BHARAT HEAVY ELECTRICALS LIMITED - BHEL PSER · PDF fileBoiler Furnace Spiral Water Wall...

TENDER NO: PSER:SCT:BAR-B1669:15

VOLUME -IF

TECHNICAL CONDITIONS OF CONTRACT

FOR

Post weld Heat Treatment (PWHT) for Butt weld joints in the area of Boiler Furnace Spiral Water Wall Panels as per BHEL approved PWHT Procedure for Unit-5 of 2x660 MW units at Barh STPP, Stage-II, Bihar.

BHARAT HEAVY ELECTRICALS LIMITED ( A GOVT. OF INDIA UNDERTAKING ) POWER SECTOR – EASTERN REGION

PLOT NO. – 9 / 1, DJ – BLOCK, SECTOR – II, KARUNAMOYEE,

SALT LAKE CITY, KOLKATA – 700091.

TENDER NO – PSER:SCT:BAR-B1669:15 VOLUME-IF-CML TECHNICAL CONDITIONS OF CONTRACT

(SERVICE) PAGE 1 OF 23

CONTENTS

CLAUSE NO

DESCRIPTION

1.0 PROJECT INFORMATION 2.0 SITE VISIT 3.0 NAME OF WORK 4.0 BROAD SCOPE OF WORK 5.0 GENERAL TECHNICAL REQUIREMENTS (CODES AND STANDARDS) 6.0 SERVICES TO BE RENDERED BY THE BIDDER 7.0 SITE ORGANISATION 8.0 DELETED 9.0 DELETED 10.0 PROJECT PROGRESS REVIEW MEETINGS 11.0 CERTIFICATE TOWARDS COMPLETION 12.0 CONTRACT EXTENSION 13.0 DELETED 14.0 PROVISION OF MANPOWER 15.0 DELETED 16.0 HEALTH, SAFETY & ENVIRONMENT (HSE) 17.0 QUALITY ASSURANCE PROGRAMME 18.0 GENERAL REQUIREMENTS - QUALITY ASSURANCE 19.0 QUALITY CONTROL & QUALITY ASSURANCE 20.0 FACILITIES TO BE PROVIDED BY BHEL/ CUSTOMER 21.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR 22.0 PROJECT MANAGEMENT 23.0 CONSUMABLE 24.0 MMD 25.0 DELETED 26.0 EXTRA/ ADDITIONAL ITEMS OF WORK 27.0 TEST CERTIFICATE FOR T&P/CONSUMABLES. 28.0 INTEREST BEARING RECOVERABLE ADVANCE/ MOBILISATION ADVANCE 29.0 AREA REQUIREMENT 30.0 CONSTRUCTION OF TEMPORARY OFFICE, STORES ETC 31.0 RECONCILIATION OF MATERIALS 32.0 SECURITY DEPOSIT (SD) AND PERFORMANCE BOND (PB) 33.0 INSURANCE 34.0 REPORTING DAMAGES AND CARRYING OUT REPAIRS 35.0 COMPLETION PERIOD 36.0 DELETED 37.0 TAXES AND DUTIES 38.0 DELETED 39.0 DELETED 40.0 TERMS OF PAYMENT 41.0 PVC, ORC & RATE REVISION 42.0 GUARANTEE PERIOD 43.0 LIQUIDATED DAMAGES (LD) 44.0 CONTRACT PRICE 45.0 PAYING AUTHORITY 46.0 OTHER TERMS 47.0 APPENDIX-I 48.0 APPENDIX-II



These Technical conditions of contract shall be construed as part of tender document and shall be read along with general conditions of contract (GCC), Volume-II and other volumes of tender. In case of any conflict or inconsistency between GCC, Volume-II, other volumes and these Technical conditions contract (TCC), the same shall be brought out by the bidder in writing to BHEL for clarification, failing which most stringent interpretation/ clause in favour of BHEL shall be adopted and the same shall be binding to the bidder. CLAUSE NO

DESCRIPTION

1.0 PROJECT INFORMATION 1.1 Barh Super Thermal Power Project, Stage-I (3x660 MW) coal based is being set up

by NTPC near Barh town in Patna district of Bihar. The capacity of the expansion Stage-II of the project to be executed under this contract is 1320 MW comprising of two (2) units of 660 MW each.The work under present tender is for Barh Stage-II (2x660MW) units. Barh Super Thermal Power Project (Barh STPP) is located in the Patna District of Bihar at latitude of 25 deg 29' 10' North and longitude 85 deg 45' 40" East. The site is approximately 4 kms from Barh town and is approachable via the Patna - Mokama National Highway. The nearest railway station is Barh on the Patna - Calcutta section of main trunk route is approximately 3.0 kms from the project site. Patna, which is approximately 75 kms from the site, is the nearest commercial airport. The site is located by the side of the river the Ganges. Further to the information's given in this sub-section, Bidders are also advised visit the project site and collect data on local site conditions

1.2 APPROACH TO SITE Project location (i) Place: BARH (ii) District: PATNA (iii) State: BIHAR Latitude and longitude of project location 25 deg. 29' 10” , 85 deg 45’ 40” Nearest railway station BARH Distance of project location from the railway station 3.0 KM (Approx) Nearest major town PATNA Distance of the town from the project site 70 KM Nearest commercial airport PATNA Distance of airport from the project site 75 KM Nearest highway National Highway No 31 Distance from nearest highway point to the site 0.5 KM.

1.3 Owner NATIONAL THERMAL POWER CORPORATION LTD.



2.0 SITE VISIT

Contractor should visit site and acquire full knowledge & information about site conditions. The bidder must visit site, to acquaint themselves with the conditions prevailing at site and in & around the plant premises, together with all statutory, obligatory, mandatory requirements of various authorities before submission of bid.

3.0 NAME OF WORK The scope of work covers to perform: 1. Post weld Heat Treatment (PWHT) for Site Butt weld joints in the area of Boiler Furnace spiral water wall Panels with SA213 T22 tube material for a total of around 11,000 joints (approx.) in Barh Unit-V (BHEL-PSER NTPC Barh, Stage-II 2X660 MW Project) as per BHEL approved PWHT Procedure and terms & conditions. 2. To install the scaffolding (CUPLOK) inside furnace (all around four wall, up to elevation 64M) of 660 MW boiler with spiral type of tubes and with a size of 20726 mm X 18593 mm Furnace, to enable approach for man & materials for the purpose of PWHT for unit #5 of 2x660 MW units at Barh STPP Stg-II,Bihar.

4.0 BROAD SCOPE OF WORK 4.1 For Post Weld heat treatment (PWHT): 4.1.1 The scope covers execution of Post weld Heat Treatment work according using

Resistance coils indicated in BHEL approved PWHT Procedure. ( copy attached) 4.1.2 The work to be carried out in-situ of existing Boiler furnace wall of SA 213 T-22 joints

in the furnace at different elevations /locations up to 60 m level. 4.1.3 The system shall confirm in all respect to high standard, quality and workmanship for

performing the required duties in a manner acceptable to BHEL/ NTPC customer, who will interrupt the meaning of drawing & specification and shall be entitled to reject any work or material, which in his judgment is not in full accordance herewith.

4.1.4 In case, any deviation noticed during verification of PWHT Chart against the conditions stipulated in the BHEL approved PWHT procedure, Agency shall redo/ rectify the whole PWHT process without any additional cost.

4.1.5 Adequate number of technicians (with capability to rectify the PWHT instruments in case of failure), electricians, tack welders and other helping manpower to cover PWHT for Minimum 200 butt weld joints (approx) in a day with 2 Shifts operation with good exposure to conduct PWHT work to be mobilized.

4.1.6 Adequate infrastructure like Resistance heating coils, k-type thermo couple, Control panel, Recorder, cables etc., with due calibration from accredited Laboratory to be mobilized to complete PWHT Minimum 200 butt weld joints (approx) in a day with 2 Shifts operation.

4.1.7 Power sources shall be provided at three different elevations of boiler floor (approximately 10M, 35M and 65M) with the power cables (from power source to heating panels). However, agency needs to provide their own Equipment power cables of enough lengths (from heating control panel to job locations/positions) to cover all the corners joints (from 10M to 63M).

4.1.8 Details specification of the tubes as specified hereunder:- Sl.No Diameter X Thickness Grade of Materials Remarks 1. 41.3 X 7.4 mm SA213 T22 In spiral wall panel form. 2. 41.3 X 8.2 mm SA213 T22 In spiral wall panel form. 3. 38.1 X 8 mm SA213 T22 In spiral wall panel form. 4. 38.1X9.5mm SA213 T22 In spiral wall panel form.

4.1.9 Approximate nos. of joints to be treated under PWHT is given hereunder.

Description of Circuit

Total Site welds in FRONT Spiral wall

Total Site welds in REAR Spiral wall

Total Site welds in LEFT Spiral wall

Total Site welds in RIGHT Spiral wall

TOTAL

TRANSITION WITH U/I VERTICAL WALL PANEL 408 408 366 366 1548

Z PANEL 128 128 126 126 508



SOFA 176 176 176 176 704 BOTTOM ASH HOPPER MIDDLE JOINTS 297 297 0 0 594

BOTTOM ASH HOPPER + BRH TER. TUBES 258 258 0 0 516

Rectified joint in BRH Area due to profile Mismatch (Extra) 80 80 0 0 160

BURNER CORNERS & LOOSE TUBES CN-1 CN-2 CN-3 CN-4

BURNER PANEL + Front/ Rear/Left/Right SPIRAL WALLS 756 756 756 756 3024

LOOSE BEND + Front/Rear/Left/Right SPIRAL WALL ABOVE BURNER PANELS

586 586 586 586 2344

LOOSE BEND + Front/Rear/ Left/ Right SPIRAL WALL BELOW BURNER PANELS

250 476 250 476 1452

TOTAL JOINTS 2939 3165 2260 2486 10850

NOTE: All Spool piece Site Weld Joints to be included for PWHT scope. 4.1.10 After completion of the PWHT of all joints, hydro test of boiler shall be done

(preferably Cyclic). Agency has to rectify (Cutting, edge preparation, preheating, welding, & PWHT as per approved procedures) the joints, in case of any failure during hydro test without any additional cost.

4.1.11 Light up of boiler shall be done after completion of the HT and boiler shall be operated at full load for achievement of subsequent milestone/ Trial run. After achievement of scheduled milestone, cyclic Hydro Test shall be done. Agency has to rectify (cutting, edge preparation, preheating, welding, & PWHT as per approved procedures) the joints, in case of any failure during hydro test without any additional cost.

4.1.12 All other points shall be as per the terms & conditions and specification along with aforesaid references together with amendments incorporated thereto.

4.2 Scope of work for the Scaffolding erection:- 4.2.1 Detailed scopes of work covers to install the scaffolding (CUPLOK) inside furnace (all

around four wall, up to elevation 64M) of 660 MW boiler with spiral type of tubes and with a size of 20726 mm X 18593mm, to enable approach for man & materials for the purpose of PWHT work at all corners joints, SOFA Joints, Panel to Panel joints.

4.2.2 The scope covers also to make a scaffold arrangement at corners only from outside of the furnace to enable easy approach to man and materials to the joints to facilitate the PWHT work.

4.2.3 The drawings and scaffold materials shall be provided to agency as per requirement and same has to be returned in sound & healthy conditions as the materials are special tools and shall be handed over to customer.

4.2.4 Agency need to collect the materials from BHEL-store yard and shall be returned to BHEL-store yard.

4.2.5 Other T&P (other than scaffolding materials i.e. BSL ledger/platforms etc) required to facilitate the job of scaffolding shall be under the scope of agency.

4.2.6 Area lighting and other power sources (if required) shall be provided to agency free of cost. However, agency needs to their own arrangements to take the power at their specified place.

4.2.7 All other points shall be as per the terms & conditions and specification along with aforesaid references together with amendments incorporated thereto.

5.0 GENERAL TECHNICAL REQUIREMENTS (CODES AND STANDARDS) 5.1 Except where otherwise specified, the plant/equipment shall comply with the

appropriate Indian Standard or an agreed internationally accepted Standard Specification as mentioned elsewhere in contract specifications, each incorporating the latest revisions at the time of tendering. Where no internationally accepted standard is applicable, the Bidder shall give all particulars and details as necessary;



to enable BHEL/ALSTOM to identify all of the plant/equipment in the same detail as would be possible had there been a Standard Specification.

5.2 Where the Bidder proposes alternative codes or standards he shall include in his tender one copy (in English) of each Standard Specification to which materials offered shall comply. In such case, the adopted alternative standard shall be equivalent or superior to the standards mentioned in the specification.

5.3 In the event of any conflict between the codes & standards referred above, and the requirements of this specification, the requirements which are more stringent shall govern.

6.0 SERVICES TO BE RENDERED BY THE BIDDER Services under the contract shall include but not be limited to the following:

6.1 Issuing materials from store/open yard as specified earlier from time to time as per programme. The contractor shall be the custodian of all the materials issued till the plant/equipment is officially taken over by the owner/ BHEL after complete of job.

6.2 Transport of material to their respective places of the complete plant & equipment as supplied under this specification.

6.3 Trial run and commissioning of system (involving T22 PWHT under scope of work) to the satisfaction of owner/ BHEL/ ALSTOM. The subject works are to be carried out as per the revised quality plan issued by BHEL at site. PWHT work are to be redone till the desired value of Hardness is achieved.

6.4 Deployment of all skilled and unskilled manpower required for PWHT supervision, watch & ward, and other services to the rendered under this specification.

6.5 Deployment of all tools & tackle, construction machinery, transportation vehicles and all other implements in adequate number and size, appropriate for the job under scope of this specification except otherwise specified.

6.6 Supply of all consumables, eg cleaning agents, diesel oil, lubricant etc as well as materials required for temporary supports, scaffolding etc as necessary for such rectification/modification work, unless specified other wise.

6.7 Providing support services for the contractor’s staff for PWHT work e.g., Construction of site offices, temporary stores, residential accommodation and transport to work site for Rectification/modification personnel, watch and ward for security and safety of the materials under the contractor’s custody etc. as required.

6.8 Maintaining proper documentation of all site activities undertaken by the contractor as per the proforma mutually agreed with BHEL, submitting monthly progress reports as also any such document as & when desired by BHEL/ owner, taking approval of all statutory authorities, ie Boiler Inspector, Factory Inspector, Inspector of Explosives etc , as applicable, for respective portions of work under the jurisdiction of such statutes of laws.

6.9 All the materials issued to the bidder by BHEL shall be reconciled by the bidder and the unused materials have to be returned back to BHEL stores/yard or any other place as specified by BHEL.

6.10 After completion of the commissioning activity of equipment /systems, the contractor shall prepare the test Reports which shall include all the relevant information related to various commissioning checks, tests carried out, any deviations / commissioning noticed w.r.t. the intended design requirements, sequence of various commissioning activities as actually adopted vis-à-vis as recommended in the procedures, programme schedule achieved and any other such information as required .These Test Reports shall be submitted in requisite number of copies to BHEL/ALSTOM/Owner /Contractor involved during the commissioning activities.

7.0 SITE ORGANISATION 7.1 The contractor shall provide adequate staffing in the following areas in addition to the

staffing requirements of execution as instructed/informed by BHEL: 7.1.1 Overall planning, monitoring & control. 7.1.2 Quality control and quality assurance. 7.1.3 Materials management. 7.1.4 Safety, fire & security. 7.1.5 Industrial relations and fulfillment of labour laws and other statutory obligations. 7.2 The contractor shall maintain a site organization of adequate strength in respect of



manpower, construction machinery and other implements at all times for smooth execution of the contract. This organization shall be reinforced from time to time, as required to make up for slippage from the schedule without any commercial implication to BHEL. The site organization shall be headed by a competent construction manager having sufficient authority to take decisions at site.

7.3 On award of contract, the contractor shall submit to BHEL site organization chart indicating the various levels of experts to be deployed on the job. BHEL reserves the right to reject or approve the list of personnel proposed by the Contractor. The persons, whose bio-data have been approved by BHEL, will have to be posted at site and deviations in this regard will not generally be permitted.

8.0 DELETED 9.0 DELETED 10.0 PROJECT PROGRESS REVIEW MEETINGS 10.1 Periodic progress reviews on the entire activities of execution in respect of

rectification and modification job in scope of bidder will be held once in a month at Kolkata/ site. These meetings will be attended by reasonably higher officials of the Contractor and will be used as a forum for discussing all areas where progress needs to be speeded up. Actions will be placed on the concerned agencies and decisions will be taken to expedite/speed up the progress. Minutes of such meetings will be issued reflecting the major discussions and decisions taken and circulated to all concerned for reference and action. The contractor shall be further responsible for ensuring that suitable steps are taken to meet various targets decided upon such meetings.

11.0 CERTIFICATE TOWARDS COMPLETION The work under the scope of the contractor will be deemed to be completed in all respects only when so certified by BHEL/ALSTOM Or trial run of the unit. The decision of BHEL shall be final and binding on the contractor.

12.0 CONTRACT EXTENSION 12.1 If the completion of work as detailed in these specification gets delayed beyond the

end of contract period then depending on the balance work left out, BHEL at its discretion may / may not extend the contract.

12.2 A joint program shall be drawn for the work to be completed during the extended contract period. Review of the program and record of shortfall as described earlier shall be done during the extended period.

12.3 The part of extension attributable to the contractor, if any, in total contract extension shall be exhausted first i.e., immediately after end of contract period. This shall be followed by the extension on account of force majeure conditions, if any, and lastly on account of BHEL.

12.4 Any other service, although not specifically called for but required for a contract of the size and nature indicated in the specification.

13.0 DELETED 14.0 PROVISION OF MANPOWER 14.1 Work to be executed on round the clock basis in all three shifts working in parallel on

each locations. Sufficient Manpower /groups of fitters, Grinder men, Gas cutters , ELECTRICANS , supporting riggers, helpers etc to be separately deployed at each location.

14.2 Agency may take note that in case of One Joint Failing in radiography and Hardness after three successive PWHT, one joint shall be replaced again by Spool Piece generating two new joints and doubling of all subsequent process. This repeat works can be minimized only by Sincere round the clock independent supervision at each location by agency and quality engineers /supervisors and honest working on purging, Heat treatment & radiography of films. Hence sufficient dedicated personnel to be deployed at each location on round the clock basis.

15.0 DELETED 16.0 HEALTH, SAFETY & ENVIRONMENT (HSE) 16.1 The contractor shall ensure the safety of all workmen, materials and equipment either

belonging to him or to others working at site. He shall observe safety rules and codes applied by the owner/ BHEL at site without exception.

16.2 Passenger lift should have safety cage with multiple rope, ie with safety rope & limit



switches etc.

16.3 Safety nets with hand railings must be provided on all both inside & outside hanging platform of equipments & temporary platforms .

16.4 Emergency vehicle must be provided. 16.5 Non-conformity of safety rules and safety appliances will be viewed seriously and

BHEL has right to impose fines on the contractor on each incident/each non-conformity as per details given below: Safety measure Fine (Rs)

16.5.1 Not wearing safety helmet. 5/workmen 16.5.2 Not wearing safety belt. 10/workmen 16.5.3 Grinding without goggles. 25/workmen 16.5.4 Not using 24V supply for internal work. 500/case 16.5.5 Electrical plugs not used for hand machines. 100/case 16.5.6 Electrical wires using insulated with proper/standard. 50/joint 16.5.7 Not removing scrap from platform. Actual cost for

removal plus 30 % 16.5.8 Gas cutting without taking proper precaution/not using sheet

below per incidence. 100/case

16.5.9 Electrical winches having no guards earthed properly etc. 500/case 16.5.10 Improper earthing of electrical T&P. 200/ equipment 16.5.11 Not protecting/ locating the gas cylinder to avoid catching of fire. 100/cylinder 16.5.12 Not providing earth leakage circuit breaker as per direction of

BHEL. 1000/point

16.6 Any other nonconformity noticed not listed above will also be fined. The decision of BHEL engineer is final on the above. The amount will be deducted from running bills of the contractor. The amount collected on the above will be utilised for giving award to the employee who could avoid accidents by following safety rules. Also, the amount will be spent for improving the safety at site.

16.7 The contractor shall also be responsible for provision of all safety notices and safety equipment required both by the relevant legislation and BHEL/ owner, as he may deem necessary.

16.8 The contractor will notify well in advance to BHEL/ owner of his intention to bring to the site any container filled with liquid or gaseous fuel or explosive or petroleum substance or such chemicals, which may involve hazards. BHEL/ owner shall have the right to prescribe the conditions, under which such container is to be stored, handled and used during the performance of the works and the contractor shall strictly adhere to and comply with such instructions. BHEL/ owner shall have the right at his sole discretion to inspect any such container or such construction plant/equipment for which material in the container is required to be used and if in his opinion, its use is not safe, he may forbid its use. BHEL/ owner shall entertain no claim due to such prohibition and BHEL/ owner shall not entertain any claim of the contractor towards additional safety provisions/ conditions to be provided for/ constructed as per BHEL/ owner’s instructions.

16.9 Further, any such decision of BHEL/owner shall not, in any way, absolve the contractor of his responsibilities and in case, use of such a container or entry thereof into the Site area is forbidden by BHEL/owner, the contractor shall use alternative methods with the approval of BHEL/owner without any cost implication to owner or extension of work schedule.

16.10 Where it is necessary to provide and/ or store petroleum products or petroleum mixtures and explosives, the contractor shall be responsible for carrying-out such provision and/ or storage in accordance with the rules and regulations laid down in Petroleum Act 1934, Explosives Act, 1948, and Petroleum and Carbide of Calcium Manual published by the Chief Inspector of Explosives of India. All such storage shall have prior approval of BHEL/ owner. In case, any approvals are necessary from the Chief Inspector (Explosives) or any statutory authorities, the contractor shall be responsible for obtaining the same.

16.11 All equipment used by contractor shall meet Indian/ International Standards and where such standards do not exist, the contractor shall ensure these to be absolutely safe. All equipments shall be strictly operated and maintained by the contractor in



accordance with manufacturer’s operation Manual and safety instructions and as per guidelines/ rules of owner in this regard.

16.12 Periodical examinations and all tests for all lifting/ hoisting equipment & tackles shall be carried-out in accordance with the relevant provisions of Factories Act 1948, Indian Electricity Act 1910 and associated laws, Rules in force from time to time. A register of such examinations and tests shall be properly maintained by contractor and will be promptly produced as and when desired by BHEL/ owner or by the person authorized by him.

16.13 The contactor shall be fully responsible for the safe storage of his and his sub-contractor’s radioactive sources in accordance with BARC/ DAE (Bhabha Atomic Research Center/ Department of Atomic Energy, Govt. of India) Rules and other applicable provisions. All precautionary measures stipulated by BARC/ DAE in connection with use, Contractor would take storage and handling of such material.

16.14 The contractor shall provide suitable safety equipment of prescribed standard to all employees and workmen according to the need, as may be directed by BHEL/ owner who will also have right to examine these safety equipments to determine their suitability, reliability, acceptability and adaptability.

16.15 Where explosives are to be used, the same shall be used under the direct control and supervision of an expert, experienced, qualified and competent person strictly in accordance with the Code of Practices/ Rules framed under Indian Explosives Act pertaining to handling, storage and use of explosives.

16.16 The contractor shall provide safe working conditions to all workmen and employees at the site including safe means of access, railings, stairs, ladders, scaffoldings etc. The contractor shall take all precautions to prevent any accident collapse of scaffolding or fall of persons from scaffolding. The contractor should ensure that scaffolding are designed d by a competent person and repairs should be done under the expert supervision. The scaffolding shall meet the required strength and other requirements for the purpose for which the scaffold is erected. The material used for scaffold should conform to the BIS / International standards

16.16A The contractor shall ensure that there is no opening in any working platform/ any floor of the building, which may cause fall of workers or material. When ever an opening on a platform/any floor of the building is unavoidable, the opening should be suitably fenced and necessary measures for protection against falling objects or building workers from such platform are taken by providing suitable safety nets, safety belts or other similar means

16.16B

All working platforms, ways and other places of construction work shall be free from accumulations of debris or any other material causing obstructions and tripping. Every opening at elevation from ground level through which a building worker, vehicle, material equipment etc. may fall at a construction work shall be covered and/or guarded suitably by the contractor to prevent such falls. Wherever the workers are exposed to the hazards of falling from height, the contractor shall provide full harness safety belts fitted with fall arresting systems to all the employees working at higher elevations and life line of 8 mm diameter wire rope with turn buckles for anchoring the safety belts while working or moving at higher elevations. Safety nets shall also be provided for saving them from fall from heights and such equipment should be in accordance with BIS standards. Wherever there is a possibility of falling of any material, equipment or construction, workers while working at heights, a suitable and adequate safety net should be provided. The safety net should be in accordance with BIS Standards. The contractor shall provide standard prefabricated ladders on the columns where the workers are required to use them as an access for higher elevations till permanent staircase is provided. The workers shall be provided with safety belts fitted with suitable fall arresting system (Fall arrestors) for climbing/getting down through ladders to prevent fall from height.

16.17 The contractor shall not interfere or disturb electric fuses, wiring and other electrical equipment belonging to BHEL/ owner or other contractors under any circumstances, whatsoever, unless expressly permitted in writing by owner to handle such fuses, wiring or electrical equipment.

16.18 Before the contractor connects any electrical appliances to any plug or socket belonging to the other contactor or BHEL/ owner, he shall comply with following.



16.18.1 Satisfy BHEL/ owner that the appliance is in good working condition. 16.18.2 Inform BHEL/ owner of the maximum current rating, voltage and phases of

appliances. 16.18.3 Obtain permission of BHEL/ owner detailing the sockets to which the appliances may

be connected. 16.19 BHEL/ owner will not grant permission to connect until he is satisfied with following. 16.19.1 The appliance is in good condition and is fitted with suitable plug; 16.19.2 The appliance is fitted with a suitable cable having two earth conductors, one of

which shall be an earthed metal sheath surrounding the cores. 16.20 No electric cable in use by the contractor/ BHEL/ owner will be disturbed without prior

permission. No weight of any description will be imposed on any cable and no ladder or similar equipment will rest against or attached to it.

16.21 No repair work shall be carried out on any live equipment. BHEL/ owner must declare the equipment safe and a permit to work shall be issued by BHEL/ owner before contractor carries out any repair work. While working on electric lines/ equipments whether live or dead, suitable type and sufficient quantity of tools will have to be provided by contractor to electricians/ workmen/ officers.

16.22 The contractors shall employ necessary number of qualified, full time electricians/ electrical supervisors to maintain his temporary electrical installations.

16.23 The contractor shall employ a qualified safety officer under approval of Construction Manager, BHEL at site before submission of first RA bill to supervise day to day safety aspects of the equipments and workmen, who will co-ordinate with BHEL/ owner safety officer. In case of work being carried out through sub-contractors, the sub-contractor’s workmen/ employees will also be considered as the contractor’s employees/ workmen for the above purpose.

16.24 The name and address of such safety officer of contractor will be promptly informed in writing to BHEL/ owner with a copy to safety officer-In charge before he starts work or immediately after any change of the incumbent is made during currency of the contract.

16.25 In case any accident occurs during the rectification /modification job or other associated activities undertaken by the contractor thereby causing any minor or major or fatal injury to his employees due to any reason, whatsoever, it shall be the responsibility of the contractor to promptly inform the same to BHEL/ owner in prescribed form and also to all the authorities envisaged under the applicable laws.

16.26 BHEL/ owner shall have the right at his sole discretion to stop the work, if in his opinion the work is being carried out in such a way that it may cause accidents and endanger the safety of the persons and/ or property, and/ or equipments. In such cases, the contractor shall be informed in writing about the nature of hazards and possible injury/ accident and he shall comply to remove shortcomings promptly.

16.27 The contractor shall not be entitled for any damages/ compensation for stoppage of work due to safety reasons above and the period of such stoppage of work will not be taken as an extension of time for completion of the facilities and will not be the ground for waiver of levy of penalty.

16.28 The contractor shall follow and comply with all Safety Rules of BHEL/ owner, relevant provisions of applicable laws pertaining to the safety of workmen, employees plant and equipment as may be prescribed from time to time without any demur, protest or contest or reservation. In case of any inconformity between statutory requirement and owner’s safety rules of BHEL/ owner referred above, the later shall be binding on contractor unless statutory provisions are more stringent.

16.29 If the contractor fails in providing safe working environment as per the owner’s safety rules or continues the work even after being instructed to stop work by BHEL/ owner as provided above, the contractor shall promptly pay to BHEL/ owner, on demand by the BHEL/ owner compensation at the rate of Rs 5,000.00 per day or part thereof till the instructions are complied with and so certified by BHEL/ owner. However, in case of accident taking place-causing injury, to any individual, the provisions contained in relevant paragraph shall also apply in addition to compensation mentioned in this paragraph.

16.30 If the Contractor does not take all safety precautions and / or fails to comply with the Safety Rules as prescribed by the Employer or under



the applicable law for the safety of the plant and equipment and for the safety of personnel and the contractor does not prevent hazardous conditions which cause injury to this own employees or employees of other contractors, or NTPC's employees or any other person who are at the Site or adjacent thereto, the Contractor shall be responsible for payment of penalty to NTPC as per the following schedule:-

16.30.1 Fatal injury or accident causing death : Penalty @ 10% of contract value or Rs.5,00,000/- per person, whichever is less.

16.30.2 Major injuries or accident causing 25% or more permanent disablement to workmen or employees : Penalty @ 2.5% of contract value or Rs.1,00,000/- per person which ever is less

16.31 Permanent disablement shall have the same meaning as indicated in the 'Workmen's Compensation Act' 1923. The penalty mentioned above shall be in addition to the compensation payable to the workmen / employees under the relevant provisions of the Workmen's Compensation Act' 1923 and rules framed there under or any other applicable laws as applicable from time to time.

16.32 These insurance covers have to be taken prior to start of his work at the subject project and he shall make available the policy to BHEL’s Construction Manager for necessary verification before commencement of work. However, irrespective of such verification/ acceptance, sole responsibility to maintain adequate insurance cover for his workmen, T&P, assets etc at all times during the period of contract shall lie with the contractor. Regarding the aforesaid insurance cover, the contractor shall directly deal with the insurance company for all matters regarding insurance in his scope.

16.32A Comprehensive Automobile Insurance for Fatal Injury Property Damage

This insurance shall be in such a form to protect the Contractor against all claims for injuries, disability, disease and death to members of public including the Employer’s men and damage to the property of other arising from the use of motor vehicles during on or off the Site operations, irrespective of the Ownership of such vehicles. The liability covered shall be as herein indicated :

Fatal Injury : Rs.100,000 each person : Rs.200,000 each occurrence Property Damage : Rs.100,000 each occurrence

16.33 The contractor will follow HSE policy of BHEL/ PSER and work as per the safety guidelines which is in line with ISO:14001 and OHSAS:18001 standards. A list of the guidelines which should be strictly followed by the contractor is as follows. The scope of contractor shall not be limited to the followings only but shall be guided by the HSE related policies/ guidelines of BHEL as revised to suit the requirement of the standards and statutory requirements.

16.33.1 Nominate a safety officer who will supervise all the HSE aspects. 16.33.2 The safety officer will participate in all safety meeting conducted by BHEL. 16.33.3 Submit site safety plan indicating safety measures to be taken, fire fighting

equipments & PPE to be deployed. 16.33.4 Report every near miss incident to BHEL. 16.33.5 Report accident report immediately after the occurrence. 16.33.6 Obtain operation control procedures (OCPs) from BHEL for the work to be executed 16.33.7 Follow factory act. 16.33.8 Every worker should use PPE as per his trade. All PPE should confirm to IS. 16.33.9 Conduct tool box meeting with workers everyday before start of work instructing

about the use of PPE. The outcome of the meeting to be recorded in a register. 16.33.10 Check fitness of the PPE and lifting tackles weekly and record in a register which will

be verified by BHEL. 16.33.11 No person below 18 years will be employed. 16.33.12 Deploy fire-fighting equipments and refill before expiry. 16.33.13 Keep fire extinguishers of adequate type near the hot job and near the electrical

machines. 16.33.14 Copy of valid Test certificates of all T&Ps should be given to BHEL as soon as the



item enters the project, without which the T&P can not be allowed to be used.

16.33.15 No body will be allowed to work above 2 meters without safety belt/ harness with lifeline secured to a fixed member.

16.33.16 Good housekeeping has to be maintained. All debris shall be removed from workplace within shortest possible time.

16.33.17 Approach roads should not be blocked with cables, materials or debris. 16.33.18 First aid boxes have to be kept and maintained with all requisite materials as per

factory act. 16.33.19 Trained person has to be kept for giving first aid. 16.33.20 Adequate illumination shall be provided where working. 16.33.21 All vehicles should have backlight, reverse horn and reversing light. 16.33.22 Crane operator shall have proper license.’ 16.33.23 Crane should have reverse horn. 16.33.24 Only skilled person maintain and operate electrical items. 16.33.25 ELCB has to be used. No temporary connection shall be allowed. 16.33.26 All fuses shall have standard rating and capacity. 16.33.27 All power supply cables should be laid above 3 meter level or underground. 16.33.28 All hand lamps should be powered by 24 volts. 16.33.29 Water-logging of working area shall be removed. 16.33.30 For operating portable machines 3 pin plugs shall be used. 16.33.31 Oxygen and DA cylinders shall be separated labeling full or empty. Full cylinders

shall be kept upright. 16.33.32 Cylinders are not transported by rolling. 16.33.33 All oil drums shall be kept horizontal. 16.33.34 Excavated area shall be barricaded off with red-& white tape. 16.33.35 Proper slope of excavation shall be maintained. 16.33.36 Proper sign board and illumination shall be maintained at excavated area. 16.33.37 Wherever possible safety net shall be provided. 16.33.38 Proper platform and hand rail has to be provided at the work place. 16.33.39 All electrical equipments shall be earthed at two points. 16.33.40 Temporary platform should be strong enough, have proper approach and

hand rails. 16.34 The above clauses are indicative only and not exhaustive. The other activities to

maintain strong HSE conditions at site which may be beyond the above list of guidelines shall have to be done by the contractor.

17.0 QUALITY ASSURANCE PROGRAMME The bidder shall adopt suitable quality assurance programme to control activities as necessary, Such programme shall be outlined by the bidder and shall be finally accepted by BHEL/ owner/ authorised representative. Bidder’s quality assurance programme shall generally cover the following.

17.1 The organisation structure & qualification data of key personnel for management and implementation of the proposed quality assurance programme.

17.2 System for site erection control including process controls and fabrication and assembly controls.

17.3 Control of non-conforming items and system for corrective actions. 17.4 Inspection and test procedure for all site related works. 17.5 Control of calibration and testing of measuring and testing equipment. 17.6 System for quality audit. 17.7 System for indication and appraisal of inspection status. 17.8 System for maintenance of records. 18.0 GENERAL REQUIREMENTS - QUALITY ASSURANCE 18.1 All materials, components and equipment covered under this specification shall be

erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme of BHEL.

18.2 Field Quality Plans will detail out for all the equipment, the quality practices and procedures etc to be followed by the bidder site quality control organisation, during various stages of site activities from receipt of materials/equipment at site.

18.3 Quality audit/ approval of the results of tests and inspection will not prejudice the right



of BHEL to reject equipment, not giving the desired performance after erection and shall not in any way limit the liabilities and responsibilities of the Bidder in earning satisfactory performance of equipment as per specification.

18.4 Repair/ rectification procedures to be adopted to make any job acceptable shall be subject to the approval of BHEL/ owner.

19.0 QUALITY CONTROL & QUALITY ASSURANCE Bidder's engineers and supervisors shall be adequately qualified and also inclined to do a quality job. The quality assurance engineer shall coordinate all aspects of quality control, inspection, implementation of quality assurance procedures laid down in quality plan and technical specification by BHEL. He shall fill-up quality assurance log sheets/ formats and submit to BHEL for joint inspection & acceptance.

20.0 FACILITIES TO BE PROVIDED BY BHEL/ CUSTOMER 20.1 LAND 20.1.1 Graded area shall be handed over to the contractor at site for construction of site

office. 20.1.2 The successful bidder shall furnish the estimated area showing layout plan/ sketch

required for the construction of his office, stores (covered, semi-covered and open), fabrication yard etc. The same will be reviewed by BHEL and allotted to the extent available/ considered necessary, depending upon the area availability. The sketch/ layout plan for labour colony shall include overhead drinking water line, electric power, sewage/ sanitary system. Bidder should construct temp CGI shed with brick wall with IPS floor etc.

20.1.3 Minimum land will be provided free of cost for construction of temporary office, stores etc.

20.1.4 No land will be provided for labour colony inside/ outside the project premises, the contractor to construct labour colony/ hutment after obtaining all necessary statutory clearances.

20.1.5 The contractor will be responsible for handing back all lands, as handed over to him for his temporary use to BHEL, as per the instruction of BHEL engineer.

20.2 WATER 20.2.1

Contractor shall make all arrangements himself for the supply of construction water as well as potable water for labour and other personnel at the worksite/ colony.

20.2.2 BHEL shall not be responsible for any inconvenience or delay caused due to any interruption of water supply and the contractor shall claim no compensation for delay in work for such interruption. Contractor may make standby arrangement for water for which no separate payment shall be made by BHEL.

20.3 ELECTRICITY 20.3.1 BHEL will provide construction power on free of charge basis at LT voltage level at

one point within project premise. Further distribution (including laying of cables/ installation of DBs and maintenance of the same) beyond this point to be arranged by the contractor at his own cost. Any other voltage as required shall be arranged by the contractor from power supply as above. Contractor will have to provide necessary calibrated meters (tamper proof, suitably housed in a weather proof box with lock & key arrangement) at point of power supply along with calibration certificate from authorized/ accredited agency for working out power consumption at his own cost. In case of recalibration required for any reason necessary charges including replacement by calibrated meters is to be borne by the contractor. Supply of electricity shall be governed by Indian Electricity Act and Installation Rules and other rules & regulation as applicable. The contractor shall ensure usage of electricity in an efficient manner and the same may be audited by BHEL time to time. In case of any major deviation from normally accepted norms is observed, BHEL will reserve the right to impose penalty as deemed fit for such cases.

20.3.2 The bidder shall have to provide earth leakage breaker at each point wherever human operated electrical drives/ T&Ps are deployed.

20.3.3 The power supply will be from the available grid. BHEL shall not be responsible for any inconvenience or delay caused due to any interruption of power supply and no compensation for delay in work can be claimed by the contractor due to such non-



supply on the grounds of idle labour, machinery or any other grounds.

20.3.4 The contractor should ensure that the work in critical areas is not held up in the event of power breakdown (especially during slip-from concreting), and shall make all necessary arrangements for uninterrupted supply, at his cost. As a part of the bid, a specific proposal in this regard has to be submitted by the contractor. In the event of breakdown in the electric supply, if the progress of work is hampered, it will be the responsibility of the contractor to step up the progress of work after restoration of electric supply so that overall progress of work is not affected.

20.3.5 The contractor shall have to make arrangement at their own cost for illumination that will be required in the working area for execution of the work & safety of workmen.

20.3.6 Bidders have to make their make arrangement for electricity at their own cost for labour colony.

21.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR 21.1 All tools and tackles, machinery, equipment, instruments required for the work have

to be arranged by the contractor including its transportation before and after work and including storage, insurance etc.

21.2 The contractor shall provide all required tools and plants, inspection, measuring and test equipment and handling & transportation equipment for the scope of work covered under these specifications. Some of the major T&Ps to be necessarily provided by the contractor is listed in relevant appendix of this tender. BHEL will provide the services of their T&Ps listed vide appendix free of charge, on sharing basis.

21.3 Timely deployment of adequate quantity of T&P is the responsibility of the contractor. The contractor shall be prepared to augment the T & P at short notice to match the planned program and to achieve the milestones.

21.4 Contractor shall maintain and operate his tools and plants in such a way that major breakdowns are avoided. In the event of major breakdown, contractor shall make alternative arrangements expeditiously so that the progress of work is not hampered.

21.5 In the event of contractor failing to arrange the required tools, plants, machinery, equipment, material or non-availability of the same owing to breakdown, BHEL will make the alternative arrangement at the risk and cost of the contractor.

21.6 SITE/ FIELD OFFICE AND STORES 21.6.1 The contractor shall make his own arrangements for Site /field office and stores for

accommodating necessary equipments, tools room for execution of the work. Only open space will be provided by BHEL / customer, free of charges within the project premises as per the availability of space.

21.6.2 On completion of work, all the temporary buildings, structures, pipelines, cables, etc. shall be dismantled and leveled and debris shall be removed as per instruction of BHEL by the contractor at his cost. In the event of his failure to do so , the same will be arranged to be removed and expenditure thereof will be recovered from the contractor. The decision of BHEL engineer in this regard shall be final. However, the scope of dismantling and leveling the area is limited only to the contractor’s site office, yard and other spaces occupied by the contractor.

21.7 AREA LIGHTING Contractor shall arrange adequate floodlights, hand lamps and area lighting. Provision of distribution lines for lighting from the single point to the required place with proper distribution boards, observing the safety rules laid down by the electrical authorities of the state shall be done by the contractor. Contractor shall use his own materials like cables, fuses, switchboards etc.

21.8 CONSTRUCTION POWER & WATER 21.8.1 In case of genuine requirement BHEL may consider providing construction power at

more than one location (maximum 2 nos.) subject to availability of power source nearby and the decision of Site-I/C-BHEL shall be final in this regard. All vendors to draw power for construction from these locations (nearest to their site forrectification/modification). Cables and all electrical gears for drawing power to consumption site have to be arranged by respective vendors.

21.8.2 It shall be the responsibility of the contractor to provide, maintain the complete installation on the load side of the supply with due regard to the safety requirements



at site. All cabling and installations shall comply in all respects with the appropriate statutory requirements. Licensed and experienced electrician shall do the installation and maintenance of this.

21.8.3 Contractor shall make all arrangements himself for the supply & distribution of construction water as well as potable water for labour and other personnel at work site /colony. Taxes, duties, levies, charges, if any, shall be born by the contractor.

21.8.4 In case of non-availability of customer supplied power, it is the responsibility of the contractor to make alternative arrangements. Contractor shall be adequately equipped to arrange standby diesel welding generators in the event of construction power failure. Essential welding jobs shall not be stopped on account of main construction power failure.

21.8.5 Records of consumption of construction power is to be maintained for information of BHEL. The meters to be used for metering of construction power shall have necessary test certificate from relevant approving authority and these meters shall be used only on clearance from client/ BHEL.

21.9 The contractor has to arrange for power and drinking water at labour colony at his cost.

21.10 BHEL is not responsible for any loss or damage to the contractor’s equipment as a result of variations in voltage or frequency or interruptions in power supply.

21.11 RESPONSIBILITIES WITH REGARD TO EMPLOYMENT OF LABOUR ETC 21.11.1 Contractor shall also comply with the requirements of local authorities/ project

authorities calling for police verification of antecedents of the workmen, staff etc. 21.11.2 BHEL / customer may insist for witnessing the regular payment to the labour. They

may also like to verify the relevant records for compliance with statutory requirements. Contractor shall enable such facilities to BHEL / Customer.

21.11.3 It is the responsibility of the contractor to arrange gate pass for all his employees, T & P etc. for entering the project premises. Necessary coordination with customer officials is the responsibility of the contractor. Contractor to follow all the procedures laid down by the customer for making gate passes. where permitted, by customer / BHEL, to work beyond normal working hours, the contractor shall arrange necessary work permits for working beyond normal working hours.

21.11.4 If at any time during the execution of work, it is noticed that the work is suffering on account of non-availability/shortfall in provision of resources from the contractor’s side BHEL will make suitable alternate arrangements at the risk and cost of contractor. The expenditure incurred with overheads thereby shall be recovered from the contractor.

21.11.5 The contractor shall deploy all the skilled/semiskilled/ unskilled labour including highly skilled workmen etc. These workmen should have previous experience on similar job. They shall hold valid certificates wherever necessary. BHEL reserves the right to insist on removal of any employee of the contractor at any time if he is found to be unsuitable and the contractor shall forthwith remove him. Contractor should furnish a tentative deployment plan of his manpower as required in GCC. Also the actual deployment will be so as to satisfy targets set by BHEL.

21.11.6 It is the responsibility of the contractor to engage his workmen in shifts and or on overtime basis for achieving the targets set by BHEL. This target may be set to suit BHEL ’s commitments to its customer or to advance date of completion of events or due to other reasons. The decision of BHEL in regard to set the targets will be final and binding on the contractor.

21.11.7 Contractor shall deploy only qualified and experienced engineers/ supervisors. They shall have professional approach in executing the work.

21.11.8 The contractor's supervisory staff shall execute the work in the most professional manner in the stipulated time. Accuracy of work and aesthetic finish are essential part of this contract. They shall be responsible to ensure that the assembly and workmanship conform to dimensions and tolerances given in the drawings/instructions given by BHEL engineer from time to time.

21.11.9 The supervisory staff employed by the contractor shall ensure proper outturn of work and discipline on the part of the labour put on the job by the contractor. Also in general they should see that the works are carried out in a safe and proper manner and in coordination with other labour and staff employed directly by BHEL or other



contractors of BHEL or BHEL's client.

21.11.10 If at any time, it is found that the contractor is not in a position to deploy the required engineers/supervisors/workmen due to any reason, BHEL shall have the option to make alternate arrangements at the contractor’s risk and cost.

21.12 COMMUNICATION The contractor shall be responsible for arranging all communication facilities for himself at site. The contractor has to establish independent internet/ e-mail facilities with mobile connection for all key site personnel and same shall have to be integrated with BHEL’s voice/ data network and database systems at site.

21.13 FIRST-AID The contractor shall provide necessary medical facilities for all his employees, representatives and workmen working at site. Enough number of contractor’s personnel shall be trained in administering first-aid.

21.14 CLEANLINESS 21.14.1 The contractor shall be responsible for keeping the entire area allotted to him clean

and free from rubbish, debris etc. during the period of contract. The contractor shall employ enough number of special personnel to thoroughly clean his work-area at least once in a day. All such rubbish and scrap material shall be stacked or disposed in a place to be identified by BHEL/ customer. Materials and stores shall be so arranged to permit easy cleaning of the area. In areas where equipment might drip oil and cause damage to the floor surface, a suitable protective cover of a flame resistant, oil proof sheet shall be provided to protect the floor from such damage.

21.14.2 Similarly the labor colony, the offices and the residential areas of the contractor’s employees and workmen shall be kept clean and neat to the entire satisfaction of BHEL/ customer. Proper sanitary arrangements shall be provided by the contractor, in the work-areas, office and residential areas of the contractor.

21.14.3 Bidders to note that following. 21.14.4 One no experienced paramedical personnel with first aid facility at site is must. No

medical facility within/ near the site shall be provided by BHEL. 21.14.5 No staff quarter shall be provided by BHEL. 21.14.6 All site execution approaches required for movement of cranes, trailers, trucks,

dumpers, etc shall be arranged by the contractor at his own cost. 21.14.7 The contractor shall solely be responsible for the safety, quality & quantity of material

after it is handed over and issued to contractor by the BHEL. 22.0 PROJECT MANAGEMENT 22.1 The bidder shall prepare detail schedule L1/ (L-2) and submit within 30-days of LOI

for BHEL approval, as per MILESTONE completion schedule given in this document.

22.2 Theses network must conform to the overall requirement of the project schedule as detailed below. The bidder should also ensure monitoring of these activities at least on weekly basis to start with and on daily basis whenever required by BHEL.

22.3 PROGRESS MEASUREMENT AND MONITORING 22.3.1 The contractor shall measure progress of the work using its own methods and

procedures preferably in primavera. 22.3.2 Weekly progress review meetings will be held at site during which actual progress

during the week vis-à-vis scheduled program shall be discussed and action to be taken for achieving targets will be decided. For discussions, the contractor shall present program of subsequent week. The contractor shall constantly update/revise his work program to meet the overall requirement.

22.3.3 Periodic progress reviews on the entire activities of execution in respect of engineering, quality, procurement, supply and works in scope of bidder will be held once in a month at Kolkata/ site/ contractor’s premise/ BHEL/ or any other convenient premise. These meetings will be attended by reasonably higher officials of the contractor along with its sub-contractors & consultant as applicable and will be used as a forum for discussing all areas where progress needs to be speeded up. The contractor shall be further responsible for ensuring that suitable steps are taken to meet various targets decided in such meetings.

22.3.4 Contractor shall identify separate overall Project Manger, Construction Manager, Engineering Manager, Quality Manager and selection of various Key personnel shall



be subject to BHEL approval.

22.4 REPORTING 22.4.1 The contractor shall submit weekly progress reports to purchaser in the agreed formats

submitted in adequate number of signed originals. The report shall include following. 22.4.1.1 Brief narrative of work performed during the week. 22.4.1.2 CMS bar chart showing progress at activity level. 22.4.1.3 Updated progress 'S' curves showing actual progress. 22.4.1.4 Milestones achieved and new activities started. 22.4.1.5 Status of critical activities. 22.5 The contractor shall submit monthly progress reports to purchaser in the agreed

formats submitted in adequate number of signed originals. The report shall include the weekly report content and shall be supplemented with the following.

22.5.1 Consumable Procurement status. 22.5.2 T&P deployment status. 22.5.3 Rectification/modification job status . 22.5.4 Safety report. 22.5.5 Updated CMS (L1/L2 schedule)indicating status. 22.5.6 Executive summary, areas of concern etc. 22.5.7 Manpower deployment status 22.5.8 Compliance of statutory rules/regulations 22.5.9 Progress photographs. 22.6 SUBMISSION OF PERIODICAL REPORTS 22.6.1 Contractor shall submit periodical reports in respect of following aspects of operation. 22.6.1.1 Consumption of consumables like welding electrodes, gases and paints. 22.6.1.2 Consumption of construction power 22.6.1.3 DELETED 22.6.1.4 Availability and utilization of contractor’s tools & plants 22.6.1.5 Daily manpower reports 22.6.1.6 Daily progress reports of activities & incidents 22.6.1.7 Test calibration reports 22.6.1.8 Records of wages , EPF payment. 22.6.1.9 BHEL/ client may specify any other report/record as required. 22.6.1.10

Record of protocol/ logsheet

22.6.2 Adequate numbers of color photographs, in triplicate, (matt paper, post card size for each area per month of the contract execution period), depicting progress of the work or damage to the machine parts, if any, as directed by BHEL site engineer is to be arranged by the successful bidder at his own cost.

22.6.3 The progress report shall be compiled in computer and is required to be furnished over “E Mail, in addition to hard copies and summary report shall be made ‘Web enabled’ in agreed format.

23.0 CONSUMABLE 23.1 All consumables, like gases, all type welding electrodes except as mentioned in

clause no. 25.0, grinding wheel, temperature resistance purging papers etc be arranged by the contractor at his cost unless otherwise specifically mentioned in the contract.

23.2 All consumables to be used for the job shall be approved by BHEL prior to use. 23.3 In the event of failure of contractor to bring necessary and sufficient consumables,

BHEL may arrange for the same at the risk and cost of the contractor. The entire cost towards this along-with overhead shall be paid by the contractor or deducted from the contractor’s bills.

24.0 MMD No IMTE /MMD shall be provide by BHEL except PMI M/c to check the materials / weld joints metal deposit composition to avoid mix up.

25.0 BHEL will provide the following consumables/T&P free of cost :

- Free length Tubes and Fins plates shall be provided by BHEL free of cost.



- No T & P shall be provided by BHEL

- No IMTE /MMD shall be provide by BHEL except PMI M/c to check the materials / weld joints metal deposit composition to avoid mix up.

26.0 EXTRA/ ADDITIONAL ITEMS OF WORK It shall be as per Cl. 2.15.7 of GCC.

27.0 TEST CERTIFICATE FOR T&P/CONSUMABLES 27.1 All Consumables /T&P to be deployed by the contractor must bear valid/ latest test

certificates ( as applicable ) issued by of authorized signatory of statutory bodies for their suitability and the documents shall be preserved at site.

27.2 In case of expiry of validity of any such test certificate during contract, the contractor shall arrange for revalidation of the same well in advance, so that the construction activities do not suffer on account of non-availability of such Test certificates.

27.3 The contractor should also submit to BHEL for approval a list of T&Ps along with their fitness certificates. The tools & tackles shall not be removed from site without written permission of BHEL.

28.0 INTEREST BEARING RECOVERABLE ADVANCE/ MOBILISATION ADVANCE Not applicable for this tender.

29.0 AREA REQUIREMENT The contractor shall furnish the estimated area required for the construction of his office, stores, etc separately. The same will be reviewed by BHEL and allotted to the extent available/ considered necessary, depending upon the area availability.

30.0 CONSTRUCTION OF TEMPORARY OFFICE, STORES ETC The contractor shall arrange at his own cost the construction of his temporary office, stores, fabrication yards, labour colony etc and also the watch & ward of all above.

31.0 RECONCILIATION OF MATERIALS 31.1 Contractor shall submit a reconciliation statement of material after completion of job. 31.2 The contractor shall return the unused plant materials under their custody to BHEL’s

store/ yard at their own cost. 32.0 SECURITY DEPOSIT (SD) AND PERFORMANCE BOND (PB) 32.1 Security deposit shall be as per respective clauses of GCC-IB for services contract. 32.2 Performance bond is not applicable. 33.0 INSURANCE 33.1 BHEL shall arrange comprehensive MCE (marine cum erection) Insurance Policy for

total project supply & services including balance of plant package covering transit risks & loss, destruction or damage during handling at Site, Storage, civil works ,erection, testing and commissioning up to trial operation completion of each unit including theft, sabotage, fire, lightning and other natural calamities.

33.2 Deleted. 33.3 Contractor shall report to BHEL in writing any damages to equipments/components

on receipt, storing, and during withdrawal of the materials from stores, in transit to site and unloading at place of work and during erection and commissioning till trial operation completion including handing over. The above report shall be as prescribed by BHEL site management. Any consequential loss arising out of non-compliance of this stipulation will be borne by contractor.

33.4 The contractor will take necessary precautions/ due care to protect the material at Project site, while in his custody from any damage/ loss till the same is handed over to BHEL/ customer at Project site. For lodging/ processing of insurance claim the contractor will submit necessary documents. BHEL will reserve the right to recover the loss from the contractor as detailed below in case the damage/loss is due to negligence/ carelessness on the part of the contractor. In case of theft of material under contractor's custody, the same shall be reported to police by the contractor immediately and copy of FIR and subsequently police investigation report shall be submitted to BHEL/ customer for taking up with insurance..

34.0 REPORTING DAMAGES AND CARRYING OUT REPAIRS 34.1 Checking all components / equipments at siding /site and reporting to transport and /

or insurance authorities of any damages / losses will be in the scope of contractor. Necessary assistance for verification / survey and lodging claims with underwriters



and follow up to logical conclusion will also be part of this contract.

34.2 Contractor, shall report to BHEL in writing any lost/damages to equipments / components during drawl of the materials from stores, in transit to site and unloading at a place of work and during erection and commissioning. The above report shall be as prescribed by BHEL site management. Any consequential loss arising out of noncompliance of this stipulation will be borne by contractor.

34.3 Contractor shall carry out fabrication of any material lost /damages as per Instructions from BHEL Engineer.

34.4 BHEL, however, retains the right to award or not to award to the contractor any of the rectification / rework / repairs of damages and also fabrication of components.

34.5 All the repairs / rectification / rework of damages and fabrication of materials lost, if any, shall be carried out by a separately identifiable gang for certification of man-hours. Daily log sheets should be maintained for each work separately and should be signed by contractor’s representative and BHEL Engineer. Signing of log sheets does not necessarily mean the acceptance of these as extra works for payment purpose.

34.6 Insurance cover under this policy will be as per clauses 26.0 to 26.4 of general conditions of contract.

34.7 In case the repairs / rectification / rework and fabrication of materials lost, the work has been done by more than one agency including the contractor, the payment towards extra charges will be on prorata basis and the decision of BHEL in this regard is final and binding on the contractor.

35.0 COMPLETION PERIOD 35.1 The entire work of PWHT in the area of panelised welding joints and furnace rear wall

hanger tubes for unit #5 of 2x660 MW units at Barh STPP Stg-II,Bihar.shall be completed within 2 months from the date of start of work.

35.2 The bidder shall arrange to mobilise and start the job within 7 days from the date of LOI.

35.3 The actual date of start of work of rectification and modification job will be certified by BHEL site in-charge/CM after adequate mobilisation of manpower, T&P by the contractor.

35.4 The work under the scope of contract will be deemed to be completed in all respects only when all the components are rectified and modified as certified by BHEL/ ALSTOM or commencement of trial runs of unit #5 . The decision of BHEL shall be final and binding on the bidder.

36.0 DELETED 37.0 TAXES AND DUTIES 37.1 All taxes (except Service Tax including Educational Cess), WCT under state VAT act,

duties, charges etc for execution of the contract shall be borne by the contractor and shall not be payable extra. Any increase of the same at any stage during execution of the contract shall have to be borne by the contractor. Quoted price of the bidder shall be inclusive of all such requirements.

37.2 Service Tax (including Educational Cess) as legally leviable & payable by the contractor under the provisions of applicable law/ act shall be paid by BHEL as per contractor’s bill. However, contractor shall have to submit proof of Service Tax deposited by them immediately after the deposit but not later than the next bill submitted after the due date of deposit. The contractor shall furnish proof of Service Tax registration with Central Excise Division covering the services covered under this contract. Registration should also bear endorsement for the premises from where the billing shall be done by contractor on BHEL for this project. The contractor shall obtain prior approval of BHEL before billing the Service Tax amount.

37.3 With introduction of CENVAT credit rules 2004 which came into force wef 10-09-04, Excise Duty paid on input goods including capital goods used for providing the output service and service tax paid on input service can be taken credit of against the Service Tax payable on output service. As such, while offering the rates, the contractors may take into account the benefit of above provisions as the cost of input to contractors will be the cost net of Excise Duty and Service Tax and adjust their offer price accordingly to make it more competitive.

37.4 As such, bidder’s quoted price shall be exclusive of Service Tax (including Educational Cess). Any changes in Service Tax rules (by Govt) shall be complied



with.

37.5 Contractor should be registered under state VAT Act. They should produce their Registration No and copy of Registration Certificate as proof of registration and contractor shall produce proof of payment of VAT so that BHEL as main contractor can get the benefit of deduction of input credit from the contractual transfer price under state VAT Act. Contractors should produce Tax Invoice, copy of tax paid challan, copy of returns of the bidder showing BHEL portion of job value separately and other necessary documents to BHEL as required under state VAT Act/ Rules so that BHEL can avail input credit under VAT Act.

37.6 The contractor has to make his own arrangement at his cost for completing the formalities, if required, with state VAT authorities, for bringing their materials, plants & materials at site for the execution of the works under this contract, road permit/ way bill, if required, shall be arranged by the contractor and BHEL/ PSER will not supply any road permit/ way bill for this purpose. The contactor must be a registered dealer with the state VAT Act, if not registered yet, and a copy of the said registration certificate along with TIN No must be provided to site RAO.

37.7 New tax & duties, if imposed subsequent to latest due date of offer submission, by statutory authority during contract period (including extension, if the same is not attributable to the contractor), shall be reimbursed by BHEL on production of relevant supporting document to the satisfaction of BHEL. However, the vendor shall obtain prior approval from BHEL before depositing new taxes and duties.

38.0 DELETED 39.0 DELETED 40.0 TERMS OF PAYMENT 40.1 You shall submit your RA bill once in a month at the end of each month. The RA bill,

complete in all respects accompanied by BHEL engineer's certificate/ jointly signed measurement sheet will be paid after 30 days of submission of bill, subject to its completeness & correctness in all respects. The measurement will be taken by BHEL engineer as per relevant clause of GCC and certify regarding the actual work executed in the measurement book and bills for work.

40.2 Subject to the deduction which BHEL may be authorised to make under the contract, you shall, on certification of the engineer at site, be entitled for payment as explained here under.

40.3 For subject job of T22 work as detailed in tender progressive payment shall be made.

40.4 As regards mode of payment and measurement of the work completed, relevant clauses of GCC shall be referred to. Detail billing schedule of shall be submitted by the successful bidder to BHEL for approval within 15-days of LOI.

40.5 The break-up for progressive payment for completion of work is as under. 40.5.1 Pro-rata Basis on successful completion of each joint after all stage inspection as

certified by BHEL- 90% 40.5.2 On completion of Boiler operation/Trial Operation and completion of final bill

formalities -10% 40.5.3 BHEL/SITE at their discretion, may further split up the above percentages and effect

payment to suit the site condition, cash flow requirement and according to the progress of work.

41.0 PVC , ORC & Rate Revision. PVC (Price variation claim) and ORC (Over-run charges) are not applicable for this contract. Rate revision is not admissible /applicable for this contract.

42.0 GUARANTEE PERIOD 42.1 Executed work to be guaranteed till commissioning and handing over of the unit to

NTPC which may take about one year’s time after completion of job. Any defect found on the executed portion of work at any stage of testing /commissioning and operation before handing over, shall have to be attended with same process without losing time on emergency basis. In case of failure in attending the same in time, BHEL may proceed to undertake the repairs of such defective works through other agency at contractor's risk and cost without prejudice to any other rights and recover the same from SD/ other dues.



43.0 LIQUIDATED DAMAGES (LD) 43.1 If the contractor fails to complete the subject job as per aforesaid completion period,

BHEL shall have the right to recover as liquidated damages (LD) a sum equivalent to 0.05 % of the contract price, including taxes, duties for delay of each day.The liability for delay shall not in any case exceed 10 % (ten percent) of the total contract price including taxes, duties.

43.2 All other terms & conditions shall be as per provision of Volume-IB. 44.0 CONTRACT PRICE 44.1 The bidder shall quote their rate as per Price bid/ rate schedule only. 45.0 PAYING AUTHORITY

Construction Manager BHEL site office 2x660 MW Barh Super Thermal Power Project,Stage-II Barh ,Patna,Bihar

46.0 OTHER TERMS 46.1 While bidder's scope include deployment of all resources, like T&P, materials,

consumables, manpower including supervision etc for proper completion of the job and no sub-contracting for execution of the job is allowed by BHEL, depending on project's requirement and on prior acceptance of BHEL/ customer, bidder may associate agencies for deployment of skilled/ un-skilled manpower only for site execution. Bidder should arrange all resources, like T&P, materials, consumables, supervision etc directly for the subject job.

46.2 All other term & conditions of this specification shall be governed by the pertinent provisions of GCC, Volume-IB as applicable.



APPENDIX – I

LIST OF TOOLS AND PLANTS TO BE DEPLOYED BY THE CONTRACTOR

SL NO DESCRIPTION CAPACITY QUANTITY

1. TIG welding test NA As per requirement 2. Plasma cutting m/c NA As per requirement 3. Pre-heating/ stress relieving set

(heating control panel, cables, heating elements etc.)

As per requirement

As per requirement.

4. Radiography arrangement including the source.

NA As per requirement

5. Radiography film viewer NA As per requirement 6. High frequency unit for TIG welding NA As per requirement 7. Digital Temperature indicator NA As per requirement 8. Infrared sensor for Temperatuire

detector NA As per requirement

9. RECORDABLE ULTRASONIC TEST EUIPMENT (UFD KRAFT KAMMER MAKE USN50 or higher version to meet the requirements )

NA As per requirement

10. GAS BURNER ARRANGEMENT NA As per requirement 11. PORTABLE HARDNESS TESTER NA As per requirement 12. SPOT WELDING MACHINNE NA As per requirement 13. HEATING AND CUTTING TORCH NA As per requirement 14. HOSES NA As per requirement 15. DIFFERENT TYPES OF GRINDING

M/C NA As per requirement

16. CUTTING AND GRINDING WHEELS NA As per requirement 17. K type Compensating Cable –

AS REQD 5 KM (Min) / As Required

18. Data logger / Temperature recorder (each 06 point)

AS REQD 15 no

19. Control panel

AS REQD 25 nos.

20. Resistance heating coil AS REQD 3 km (Min)/As Reqd. 21. Scaffolding materials As per

requirement As per requirement

NOTE The above major T&P list/consumables is indicative only. Additional T & Ps/consumables, if required have to be mobilized by the contractor within the quoted/accepted rate.



APPENDIX-II

MAJOR CONSUMMABLES TO BE PROVIDED BY BHEL FREE OF COST SL NO

DESCRIPTION OF ITEMS

01 Filler Wires and Special Welding Electrodes required for T22 Butt Joints 02 Free length Tubes and Fins plates. 03 Any other special consumables as supplied by BHEL manufacturing units



APPENDIX-III

MAJOR CONSUMABLES TO BE DEPLOYED BY THE CONTRACTOR SL NO

DESCRIPTION OF ITEMS

01 All types of Welding Electrodes – As required except for the special electrodes supplied by BHEL/Manufacturing Units

02 Different gases like O2, CO2, Argon, D/A etc. 03 Grinding Wheel 04 Temperature Resistance Purging Papers 05 Hardness Testing Machine-2 Nos 06 All arrangement of Heat Treatment and NDT with sufficient manpower

NOTE The above list is not exhaustive and all required the consumables required to complete the work shall have to be arranged by the successful contractor at his cost.

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HEAT TREATMENT PROCEDURE for T22 Butt Joints at Barh Unit V Site

Prepared

A.Sakthi Ganesh

Reviewed

A.Sampath

Approved

M V Selvan

1.1 Scope: This procedure is applicable for heat treating tube to tube site butt joints in areas of

Spiral wall panels, Bottom Ash Hopper panels and interface joints between spiral wall and vertical wall panels at Barh Unit V site.

1.2 Material:

SA 213 Gr.T22.

1.3 Reference Documents:

IBR & ASME Sec I

1.4 Procedure:

1.4.1. Identify the joints for Post weld Heat Treatment. The joints shall be selected as follows;

a. A maximum of 10 joints in the areas where there is no obstruction such that 6 coils of each 21m length (approx) can be placed on the joints, with 3 nos. on each side, namely hot and cold sides .

b. Or less than 10 joints, based on feasibility, in case of obstruction. 1.4.2. Clean the surface of the weld joints and the adjacent tube surfaces to remove ash and

other insulating dust, if any. 1.4.3. Since the boiler is fabricated completely, the joints cannot be wound with resistance

coils around the circumference. Hence finger element type placement of coils is necessitated.

1.4.4. The coils shall be placed very close to each other as shown in Fig 1. Also the coils shall be placed normal to the weld joints such that the centre of the coil bunch overlaps with the joint.

1.4.5. The coils shall cover 2 extra joints on either ends, over and above the joints to be heat treated to ensure effective heating on the selected joints for PWHT.

1.4.6. The same type of arrangement is to be followed for the other side as well, namely the cold side of the boiler. Wherever beam or other component obstructs, the area shall be devoid of resistance coils and all the visible joints in the scope of PWHT cycle shall be covered with resistance coils as explained above.

1.4.7. Insulation wool shall be sufficiently provided on either sides of the boiler. (i.e. both hot and cold sides) to avoid heat dissipation. Even in the areas devoid of resistance coils, insulation wool shall be provided covering tension bars, flanges of beams, tube gaps in between tube to beam interface and tube to tension bar interface, etc.

1.4.8. Wherever possible, width of the insulation band beyond the heating band shall be at least twice the total width of the heating band.

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TENDER NO. PSER:SCT:BAR-B1669:15

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Prepared

A.Sakthi Ganesh

Reviewed

A.Sampath

Approved

M V Selvan

1.4.9. In one heat treatment cycle, six TCs shall be placed such that one TC is placed per coil. Wherever the no. of coils is restricted, a minimum of 4 TCs shall be selected (two nos. on each side).

1.4.10. The heat treatment parameters shall be selected as per WPS:1080 Rev:01 Dtd.16.03.15. However the following shall be ensured for effective PWHT.

a. PWHT Soaking Temperature : 750 °C (Max range) b. Soaking : 1hour ( for effective soaking) c. Rate of Heating/Cooling : 200°C/hour from ambient temperature.

1.4.11. After PWHT, The Heat treatment chart shall be verified for correctness and filed for records.

1.4.12. After PWHT, the MCF value shall be measured on the every individual joint on both sides. Accept the joints if the MCF values measured on both sides are less than 10. If not, repeat the PWHT cycle once again and measure the MCF values. Accept the joint, if the measured MCF value is less than 10, otherwise cut and re-weld the joint.

of 3


Prepared

A.Sakthi Ganesh

Reviewed

A.Sampath

Approved

M V Selvan

Fig 1: Placement of Resistance Coils

Fig 2: Insulation

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