2 DETAILED DIMENSIONED, CROSS SECTION DRAWING WITH PARTS/MATERIAL LIST, WEIGHT ETC. FOR THE VALVES TO MANUFACTURER’S STANDARD IN ACCORDANCE WITH BS:1868/6755, AS APPLICABLE.

2.1.1.3 DRAWINGS FOR VALVES WITH ACCESSORIES ETC., GIVING MAJOR SALIENT DIMENSIONS.

2.1.1.4 ONE COPY OF THE ENTIRE SPECIFICATIONS COVERED IN TECHNICAL SPECIFICATION FOR VALVES AND VALVE SPECIFICATION DATA SHEET(S) SIGNED AS “ACCEPTED “ BY THE MANUFACTURER WITH ALL DEVIATIONS MARKED CLEARLY.

2.1.1.5 IF THE VALVE SPECIFICATION IS REGRETTED OR HAS NO DEVIATION, VENDOR HAS TO MENTION AS REGRET OR NO DEVIATION, RESPECTIVELY.ACCORDINGLY, THE MANUFACTURER SHALL WRITE

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CLEARLY ON VALVE SPECIFICATION SHEETS AS: “REGRET” OR “NO DEVIATION”.

2.1.1.6 FOR SUBJECT SPECIFICATIONS, IF THERE IS ANY DEVIATION THE SAME SHALL BE QUALIFIED CLAUSE WISE; CLAUSES WHICH ARE ACCEPTABLE SHALL BE CATEGORICALLY CONFIRMED AS “ACCEPTED”.

2.1.1.7 UPON FAILURE TO SUBMIT DOCUMENTS AS SPECIFIED IN CLAUSES 2.1.1.1 TO 2.1.1.6 ABOVE, THE SUBJECT VENDOR’S OFFER IS LIABLE TO BE REJECTED.

2.1.1.8 SUBMISSION OF QAP/ITP AS INDICATED IN QUALITY ASSURANCE PLAN -CHAPTER III (CL. 1.1 TO 1.13) OF THIS SECTION.

2.2 UPON PLACEMENT OF FOI/PURCHASE ORDER, WHICHEVER IS EARLIER, VENDOR SHALL SUBMIT DRAWINGS FOR APPROVAL BEFORE START OF MANUFACTURE.

2.3. TEST REPORTS SHALL BE SUPPLIED FOR ALL MANDATORY TESTS AS PER THE APPLICABLE CODE AND AS PER QAP/ITP DULY APPROVED BY HPCL. VENDOR SHALL SUBMIT A COPY OF THE RELEVANT EXTRACT FROM BS: 1868/6755 FOR CONFIRMATION.

2.4 MATERIAL TEST CERTIFICATES (PHYSICAL PROPERTIES, CHEMICAL COMPOSITION & HEAT TREATMENT REPORT) OF THE PRESSURE CONTAINING PARTS SHALL BE FURNISHED IN ACCORDANCE TO APPLICABLE CODES/STANDARDS AND QAP/ ITP DULY APPROVED BY HPCL FOR THE VALVES SUPPLIED. MATERIAL TEST CERTIFICATES FOR THE OTHER PARTS SHALL ALSO BE FURNISHED FOR VERIFICATION IN ACCORDANCE WITH HPCL APPROVED QAP/ITP DURING THIRD PARTY INSPECTION.

3 DESIGN AND CONSTRUCTION

3.1 ONLY SWING CHECK VALVES ARE ACCEPTABLE.

3.2 VALVE DESIGN SHALL MEET THE REQUIREMENTS OF BS:1868. FACE TO FACE DIMENSIONS SHALL BE AS PER ANSI B 16.10; FLANGES AS PER ANSI B16.5 RF AND TESTING SHALL BE CARRIED OUT IN ACCORDANCE WITH BS : 6755 (PART-1). THE VALVE SHALL BE DESIGNED AND CONSTRUCTED IN ACCORDANCE WITH THE DATA SHEET AND HPCL APPROVED QAP/ITP.

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3.3 VALVE SHALL BE PROVIDED WITH NON-RENEWABLE INTEGRAL TYPE SEATS OR NON-INTEGRAL SEAT RING SEAL WELDED TYPE.

3.4 VALVES SHALL BE DESIGNED, MANUFACTURED, TESTED INSPECTED AND MARKED AS PER THE MANUFACTURING STANDARDS, DESIGN CODES AND STANDARDS (LATEST EDITION) INDICATED IN THE RESPECTIVE VALVE SPECIFICATION SHEETS. ANY CONFLICT BETWEEN THE REQUISITION, ENCLOSURE, SPECIFICATION SHEETS AND REFERRED STANDARD CODES SHALL BE BROUGHT TO THE NOTICE OF THE PURCHASER FOR CLARIFICATION, BUT GENERALLY SPECIFICATION SHEETS AND ENCLOSURES OF THE REQUISITION INCLUDING SUBJECT NOTES SHALL GOVERN. NO DEVIATION TO SPECIFICATION / STDS SHALL BE PERMITTED THROUGH VENDOR DRAWING APPROVAL. APPROVAL OF DRAWING SHALL BE VALID ONLY FOR DESIGN FEATURES.

3.5 FOR HEAVY CHECK VALVES OF 10INCH DIA AND ABOVE, PROVISION SHALL BE AVAILABLE FOR LIFTING BY WAY OF LUGS, EYE BOLTS AND SUCH STANDARD DEVICES.

3.6 ALL FLANGED GATE VALVES SHALL HAVE FLANGES INTEGRAL (EXCEPT FORGED VALVES) WITH THE VALVE BODY. FLANGE FINISH SHALL BE SERRATED FINISH 125 AARH (125 AARH TO 250 AARH) OR (32 AARH TO 63 AARH) AS PER VALVE SPECIFICATION SHEET.

3.7 AN ARROW INDICATING THE DIRECTION OF FLOW SHALL BE EMBOSED OR CAST ON THE BODY OF ALL VALVES.

3.8 ALL WELDS SHALL BE MADE BY WELDERS AND WELDING PROCEDURES QUALIFIED VIDE ASME SECTION IX.

3.9 REPAIR BY WELDING IS PERMITTED FOR CAST BODY VALVES SUBJECT TO WRITTEN APPROVAL BY HPCL AS PER ANSI B16.34 PRIOR TO HEAT TREATMENT ON CASTING.

3.10 UNLESS SPECIFIED OTHERWISE IN THE DATA SHEET ALL CHECK VALVES 3” AND ABOVE SHALL HAVE A DRAIN BOSS AT LOCATION ‘G’ (REFER FIG NO.1 OF ANSI B16.34). A TAPPED DRAIN HOLE WITH PLUG SHALL BE PROVIDED AS PER ANSI B16.34. THREAD SHALL BE AS PER ANSI B2.1 (TAPER) NPT. DRAIN TAPPING SHALL BE PROVIDED IN A POSITION SUITABLE TO COMPLETELY DRAIN THE VALVE WITH VALVE IN HORIZONTAL POSITION.

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3.11 WHEREVER CHECK VALVE DISC ASSEMBLY IS SUPPORTED FROM THE COVER OF THE CHECK VALVES, THE FOLLOWING SHALL BE ASCERTAINED.

I) POSITIVE LOCATION/POSITIONING OF COVER MUST BE PROVIDED TO ENSURE CORRECT ALIGNMENT OF THE VALE DISC.

II) HINGE PIN DESIGN MUST PERMIT ACCURATE ALIGNMENT OF THE DISC AND VALVE SEAT.

3.12 THE DISC HINGE SHALL BE MOUNTED ON THE VALE BODY AND SHALL NOT BE ATTACHED TO THE BODY COVER. VALVE BODY COVER SHALL BE OF BOLTED DESIGN AND SCREWED COVERS ARE NOT PERMITTED.

3.13 IF AN OVERLAY WELD DEPOSIT IS USED FOR THE BODY SEAT RING, SEATING SURFACE, THE SEAT RING BASE MATERIAL SHALL BE ATLEAST EQUAL TO THE CORROSION RESISTANCE OF THE MATERIAL OF THE SHELL.

3.14 VAVLE BODY/BONNET SHALL BE FORGED/ CAST AS SPECIFIED. FORGINGS ARE ACCEPTABLE IN PLACE OF CASTING BUT NOT VICE-VERSA.

3.15 STELLITING / HARD FACING BY DEPOSITION SHALL BE MINIMUM 1.6MM. RENEWABLE SEAT RING MAY BE SEAL WELDED.

3.16 SPIRAL WOUND BONNET GASKETS ARE TO BE PROVIDED WITH INNER/OUTER RING EXCEPT WHEN ENCAPSULATED GASKET TYPE BODY-BONNET JOINTS ARE EMPLOYED. OUTER RING MAY BE AVOIDED IN CASE OF NON-CIRCULAR SPIRAL WOUND GASKET USED IN 150# VALVE PROVIDED THE OUTERMOST LAYER OF SPIRAL TOUCHES THE BOLTS ASCERTAINING THE CENTERING.

5 INSPECTION AND TESTING

5.0 EVERY VALVE, ITS COMPONENTS AND AUXILIARIES SHALL BE SUBJECTED BY THE MANUFACTURER TO ALL THE MANDATORY TESTS AND CHECKS CALLED FOR IN THE RESPECTIVE CODES/DATA SHEETS AND HPCL APPROVED QAP/ITP. THE LIST OF SUCH TESTS SHALL INCLUDE THE FOLLOWING AS A MINIMUM IN QAP/ITP SUBMITTED TO HPCL FOR APPROVAL:

1) VISUAL INSPECTION OF ALL THE VALVES.2) DIMENSIONAL CHECK ON ALL VALVES.

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3) CHEMICAL COMPOSITION FOR EACH HEAT OF STEEL USED AS PER RELEVANT MATERIAL STANDARDS AND THIS SPECIFICATION.

4) MECHNICAL PROPERTIES FOR EACH HEAT OF STEEL USED AS PER RELEVANT MATERIAL STANDARDS AND THIS SPECIFICATION.

5) NON-DESTRUCTIVE EXAMINATION OF INDIVIDUAL VALVE MATERIAL/COMPONENT CONSISTING OF CASTINGS, FORGINGS AND PLATES.

6) 100% WET MAGNETIC PARTICLE INSPECTION OF INTENAL SURFACE OF CASTINGS; METHOD AND ACCEPTANCE AS PER MSS-SP-53.

7) ALL VALVES SHALL BE TESTED IN ACCORDANCE WITH BS:1868/16755(PART-1) AND AS PER DATA SHEET.

5.1 THE SCOPE OF THIRD PARTY INSPECTION SHALL BE BROADLY AS GIVEN BELOW IN ACCORDANCE WITH HPCL APPROVED QAP/ITP

CAST STEEL CHECK VALVES:

1. VISUAL AND DIMENSIONAL INSPECTION OF ALL THE VALVESS.2. REVIEW OF MATERIAL TEST CERTIFICATES-CHEMICAL &

MECHANICAL FOR EACH HEAT OF STEEL.3. REVIEW OF RADIOGRAPH / RADIOGRAPHIC REPORTS OR ANY

OTHER NDT TESTS WHEREVER APPLICABLE (SL.NO.5&6 OF CL.5.1 ABOVE).

4. REVIEW/WITNESS OF ANY MANDATORY TEST AS PER BS:1868/6755 (PART-1).

5. WITNESS HYDROSTATIC TEST- 100%.6. WITNESS AIR TEST-100%.7. ANY OTHER DOCUMENT REVIEW/WITNESS AS PER HPCL

APPROVED QAP/ITP.

THE THIRD PARTY SHALL BE EITHER OF THE FOLLOWING :1) DNV2) BV3) IRS4) BAX COUNCIL5) CEIL6) SGS

6 RADIOGRAPHY OF CAST STEEL VALVES

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6.0 VALVES SHALL BE RADIOGRAPHED AS SPECIFIED IN RESPECTIVE DATA SHEET. WHEN SPECIFICALLY NOT MENTIONED IN INDIVIDUAL DATA SHEETS, VALVE CASTING SHALL UNDERGO RADIOGRAPHIC EXAMINATION AS SPECIFIED HEREUNDER :

____________________________________________________MATERIAL RATING SIZE RANGE RADIOGRAPHY

ALL 150 # 24” AND BELOW NIL

7 MARKING

7.1 VALVE MARKINGS, SYMBOLS, ABBREVIATIONS ETC. SHALL BE IN ACCORDANCE WITH MSS-SP-25 OR THE STANDARD REFERRED IN SPECIFICATION SHEET AS APPLICABLE. VENDOR NAME, VALVE RATING, MATERIAL DESIGNATION, NOMINAL SIZE, DIRECTION OF FLOW, (IF ANY) ETC. SHALL BE INTEGRAL ON THE BODY.

7.2 EACH VALVE SHALL HAVE A CORROSION RESISTANT TAG GIVING SIZE, VALVE TAG/CODDE NO, SECURITY ATTACHED ON THE VALVE.

7.3 PAINT OR INK FOR MARKING SHALL NOT CONTAIN ANY HARMFUL METAL OR METAL SALTS SUCH AS ZINC, LEAD OR COPPER WHICH CAUSES CORROSIVE ATTACK ON HEATING.

7.4 CARBON STEEL VALVES SHALL BE BLASTED WITH SAND/ GRIT TO SA 2 ½, COATED WITH TWO COATS OF ZINC RICH PRIMER.

8 DESPATCH

8.1 VALVES SHALL BE DRY, CLEAN AND FREE FROM MOISTURE, DIRT AND LOOSE FOREIGN MATERIALS OF ANY KIND.

8.2 VALVES SHALL BE PROTECTED FROM RUST, CORROSION AND ANY MECHANICAL DAMAGE DURING TRANSORTATION, SHHIPMENT AND STORAGE.

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8.3 RUST PREVENTIVE ON MACHINED SURFACE TO BE WELDED SHALL BE EASILY REMOVABLE WITH PETROLEUM SOLVENT OR NOT HARMFUL TO WELDING.

8.4 EACH END OF VALVES SHALL BE PROTECTED WITH THE FOLLOWING MATERIALS :

FLANGE FACE : WOOD, METAL OR PLASTIC COVER

BEVELLED END : WOOD, METAL OR PLASTIC COVER

SW & SERD, END : PLASTIC CAP

8.5 END PROTECTORS TO BE USED ON FLANGE FACES SHALL BE ATTACHED BY AT LEAST THREE BOLTS OR WIRING THROUGH BOLT HOLES AND SHALL NOT BE SMALLER THAN THE OUTSIDE DIAMETER OF THE FLANGE.

CS CHECK VALVE DATA SHEET

Valve Tag No. Piping Class: A10A Corrosion

Allowance 1.50 mm

Standard: BS:1868 Rating: 150 # ServiceMTO/HEXANE/ SOLVENT

Size Range: 4 inch to 14 inch Ends: Flanged to B16.5 RF serr.Fin.; 125AARH

VALVE PORT REDUCED OPENING PORT MANUFACTURER'S OFFER

PART DESCRIPTION CONSTRUCTION MATERIAL CONSTRUCTION MATERIALBODY CAST ASTM A 216 GR. WCB COVER BOLTED ASTM A 216 GR. WCB

DISC ASTM A 216 GR. WCB + 13% CR STEEL FACING

BODY SEAT RING RENEWABLE ASTM A 216 GR. WCB + 13% CR STEEL FACING

DISC HINGE ASTM A 216 GR. WCB

HINGE PIN 13% CR STEEL (NO CASTING)

COVER STUD BOLTS ASTM A 193 GR. B 7 COVER NUTS ASTM A 194 GR. 2 H

BONNET GASKET SPIRAL WOUND SS316-GRAPHITE FILLER

HYDROSTATIC TEST PRESSURE BODY:450 PSI SEAT:315 PSI

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TEST PRESSURE WITH AIR 80 PSI NOTES:1, 2, 3, 4 & 5 BELOW 1.This valve specification sheet shall be read in conjunction with Technical Specification for valves.

4. Seats shall be non-renewable integral type only.

2.Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided .

5. Valves shall be suitable for Horizontal/vertical installation.

3.Testing shall be as per BS:6755 (PART-1)

APPROVED MAKES

ITEMS APPROVED MAKES

PIPES INDUSTUBES/ LALIT/ MAHARASHTRA SEAMLESS/ TATA

GATE VALVES L&T/ AV VALVES/ STEEL STRONG/ NSSL

SWING CHECK VALVES

L&T/ A.V.VALVES/ PANCHVATI VALVES/ HAWA ENGINEERING LTD.

STRAINERS MICON/ MEHTA NANAVATI

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QUALITY ASSURANCE PLAN AND INSPECTION & TESTING PLAN REQUIREMENTS

1.1] QA PLAN

VENDOR DURING BIDDING STAGE SHALL SUBMIT HIS QUALITY ASSURANCE PLANS (QAP) CONSISTING OF RELEVANT PROCEDURES COVERING VARIOUS ACTIVITIES LIKE DESIGN AND ENGINEERING, MATERIAL PROCUREMENT , MANUFACTURE INSPECTION AND TESTING, DOCUMENTATION, DISPATCH TO SITE , ERECTION AND COMMISSIONING WHEREVER APPLICABLE AND MAINTENANCE OF QUALITY RECORDS IN THE POST ORDER STAGE. THE VENDOR SHALL SUBMIT THE QAP TO THE SITE ENGINEER FOR APPROVAL WITHIN 2 WEEKS FROM THE DATE OF RECEIPT OF LOI/PO WHICHEVER IS EARLIER. THE QAP SHALL BE APPROVED BY THE AUTHORIZED REPRESENTATIVE OF HPCL WITHIN A WEEK OF SUBMISSION

1.2] ITP

VENDOR SHALL SUBMIT INSPECTION AND TEST PLAN FOR APPROVAL WITHIN 2 WEEKS OF LOI/PO AND BEFORE COMMENCEMENT OF MANUFACTURE TO THE SITE ENGINEER AS WELL AS TO THE THIRD PARTY INSPECTION AGENCY (TPIA) THAT THE VENDOR WISHES TO APPOINT FOR CARRYING OUT INSPECTION AND TESTING. THIS DOCUMENT SHOULD CLEARLY SPECIFY THE NAME, DESIGNATION OF THE PERSON CONCERNED (WITH TELEPHONE/MOBILE NO AND EMAIL) AND COMMUNICATION ADDRESS OF THE TPI.

1.3] DRAWING SCHEDULE

VENDOR SHALL SUBMIT A TOTAL INDEX OF DRAWINGS AND DOCUMENTS REQUIRED FOR APPROVAL/REVIEW/RECORDS ALONG WITH THE SCHEDULED

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DATE OF SUBMISSION OF EACH DRAWING/DOCUMENT WITHIN 2 WEEKS FROM DATE OF ISSUE OF LOI/ PO WHICHEVER IS EARLIER.

1.4] PROGRESS REPORT AND SCHEDULE

VENDOR SHALL SUBMIT MONTHLY PROGRESS REPORT AND UPDATE PROCUREMENT ENGINEERING AND MANUFACTURING SCHEDULE EVERY MONTH STARTING FROM 2 WEEKS FROM DATE OF ISSUE OF FOI/PO WHICHEVER IS EARLIER.

1.5] WAIVER AND DEVIATION

VENDOR SHALL STRICTLY COMPLY WITH THE PO STIPULATIONS AND NO DEVIATIONS SHALL BE PERMITTED.

1.6] PROCUREMENT OF BOUGHT OUT MATERIALS

ALL CRITICAL MATERIALS SUCH AS CASTING, FORGING, FITTING, PRESSURE HOLDING PARTS ELECTRICAL AND INSTRUMENT ACCESSORIES ETC. SHALL BE PURCHASED BY THE VENDOR FROM SUB- VENDORS HAVING BV, LRIS OR CEIL APPROVAL. VENDOR SHALL SUBMIT A LIST OF BOUGHT OUT MATERIALS FOR HPCL APPROVAL WITHIN 2 WEEKS FROM THE DATE OF ISSUE OF FOI/PO WHICHEVER IS EARLIER.

1.7] CALIBRATION RECORDS

VENDOR SHALL USE ONLY CALIBRATED MEASURING AND TEST INSTRUMENTS AND MAINTAIN CALIBRATION RECORDS. VENDOR SHALL FURNISH RECORDS OF CALIBRATION OF MEASURING AND TEST INSTRUMENTS INCLUDING RECALIBRATION RECORDS TO THIRD PARTY INSPECTION AGENCY ON DEMAND.

1.8] INSPECTION TEST STATUS

INSPECTION AND TEST STATUS OF PRODUCTS SHALL BE IDENTIFIED BY USING MARKINGS. AUTHORIZED STAMPS, TAGS, ROUTE CARDS, INSPECTION CARDS ETC. DURING THE COURSE OF MANUFACTURE TO CLEARLY INDICATE ACCEPTANCE/ REJECTION OF TESTS/STAGES OF INSPECTION PERFORMED DURING ITS MANUFACTURING CYCLE. THE IDENTIFICATION OF TEST STATUS SHALL BE MAINTAINED AND RECORDS SUBMITTED AS AND WHEN DEMANDED BY HPCL/TPIA.

1.9] QUALITY RECORDS

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VENDOR SHALL MAINTAIN QUALITY RECORDS AS PER HIS PROCEDURES. INSPECTION REPORTS & TEST RECORDS COPIES SHALL BE FURNISHED TO HPCL/TPIA.

1.10] IDENTIFICATION AND TRACEABILITY

VENDOR SHALL ESTABLISH AND MAINTAIN A STANDARD WRITTEN PROCEDURE FOR IDENTIFYING THE PRODUCTS FROM APPLICABLE DRAWING SPECIFICATIONS OR OTHER DOCUMENTS DURING ALL STAGES OF PRODUCTION DELIVERY AND INSTALLATION. A COPY OF THIS STANDARD PROCEDURE SHALL BE MADE AVAILABLE TO HPCL/TPIA. THE VENDOR SHALL ENSURE THAT EACH PRODUCT WHICH IS GOING IN THE PROCESS OF FABRICATION / MANUFACTURE / CONSTRUCTION / ERECTION HAS PROPER IDENTIFICATION THROUGHOUT THE PROCESS INCLUDING THE FINAL OUTPUT.

1.11] VENDOR DOCUMENT FOR REVIEW AND RECORDS

GENERAL

1] ALL DOCUMENTS SHALL BE IN ENGLISH LANGUAGE AND SI SYSTEM OF UNITS.

2] REVIEW OF THE VENDOR DRAWING BY THIRD PARTY INSPECTION AGENCY / HPCL WOULD BE ONLY TO REVIEW THE COMPATIBILITY WITH BASIC DESIGN AND CONCEPTS AND IN NO WAY ABSOLVE THE VENDOR OF HIS RESPONSIBILITY TO COMPLY WITH PO REQUIREMENTS, APPLICABLE CODES, SPECIFICATIONS AND STATUTORY RULES/REGULATIONS.

3] SUBMISSION OF DOCUMENTS FOR REVIEW/RECORDS SHALL COMMENCE WITHIN 2 WEEKS FROM THE DATE OF ISSUE OF FOI/PO

4] THE VENDOR SHALL SUBMIT ALL DRAWINGS AND DOCUMENTS IN THREE COPIES AS STIPULATED IN THE VENDOR DATA REQUIREMENT ALONG WITH DOCUMENTS INDEX. THE DOCUMENTS SHALL ALSO BE SUBMITTED IN SOFT COPIES TO EXPEDITE THE PROCESS OF APPROVAL/REVIEW.

VENDOR SHALL ENSURE THAT EACH DRAWING SHALL CONTAIN THE FOLLOWING INFORMATION:

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PO NO NAME OF EQUIPMENT, TAG NO., NAME OF PROJECT, CLIENT, DRAWING/ DOCUMENT TITLE, DRAWING NO., REVISION AND DATE.

THE DRAWING DOCUMENT SHALL BE CHECKED APPROVED AND DULY SIGNED STAMPED BY THE VENDOR REVISIONS AND DATE.

1.12] DOCUMENTS UNDER REVIEW CATEGORY.

FOLLOWING REVIEW CODES SHALL BE USED FOR REVIEW OF VENDOR DOCUMENTS / DRAWINGS.

AFI: APPROVED FOR INSPECTION

AFM: APPROVED FOR MANUFACTURING / FABRICATION AS PER COMMENTS

VENDOR SHALL RESUBMIT THE SAME AFTER INCORPORATING THE COMMENTS BEFORE CARRYING OUT FINAL INSPECTION BY TPIA AND DESPATCH.

NOT APPROVED: RESUBMISSION REQUIRED IN CASES OF MAJOR NON- CONFORMITIES WITH RESPECT TO PO SPECIFICATIONS.

1.13] FINAL DOCUMENTS

FINAL DRAWINGS/DOCUMENTS CONSISTING OF TECHNICAL DATA MANUAL AS A COMPILATION OF AS-BUILT CERTIFIED DRAWING AND MANUFACTURING DATA AND TEST RECORDS DULY CERTIFIED BY HPCL/TPIA SHOULD BE SUBMITTED IN THREE SETS ALONG WITH SOFT COPY OF THE SAME.

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS OF THE MATERIAL/EQUIPMENTS (WHEREVER APPLICABLE) SHALL ALSO BE SUBMITTED IN THREE SETS AND IN SOFT FORMAT.

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SPECIAL CONDITIONSOF

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CONTRACT

1.0 GENERAL

1.1 Special Conditions of Contract (SCC) shall be read in conjunction with the General Conditions of Contract (GCC) also referred to as General Terms & Conditions of Works Contract, Schedule of Quantities, specifications of work, drawings and any other document forming part of this Contract wherever the context so requires.

1.2 Notwithstanding the sub-division of the document into these separate sections and volumes, every part of each shall be deemed to be supplementary of every other part and shall be read with and into the Contract so far as it may be practicable to do so.

1.3 Where any portion of the GCC is repugnant to or at variance with any provisions of the Special Conditions of Contract, then unless

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a different intention appears, the provision(s) of the Special Conditions of Contract shall be deemed to override the provision(s) of GCC only to the extent that such repugnancy or variations in the Special Conditions of Contract are not possible of being reconciled with the provisions of GCC.

1.4 Wherever it is stated in this Bidding Document that such and such a supply is to be affected or such and such a work is to be carried out, it shall be understood that the same shall be affected and /or carried out by the Contractor at his own cost, unless a different intention is specifically and expressly stated herein or otherwise explicit from the context. Contract Price shall be deemed to have included such cost.

1.5 The materials, design & workmanship shall satisfy the applicable relevant Indian Standards, the job specifications contained herein & codes referred to. Where the job specifications stipulate requirements in addition to those contained in the standard codes and specifications, these additional requirements shall also be satisfied. In the absence of any Standard / Specifications / Codes of practice for detailed specifications covering any part of the work covered in this bidding document, the instructions / directions of Engineer-in-Charge will be binding upon the Contractor.

1.6 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) Fax of Intent (FOI)/Letter of Intent(LOI)iii) Schedule of Quantitiesiv) Special Conditions of Contractv) Instructions to Bidders vi) General Conditions of Contractvii) Technical Specificationsviii) Relevant Indian Standards.ix) Drawings/ Data Sheets

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1.7 SAFETY, FIRE FIGHTING AND SPECIFIC REQUIREMENTS OF HPCL

1.7.1 Contractor shall provide adequate number of standard lengths of IS Stamped Fire hoses, IS Stamped DCP Fire extinguishers, fire buckets with sand and nozzles. These items can be taken back by the Contractor after completion of work. Sand shall also be maintained dry by the Contractor with fresh supply, whenever required. Work permit may not be issued by HPCL in the absence of above items.

1.7.2 Safety Helmets shall be provided to all the employees of Contractor including that of his labour contractors.

1.7.3 Safety Belts and Harnesses shall be provided by the Contractor in adequate number for the workers working at heights.

1.7.4 Proper earthing shall be provided for all equipments and generators. 2.0 THE WORK

2.1 Scope of Work & Scope of Supply

2.1.1 The scope of work and Scope of Supply covered in this Contract will be as described in Scope of work provided in the Instructions to bidders, Schedule of Quantities, Technical Specifications, Drawings, etc.

2.2 Time Schedule

The Completion period for this job shall be 4 (FOUR) Months from the date of LOI.

2.2.1 Time is the essence of this Contract. The period of completion given includes the time required for mobilization as well as testing, rectifications, if any, retesting, demobilization and completion in all respects to the satisfaction of the Engineer-in-Charge.

2.2.2 A joint program of execution of work will be prepared by the Engineer-in-Charge and Contractor. This program will take into account the time of completion period of the Contract.

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2.2.3 Monthly execution program will be drawn up by the Engineer-in-Charge jointly with the Contractor based on availability of materials, work fronts and the joint program of execution as referred to above. The Contractor shall scrupulously adhere to the Targets / Program by deploying adequate personnel, Construction Equipment, Tools and Tackles and also by Timely Supply of required materials coming within his scope of supply as per Contract. In all matters concerning the extent of target set out in the monthly program and the degree of achievement, the decision of the Engineer-in-Charge will be final and binding upon the Contractor.

2.2.4 Contractor shall give every day category-wise labour and equipment deployment report along with the progress of work done on previous day in the proforma prescribed by the Engineer-in-Charge.

2.3 Measurement of Works

2.3.1 Mode of measurement will be as specified in Specifications or SOR.

2.4 Payment Terms

2.4.1 Payment will be released within 15 days of submission of duly certified Running Account Bills at Disbursement section at Mumbai after deduction of WCST(Works Contract Sales Tax) or VAT whichever is applicable, IT(Income Tax) and any other statutory deduction as applicable from time to time, Any MRR(Materials Received Report- An internal document forwarded by HPCL Site –in-Charge/ Engineer to Disbursement Section along with Contractor’s Bill and duly certified measurement sheets for release of payment) Deductions, LD, etc. In case of Final Bill, Payment will be released within 45 days of submission of duly certified Final Bill along with all requisite documents, drawings, etc. Payment break up for various items covered in SOR/PRICED BID is as indicated as Appendix 1 to SCC. No further alteration is permitted in approved payment break up.

2.5 Temporary Works

2.5.1 All temporary works, enabling works, including dewatering of surface and subsoil water, preparation and maintenance of temporary drains at the work site, preparation and maintenance

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of approaches to working areas, adequate lighting, wherever required, for execution of the work, shall be the responsibility of the Contractor and all costs towards the same shall be deemed to have been included in the quoted prices.

2.6 Quality Assurance

2.6.1 Detailed quality assurance program to be followed for the execution of Contract under various divisions of works will be mutually discussed and agreed to.

2.6.2 The Contractor shall establish, document and maintain an effective quality assurance system as outlined in the specifications and various codes and standards.

2.6.4 The Owner/Consultant or their representative shall reserve the right to inspect/witness, review any or all stages of work at shop/site as deemed necessary for quality assurance and / or timely completion of the work.

2.6.5 In case Contractor fails to follow the instructions of Engineer-in-Charge with respect to above clauses, next payment due to him shall not be released unless and until he complies with the instructions to the full satisfaction of Engineer-in-Charge.

2.7 Leads

2.7.1 For the various works, in case of contradiction, leads mentioned in the Schedule of Quantities shall prevail over those indicated in the Technical specifications.

3.0 ROYALTY, INCOME TAX, SERVICE TAX AND PRICES

3.1 Royalty3.1.1 All royalties etc., as may be required for any Borrow Areas,

including right of way etc., to be arranged by Contractor shall be deemed to have been included in the quoted prices.

3.1.2 Contractor’s quoted rates should include the royalty on different applicable items as per the prevailing State Government rates. In case, Owner is able to obtain the exemption of royalty from the State Government the Contractor shall pass on the same to

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Owner for all the items involving royalty. Any increase in prevailing rate of royalty shall be borne by the Contractor at no extra cost to the Owner.

3.2 Income Tax

3.2.1 Income Tax at the prevailing rate as applicable from time to time shall be deducted from Contractor’s Bills as per Income Tax Act and quoted rates shall be inclusive of this. Owner will issue the TDS (Tax Deduction at Source) Certificate.

3.3 Firm Prices

3.3.1 The contract price shall remain firm and fixed till the completion of work in all respects and no escalation in prices on any account shall be admissible to the Contractor.

4 PROVIDENT FUND,LABOUR, LABOUR LAWS AND SITE REQUIREMENTS

4.1 Provident Fund4.1.1 The Contractor shall strictly comply with the provisions of

Employees Provident Fund Act and register himself with Regional Provident Fund Commissioner (RPFC) before commencing work. The Contractor shall deposit Employees and Employers contributions to the RPFC every month. The Contractor shall furnish along with each Running bill, the challan / receipt for the payment made to the RPFC for the preceding month. The Contractor shall furnish the code number allotted by the RPFC Authority to the Engineer-in-Charge before commencing the work.

4.1.2 In case the RPFC challan / receipt, as above, is not furnished, Owner shall deduct 16% (sixteen percent) of the payable amount from Contractor’s running bill and retain the same as a deposit. Such retained amounts shall be refunded to Contractor on production of RPFC Challan / receipt for the period covered by the related running bill.

4.2Labor License

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4.2.1 Before starting of work, Contractor shall obtain a license from concerned authorities under the Contract Labor (Abolition and Regulation) Act 1970, and furnish copy of the same to Owner.

4.3 Labour Relations

4.3.1 In case of labour unrest/labour dispute arising out of non-implementation of any law, the responsibility shall solely lie with the Contractor and they shall remove/resolve the same satisfactorily at his cost and risk.

4.3.2 The Contractor shall at all times take all reasonable precautions to prevent any unlawful, riotous or disorderly conduct by or amongst his staff and labour and to preserve peace and protection of persons and property in the neighbourhoods of the Works against such conduct.

4.4 Employment of Local Labour

4.4.1 The Contractor shall ensure that local labour skilled and / or unskilled, to the extent available shall be employed in this work. In case of non – availability of suitable labour in any category out of the above persons, labour from outside may be employed.

4.4.2 The Contractor shall not recruit personnel of any category from among those who are already employed by other agencies working at site but shall make maximum use of local labour available.

4.5 Site Cleaning

4.5.1 The Contractor shall clean and keep clean the work site from time to time to the satisfaction of the Engineer-in-Charge for easy access to work site and to ensure safe passage, movement and working.

4.5.2 The Contractor shall dispose off the unserviceable materials, debris etc., to the earmarked area within the premises or any other location outside the premises as decided by the Engineer-in-Charge. No extra payment shall be paid on this account.

4.5.3 Review/Approval of Drawings, Design and other documents submitted by Contractor

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4.5.3.1 HPCL/consultant will normally require and utilize a maximum time frame of seven (07) working days from the date of Receipt for Review/Approval of Drawings, Design and other documents submitted by Contractor. Upon Review of the submitted documents, HPCL may give their comments and ask for redesign/ resubmission after necessary rectifications/ modifications and the time frame of 7 working days will be applicable for same.

4.6Protection of Existing Facilities

4.6.1 Contractor shall obtain all clearance (work permit) from the Owner, as may be required from time to time, prior to start of work. Work without permit shall not be carried out within the existing premises.

4.6.2 Contractor shall obtain plans and full details of all existing and planned facilities/services/utilities from the Owner and shall follow these plans closely at all times during the performance of work. Contractor shall be responsible for location and protection of all facilities/utilities and structures at his own cost.

4.6.3 Despite all precautions, should any damage to any structure / utility etc. occur, the Contractor shall contact the Owner / authority concerned and Contractor shall forthwith carry out repair at his expenses under the direction and to the satisfaction of Engineer-in-Charge and the Owner/concerned authority.

4.6.3 Contractor shall take all precautions to ensure that no damage is caused to the existing facilities etc., during construction. Existing structures/facilities/utilities damaged / disturbed during construction shall be repaired and restored to their original condition by Contractor after completion of construction to the complete satisfaction of Owner.

4.7Work Front

4.7.1 The work involved under this Contract may include such works as have to be taken up and completed after other agencies have completed their jobs. The Contractor will be required and bound to take up as and when the fronts are available for the same and no claim of any sort whatsoever shall be admissible to the

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Contractor on this account. Only extension of time limit shall be admissible, if the availabilities of work fronts to the Contractor are delayed due to any reason not attributable to the Contractor and the same is clearly recorded.

4.8Site Facilities

4.8.1 The Contractor shall arrange for the following facilities at site, for workmen deployed/engaged by him / his sub-contractor, at his own cost:

i) Arrangement for First Aid.ii) Arrangement for clean & potable drinking water.iii) A crèche where 10 or more women workers are having children

below the age of 6 years.iv) Any other facility/utility as may be required under the Contract

as per the existing legislation/regulations.

4.9Contractor’s Site Office and Stores

4.9.1 Owner shall provide land only for contractor’s site office and stores and fabrication yard, if any at site. However, same shall be dismantled prior to submission of Final Bill.

4.9.2 The Contractor shall remove all temporary buildings / facilities etc., before leaving the site after completion of works in all respect.

4.10 Construction Power and Water

4.10.1 Owner shall not provide power and the Contractor shall be exclusively responsible to make his own arrangements for supply of power, without any extra cost to the Owner.

4.10.2 Water required for the works shall be arranged by the Contractor. The contractor has to make all necessary arrangement for drawing water including making temporary storage, pumping etc.

4.10.3 CEMENT:

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Cement required for execution of the job under the entire scope of work (other than for Ready Mix Concrete where the cement is from the RMC manufacturer scope ) contained in this tender shall be supplied at provided at site by the contractor at his own cost. Contractor to include the cost of cement required for execution of various items included in this tender in their quoted rates. Cement shall be of 43 / 53 Grade OPC/PPC as specified in the SOQ of Ultra Tech Cement/ Gujarat Ambuja / ACC / Birla Makes only and shall conform to IS relevent standards of latest edition.. Contractor to produce Invoice Copy of every batch of cement procured at site to EIC. However, HPCL’s decision with regard to the specific brand of cement to be procured for the execution of the work shall be final and binding on the contractor.

Cement shall be procured and brought to site atleast 15 days in advance. Sample from every batch of cement brought to site shall be tested for standard test as per the specification of relevant IS standards in approved Laboratory and Test Certificate shall be submitted to EIC for verification. Only after obtaining approval of EIC, cement shall be put into use. Manufacturer’s Batch Test Certificates 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 work on account of non-availability of cement / delays is testing procedures will be entertained/accepted by HPCL.

For all computation purposes, the theoretical cement consumption shall be considered as per CPWD standards. Cement cost shall be recovered for under-consumption at the penal rate of Rs.7000/- per MT. Empty cement bag shall be the property of the contractor. Theoretical weight of cement in a bag will be considered as 50 Kgs. Bags weighing upto 4% less shall be accepted by HPCL. Any shortage is weight of any cement bag by more than 4% will be to contractor’s account. Contractor shall maintain necessary weighing scale at site for the purpose of random checking of the weight of cement bags by representative of HPCL.

The contractor will be required to maintain a stock register for receipt, issuance and daily consumption of cement at site. Cement shall be regulated on the basis of 1st receipt to go as 1st issue. Cement not consumed within 3 months after bringing to site shall not be used and shall be removed from site with prior written permission of EIC.

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All RA bills including the final bills will be accompanied by Cement Consumption Statements giving the detailed working of cement used.

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 damages to cement. Contractor shall not remove from the site any cement bags at any time.Permissible wastage shall be total 3% of the theoretical consumption. However, these wastage shall be considered in excess of the theoretical quantity required for the various items of work. No extra payment will be made towards this wastage and the same will be in the contractor’s account. The contractor shall be penalised for any under-consumption of cement at the rate of Rs 7000/- per MT.

4.10.4 STEEL :

Entire quantity of reinforcement / structural steel required for the project shall be supplied and provided at site by the contractor at his own cost. Contractor to include the cost of steel reinforcement / structural steel required to be used against various items of this scope of work in their quoted rates. HPCL shall not supply any reinforcement / structural steel. The contractor shall make necessary arrangement at his own cost for unloading, storage of steel in the open duly fenced under locking arrangement. The reinforcement steel shall be procured from Tata/SAIL/Vizag Steel and will produce invoice for the same to EIC for every batch of procurement alongwith Manufacturer’s Test Certificate.

In the case of steel reinforcement or structural steel the theoretical quantity of steel shall be taken as the quantity required as per design or as authorised by Architect/Consultant /HPCL’s Engineer including authorised lap lengths/chairs etc. No further claim towards additional wastage due to lap length / full length bars or other consideration including rolling margin will be entertained. No payment will be made or measurement recorded for binding wires which shall be of 18 SWG gauge and shall be provided by the contractor.

For the purpose of dealing and accounting, only linear measurements will be taken and any difference in weight based on linear

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measurement and actual weight shall be to contractor’s account. Quoted rate shall be deemed to include the above and the wastage mentioned below. No claim whatsoever shall be entertained on account of wastage and difference in weight as referred to above.

All binding wires required for tying the reinforcement in position etc. will be supplied by the contractor. Cost of this binding wire and labour will be included in the item for binding and placing reinforcement in position.

It will be necessary that the contractor get the steel tested at his own cost at a Govt. approved laboratory as per the testing schedule or as per the EIC’s advise, for strength and other properties specified in IS – 1786 latest edition before using it in the work.

The contractor will be required to maintain a register for recording details of steel receipt, steel utilised and balance at site.

Final bill will be accompanied by steel consumption statement.

In every case, it shall be the contractor’s responsibility to ensure the standard of quality and the correctness of quantity of steel procured at site by him.

The permissible wastage (wastage defined as bars having less than 3 mt. Length) shall be of 3% of theoretical consumption. Recovery for less consumption as per theoretical consumption will be recovered at Rs. 50,000/- per MT. All scrap (scrap defined as pieces of steel bars measuring less than 3 mt. in length) shall be the property of the contractor. The wastage quantity shall not be considered to be included within the theoretical quantity and no extra shall be payable on account of wastage.

4.11 Construction

4.11.1 Rules and Regulations

4.11.2 Contractor shall observe in addition to Codes specified in respective specification, all national and local laws, ordinances,

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rules and regulations and requirements pertaining to the work and shall be responsible for extra costs arising from violations of the same.

5.0 Procedures

5.1 Various procedures and method statements to be adopted by Contractor during the construction as required as per the respective specifications shall be submitted to Engineer-in-Charge in due time for approval.

5.2 Security

5.2.1 As the premises will be protected area, entry into the area shall be restricted and may be governed by issue of photo gate passes. The Contractor shall arrange to obtain through the Engineer-in-Charge, well in advance, all necessary entry permits/gate passes for his staffs and labourers and entry and exit of his men and materials shall be subject to vigorous checking by the security staff. The Contractor shall not be eligible for any claim or extension of time whatsoever on this account.

5.2.2 It shall be the responsibility of the contractor to safeguard all his materials/owned from theft, damage etc. For this purpose the contractor shall be allowed to keep his own security inside HPCL premises

5.3Drawings and Documents

5.3.1 Drawings accompanying the Bidding Document are indicative of scope of work and issued for bidding purpose only. Purpose of these drawings is to enable the bidder to make an offer in line with the requirements of the owner.

5.3.2 The contractor as per ‘scope of work’ shall carry out preparation of detailed and working drawings. Detailed construction layout drawings as needed shall be prepared by contractor and got reviewed/approved by Engineer-in-Charge/Architect before taking up the work.

5.4 Rounding off

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5.4.1 All payments to and recoveries from the Contractor shall be rounded off to the nearest rupee. Wherever the amount to be paid / recovered consists of a fraction of a rupee (paise), the amount shall be rounded off to the next higher rupee if the fraction consists of 50 (fifty) paise or more and if the faction of a rupee is less than 50 (fifty) paise, the same shall be ignored.

5.5 Contractor’s Billing System

5.5.1 HPCL will provide an approved format for Measurement sheets, Bill Summary and Bill Abstract. Contractor has to ensure that these data are updated for each subsequent RA and Final Bill.

5.5.1 HPCL will utilize these data for processing and verification of the Contractor’s bill.

5.6 Site Organization

5.6.1 The Contractor shall without prejudice to his overall responsibility to execute and complete the works as per specifications and time schedule progressively deploy adequate qualified and experienced personnel together with skilled / unskilled manpower and augment the same as decided by Engineer-in-Charge depending on the exigencies of work to suit the construction schedule without any additional cost to Owner.

5.6.2 The Contractor shall provide all necessary superintendence during the execution of the Works and as long thereafter as the Engineer-in-Charge may consider necessary for the proper fulfilling of the Contractor’s obligations under the Contract Such superintendence shall be given by sufficient persons having adequate knowledge of the operations to be carried out (including the methods and techniques required, the hazards likely to be encountered and methods of preventing accidents) for the satisfactory and safe execution of the Work. The workmen deployed by the Contractor should also possess the necessary license etc., if required under the existing laws, rules and regulations.

5.7 Additional / Extra Works

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Owner reserves the right to execute any additional works / extra works, during the execution of work, either by themselves or by appointing any other agency, even though such works are incidental to and necessary for the completion of works awarded to the Contractor.

5.8 Responsibility of Contractor

5.8.1 It shall be the responsibility of the contractor to obtain the approval for any revision and/or modifications decided by the contractor from the Owner / Engineer-in-Charge before implementation. Also such revisions and / or modifications if accepted / approved by the Owner / Engineer-in-Charge shall be carried out at no extra cost to the owner. Any change required during functional requirements or for efficient running of system, keeping the basic parameters unchanged and which has not been indicated by the contractor in the data / drawings furnished along with the offer shall be carried out by the contractor at no extra cost to the owner.

5.8.2 All expenses towards mobilization at site and demobilization including bringing in equipment, work force, materials, dismantling the equipment, clearing the site etc. shall be deemed to be included in the prices quoted and no separate payments on account of such expenses shall be entertained.

5.8.3 It shall be entirely the contractor’s responsibility to provide, operate and maintain all necessary construction equipment, steel scaffoldings and safety gadgets, cranes and other lifting tackles, tools and appliances to perform the work in a workman like and efficient manner and complete all the jobs as per time schedule.

5.8.4 Preparing approaches and working area for the movement of his men and machinery.

5.8.5 The procurement and supply in sequences and at the appropriate time of all materials, and consumables shall be entirely the contractor’s responsibility and his rates for execution of work will be inclusive of supply of all these items.

5.9 Coordination with other agencies

5.9.1 Contractor shall be responsible for proper coordination with other agencies operating at the site of work so that work may be

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carried out concurrently, without any hindrance to others. The Engineer – in – Charge shall resolve disputes, if any, in this regard, and his decision shall be final and binding on the Contractor.

5.10 Underground and overhead structures

5.10.1 The Contractor will familiarize himself with and obtain information and details from the Owner in respect of all existing structures, and utilities existing at the job site before commencing work. The Contractor shall execute the work in such a manner that the said structures, utilities, etc. are not disturbed or damaged, and shall indemnify and keep indemnified the Owner from and against any destruction thereof or damages thereto.

5.11 Documents required with final bill

5.11.1 Statement of final bills – issue of No Claim/ No Due Certificate

5.11.2 The Contractor shall furnish a No-Claim/No-Due declaration indicating that there are no balance dues to his sub-vendor/sub-contractors/labor contractors along with the Final Bill.

5.12 Working hours

5.12.1 Depending upon the requirement, time schedule / drawing/ programme and the target set to complete the job in time, the works may also have to continue beyond normal working hours/night hours / holidays or during such periods without causing any inconvenience to the neighbours/others with due permission from EIC, for which no extra claim shall be entertained. However for all such working contractor’s responsible representative shall be available at site to receive the work permit to be issued by HPCL. Without responsible representative of the contractor, no work shall be allowed inside the premises.

6.0 TESTS, INSPECTION AND COMPLETION

6.1 Tests and Inspection

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6.1.1 The Contractor shall carry out the various tests as enumerated in the technical specifications of this Bidding Document and technical documents that will be furnished to him during the performance of the work at no extra cost to the Owner.

6.1.2 All the tests either on the field or at outside laboratories concerning the execution of the work and supply of materials by the Contractor shall be carried out by Contractor at his cost.

6.1.3 The work is subject to inspection at all times by the Engineer-in-Charge. The Contractor shall carry out all instructions given during inspection and shall ensure that the work is being carried out according to the technical specifications of this bidding document, the technical documents that will be furnished to him during performance of work and the relevant codes of practice.

6.1.4 Compressed air for carrying out works ,if required shall be arranged by the Contractor at his own cost.

6.1.5 For material supplied by Owner, Contractor shall carry out the tests, if required by the Engineer-in-Charge, and the cost of such tests shall be reimbursed by the Owner at actual to the Contractor on production of documentary evidence.

6.1.6 All results of inspection and tests will be recorded in the inspection reports, proforma of which will be approved by the Engineer-in-Charge. These reports shall form part of the completion documents. Any work not conforming to execution drawings, specifications or codes shall be rejected and the Contractor shall carry out the rectifications at his own cost.

6.2 Final Inspection

After completion of all tests as per specification the whole work will be subject to a final inspection to ensure that job has been completed as per requirement. If any defect is noticed, the Contractor will be notified by the Engineer-in-Charge and he shall make good the defects with utmost speed. If however, the Contractor fails to attend to these defects within a reasonable time (time period shall be fixed by the Engineer-in-Charge) then Engineer-in-Charge may have defects rectified at Contractor’s cost.

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6.3 Inspection of Supply Items

6.3.1 All inspection and tests on bought out items shall be made as required by specifications forming part of this contract. Various stages of inspection and testing shall be identified after receipt of Quality Assurance Programme from the contractor / manufacturer.

6.3.2 Inspection calls shall be given for association of Owner , as per mutually agreed programme in prescribed proforma, giving details of equipment and attaching relevant test certificates and internal inspection report of the contractor. All drawings, general arrangement and other contract drawings, specifications, catalogues etc. pertaining to equipment offered for inspection shall be got approved by Owner and copies shall be made available to Owner before hand for undertaking inspection.

6.3.3 The contractor shall ensure full and free access to the inspection engineer of Owner at the contractor’s or their sub-contractor’s premises at any time during contract period to facilitate him to carry out inspection and testing assignments.

6.3.4 The contractor / sub – contractor shall provide all instruments, tools, necessary testing and other inspection facilities to inspection engineer of Owner free of cost for carrying out inspection.

6.3.5 Where facilities for testing do not exist in the contractor’s / sub-contractor’s laboratories, samples and test pieces shall be drawn by the contractor / sub-contractor in presence of Inspection Engineer of Owner and duly sealed by the later and sent for tests in Government approved test house or any other testing laboratories approved by the Inspection Engineer at the contractor’s cost.

6.3.6 The contractor shall comply with the instructions of the Inspection Engineer fully and with promptitude.

6.3.7 The contractor shall ensure that the equipment / assemblies / component of the plant and equipment required to be inspected are not assembled or dispatched before inspection.

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6.3.8 The contractor shall not offer equipment for inspection in painted conditions unless otherwise agreed in writing with the Owner .

6.3.9 The contractor shall ensure that the parts once rejected by the inspection engineer are not used in the manufacture of the plant and equipment. Where parts rejected by the inspection engineer have been rectified or altered, such parts shall be segregated for separate inspection and approval, before being used in the work.

6.3.10 On satisfactory completion of final inspection and testing, all accepted part of the work and equipment shall be stamped suitably and inspection certificate shall be stamped suitably and inspection certificate shall be issued in requisite copies for all accepted items. For stage inspection and for rejected items, only inspection memo shall be issued indicating therein the details of observations and remarks.

6.3.11 All inspections and tests shall be made as required by the specifications forming part of this contract. Contractor shall advise HPCL in writing at least fifteen days in advance of the date of final inspection / tests. Manufacturers inspection or testing certificate for equipment and materials supplied may be considered for acceptance, at the discretion of Engineer-in-Charge. All costs towards testing etc. shall be borne by the contractor within their quoted rates.

6.4 Documentation

6.4.1 Completion Documents

The following documents shall also be submitted by the Contractor in triplicate as part of completion documents :

a) Test certificate for materials supplied by the Contractor.b) Certified records of field tests on materials / equipment, as

applicable.c) Material appropriation statement as required.d) Six sets of drawings showing therein the as built conditions

of the work duly approved by the Engineer-in-Charge along with one set of reproducible on polyester film (drawings prepared by Contractor) along with soft form of the same.

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e) Other documents as mentioned in Technical Specification.

6.4.2 “AS BUILT” Drawings

Upon completion of work, the Contractor shall complete all drawings to “As built” status (including all vendor / Sub – vendor’s drawings for bought out items) and provide the Owner, the following :

a. One complete set of all original tracings / reproducible along with the soft form of the same.

b. Six complete sets of prints.

7.0 OTHERS

7.1 Dispute Settlement between Govt. Dept. / PSU & PSE

7.1.1 In the event of any disputes or differences between the Contractor and the Owner, if the Contractor is a Government department, a Government company or an undertaking in the public sector, then such disputes or differences shall be resolved amicably by mutual consultation or through the good offices or empowered agencies of the Government. If such resolution is not possible, then the unresolved disputes or differences shall be referred to arbitration of an arbitrator to be nominated by the Secretary. Department of legal affairs (Law Secretary) in terms of the Office Memorandum No. 55 / 1 / 75 – CF dated 19 th

December 1975 issued by the Cabinet Secretariat (Dept. of Cabinet Affairs) as modified from time to time. The Arbitration Conciliation Act 1996 shall not be applicable to the arbitrator under this clause. The award of the arbitrator shall be binding upon parties to the dispute, provided, however any party aggrieved by such award may make a further reference for setting aside or revision of the award to Law Secretary whose decision shall bind the parties finally and conclusively.

7.2 Project Scheduling and Monitoring

7.2.1 The following schedules / documents / reports shall be prepared and submitted by the CONTRACTOR for review / approval at various stages of the contract.

7.2.3 After placement of Purchase Order

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Upon placement of Purchase Order, Contractor has to furnish a detailed bar chart within 15 days of issue of FOI/LOI.

7.2.4 Project Review Meetings

7.2.4.1 The CONTRACTOR shall present the programme and status at various review meetings as required.

Monthly Review Meeting

Level of Participation : Senior Officers of Owner & Contractor.

Agenda a) Progress Status/ statistics. . b) Completion Outlook c) Major hold ups / slippages. d) Assistance required. e) Critical issues. f) Client query / approval. Venue : Bijwasan Depot, Delhi 7.2.5 Progress Reports

I) Monthly Progress ReportThis report shall be submitted in three copies on a monthly basis within Ten calendar days from cut-off date as agreed upon, covering overall scenario of the work. The report shall include but not be limited to the following :

a) Brief introduction of the work.b) Activities executed / achievements during the month.c) Scheduled vs actual percentage progress and progress

curves for sub-ordering, manufacturing / delivery, sub-contracting, construction activities and overall quantum wise status of purchase orders against scheduled.

d) Areas of concern / problems / hold ups, impact and action plans.

e) Resource deployment status.f) Annexure giving status summary for Material Requisitions

and deliveries, sub-contracting and construction

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Distribution: OWNER Two copies & One at Site.

II) Daily Report:

Daily report in duplicate as out lined in 2.2.4 of SCC and any other additional information/data/guideline/job procedure sought by Engineer-in-Charge shall be submitted without fail to HPCL at site by contractor.

7.3 General Environment Requirement

The contractor has to ensure efficient use of natural resources like water, fuel oil and lubricants. The contractor should ensure proper awareness to workers to maintain a green and clean environment inside / outside the building premises. The contractor must collect and dispose of all the waste and scrap materials at the designated place only as directed by Engineer – in – Charge.

7.4 DEFECT LIABILITY PERIOD/Warranty PeriodAs per of GTC.

7.5 Form C/D etc will not be issued by M/s HPCL

NOTE:- Item No’s. 14 to 20 and 48 to 51 can be split from the overall order based on the lowest offer.

APPENDIX -1 TO SCC

TERMS OF PAYMENTS

1.1 The basis and terms of payment without prejudice to any other mode of recovery available to Owner, shall be as given below :

1.2 The Contractor shall be paid monthly running account bills at stages of completion of individual item / work, based on the joint measurement, in the following manner after deductions of necessary dues payable by Contractor to the Owner such as

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Retention money, Taxes, Duties etc. in accordance with various provisions made elsewhere in this document.

1.3 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.

1. Structural steel Works /Grating

50% on supply of materials at site 20% after fabrication 25% after erection/Welding/bolting 5% on completion and acceptance of all jobs as per SOR

2. Reinforcement

50% on supply of materials at site 20% after laying of reinforcement as per reinforcement schedule 10 % after concreting 20% after 28 days strength of RCC cubes in line with IS standards

3. Roof Sheeting 50% on supply of materials at site 45% after completion of laying 5% on completion and acceptance of all jobs as per SOR

4. Pipeline fabrication /laying/welding Works

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

5. Supply of Pipes/ Valves/ Strainers

75% on supply of the material at the site and submission of bills.20% on verification of the documents.5% on completion and acceptance of all jobs as per SOR.

6. All other items except above (i.e.1,2,3,4 & 5 )

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95% on completion of the job 5% on completion and acceptance of all jobs as per SOR

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SAFETY, HEALTHAND

ENVIRONMENTREQUIREMENTS

(S.H.E POLICY)

SAFETY, HEALTH & ENVIRONMENT POLICY

SPECIFICATION FOR SAFETY HEALTH AND ENVIRONMENT (SHE) MANAGEMENT

CONTENTS

________________________________________________________________________

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CLAUSE NO. TITLE________________________________________________________________________

1.0 SCOPE 2.0 REFERENCES 3.0 REQUIREMENT OF SAFETY, HEALTH AND

ENVIRONMENT (SHE)

3.1 MANAGEMENT RESPONSIBILITY

3.2 HOUSE KEEPING

3.3 SAFETY, HEALTH & ENVIRONMENT

4.0 DETAILS OF SHE MANAGEMENT SYSTEM

BY CONTRACTOR

4.1 ON AWARD OF CONTRACT

4.2 DURING JOB EXECUTION

1.0 SCOPE

This specification establishes the Safety Health and Environment (SHE) management requirement to be complied with by the Contractors during construction.

Requirements stipulated in this specification shall supplement the requirements of SHE 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

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This document should be read in conjunction with following:

- General Conditions of Contract (GCC)- Special Conditions of Contract (SCC)- Job Specifications

3.0 REQUIREMENTS OF SAFETY HEALTH & ENVIRONMENT (SHE) MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1 MANAGEMENT RESPONSIBILITY

3.1.1 The Contractor should have a documented SHE policy to cover commitment of their organization to ensure health, safety and environment aspects in their line of operations.

3.1.2 The SHE management system of the Contractor shall cover the SHE 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 SHE 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 & up to 500 - Deploy one qualified and experienced safety Engineer / officer

Above 500 - One additional safety (for every 500 or less) engineer/officer as above.

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Contractor shall indemnify & hold harmless Owner / HPCL & either representatives free from any and all liabilities arising out of non – fulfillments of SHE requirements.

3.1.4 The Contractor shall ensure that the Safety, Health and Environment (SHE) requirements are clearly understood & faithfully implemented at all levels at site.

3.1.5 The Contractor shall promote and develop consciousness for Safety , Health and Environment among all personnel working for the Contractor. Regular awareness, program site meetings shall be arranged on SHE 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 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 SHE 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 SHE requirements implemented at his sub-contractor(s) work site/office. However, compliance of SHE 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 SHE 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 / SHE Committees meetings arranged by HPCL/Owner. The compliance of any observations shall be arranged urgently.

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He shall assist HPCL/Owner to achieve the targets set by them on SHE during the project implementation.

3.1.10 The Contractor shall adhere consistently to all provisions of SHE requirements. In case of non-compliance or continuous failure in implementation of any of SHE 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, up to 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 KEEPING3.2.1 Contractor shall ensure that a high degree of house keeping is

maintained and shall ensure inter alia the followings wherever applicable:

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).

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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 pulverised materials etc. shall be covered while moving within the premises.

j Only properly designed steel scaffolding materials to be used for working at heights more than 3.0M . Double scaffolding using wooden ballis may be allowed for working at height less than 3.0M

3.3 SAFETY, HEALTH 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.

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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 labelled 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.

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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 the 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 SHE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 On Award of Contract

The Contractor shall prior to start of work submit his Safety Health and Environment Manual or procedure and SHE Plans for approval by

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HPCL/Owner. The Contractor shall participate in the pre-start meeting with HPCL/Owner to finalise SHE 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 SHE activities.

4.2 During job execution

4.2.1 Implement approved Safety Health, 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 SHE activities, Monthly SHE report, accident reports, investigation reports etc. as per HPCL/Owner requirements. Compliance of instructions on SHE 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 / SHE meetings arranged by HPCL/Owner. Only in case of his

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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 SHE document and submit the reports for HPCL/Owner review.

- assist in SHE audits by HPCL/Owner, and submit compliance report.

- generate & submit HSE records / report as per SHE Plan.

- appraise HPCL/Owner on SHE activities at site.

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DRAWINGS

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