Ref.: NIT NO. 6758A TCE/BPCL RFQ-001 Tender No. TCE ......OISD-GDN-192 SAFETY PRACTICES DURING...

Ref.: NIT NO. 6758A_TCE/BPCL_RFQ-001 Tender No. TCE.6758A-B-300-001 14-08-2012 Tender for Blending unit

Due Date: 03-09-2012

Dear Sirs,

Please submit your competitive offer in strict conformity to the documents enclosed herewith. Kindly return the “Acknowledgement & Intention to Bid” form, duly filled, immediately on receipt of this enquiry document.

Offers may kindly be furnished as per the Instructions to Bidders (ITB) enclosed herewith.

Thanking You,

Yours truly

For TATA Consulting Engineers Limited,

K Rammohan Project Manager

TENDER NO.: TCE.6758A-B-300-001

TATA CONSULTING ENGINEERS LIMITED SECTION: Title

Master Index SHEET i OF i

BHARAT PETROLEUM CORPORATION LIMITED

REQUEST FOR QUOTATION

NIT NO : 6758A_TCE/BPCL_RFQ_003

RFQ NO: TCE.6758A-B-300-003

MECHANICAL WORKS

Owner : BHARAT PETROLEUM CORPORATION LIMITED

Project : MECHANICAL WORKS

Location : URAN, MUMBAI (INDIA)

Job No. : TCE.6758A

TATA CONSULTING ENGINEERS LIMITED RAJ PLAZA, 2ND FLOOR, L.B.S. MARG, VIKHROLI (WEST)

MUMBAI - 400 083. INDIA. TEL 91-22-66472111 Fax 91-022-66472000

EMAIL: [email protected]

ISSUER0

mailto:[email protected]



Master Index SHEET i OF iii

ISSUE

R0

MASTER INDEX

TO

BIDDING DOCUMENT FOR MECHANICAL WORKS

BHARAT PETROLEUM CORPORATION LIMITED, URAN, MUMBAI

(BIDDING DOCUMENT NO: TCE-6758A-B-300-003)



Master Index SHEET ii OF iii OF 45

ISSUE

R0

PART - I: GENERAL & COMMERCIAL

SL. NO. SPECIFICATION NO. REV NO.

DESCRIPTION NO. OF SHEETS

1. Acknowledgement & Intention To Bid (to be sent immediately after down loading of the tender)

2

2. TCE.6758A-B-300-001 Instructions To Bidders 25

3. TCE.6758A-B-300-001 R0 Concurrent Assignments and Experience list

2

4. TCE.6758A-B-300-001 R0 Deviation List 2

5. TCE.6758A-B-300-001 R0 Integrity Pact 4

6. TCE.6758A-B-300-001 R0 ANNEXURE-II TO SPC Scope of Supply

3

7. TCE.6758A-B-300-001 R0 ANNEXURE-III TO SPC Terms of Payment

3

8. TCE.6758A-B-300-001 R0 Quality Management System 6

9. TCE.6758A-B-300-001 R0 General Purchase Conditions 36

10. TCE.6758A-B-300-001 R0 Special Purchase Conditions 11

11. TCE.6758A-B-300-001 R0 List of Approved Makes /

Vendors 29

12. TCE.6758A-B-300-001 R0 Commercial

Questionnaire 10

13. TCE.M4-903 R5

Drawings, Engineering Documents and Instruction Manuals

6

14. TCE.M4-914 R7 Progress Schedule and

Reports 2

15. TCE.6758A-954 R0 Schedule of Distribution of Drawings and Documents

3

16. TCE.6758A-B-300-001 R0 Schedule Of Price 7

NIT NO. - 6758A_TCE/BPCL_RFQ_003 of 300



Master Index SHEET iii OF iii OF 45

ISSUE

R0

PART II – TECHNICAL

Sec. No. Specification No. Rev.

No. Title No. of Sheets

C 6758A-TCE/BPCL-RFQ-003

R0 Scope of work – Process / Mechanical / Piping and fire protection

8

B3 TCE.6758A-B-300-003 R0 Painting Specification 3

FIRE PROTECTION SYSTEM

D

TCE.M4-111-02

-- R6 R6 R6

Hydrant valves Data Sheet-A Data Sheet-B Data Sheet-C

-- 2 1 1

D TCE.M4-111-04

-- R4 R4 R4

Branch pipe and nozzles Data Sheet-A Data Sheet-B Data Sheet-C

-- 1 1 1

D TCE.M4-111-05 -- R4 R5

Fire Hoses Data Sheet-A data Sheet-C

1 1

D TCE. M4-111-08 -- R7 R7 R7

Hose cabinets Data Sheet-A Data Sheet-B Data Sheet-C

-- 2 1 1

D TCE. M4-111-16 -- R5 R5 R5

Fire Extinguishers Data Sheet-A Data Sheet-B Data Sheet-C

-- 3 2 1

D TCE. M4-111-23 -- R5

Fixed Spray System Data Sheet-A

4 2

D TCE. M4-111-03 -- R4 R4 R3

Water Monitors Data Sheet-A Data Sheet-B Data Sheet-C

-- 2 1 1




Master Index SHEET iv OF iii OF 45

ISSUE

R0



D TCE.M4-134-102 R5 R0

Underground Protection for Piping Data Sheet A & C

5 1

D TCE.6758A-B-300-003 R0 Thermal Insulation for Cold Surfaces-Datasheet 2

D TCE.M4-134-06 R2 Fabrication, Erection & Testing Of Piping Systems

13

PIPING

D TCE.6758A-590-LS-1001

R0 Piping Material Specification 13

D TCE.6758A-E-590-003 R0 Insulation Specification 7

D TCE.6758A-B-300-003 R0 Welding Specification - Equipment and Piping 23

D TCE.6758A-E-590-001 R5 Structural Steel Fabrication 8

D TCE.6758A-E-590-002 R0 Structural Steel Erection 3

SHOP INSPECTION REQUIREMENTS

E TCE.M4-904 R9 Shop Inspection and Tests 7

D TCE.M4-186-04 R2 Valves – Metallic 1

D TCE.M4-186-05 R2 Pipes & Pipe Fittings – Metallic 1

D TCE.M4-186-30 R2 Fire Protection Equipment 2

D TCE.M4-186-35 R2 Structural Fabrication 1

ANNEXURE-I

TCE.6758A-590-PP-8701

R0 OVERALL PIPING PLAN FOR BLENDING UNIT 1

6457-PE-UPI-002,005,006

P2 P & ID FOR BLENDING UNIT 3

TCE.6758A-300-PI-8601

P3 P & ID FOR BLENDING SKID 1

OISD-GDN-192 SAFETY PRACTICES DURING CONSTRUCTION 1


SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION:

TCE.6758A-B-300-001 SHEET OF 4

ISSUE R0

PART I


ACKNOWLEDGEMENT & INTENTION TO BID

Attention: Mr. K Rammohan / Deepak Vijaykumar TATA Consulting Engineers Limited, Raj Plaza, Second Floor, LBS Marg, Vikhroli (W). Mumbai- 400 083. Phone: 022-6647 2061 / 2060 Fax: 022-6647 2000

SUB: CONFIRMATION TO BID

TENDER / ENQUIRY NO.___________________ DTD._______

WORK / ITEM: _______________________________________ Dear Sirs,

We hereby acknowledge receipt of a complete set of bid document along with enclosures for the subject work / item as per the table of contents for our use in preparing the bid.

We undertake that the contents of the above tender document shall be kept confidential and further that the drawings, specifications, and documents shall not be transferred and the said documents will be used only for the purpose which they are intended.

(A) We intend to bid as requested for the subject items and furnish following details with respect to our offices:

Quoting Office Contact Person at Mumbai, if any, for Indian Bidders & Contact Person in India for Foreign Bidders

Postal Address:

Postal Address:

Telephone Number: Telephone Number:

Fax Number: Fax Number:

e-mail address: e-mail address:

Contact Person: Contact Person:

Mobile Number: Mobile Number:


(B) We confirm that our offer shall be submitted within the due date.

(C) We are unable to bid for reasons given below and we are returning the entire set of tender documents

Reasons for Non-Submission of Bid:

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

______________________________________________________

Company‟s Name: ______________________________

Signature: ______________________________

Name: ______________________________

Designation: ______________________________

Date: ____________

Note: Bidders are requested to furnish the details mentioned in (A), (B) or (C) above, immediately after down loading of tender documents


TATA CONSULTING ENGINEERS LIMITED

ITB for MECHANICAL WORKS Page 1 of 25

Instructions To Bidders (ITB)

Project No.: TCE-6758A

BLENDING UNIT AT URAN LPG PLANT

Client: Bharat Petroleum Corporation Limited

CONTENTS

1.0 INTRODUCTION

2.0 COST OF BIDDING

3.0 SITE LOCATION / SITE VISIT

4.0 BIDDING DOCUMENTS

5.0 AMENDMENT OF BIDDING DOCUMENTS

6.0 LANGUAGE OF BIDS

7.0 BIDDING METHODOLOGY

8.0 PRICE BID

9.0 CURRENCIES OF BID AND PAYMENT

10.0 BID SECURITY / EARNEST MONEY DEPOSIT (EMD)

11.0 PERIOD OF VALIDITY OF BIDS

12.0 QUERIES / CLARIFICATIONS

13.0 FORMAT AND SIGNING OF BID

14.0 BIDDING DOCUMENTS AND DEVIATIONS

15.0 DEADLINE FOR SUBMISSION OF BIDS

16.0 ALL PAGES TO BE INITIALLED

17.0 PRICES TO BE IN FIGURES AND WORDS

18.0 CORRECTIONS AND ERASURES

19.0 LATE BIDS / BIDS RECEIVED BY FAX / TELEX / TELEGRAMS

20.0 MODIFICATION AND WITHDRAWAL OF BIDS

21.0 OPENING OF BIDS

22.0 CLARIFICATION OF BIDS

23.0 TECHNO-COMMERCIAL EXAMINATION OF BIDS

24.0 BID EVALUATION CRITERIA

25.0 COMPLETE SCOPE OF SUPPLIES / WORK

26.0 OPENING OF PRICE BIDS

27.0 EVALUATION AND COMPARISON OF PRICES

28.0 REBATE

29.0 CONTACTING BPCL

30.0 BPCL’S RIGHT TO ACCEPT/REJECT BIDS

31.0 NOTIFICATION OF AWARD

32.0 CONTRACT AGREEMENT /PURCHASE ORDER / WORK ORDER

33.0 ACCEPTANCE OF PURCHASE / WORK ORDER

34.0 CONFIDENTIALITY OF DOCUMENTS

35.0 CHECKLIST

36.0 PROFORMA OF LETTER OF AUTHORITY FOR ATTENDING UNPRICED BID OPENING AND PRICED BID OPENING

37.0 PROFORMA OF DECLARATION OF BLACK LISTING / HOLIDAY LISTING

38.0 CUT-OUT SLIPS TO BE USED BY VENDORS FOR PASTING ON COVERS CONTAINING BIDS



Ir 66-6457-700 Page 2 of 25

1.0 INTRODUCTION

1.1 M/S Bharat Petroleum Corporation Ltd.(BPCL), Fortune 500 Company

proposes to set up a Propane and Butane handlng and blending facility at Uran LPG Plant and have appointed TATA Consulting Engineers Limitedas a consultant for the implementation of the same

1.2 TCE for and on behalf of BPCL invites Sealed Bids under single stage two

envelope bid system, for the entire work / supply covered under the Bidding Document. All bids are to be completed and returned in accordance with and within the time provided in these Instructions to Bidder.

2.0 COST OF BIDDING

The bidder shall bear all costs associated with the preparation and delivery of its bid including (but not limited to) costs and expenses related to visits to the site(s) and other locations, and the cost of any tests, investigations,

evaluations and consultations. BPCL/TCE will in no case be responsible or

liable for any costs regardless of the outcome of the bidding process.

3.0 SITE LOCATION / SITE VISIT

The Project Site is located in Uran (about 45 kms from the Mumbai City) in

the State of Maharashtra. Mumbai City is well connected by Rail and Road from other parts of India. Nearest Airport is at Mumbai, at a distance of about 45 kms from the Project Site.

The bidder is advised to visit and examine the site of works and its

surroundings and obtain for itself on its own responsibility all information that may be necessary for preparing the bid and entering into the Contract. Claims of any kind due to variation or ignorance of site conditions and environmental conditions will not be eligible in any circumstances.

The bidder and any of its personnel or authorised representatives will be

granted permission by BPCL to enter upon its premises and lands for the purpose of such inspection. It is understood that as an implicit condition of such permission, the bidder, its personnel and/or authorised representative(s) shall be understood to have released and indemnified BPCL and its personnel from and against all liability in respect thereof and to have assumed all responsibility for personal injury (whether fatal or otherwise), loss of or damage to person or property and any other loss, damage, cost and expenses incurred as a result of such visit, including those sustained by any negligence or other act of tort on the part of BPCL and/or its personnel and




Consultants. During such visits the Bidder shall abide by all the rules and regulations, as applicable.

Bidders may contact TCE for site visit purpose.

4.0 BIDDING DOCUMENTS

The bidder is expected to examine the bidding documents, including all instructions, FORMs, General Purchase Conditions, Terms and conditions of Contract, Specifications, Drawings and other documents and to fully familiarise itself with the requirements of the bidding documents. Failure to furnish all the information required by the Bidding Documents or the submission of a bid not substantially responsive to the Bidding Documents in every respect may result in the rejection of the Bid.

Within 5 days of receipt of Bidding Document, Bidder shall acknowledge the

receipt and confirm his intention to bid for the tendered work as per Proforma given in Bidding Document.

5.0 AMENDMENT OF BIDDING DOCUMENTS

5.1 At any time prior to the deadline for submission of bids as well as up to

priced bid opening, BPCL/TCE may, for any reason whether at its own

initiative or in response to a clarification or modification requested by any prospective Bidder(s), modify the Bidding documents.

5.2 The modifications/amendment will be notified in writing or by fax to all

prospective bidders who have been issued the Bidding documents, and shall be part of the Bidding documents and shall be binding on all bidders. The Bidders will be required to acknowledge receipt of any such amendment to the Bidding documents. Bidders shall confirm the inclusion of Addendum / Corrigendum in their bid and shall follow the instructions issued along with addendum / corrigendum.

5.3 Bidders shall examine the Bidding documents thoroughly and inform

BPCL/TCE of any apparent conflict, discrepancy or error, so that

BPCL/TCE may issue appropriate clarification(s) or amendment(s), if

required.

6.0 LANGUAGE OF BIDS

6.1 The Bid prepared by the bidder, all documents attached to and/or relating to the bid and all correspondence exchanged by the Bidder and

BPCL/TCE, shall be written in English language only.




6.2 Any printed literature furnished by the bidder may be written in any other language provided that this literature is accompanied by an authenticated English translation, in which case, for purpose of interpreting the Bid, the English translation shall govern.

7.0 PREPARATION OF BIDS – TWO BID SYSTEM

7.1 The bidder is required to prepare bid in a format as outlined below in order to achieve the objective of maintaining a uniform proposal structure from all bidders.

7.2 The Bid shall be prepared and submitted in sealed Covers :

Cover – 1 Technical Bid and Price Bid

7.3 Cover-1: Original Technical Bid and Price Bid: Bidder(s) will be required to submit in their one bigger sealed cover marked as “ TECHNICAL” & “PRICE BID” containing the following documents in three separate sealed envelops before the due date & time in BPCL’s Sewree Office at the address,

CEM (Engineering & Projects) West,

Bharat Petroleum Corporation Ltd, A – Installation, Floore no. 1 Sewree Fort Road, Sewree (E), Mumbai – 400015 (Maharashtra). India

Contact person: Mr. K V R Subudhi / Mr.K. Prakash

Tel No. : +91 022 2417620 / +91 022 24174629

Cell No. +919892351452 / +919833982858 (on the bid opening date)

i) Envelope 1: Techno-Commercial Bid (1 Set Original + 2 Set

Photocopy)

a) Information about the Bidder b) Original Technical Details c) One set of Tender Documents duly signed and stamped on

each page in original, as token of its acceptance. Signed & sealed NIT documents, specifications.

d) Schedule of Deviations (if any) to the commercial and Technical bid documents. Deviations must be furnished on a separate “Deviation Sheet”. Deviations indicated elsewhere in the bid document will not be considered.



ITB for Mechanical Works Page 5 of 25

e) Delivery / Completion schedule and all commercial conditions. f) Unpriced copy of the “Price Bid” mentioning “Q” for quoted items

& “NQ” for not quoted items. g) Confirmation regarding readiness for signing of Integrity pact in

the event of award of contract / order h) Financial details including Audited Balance Sheet, including

Profit and Loss A/c for the preceding 3 financial years. i) Duly filled Commercial Questionnaire. j) Bidder’s Qualification Documents. (Vendors fulfilling all the

qualification criteria as mentioned in the “Bidders Qualification Document” will only be considered for further technical & commercial evaluation)

k) Check-List for bidding documents

For convenience, the Bid shall be compiled in the form of specific Sections conforming to the above points a to j. In case of non-submission of above documents or submission of incomplete

documents, BPCL/TCE reserves the right not to evaluate such offers

further and not to enter into correspondence in this regard after opening the Techno-commercial / Unpriced Bid.

ii) Envelope 2: Original EMD (1 Original + 2 Photo copy)

Bidder shall furnish, as part of his Bid, EMD for the amount as indicated in the Notice inviting Tender. The Bids not accompanied with EMD or EMD not as per Proforma given in the Bidding Document shall be considered as non-responsive and such Bids shall be rejected.

iii) Envelope 3: Original Priced Bid (1 Original + 2 Photo copy)

Each envelope shall be super scribed with Tender Number, Bidder

Name and the names of documents it contains.




7.5 Although all the details presented in this Bid document have been

compiled with all reasonable care, it is the Bidder’s responsibility to ensure that the information provided is adequate and clearly understood.

7.6 The bid requirements are explicitly stated in the Bidding Documents. The

Bidder is required to study these requirements in detail and to make a proposal in an outline as defined above completely meeting these requirements. The Bid must be complete in all respects, leaving no scope for ambiguity. It is in the interest of the Bidder to submit a complete and

comprehensive proposal leaving no scope for BPCL/TCE to raise or ask

for any further questions or clarifications, with a view that the proposal




may be evaluated only on the basis of what has been submitted by the bidder in the first instance in order to adhere to a very strict project schedule. Bidder’s quotation is the responsibility of the bidder and no relief or consideration can be given for errors and omissions.

7.7 For the purpose of these documents the terms “bid” and “tender”, “bidding”

and “tendering” and other similar expressions are synonymous.

7.8 Also, “Bid Document”,"Tendering Document” and “Bidding Document” and similar expressions are synonymous.

8.0 PRICE BID

8.1 The item wise Bid prices shall be filled in the “Format For Submitting Price

Schedule” in the Special Conditions of Purchase.

8.2 Bidders shall quote landed cost indicting separately basic cost, all taxes, duties, levies, octroi applicable, packing & forwarding charges, transportation charges etc. and the final landed cost at site.

8.3 Bidders shall indicate the applicable present rate of excise / customs duty,

CVD, education cess and VAT/CST, Service Tax, the same shall be payable on production of documentary evidence issued from concerned authority.

8.4 This part shall not contain any condition whatsoever failing which the Bids

shall be liable to be rejected. In case of any correction, the bidder shall put its signature and its stamp. Eraser fluid will not be allowed for making any correction.

8.5 The prices quoted by the bidder shall remain firm and fixed and shall be

valid until completion of the Contract and shall not be subject to variation/escalation on any account except as otherwise specifically provided in the Contract documents.

8.6 A Counter trade proposals shall not be considered in the evaluation of

Bids or otherwise.

8.7 It shall be the duty of the supplier to duly observe and perform all laws, rules, regulations, orders and formalities applicable to Excise Duty, Sales Tax, VAT, Service tax, Customs Duty, Countervailing Duty etc. on the import, manufacture, sale and/or supply of any material to the BPCL and performance of the works under the Contract. The supplier/contractor shall keep BPCL indemnified from and against any and all claims,




demands, prosecutions, actions, proceedings, penalties, damages, demurrages and/or other levies whatsoever made or levied by any Court, Tribunal or the Customs or other Authorities with respect to any alleged breach, evasion or infraction of such duties, taxes, charges or levies or any breach or infraction of any applicable laws, rules, regulations, orders or formalities concerning the same and from the consequence thereof.

9.0 CURRENCIES OF BID AND PAYMENT

9.1 Foreign Bidders may quote prices for materials and services to be imported into India either in Indian Rupees or in Foreign Currency or in a combination of Indian Rupees and Foreign Currency.

9.2 Bidders shall quote the price for materials and services to be procured

from India and for expenses to be incurred in Indian Rupees only in Indian Rupees.

9.3 Indian bidders shall quote the prices for materials and services in Indian Rupees only.

9.4 For evaluation purposes, the foreign currency bid price shall be converted

to Indian Rupees by considering Bill selling foreign exchange rate as on the date of priced bid opening.

10.0 BID SECURITY / EARNEST MONEY DEPOSIT (EMD)

10.1 Bidders will be required to submit bid security in the form of demand draft/ bank guarantee from any Indian scheduled bank; or an international bank of repute having a branch in India or having correspondent banking relationship with an Indian scheduled bank. The bid security shall be in US$ for foreign bidders and in Indian Rupees for domestic bidders. The bid security shall be valid for six months beyond the bid validity date.

10.2 Foreign Bidders may also submit bank guarantee from an international

bank of repute having a branch in India or having correspondent banking relationship with an Indian scheduled bank, in which case the Bank Guarantee shall be countersigned by their Indian Branch or by any Scheduled Indian Bank.

10.3 The EMD / bid security shall be in equivalent US Dollars for foreign

bidders and in Indian Rupees for domestic bidders.




10.4 The Bank Guarantees shall be valid for a period of 6(six) months beyond

the bid validity date for item rate tenders and 9 months for Global tenders, (i.e. including 3 months claim period).

10.5 EMD /Bid Security value shall be as indicated in Special Purchase Conditions.

10.6 EMD is shall not be applicable in case of

a) Small Scale Units registered with the National Small Industries Corporation.

The exemption shall, however, be only to the items for which the small-scale industries hold the registration with National Small Industries Corporation. The certificate issued by the National Small Industries Corporation should be valid on the date of opening of the tender.

b) Govt. organization & Public Sector Undertaking of the Central/ State Government

10.7 Bid securities of unsuccessful bidders will be returned upon placement of

Contract/ order. However, EMD of the successful Bidder will be returned upon the Bidder executing the Contract, and furnishing the Initial Security Deposit/ Security Deposit as specified in the General Conditions of Contract.

10.8 The EMD may be forfeited:

i) if a Bidder withdraws/modifies/changes/alters suo-moto his bid during

the period of Bid Validity or does any breach of tendering terms and conditions, or,

ii) in case of a successful Bidder, if the Bidder fails, within the specified

period:

a. to sign the Contract. b. to furnish the Initial Security Deposit/ Security Deposit

11.0 PERIOD OF VALIDITY OF BIDS

11.1 Bids shall remain valid for 6(Six) months after the deadline for bid submission. A bid valid for a shorter period may be rejected by the

BPCL/TCE as non-responsive.

11.2 Not withstanding the above, the BPCL/TCE may solicit the bidder’s

consent to an extension of the period of bid validity. The request and the responses thereto shall be made in writing (by fax/ email).




11.3 If the bidder agrees to the extension request, the validity of the bid security shall also be suitably extended.

11.4 A bidder may refuse the request without forfeiting his bid Security.

11.5 A bidder accepting the request for extension shall not be permitted to

modify his bid because of the extension, unless specifically invited to do so.

12.0 QUERIES / CLARIFICATIONS

12.1 The bidder is requested to submit any queries / clarification / information pertaining to Bidding Document in writing delivered by hand or by mail.

This shall be addressed to Mr. K Rammohan / Mr. Sagar Saha – TATA

Consulting Engrs. Ltd., Mumbai within one week from the date of receipt of bidding

documents. Any failure by Bidder to submit queries / clarification / information pertaining to Bidding Documents in writing shall not absolve the Bidder, after subsequent placement of Order / Contract, of his responsibility to perform the work in accordance with the Order / Contract.

12.2 TCE’s responses to Bidder’s queries/clarifications raised will be furnished

as expeditiously as possible to all the vendors who have been issued Bidding Documents. Any modification of the Bidding Documents which may become necessary, shall be sent to all bidders through the issue of an Addendum.

13.0 FORMAT AND SIGNING OF BID

13.1 The original and all copies of the bid shall be typed or written in indelible ink and shall be signed by the bidder or a person or persons duly authorised to sign on behalf of the bidder. Such authorization shall be indicated by written power of attorney accompanying the bid. All pages of the bid, except for unamended printed literature, shall be initialed by the person signing the bid. The name and position held by each person signing must be typed or printed below the signature.

13.2 The bid shall contain no interlineations, erasures or overwriting except as

necessary to correct errors made by the bidder, in which case, such corrections shall be signed in full by the person or persons signing the bid.




14.0 BIDDING DOCUMENTS AND DEVIATIONS

14.1 One complete set of Bidding Document shall be issued to the Pre-Qualified Bidders in the form of CD with the hard copy of the table of contents (With a Master Index).

14.2 It is expected that bidders will submit bids based strictly on the terms and

conditions and specifications contained in the bidding documents and will not stipulate any deviations. Should it, however, become unavoidable, deviations should be separately and specifically stipulated only in the

prescribed format. BPCL/TCE reserves the right to reject as non-

responsive any bid containing major deviation(s).

15.0 DEADLINE FOR SUBMISSION OF BIDS

15.1 The Original bid, together with required copies must be received by the designated authority on or before the date, time and venue specified in the Letter Inviting Bid.

15.2 The BPCL/TCE may, at its discretion, extend the deadline for the

submission of bids by amending the bidding documents, in which case all

rights and obligations of the BPCL/TCE and bidders previously subject to

the deadline, will thereafter be subject to the deadline as extended. 16.0 ALL PAGES TO BE INITIALLED

16.1 All signatures in bids shall be dated and shall bear a seal of the bidder. In addition, all pages of the bids before submission of the bid shall be initialed at lower right hand corner by the Bidder or by a person holding a Power of Attorney authorising him to sign on behalf of the bidder.

16.2 The Bidder shall sign and affix its seal on all pages of the Priced bid.

17.0 PRICES TO BE IN FIGURES AND WORDS

17.1 The bidder shall fill the Schedule of Prices both in figures as well as in words in the Price Schedule forming part of the bidding Documents, in such a way that interpolation is not possible. The tendered amount for the work shall be entered in the Price schedule and duly signed by the bidder.

17.2 When there is a difference between the prices in figures and words, the

amount which corresponds to it in words shall prevail.




18.0 CORRECTIONS AND ERASURES

18.1 Bidders are required to fill in the tender documents with due care so as to avoid any cuttings/corrections/alterations in the entries made in the tender papers.

18.2 In case any corrections are required, the original writings shall be neatly

cut/ penned through and re-written nearby. No overwriting or erasure of original writings by use of ‘white fluid’ or the like is permitted. In case any erasure using ‘white correcting fluid’ is found, the tender shall be liable to be rejected.

18.3 All cuttings/ corrections/ alterations shall be signed in full by the tenderer

with date. Numerical figures shall be written both in figures as well in words.

19.0 LATE BIDS / BIDS RECEIVED BY FAX / TELEX / TELEGRAMS:

Any bid received by BPCL/TCE after the deadline for submission of the

bids (including any extension(s) hereof) will be declared “Late” and rejected and returned unopened to the bidder. Bids received by way of Fax or Telex or Telegram or email or in open condition shall not be considered shall not be considered

20.0 MODIFICATION AND WITHDRAWAL OF BIDS

20.1 The bidder may modify or withdraw his bid after the bid’s submission, provided that written notice of the modification or withdrawal is received by

BPCL/TCE prior to the deadline prescribed for submission of bids.

20.2 The bidder’s modification or withdrawal notice shall be prepared, sealed,

marked and dispatched in accordance with the provisions for submission of bids.

20.3 A bid may not be withdrawn or modified after the deadline for submission

of bids during the period of bid validity without forfeiting the bid security unless the modification shall be made upon an invitation by the

BPCL/TCE permitting the bidder to modify the bid.

20.4 If a bid is properly modified within the foregoing provisions, the bid as

modified shall constitute the bid offer.




21.0 OPENING OF BIDS

21.1 BPCL/TCE may open Unpriced Bids in the presence of Bidder’s

representative(s) duly authorized to attend such opening by a person competent and having the Power of Attorney to bind the Bidder. The Bidder’s representative(s) who choose to attend and are present shall sign a register evidencing their attendance.

21.2 The Bidder’s names, modification and Bid withdrawals, and the presence

or absence of the requisite Bid Security, and such other details as

BPCL/TCE may, at its discretion, consider appropriate, will be announced

and recorded at the opening. 22.0 CLARIFICATION OF BIDS

To assist in the examination, evaluation and comparison of bids,

BPCL/TCE may, at its discretion, ask the bidder for a clarification of his

bid. All responses to a request for clarification shall be in writing, and no change in the price or substance of the bid shall be permitted unless

specifically sought by BPCL/TCE.

23.0 TECHNO-COMMERCIAL EXAMINATION OF BIDS

23.1 BPCL/TCE will examine or cause to be examined the bids to determine

whether they are complete, whether required bid securities have been furnished, whether the documents have been properly signed, and whether the bids are generally in order.

23.2 The bids without requisite Bid Security and/or not in the prescribed

proforma will not be considered and bids of such bidders shall be rejected.

23.3 BPCL/TCE will determine to its subjective satisfaction whether the bidder

has submitted a responsive bid and is qualified to satisfactorily perform the work, and such determination shall not be open to question.

23.4 The determination will also take into account the bidder’s financial and

technical capabilities, as well as such other qualifications as BPCL/TCE

deem necessary and appropriate.




24.0 BID REJECTION CRITERIA

24.1 Prior to detailed bid evaluation, BPCL will determine the substantial

responsiveness of each bid with respect to the bidding documents. A substantially responsive bid is one which conforms to the terms, conditions and specification of the Bidding Documents without material deviation. A material deviation is one which affects in any substantial way the scope, quality or performance of the works, or which limits in any substantial way, inconsistent with the bidding documents, the BPCL’s rights or the bidder’s obligations as envisaged in the bidding documents, and the rectification of which deviation or reservation would affect unfairly the competitive position of other bidders presenting substantially responsive bids. Further examination of only such bids as are determined to be substantially responsive shall be taken up, unless otherwise

determined by BPCL/TCE.

24.2 The following provisions of the bidding document must be adhered to

without any deviations, failing which the bid shall be considered to be non-responsive and may be rejected.

i. Bid Security

ii. Bid Validity period

iii. Defects Liability Period

iv. Performance Bank Guarantee

25.0 COMPLETE SCOPE OF SUPPLIES/WORK

25.1 The complete scope of supplies and work/services has been defined in

the bidding documents. Only those bidders who take complete responsibility and who bid for the complete scope of supplies and work/services as contained in the bidding document shall be considered for further evaluation.

25.2 Waiver of deviations and conditions (if any), should be submitted by the

Bidders before the opening of the Priced Bid failing which the Priced Bid of concerned Bidder shall not be opened.

26.0 OPENING OF PRICE BIDS

26.1 Substantially responsive bidders will be shortlisted by the BPCL/TCE for

opening of price part of their bids. Date, time and venue for opening of price bids will be informed to the shortlisted bidders subsequently.




26.2 The price bids of the technically and commercially acceptable Bidders will

be opened in the presence of Bidder’s representative who chooses to attend, on the date and time to be intimated. The bidder’s name, bid price

and such other details as the BPCL/TCE at its discretion may consider

appropriate, will be announced at the opening of price bids. 27.0 EVALUATION AND COMPARISON OF PRICES

27.1 In evaluating the bids, BPCL will determine for each bid the evaluated Bid Price by adding the prices for following items:

a) Landed Price at site for supplies & services after taking in to

consideration quoted Packing & Forwarding charges, all taxes & duties, Statuary levies, octroi and Transportation Charges.

b) Any other loading towards factors like Power & Utilities consumption etc as indicated in Special Conditions of Purchase.

27.2 To facilitate evaluation and comparison of prices, the BPCL/TCE will

convert all bid prices expressed in Foreign Currency into Indian Rupees at selling rate of the concerned foreign currency on the date of opening of price Bids.

27.3 BPCL shall allow preference to Indian Central Government Public

Sector Undertakings/Enterprises as admissible under the existing

policies of Government of India. Preference shall also be given to Joint

Venture company of BPCL. 28.0 REBATE

No suo-moto reduction in price(s) by bidders is permissible after opening of the bid. If any Bidder unilaterally reduces the price(s) quoted by him in his bid after opening of bids, such reduction shall not be considered for comparison of prices but shall be binding on the Bidder if he happens to be selected for award of work.

29.0 CONTACTING BPCL

A bidder shall not contact BPCL on any matter relating to his bid from the time of bid opening to the time, that the Contract is awarded, unless requested to do in writing. Any effort by a bidder to influence BPCL in BPCL’s decisions in respect of bid evaluation or contract award will result in the rejection of that bidder’s bid.




30.0 BPCL’S RIGHT TO ACCEPT/REJECT BIDS

30.1 BPCL/TCE reserves the right to accept or reject any bid and to annul the

bidding process and reject all bids at any time prior to award of Contract without thereby incurring any liability to the affected bidder(s) or any

obligation to inform the affected bidder(s) of the ground of BPCL’s/TCE’s

action.

30.2 BPCL/TCE shall not be obliged to award the Order / Contract to the

lowest evaluated bidder if BPCL/TCE apprehends that it will not be in the

interest of BPCL/TCE to award the Order / Contract at the lowest

evaluated price or to the lowest evaluated bidder. 31.0 NOTIFICATION OF AWARD

BPCL/TCE will notify the successful bidder in writing by letter and/or by

Fax of Acceptance that his bid has been accepted. The Acceptance of Bid will constitute the formation of Contract. Effective date of Contract shall be the date of issue of Fax of Acceptance (FOA)

32.0 CONTRACT AGREEMENT /PURCHASE ORDER / WORK ORDER

32.1 Contract documents for agreement / Purchase order / Work Order shall be prepared after the notification of Acceptance of Bid. Until the formal Contract is signed, the bidding documents and Addendum(s) and any modifications thereto and/or there from agreed upon by BPCL with the bidder’s final bid shall be considered as Contract.

32.2 The Contract document / Purchase Order / Work Order thus shall consist

of the following:

a) Original Bidding documents issued with its enclosures including General Conditions of Contract, General Conditions of Purchase, Special Conditions of Contract, Special Conditions of Purchase, drawings etc.

b) Addendum/Corrigendum/Amendment to Bidding documents issued, if any.

c) The notification of Acceptance of bid / Fax of Acceptance.

d) The Detailed Letter of Acceptance including Statement of Agreed Variations, if any, and accepted price-schedule.

e) Secrecy Agreement.

f) Formal Contract / Purchase Order / Work Order




32.3 A Statement of Agreed Variations shall be prepared based on the finally agreed deviations, if any, to the bidding documents and all other correspondences forming part of the offer prior to issue of Notification of Acceptance of bid shall be treated as null & void.

32.4 The statement of Agreed Variations shall form part of the contract /

purchase order / work order which shall be issued within 30 (thirty) days of the Notification of Acceptance of Bid.

32.5 Any deviations or stipulations made and accepted by BPCL after

acceptance of the bid shall be treated as amendment(s) to the Contract / Order and shall be governed by the conditions relating to amendment of Contract / Order.

33.0 ACCEPTANCE OF PURCHASE / WORK ORDER

The vendor shall confirm the acceptance of purchase order / work order by a signing a copy of the order as a token of acceptance and submitting the same to BPCL within 7 (seven) days from the date of receipt of the order.

34.0 CONFIDENTIALITY OF DOCUMENTS

Bidders shall treat the bidding documents and contents therein as strictly confidential. If at any time, during the bid preparation period, Bidder decides to decline to bid; all documents must be immediately returned to BPCL.

35.0 CHECKLIST FOR SUBMISSION OF BID

Bidder is required to fill the checklist and submit along with the bid for

ready reference.




CHECK LIST FOR SUBMISSION OF BID

Bidder is requested to fill this check list and ensure that all details/documents have been

furnished as called for in the Bidding Document along with duly filled in, signed & stamped

checklist

Please confirm & ensure compliance:

SR Description Yes / No

1 Cover-1: Technical Bid and Price Bid

i Envelope 1: (1 Set Original + 1 Set Photocopy)

a) Information about the Bidder

b) Original Technical Details

c) One set of Tender Documents duly signed and stamped on each page in original, as token of its acceptance.

Signed & sealed NIT documents, specifications.

d) Schedule of Deviations (if any) to the commercial and Technical bid documents. Deviations must be

furnished on a separate “Deviation Sheet”. Deviations indicated elsewhere in the bid document will not be

considered.

e) Delivery / Completion schedule and all commercial conditions.

f) Unpriced copy of the “Price Bid” mentioning “Q” for quoted items & “NQ” for not quoted items.

g) Confirmation regarding readiness for signing of Integrity pact in the event of award of contract / order

h) Financial details including Audited Balance Sheet, including Profit and Loss A/c for the preceding 3

financial years.

i) Duly filled Commercial Questionnaire.

ii

Envelope 2: Original Bid Security / EMD (1 Original + 1 Photo copy): Bidder shall furnish, as part of his Bid,

EMD for the amount as indicated in the Notice inviting Tender. The Bids not accompanied with EMD or EMD

not as per Proforma given in the Bidding Document shall be considered as non-responsive and such Bids shall

be rejected.

1 BY BANK GUARANTEE

BG No. ________________ Dt. _______________

Bank __________________ Branch ________________

For Rs. _______________________________________

Valid till _______________________________________

OR

1 BY DEMAND DRAFT

DD No. ________________ Dt. ____________________




SR Description Yes / No

Drawn on __________________ ___________________

For Rs. _______________________________________

Envelope 3: Original Priced Bid (1 Original + 1 Photo copy)

CONFIRM : All pages of the bid have been page numbered in sequential manner.

Confirm : The bid has been submitted in requisite number of copies as specified in ITB

Confirm - Compliance letter for addendum / amendment, if any, has been submitted along with offer, duly

signed and stamped

SIGNATURE OF BIDDER : ___________________

NAME OF BIDDER : ___________________

COMPANY SEAL : ___________________




PROFORMA OF LETTER OF AUTHORITY FOR ATTENDING UNPRICED BID OPENING AND PRICED BID OPENING

NO. DATE:

CEM (Engineering & Projects) West,

Bharat Petroleum Corporation Ltd, A – Installation, Sewree Fort Road, Sewree (E), Mumbai – 400015 (Maharashtra). India Dear Sirs, We …………………. Hereby authorise following representative (s) to attend the unpriced bid opening and priced bid opening against your Tender / Enquiry No. ………….. for …………………………………… 1. Name & Designation………………….. Signature …………….. 2. Name & Designation………………….. Signature …………….. We confirm that we shall be bound by all and whatsoever our representative (s) shall commit. Yours faithfully,

Signature ………………….

Name & Designation …………………. For & on behalf of ………………….

Note: This Letter of Authority should be on the letterhead of the bidder and should be signed by a person competent and having the power of attorney to bind the bidder.




PROFORMA OF DECLARATION OF BLACK LISTING / HOLIDAY LISTING In the case of a Proprietary Concern: I hereby declare that neither I in the name of my Proprietary concern M/s. ………….. which is submitting the accompanying Bid / Tender nor any other concern in which I am proprietor nor in any partnership firm in which I am involved as a Managing Partner have been placed on black list or holiday list declared by Bharat Petroleum Corporation Limited or its Administrative Ministry, except as indicated below : (Here given particulars of black listing or holiday listing and in absence thereof state “NIL”). In the case of a Partnership Firm We hereby declare that neither we, M/s. …………………… submitting the accompanying Bid / Tender nor any partner involved in the management of the said firm either in his individual capacity or as proprietor of any firm or concern have or has been placed on black list or holiday list declared by Bharat Petroleum Corporation Limited or its Administrative Ministry, except as indicated below: (Here given particulars of black listing or holiday listing and in absence thereof state “NIL”). In the case of Company We hereby declared that we have not been placed on any holiday list or black list declared by Bharat Petroleum Corporation Limited or its Administrative Ministry, except as indicated below : (Here given particulars of black listing or holiday listing and in absence thereof state “NIL”). It is understood that if this declaration is found to be false in any particular, Bharat Petroleum Corporation Limited or its Administrative Ministry, shall have the right to reject my / our bid, and, if the bid has resulted in a contract, the contract is liable to be terminated. Place: ……………… Signature of the Bidder……….. Date: ……………… Name of the Signatory ………….




CUT-OUT SLIPS TO BE USED BY VENDORS FOR PASTING ON COVERS CONTAINING BIDS

Cover – 1 Technical Bid and Price Bid:

E

DO NOT OPEN – THIS IS A QUOTATION

Cover-1: Technical Bid and Price Bid (Containing sealed Envelop 1 , Envelpo 2 & Envelope 3 )

(Project No. TCE-6758A)

Project : Blending unit at Uran LPG PlantClient: BHARAT PETROLEUM CORPORATION LTD

PMC : M/s. TATA CONSULTING ENGNEERS LTD.

RFQ / ENQ No. : -----------------------------------------------------------------------------------------

Item : ------------------------------------------------------------------------------------------------------Bid due date & time : -------------------------------------------------------------------------------

From:

To:

CEM (Engineering & Projects) West, Bharat

Petroleum Corporation Ltd, A – Installation,

Floor No.1, Sewree Fort Road, Sewree (E), Mumbai – 400015 (Maharashtra), INDIA.




Envelope 1: Techno-Commercial Bid (1 Set Original + 2 Set Photocopy)


Envelope-1: Techno-Commercial Bid

(1 Set Original + 2 Set Photocopy )

(Project No. TCE 6758A)

Project : Blending Unit at Uran LPG Plant.

Client: BHARAT PETROLEUM CORPORATION LTD

PMC : M/s. TATA CONSULTING ENGINEERS LTD.

RFQ / ENQ No.: -----------------------------------------------------------------------------------------

Item : ------------------------------------------------------------------------------------------------------------ Bid due date & time : --------------------------------------------------------------------------------------

From:

To:



Floor 1, Sewree Fort Road, Sewree (E), Mumbai – 400015 (Maharashtra), INDIA.




Envelope 2: Original EMD (1 Original + 2 Photo copy)


Envelope-2: Original EMD

(1 Original + 2 Set Photocopy )

(Project No. TCE-6758A)

Project : Blending Plant at Uran LPG Plant.



RFQ / ENQ No. : -----------------------------------------------------------------------------------------

Item : ------------------------------------------------------------------------------------------------------------

Bid due date & time : --------------------------------------------------------------------------------------

From:

To:



Floor 1, Sewree Fort Road, Sewree (E), Mumbai – 400015 (Maharashtra), INDIA.




Envelope 3: Original Priced Bid (1 Original + 2 Photo copy)

(Envelop – 2 : ORIGINAL EMD)

Client : BHARAT PETROLEUM CORPORATION LTD

PMC : M/s. UHDE INDIA PVT LTD.

Project : Import of LPG at JNPT & Development of refrigerated storage at Uran LPG Plant.

Bid document No. : -----------------------------------------------------------------------------------------

Item : ------------------------------------------------------------------------------------------------------------

Bid due date & time : --------------------------------------------------------------------------------------

From : ---------------------------------------------------- To :----------------------------------------------

(To be pasted on the envelop containing ORIGINAL EMD)


Envelope-3: Original Price Bid

(1 Original + 2 Set Photocopy )

(Project No. TCE.6758A)

Project : Blending Unit at Uran LPG Plant.



RFQ / ENQ No. : -----------------------------------------------------------------------------------------

Item : ------------------------------------------------------------------------------------------------------------ Bid due date & time : --------------------------------------------------------------------------------------

From:

To:


Petroleum Corporation Ltd, A – Installation, Floor 1, Sewree Fort Road, Sewree (E),

Mumbai – 400015 (Maharashtra), INDIA.


TENDER.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: ITB

TCE.6758A-B-300-001 CURRENT COMMITMENTS AND EXPERIENCE LIST SHEET 1 OF 2

ISSUE R0

CONCURRENT COMMITMENTS (To be filled by Bidder)

I / We furnish below the details of the works currently being executed by me / us:

Sl. No.

Full particulars of similiar work carried out by tenderer

Name, address of client and contact person

Total Contract Value

Contractual Completion period (Months)

Actual Completion Period (Months)

Expected Date of Completion

Current Progress (Percen-tage)

Signature of Tenderer with seal Name and Address of Tenderer



TCE.6758A-B-300-001 CURRENT COMMITMENTS AND EXPERIENCE LIST SHEET 2 OF 2

ISSUE R0

SCHEDULE OF BIDDER’S EXPERIENCE (To be filled by Bidder)

The BIDDER shall indicate below a list of similar jobs executed by him, to whom a reference may be made by the PURCHASER.

Sl.

No.

Nam

e,

Add

ress

, Tel

. N

o., F

ax N

o.

And

E-M

ail I

d O

f Clie

nt A

nd

Pro

ject

Nam

e P

urch

aser

O

rder

/ C

ontra

ct N

o.

And

Dat

e B

rief D

etai

ls O

f E

quip

men

t/ S

yste

m

Sup

plie

d

Sco

pe O

f S

ervi

ces

(See

Le

gend

)

Con

tract

Pric

e In

Rs.

Sch

edul

ed

Dat

e O

f C

ompl

etio

n

Act

ual D

ate

Of

Com

plet

ion

Rea

son

For

Del

ay In

C

ompl

etio

n, If

A

pplic

able

Rem

arks

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13. LEGEND: E - ERECTION, S - SUPPLY, SUP - SUPERVISION OF ERECTION, TC - TESTING AND COMMISSIONING

COMPANY SEAL SIGNATURE

NAME

DESIGNATION

COMPANY

DATE

Note: PO / Contract copies, Completion Certificates attached.



TCE.6758A-B-300-001 DEVIATION LIST SHEET 1 OF 2

ISSUE R0

SCHEDULE OF DEVIATIONS FROM GENERAL CONDITIONS (To be filled by Bidder)

The BIDDER shall indicate below all deviations from the General Conditions:

SL. NO.

SECTION SPECIFICATION NO.

PARA NO. DEVIATION

1.

2.

3. 4.

5.

6.

7.

8.

9.

10.

The Bidder hereby certifies that the above mentioned are the only deviations from the Purchaser‟s/Consultant‟s General Conditions for this Enquiry Document. The Bidder further confirms that in the event any other data and information presented in the Bidder‟s proposal and accompanying documents including drawings and catalogues etc. are at variance with the specific requirements laid out in the Purchaser‟s/Consultant‟s General Conditions, the latter shall govern and shall be binding on The Bidder without any price implication.


NAME

DESIGNATION

COMPANY

DATE



TCE.6758A-B-300-001 DEVIATION LIST SHEET 2 OF 2

ISSUE R0

SCHEDULE OF DEVIATIONS FROM TECHNICAL SPECIFICATIONS (To be filled by the bidder)

The BIDDER shall indicate below all deviations from the Technical Specifications:

SL. NO.

SECTION SPECIFICATION NO.

PARA NO. DEVIATION

1.

2.

3. 4.

5.

6.

7.

8.

9.

10.

11.

The Bidder hereby certifies that the above mentioned are the only deviations from the Purchaser‟s/Consultant‟s Technical Specifications for this Enquiry Document. The Bidder further confirms that in the event any other data and information presented in the Bidder‟s proposal and accompanying documents including drawings and catalogues etc. are at variance with the specific requirements laid out in the Purchaser‟s/Consultant‟s Technical Specifications, the latter shall govern and shall be binding on the Bidder without any price implication.


NAME

DESIGNATION

COMPANY

DATE


SPEC.NO. TATA Consulting Engineers Limited SECTION: WRITE-UP

TCE.6758A-B-610-025 ANNEXURE-I TO SPC

SCOPE OF WORK

SHEET 1 OF 2 OF 4

ISSUE

R0

SCOPE OF WORK


SPEC. NO. TCE.6758A-B-300-003

TATA CONSULTING ENGINEERS LIMITED SECTION: C

SCOPE OF WORK / SPECIFIC REQUIREMENTS - PROCESS / UTILITY/ MECHANICAL PIPING AND FIRE

PROTECTION SHEET 1 OF 9

TCE FORM NO. 329 R5 FILE NAME: F329R5.DOC

ISSUE R0

1. INTRODUCTION

1.0 Bharat Petroleum Corporation Limited (BPCL) has set up a facility for unloading, storage, and transfer of refrigerated LPG at their Uran LPG Bottling Plant. This facility consists of importing LPG from ship at JNPT, its transferred through 12” pipeline and storing the same in 2 X 8000MT refrigerated storage tanks. The stored LPG will be sent to TLF Gantry / mounded storage vessel after pre heating. This project is recently commissioned.

1.1 Keeping in focus, international supply/ demand scenario of LPG & its constituents ( Propane & Butane), BPCL plan to augment the plant operational & commercial flexibility by modifying the facility. The modified facility will consist of importing & storing propane and butane separately and blending them to LPG to export.

1.1 This tender document covers specification for design of bought out items /

equipments, field engineering, fabrication, installation, construction, inspection, testing for LPG Blending Facility at BPCL, Uran.

2. SCOPE OF WORK

2.1 SUPPLY 2.1.1 Supply of the following bought out items for fire protection system

a) MVWS spray nozzles

b) Fire hydrants – Single / Double

c) Water monitors

d) Portable fire extinguishers

e) Interconnecting piping / valves.

2.1.2 Supply of pipes / fittings / valves / Specialties for interconnecting piping. 2.1.3 Supply of paint material

2.1.4 Supply of special tools and tackles required for maintenance included in

the supply price.

2.1.5 Supply of commissioning spares included in the supply price.

2.1.6 Supply of Pipe Supports for Piping.

2.1.7 Supply of PIR Insulation with Cladding.


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0

2.2 Third party inspection for all supply items. Third party inspection prices are

included in the supply price. Contractor to appoint TPIA from the approved vendor list for carrying out various stage-wise and final inspection.

2.3 Mechanical completion / testing and commissioning and handing over of

all the above system.

2.4 WRAPPING & COATING OF UNDERGROUND PIPING Supply and application of corrosion tape coating for Underground Piping IS-1239/3589 - Cleaning of external pipe surface by wire brush - Application of primer and allow it to touch dry - Heat the primer coated pipe and the bottom surface of 4mm tape - Wrap the 4mm tape (Tar based polymeric mix supported on a fabric of high tensile strength fibre glass

2.5 DISMANTLING OF FIRE WATER PIPING SYSTEM Disconnecting all the Piping connections to make free of all attachements (as per Marked P&ID and instructions of Engineer in charge). Spading/ Despading of connected piping, removal of pipes, valves, fittings, and placing them in sorted manner at designated place as per instructions of Engineer in charge. Providing all required tools and tackles, crane etc, scaffolding as per requirements to complete the work in all respects as per instructions of Engineer in Charge. Adequate care shall be taken by the contractor not to damage the existing equipment /piping system while dismantling.

2.6 ERECTION 2.6.1 Erection of the following bought out items for fire protection system

f) MVWS spray nozzles

g) Fire hydrants – Single / Double

h) Water monitors

i) Portable fire extinguishers

2.6.2 Erection of pipes / fittings / valves / Specialities for interconnecting piping. 2.6.3 Works and Services for the equipments, fire protection and piping. 2.6.4 Fabrication of interconnecting piping.

2.6.5 Fabrication of fire water hydrant piping. 2.6.6 Fabrication of MVWS piping.


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0

2.6.7 Fabrication of supports for piping, equipment, etc.

2.6.8 Wrapping & Coating of UnderGround Piping.

2.6.9 Dismantling & Rerouting of Fire Water Piping.

2.6.10 Surface preparation and painting. 2.6.11 Erection of all the above items.

2.6.12 Application of PIR Insulation with Cladding. 2.6.13 Erection of piping for Wagon Filling & Horton Sphere(approx 300NB &

200NB) which will be a Free Issue Material (By BPCL). 2.7 Mechanical completion / testing and commissioning and handing over of

all the above system.

2.8 Preparation of as built markup.

3. DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR

3.1 It shall be Contractor's responsibility to furnish all necessary documents as given below;

a) Manufacturing schedule / Bar chart

b) Quality Assurance Plan

c) Purchase specifications / requisitions for bought out items.

d) Quality control procedures.

e) Procedures for Fabrication, Inspection and Testing along with acceptance criteria

f) List of components to be pre-fabricated at shop and activities which shall be performed at shop.

g) Measurement and record of settlement during hydro-test / construction.

h) Procedure for installation, maintenance and operation manual for bought out items.

4. PRE CONDITIONS FOR MECHANICAL WORKS

The Mechanical Works is to be done in the existing Import/ Export terminal area where the facilities is in operation. The contractor has to prepare a detailed methodology with respect to safety and emergency mitigation measures and submit to BPCL / TCE for review. Any special safety requirements in case of emergency etc. shall be provided by the CONTRACTOR. The works is


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0

to be extensively planned to ensure the Mechanical Works is carried out without impeding on the adjacent plant and structures and without risk to operatives and Owner personnel.

The bidder is advised to visit and examine the site of works and its surroundings and obtain for itself on its own responsibility all information that may be necessary for preparing the bid and entering into the Contract.

5. CLEAN UP

The Contractor shall maintain the construction area in a clean condition throughout the entire working period. Accumulated debris and waste materials shall be hauled from the site and disposed off at an approved location on daily basis to maintain clean conditions. Field offices and sanitary facilities shall be kept in a hygienic condition in accordance with the regulations of local authorities and good practice. 6. SAFETY PRECAUTIONS

General Safety Precautions to be taken by Contractor

Contractor shall follow all safety guidelines put forth by BPCL/TCE – Safety.

Contractor shall follow all precautions as per “Guidelines for undertaking Site Work”.

The contractor shall adhere to safe construction practices at all stages of

work to guard against accidents, hazardous and unsafe working procedures.

Temporary enclosures/fencing, danger lights etc. as per safety requirements shall be provided by contractor to prevent accidents.

All equipment, pipes, fixtures etc. located in the vicinity shall be protected by

suitable means, during demolishing and dismantling operation.

Necessary measures shall be taken to keep the dust nuisance minimum

All safety rules shall be strictly followed by contractor during the entire job.

Contractor shall deploy a dedicated safety engineer during the job.

Good housekeeping shall be maintained by the contractor during the entire job.

Adequate fire fighting and safety equipment in according to the requirement

shall be arranged by the contractor at site including fire hoses, fire extinguishers, safety belt, lifelines ,hard helmets, safety shoes, hand gloves etc.

Fireproof asbestos cloth where ever required to restrict the flying sparks due

to cutting,welding, grinding etc will be required to be provided by the contractor.


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0

All workmen should wear safety belts / lifeline wherever they work above 2 m elevation without permanent support /platform. Workmen shall always wear helmet & safety shoes while on the site / work area.

Contractor should start the work only after obtaining authorized valid work

permits.

Contractor shall allow only those workers to work who have the authorized gate entry permit.

In case of fire/ fire alarm, the contractor should stop the work, withdraw the

manpower from the work site and inform the engineer in charge immediately.

All safety and security rules of the corporation as prevailing in the refinery at the time of execution of the job are to be strictly adhering to.

Contractor shall be fully responsible for all acts of commission of his/their

workmen. Work Permits and Entry Permits. The following safety precautions to be taken in addition to hot work and working at height permit system.

1. Scaffolding for working at elevations along suitable safety harness for personnel shall be used by Contractor.

2. Proper purging of lines (Line Number: 200-LPHM1-10618-BE57C-K30, 200-

LPHM1-10523-BE57C & 200-LPHL-10201-BE57C-K60) which are in operation presently& spading to be done prior to gas cutting of the lines.

3. Fall arrestor to be used for working at height. Fall arrestor to be fixed /

attached to the rigid strong structure. Metal plank used as platform to be properly tightened with wires to rigid structure.

4. Safety net to be used at above grade level and below the hot work site to

arrest any falling objects. 5. At grade level, Blending Skid/ Butane Pre-Heater area to be barricaded and

entry to be given to the authorized persons only. Rigid Tin sheet barrication to be provided around this area upto 6.5 mts. height.(Refer 6758APP8701P0-Conceptual Piping Layout indicating the Blending Skid/ Butane Pre- Heater Area)

6. All workers shall be medically fit for working at height.

7. During gas cutting of lines, slight purging to be kept ON continuously.

8. Wooden scrap near to the work site to be removed prior to the hot work.

9. No job to be done during high wind flow and heavy rain. While working at

height no other job to be done at grade level.


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0

10. Local barricading to be provided for arresting flying sparks at work site. Use welding blanket for barrication. No spark to be seen from outside.

11. All work men should use PPE. Operation & Projects to close vigil at job and

ensure 100% compliance of PPE. All Workmen should have valid safety passes. Double life line safety belt shall be used for the job at height.

12. Job to be done in day light only.

13. Conduct tool box meeting prior to the job. 100 % contractor supervisors stand

by to be provided. 7. QUALIFICATION AND EXPERIENCE OF MANPOWER TO BE DEPLOYED Contractors shall deploy only experienced and qualified supervisors and workman, who are well conversant with the safety & environment regulations in the LPG Plant/ Oil Depots. The minimum qualification requirements of supervisors for field jobs ( other than office jobs, grass cutting, housekeeping, general cleaning jobs etc.) shall be:

Diploma in relevant branch of engineering with 3 years of experience or

SSC + ITI in the relevant field with 10 years experience. 8. ISSUE OF GATE ENTRY PASS On award of contract and prior to commencement to work, the Contractor must

a) Provide list of personnel necessary documents (viz. Bio-Data , medical certificate etc.) of each employee

b) Obtain labor license and complete ESIC & PF related formalities.

c) Submit ESIC, PF & Labor License details to BPCL.

d) Ensure completion of safety training by all supervisors and workmen. 9. OBLIGATION TO FOLLOW WORK PERMIT SYSTEM

a) Do not carry out any work without a valid work permit issued by authorized persons in the refinery, as per Work Permit System.

b) After obtaining a valid work permit and before the actual commencement of work, also obtain a clearance certificate from the officer of the unit/ plant where the work is to be carried out.

c) Register permit and clearance at refinery fire station as required under the

Work Permit System.


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0

d) Comply with all the Fire/ Safety/ Excavation/ Radiography permit conditions specified in the permit and clearance.

e) Prepare a safety action plan specific to the work before starting the work. Also ensure that all the supervisors and workers involved in the work, properly understand and follow the safety action plan.

f) Display permit/ clearance at site for checking, by the refinery officials

whenever required. 10. REQUIREMENT OF SUPERVISION

a) Contractor will not carry out any work without having a supervisor present at site. If it is required to work simultaneously in more than one location under the same contract, one supervisor must be put in each of the locations. If a supervisor has to leave his site for any reason, he must stop his site activities for that period of time.

b) Contractor must provide at least one full time onsite safety supervisor.

c) Contractor’s safety supervisor or the supervisor responsible for safety shall maintain separate register which will include

List of activities being carried out at site

Safety Training details of all supervisors and workmen

Records of all accidents, first aid cases and near misses

Records of all PPE’s being used at site

Records of lifting tools and tackles inclusing slings of all types

Records of pressure vessels if any at his site

Records of all welding machines, gas cutting sets, compressors, generators, pressure regulators, portable power tools, hand tools etc.

Copies of safety inspection reports made by the Contractor safety

supervisor as well as by the BPCL .

The Contractors whose safety records are not satisfactory will be viewed seriously and necessary actions for cancellation of Registration/ Contract shall be taken.

11. USE OF PERSONAL PROTECTIVE EQUIPMENT Contractor’s all supervisors and workmen must use following Personal Protective Equipment(PPE’s) without which permission to work will be denied.

a) Hard Hat b) Safety Shoes c) Boiler Suits


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0

d) Hand Gloves as per job requirement e) Safety belt as applicable f) Eye protection goggles etc.

The PPE’s shall be of standard quality and ISI approved. Only Special Protective Equipment like “ Breathing Apparatus Set” and Fire Extinguishers shall be provided by BPCL to the contractor, on loan basis. If the same is not returned after completion of the contract or damaged beyond repair, recovery as appropriate will be made from his dues, from the company. 12. HAZARD COMMUNICATION Contractor must familiarize himself from BPCL Engineer-in-charge about all known potential fire, explosion or toxic release hazards related to his contract. He in turn will ensure that same information has been passed to his supervisors and workmen. Proper record of such dis-semination of information must be made by the contractor and submit to the Engineer-in-charge on demand, failing which further continuation of work will be withheld.

13. INJURY NOTIFICATION AND INVESTIGATION Contractor must

a) Report to BPCL Supervisor on-the-job any injury sustained by any of his employees or any near missed or any hazardous/ dangerous incident at his work site within the work premised. Hiding of any incident or near misses would be viewed as serious misconduct.

b) Arrange to provide FIRST AID immediately to the injured employee.

c) Keep and maintain proper records of all such incidents in respect of his

personnel/ worksite.

d) Submit to the Engineer-in-charge, a first information report as per prescribed Proforma within 4 hours of the incident.

e) Arrange to immediately investigate the incident and furnish within 24 hrs a

written investigation report in prescribed Proforma to BPCL Engineer-In-Charge.

14. REQUIREMENT OF HOUSE KEEPING Contractor must ensure highest standard of housekeeping in his area of work.


SPEC. NO. TCE.6758A-B-300-003





ISSUE R0


SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP

TCE.6758A-B-300-001 ANNEXURE-III TO SPC

TERMS OF PAYMENT

SHEET 1 OF 2 OF 4

ISSUE

R0

TERMS OF PAYMENT



TCE.6758A-B-300-001 ANNEXURE-III TO SPC

TERMS OF PAYMENT

SHEET 2 OF 2 OF 4

ISSUE

R0

2.0 TERMS OF PAYMENTS

2.1 PAYMENTS FOR SUPPLIES (SOR-1 FORM) Subject to the other provisions of Contract documents, on account payments for the

supplies will be made as follows:

(i) 70% (Seventy) payment shall be released on prorata basis against receipt of

equipment / material at site in good condition, submission of third part inspection

clearance certificate and acceptance by Engineer-in-charge.

(ii) 20% (Twenty) payment shall be released on prorata basis on completion of Erection/

Installation for Equipments/ Materials.

(iii) 10% (Ten) payment shall be released on Mechanical Commissioning on prorata basis

and submission of Performance Bank Guarantee.

2.2 PAYMENTS FOR WORKS/SERVICES(SOR-2 FORM)

(i) 80% (Eighty) payment shall be released on prorate basis on completion of erection/

works in all respects and inspection and acceptance by Engineer-In-Charge.

(ii) 20% (Twenty) payment shall be released on Mechanical Commissioning on prorata

basis and submission of Performance Bank Guarantee for 10%

2.3 All other payment terms given in Special Conditions of Contract item 11.0

will be superseded.



TCE.6758A-B-300-001 QUALITY MANAGEMENT SYSTEM SHEET 1 OF 6 OF 4

ISSUE R0

BIDDER’S QUALITY MANAGEMENT SYSTEM

REQUIREMENTS




ISSUE R0

1.0 INTRODUCTION This specification establishes the Quality Management System requirements to be met by BIDDER. In case of any conflict between this specification and other provisions of the tender document / MR / PR, the same shall be brought to the notice of BPCL, at the stage of bidding and shall be resolved with BPCL, prior to the placement of order.

2.0 DEFINITION 2.1 BIDDER

For the purpose of this specification, the word “BIDDER” means the person(s), firm, company or organization who is under the process of being contracted by BPCL for delivery of some products (including service). The word is considered synonymous to supplier, contractor or vendor.

2.2 PROJECT QUALITY PLAN

Document tailored from Standard Quality Management System Manual of BIDDER, specifying how the quality requirements of the project will be met.

2.3 OWNER

Owner means the owner of the project for which services / products are being purchased and includes their representatives, successors and assignees.

3.0 REFERENCE DOCUMENTS

ISO:9001-2000 (Quality Management Systems - Requirements)

ISO:9004-2000 (Quality Management Systems - Guidelines for Performance Improvements)

ISO:9000-2005 (Quality Management Systems - Fundamentals and Vocabulary)

4.0 QUALITY MANAGEMENT SYSTEM – GENERAL

Unless otherwise agreed with BPCL, the BIDDER proposed quality system shall fully satisfy all the elements of ISO 9001 – 2000 “Quality Management Systems – Requirements.” Evidence of compliance shall be current certificate of quality system registration to ISO 9001 or a recent compliance audit recommending registration from a Registrar acceptable to BPCL. The quality system shall provide for the planned and systematic control of all quality related activities for execution of contract. Implementation of the system shall be in accordance with BIDDER‟S Quality Manual and PROJECT specific Quality Plan, which shall both, together with all related/referred procedures, be submitted to BPCL for review, comment and approval.

5.0 QUALITY SYSTEM REQUIREMENTS

5.1 BIDDER shall ensure that the responsible authority for execution of the order / contract has communicated the P0/ contract requirements including any




ISSUE R0

identified or intended statutory and regulatory requirements to all concerned in sub-contractor‟s organization who are contributing to the execution of the PO/ contract.

5.2 BIDDER shall establish a documented Quality Policy and Quality Objectives to achieve the specified and intended requirement of purchase order / contract.

5.3 BIDDER shall identify and communicate the responsibilities and authorities of the personnel contributing to the execution of the order / contract.

5.4 BIDDER shall deploy competent and trained personnel for various activities for fulfillment of PO / contract. BIDDER shall arrange adequate infrastructure and work environment to ensure that the specification and quality of the deliverable are maintained.

5.5 BIDDER shall do the quality planning for all activities involved in delivery of order. The quality planning shall cover as minimum the following:

• Resources

• Product / deliverable characteristics to be controlled.

• Process characteristics to ensure the identified product characteristics are realized

• Identification of any measurement requirements, acceptance criteria

• Records to be generated

• Need for any documented procedure.

5.6 Requirements for sub-contracting / purchasing of services specified in contract / tender shall be adhered to. Wherever requirements are not specified, the sub-contractor shall establish and maintain a system for purchasing / sub-contracting to ensure that purchased product / service conforms to specified requirements. Criteria for selection of sub-contractor, evaluation, re-evaluation, maintenance of purchasing data and verification of purchased product (sub-contractor services), constitute important components of this requirement.

5.7 BIDDER shall plan and carry production and service provision under controlled conditions. Controlled conditions shall include, as applicable

a) The availability of information that describes the characteristics of the product

b) The availability of work instructions

c) The use of suitable equipment

d) The availability and use of monitoring and measuring devices

e) The implementation of monitoring and measurement




ISSUE R0

f) The implementation of release, delivery and post delivery activities.

5.8 BIDDER shall validate any processes for production and service provision where resulting output cannot be verified by subsequent monitoring and measurement. This includes any process where deficiencies become apparent only after the product is in use or service has been delivered.

5.9 BIDDER shall establish a system for identification and traceability of product / deliverable throughout product realization. Product status with respect to inspection and testing requirements shall be identified.

5.10 BIDDER shall identify, verify, protect and safeguard Owner property (material / document) provided for use or incorporation into the product. If any Owner property is lost, damaged or otherwise found to be unsuitable for use, this shall be reported to the Owner.

5.11 BIDDER shall preserve the conformity of product / deliverable during internal processing and delivery to the intended destination. Requirements mentioned in the tender shall be adhered to.

5.12 BIDDER shall establish system to ensure that inspection and testing activities are carried out in a manner that is consistent with the inspection and testing requirements. Where necessary, measuring equipments shall be calibrated at specified frequency, against national or international measurement standards; where no such standard exists, the basis used for calibration shall be recorded. The measuring equipments shall be adjusted or re-adjusted as necessary, identified to enable the calibration status to be determined. The measuring equipments shall be protected from damage during handling, maintenance and storage.

5.13 BIDDER shall ensure effective monitoring, using suitable methods, of the processes involved in production and other related processes for delivery of the scope of contract.

5.14 BIDDER shall monitor and measure the characteristics of the product deliverable to verify that product requirement has been met. The inspection (stage as well as final) by BIDDER and Owner personnel shall be carried out strictly as per the ITPs forming part of the contract. Product release or service delivery shall not proceed until the planned arrangements have been satisfactorily completed, unless otherwise approved by relevant authority and where applicable by Owner.

5.15 BIDDER shall establish and maintain a documented procedure to ensure that the product which does not conform to requirements is identified and controlled to prevent its unintended use or delivery

5.16 All non-conformities (NCs) / deficiencies found by the BIDDER‟S inspection / surveillance staff shall be duly recorded, including their disposal action shall be recorded and resolved suitably. Effective corrective and preventive action shall be implemented by the BIDDER so that similar NCs including deficiencies do not recur.




ISSUE R0

5.17 All deficiencies noticed and reported by Owner shall be analyzed by the BIDDER and appropriate corrective and preventive actions shall be implemented. BIDDER shall intimate Owner of all such corrective and preventive action implemented by him.

5.18 BIDDER shall have documented procedure for control of documents and it shall be submitted for Owner comments.

5.19 All project records shall be carefully kept, maintained and protected for any damage or loss until the project completion, then handed over to Owner as per contract requirement, or disposed as per relevant project procedure.

6.0 AUDITS

BIDDER shall plan and carry out the QMS audit for the job. Quality audit programme shall be for systematic audit and surveillance of detailed design, procurement, construction management and commissioning, vendor and sub-contractors (as applicable). This shall be additional to the certification body surveillance audits carried out under BIDDER‟S own ISO 9001 certification schemes. The audit programmes and audit reports shall be submitted to OWNER /TCE as per BIDDER‟S documentation requirement matrix. TCE or OWNER‟S representative reserves the right to attend, as a witness, any audit conducted during the execution of the WORKS. In addition TCE / Owner appointed third party may also perform a program of Quality and Technical compliance audits. BIDDER shall provide assistance and access to their systems and sub-contractor / vendor systems as required. Any deficiencies noted shall be immediately rectified by BIDDER.

7.0 PROJECT QUALITY PLAN REQUIREMENTS BIDDER shall prepare and submit Project Quality Plan for review and approval. The BIDDER‟S quality Plan shall address all of the applicable elements of ISO 9001, identify responsible parties within BIDDER‟S organization, for the implementation / control of each area, reference the applicable procedures used to control / assure each area, and verify the documents produced for each area. The Project Quality Plan shall necessarily define control or make reference to the relevant procedures, for design and engineering, purchase, documentation record control, bid evaluation, inspection, quality control at contractor / sub-contractors, preservation, packaging and storage, quality control at contruction site, pre-commissioning, commissioning and handing over (as applicable) in line with contract requirement and scope of work.

8.0 DOCUMENTATION REQUIREMENTS The required QMS documents specified in BIDDER‟S documentation requirements matrix shall be submitted for review / approval by TCE / Owner otherwise work shall not be allowed to continue. BIDDER‟S DOCUMENTATION REQUIREMENTS MATRIX




ISSUE R0

Sr. No.

Document To Be Submitted No. of Copies At Bid Stage After Award

of Job

1. Quality Manual 04

2. CVs of the personnel in BIDDER‟S QA Organogram

03

3. Certificate of approval for compliance to ISO:9001 standard

02

4. Organization chart a) for complete organization b) for the project

04 04

5. Procedure for Control of Non-conforming Product

04

6. Procedure for Control of Documents

04

7. Sample audit report of the QMS internal and external audits conducted during last one year.

03

8. Project Quality Plan 04

9. Customer satisfaction reports from at least 2 customers, during the last five years.

03

10. Audit program for the project 03

11. a) project audit report b) corrective action report on

the project audits

As per audit plan

03 03

12. Technical audit reports for the project

As per audit plan

03


TATA CONSULTING ENGINEERS LTD.

GPC (TCE-6758A) Page 1 of 26

General Purchase Conditions (GPC) Project No.: TCE-6758A

BLENDING UNIT AT URAN LPG PLANT Client: Bharat Petroleum Corporation Limited

TABLE OF CONTENTS

1 DEFINITIONS 2 INTERPRETATION OF CONTRACT DOCUMENTS 3 IRRECONCILABLE CONFLICTS 4 CONFIRMATION OF ORDER 5 PRICE 6 FREIGHT, TAXES AND DUTIES 7 EARNEST MONEY 8 VENDORS’ DRAWINGS AND DATA REQUIREMENT 9 FREE ISSUE MATERIALS (for incorporation in the Indigenous supply)

10 THE BILL OF MATERIAL(S) 11 MODIFICATION 12 SUB-CONTRACTS 13 EXPEDITING 14 RESPECT FOR DELIVERY DATES AND PRICE DISCOUNT 15 DELAYS DUE TO FORCE MAJEURE 16 WARRANTY OF TITLE 17 INSPECTION AND TESTING 18 ACCEPTANCE OF MATERIALS & GUARANTEES 19 WEIGHTS AND MEASUREMENTS 20 PACKING & MARKING 21 SHIPMENT AND SHIPMENT NOTICES 22 MARINE AND TRANSIT RISK INSURANCE 23 SHIPPING AND SHIPPING DOCUMENTS 24 ARBITRATION

Attachments: ANNEXURE I: INTEGRITY PACT ANNEXURE II: PROFORMA FOR BANK GUARANTEE (EARNEST MONEY DEPOSIT) ANNEXURE III: PROFORMA OF BANK GUARANTEE (SECURITY DEPOSIT) ANNEXURE IV: PROFORMA OF BANK GUARANTEE (PERFORMANCE) ANNEXURE V: NATIONAL ELECTRONIC FUND TRANSFER (NEFT) MANDATE FORM




1.0 DEFINITIONS Unless repugnant to the subject or context thereof, the following expressions

herein used shall carry the meaning hereunder respectively assigned to each, namely:

(a) “Bulk Consumables” mean items specifically defined in the Contract

Documents to constitute bulk consumables. (b) “Contract” shall mean the contract as derived from:

i) The Tender Documents / Request For Quotation; ii) Agreed Variations to the Tender Documents / Request For

Quotation; iii) Vendor’s Priced bid; and iv) The Purchase Order / Work Order / Contract.

(c) “Contract Document(s)” shall mean individually and collectively the documents constituting the contract.

(d) “Defect Liability Period” in respect of:

(i) Bulk Consumables shall be the date of delivery plus 6 (six) months (ii) In the case of other Material(s) shall be 18 (eighteen) months from

the date of delivery or 12 (twelve) months after the same have been put in service or commissioned, whichever is earlier;

(iii) In the case of altered or replaced Material(s):

(a) With respect to Bulk Consumables, shall be 6 (six) months from the date of alteration, repair or replacement as the case may be; and

(b) With respect to other Material(s), shall be 12 (twelve) months from the date of alteration, repair or replacement as the case may be.

(e) “Delivery”

(i) with respect to Imported Material(s) means the date of completing shipment of the Material(s) on board the designated vessel or aircraft at the designated port or place of shipment, securely packed and loaded below deck and unless otherwise determined, shall be deemed to be the date of the relative Bill of Lading or Airway Bill; and




(ii) with respect to Indigenous Material(s) means the date of completing shipment of Material(s) F.O.R./F.O.T. securely packed and loaded and unless otherwise determined, shall be deemed to be the date of the relative Truck/lorry Receipt or Railway Receipt.

(f) “Earnest Money Deposit” means the Demand Draft or Banker’s Pay Order

or the bank guarantee furnished by the Vendor in lieu of cash in support of his/its bid as required by the Bid Documents.

(g) “Equipment” means plant, machinery, equipment, instruments, computer,

control and other electronic and electrical systems, and shall include parts, components, assemblies and sub-assemblies thereof.

(h) “Free Issue Material(s)” means any equipment, parts or components or

spares to be supplied by BPCL to the vendor, which are to be incorporated in any supply of Indigenous Material(s).

(i) “BPCL” Bharat Petroleum Corporation Limited having its Registered office

at 4&6, Currimbhoy Road, Ballard Estate, Mumbai – 400 001and includes its successors, assigns and all persons through whom it acts in any matter for the purpose of the Tender or the Contract.

(j) PMC shall means M/s. TATA CONSULTING ENGINEERS LTD (TCE) having

its office at Raj Plaza, L.B.S Marg, Vikhroli (W), Mumbai 400 083 Indiaand engaged by BPCL as Consultant for their Project.

(k) “Imported Material(s)” mean(s) the materials to be fabricated,

manufactured or procured by the Vendor outside India for shipment to India under the Contract.

(l) “Indigenous Material(s)” mean(s) materials to be fabricated, manufactured

or procured by the Vendor within India for supply under the Contract.

(m) “Inspectors” means Inspectors nominated, appointed, approved or deputed

by BPCL/TCE for inspection of the Material(s) prior to Delivery.

(n) “Material(s)” means any and all raw materials, manufactured articles,

equipment, spares and other goods and supplies whatsoever and includes wherever applicable drawings, data, specifications and intellectual property rights and all services (including but not limited to design, fabrication, inspection, delivery and testing) required to be supplied, done, performed, prepared or undertaken to meet the requirements of the Contract.

(o) “Procurement Coordinator” means the representative or agency appointed

by BPCL/TCE for managing, expediting and/or coordinating the supply of

Material(s).




(p) “Project” means LPG Plant & construction of Propane and Butane Blending facility at Uran LPG Plant.

(q) “Project Site” means the site of the Project for which the Material(s) is/are required.

(r) "NIT" means Notice Inviting Tender/ "NIB" means Notice Inviting Bid/ “IFP”

means Invitation for pre-qualification. (s) "LIT" means Letter Inviting Tender/ "LIB" means Letter Inviting Bid. (t) "EMD" means Earnest Money Deposit (u) "GCC" means General Conditions of Contract (v) “GPC” means General Purchase Conditions

(w) “SPC” means Special Purchase Conditions (x) "ITB" means Instructions to Bidder (y) "SCC" means Special Conditions of Contract (z) “SOP” means Schedule of Price(s)/ “SOR” means Schedule of Rate(s). (aa) “BEC” means Bid Evaluation Criteria. (bb) “BQC” means Bidders’ Qualification Criteria. (cc) “Bidder/Tenderer” means any person, company, firm or body who are

issued the Bidding Document by BPCL/TCE and submits the bid.

(dd) “Bidding Document/Tender Document" means document to be issued to Bidder based on which Bid is to be submitted. (ee) “Bid/Offer” means the documents/proposal submitted by Bidder. (ff) "CD" means Compact Disc. (gg) Suppliers /Vendor – shall mean the person, firm or corporation to whom Purchase Order is placed and includes its successors and assigns. (hh) Goods / Materials - Goods and / or materials shall mean any of the

articles / materials / machinery / equipment / supplies / drawings / data & other property and all services including but not limiting to design, delivery, installation, instructions, testing and commissioning specified or required to complete the order.




(ii) “Purchase Order” means BPCL’s acceptance of the Vendors’ offer/bid and includes any formal or detailed Purchase Order issued by BPCL pursuant to the acceptance of the bid.

(jj) “Stipulated Delivery Period” means the date(s) for delivery of the

Material(s) as stipulated in the Contract and failing such stipulation, shall mean the date(s) for such delivery(ies) as agreed between the Vendor and BPCL.

(kk) “Tender Documents” with reference to the Purchase Order mean:

(i) Material Requisition/Request for Quote; (ii) General Terms and Conditions of Purchase; (iii) Technical Specifications; (iv) Special Conditions of Purchase (if any); (v) Addendum(s) (if any) to the Tender Documents.

(ll) “Total Contract Value” means total value of the Material(s) and services to

be supplied as specified in the Purchase Order / Contract, exclusive of reimbursable taxes and duties.

(mm) "Contractor" means any person, company, firm or body who may be

engaged by BPCL for works and services connected with construction, installation, erection and commissioning of the facilities for the Project with or without supply of equipment/material.

2.0 INTERPRETATION OF CONTRACT DOCUMENTS

2.1 The several Contract Documents forming the Contract are to be read together as a whole and are to be taken as mutually explanatory.

2.2 Should there be any doubt or ambiguity in the interpretation of the

Contract Documents or in any of them, the Vendor shall prior to commencing the relative supply or work for supply under the Contract apply in writing to BPCL for resolution of the doubt or ambiguity. Should the Vendor fail to apply to BPCL within 7 days from the date of receipt of the Order for its clarification as aforesaid, the Vendor shall perform the relative work and/or make the relative supply at his own risk.

2.3 Any item of supply or service relative thereto shown, indicated or

included by expression or implication in any document forming part of the Contract shall be deemed to form part of the Scope of Supply with the intent that the indication or inclusion of the supply or service within any of the said documents shall be a sufficient indication of the Scope of Supply or service covered by the Contract.

2.4 No verbal agreement or assurance, representation or understanding

given by any employee or officer of BPCL/TCE or so understood by the

Vendor shall anywise bind BPCL or alter the Contract Documents unless specifically given in writing and signed by or on behalf of BPCL as an Agreed Variation to the relative term(s) in the Contract Document(s).




2.5 Clause headings given in this or any other Contract Documents are

intended only as a general guide for convenience in reading and segregating the general subject of the various clauses, but shall not govern the meaning or import of the clauses there under appearing or confine or otherwise affect the interpretation thereof.

3.0 IRRECONCILABLE CONFLICTS

Subject to the provisions of Clause 2 hereof, in the event of an irreconcilable conflict between the provision of these General Terms and Conditions of Purchase and/or the Special Conditions of Purchase and/or Addendum (s) and/or the Agreed Variations to the Tender Documents and/or the Purchase Order and/or between any of the other said documents so that the conflicting provision(s) cannot co-exist, to the extent of such irreconcilable conflict, the following order of precedence shall apply so that the conflicting provision(s) in the document lower in the order of precedence set out below shall give way to the conflicting provision(s) in the document higher in the order of precedence, namely: (i) Agreed Variations to the Tender Documents; (ii) Purchase Order; (iii) Addendum(s) / Addenda (s) to the Tender Document; (iv) Special Conditions of Purchase; (v) General Terms and Conditions of Purchase; (vi) Other Contract Documents.

4.0 CONFIRMATION OF ORDER

4.1 Without prejudice to the formation of contract by acceptance of bid, the Vendor shall acknowledge the acceptance of the Purchase Order by signing and returning the duplicate/photocopy within 7 (seven) days following receipt of the Purchase Order and such acknowledgement shall constitute conclusive evidence of a concluded contract without exception, on the terms and conditions set out in the Bid Documents.

4.2 Should the Vendor fail to acknowledge acceptance of the Purchase Order within the period specified above, BPCL may, without prejudice to any other right or remedy available to it, forfeit the Earnest Money Deposit.

5.0 PRICE

5.1 Unless otherwise specifically stipulated, the price shall be firm and shall not be subject to escalation for any reason.

5.2 Oils & Lubricants: The first fill of oils and lubricants for every

equipments shall be included in the price. Bidders shall also recommend for quality and quantity of oils and lubricants required for one year continuous operation.




5.3 Spare Parts: Bidders must furnish itemized price list of spare parts required for

a) Vendor recommended mandatory spares b) Commissioning spares, tools & tackles

c) Five years spars for trouble free operation and maintenance

d) Vendor recommended Insurance spares

5.4 The bidders shall furnish the present rate of excise / customs duty CVD, education cess and VAT / CST as applicable and is payable on production of documentary evidence. VAT credit shall be considered while evaluating (where ever applicable).

5.5 The bidders should mention clearly in his bids whether he has opted for composition scheme or standard deduction method or Actual non-materials value method. Rate and amount of such VAT (WCT) being quoted, has to be given for evaluation. Preferred method to be followed is composition scheme.

5.6 BPCL may claim Cenvat on service tax. The bidders should quote service tax separately (In rates as well as in values). Bidders are required to furnish serially numbered and signed invoices/bill / challan containing the following details:

i Name, address and registration number of service provider.

ii Name and address of person receiving taxable service.

iii Description, classification and value of taxable service provided.

iv Service Tax Payable.

5.7 Service tax & Education cess thereon shall be payable extra as actual against copy of Service tax invoice. Bidders shall furnish the present rates of service tax and education cess as applicable.

5.8 Any Statutory variation in excise duty / VAT on finished goods, within the contractual delivery date, shall be on owner’s account, against submission of documentary evidence. However, in case of delay in delivery beyond the contractual date, for reasons attributable to seller, any increase in these rates shall be borne by seller, whereas any decrease shall be passed on to the owner.

5.9 Further, in case of delay in delivery, due to reasons attributable to seller, any new or additional taxes, duties or levies imposed after the contractual delivery date shall be on seller’s account.

5.10 For the purpose of applicability of statutory variations on trade tax/sales tax, excise duty and education cess (including imposition of any new taxes/duties/levies, etc.) under above terms, each staggered delivery lot (due in a specific month as per delivery schedule) shall be considered delivery date for the respective lot(s).




5.11 Foreign suppliers’ bid shall be compared considering Bill selling foreign exchange rate as on the date of priced bid opening, as provided by

BPCL, on request of TCE.

5.12 Suppliers’ prices shall be inclusive of third party inspection charges.

Third Party Inspection agency shall be nominated by TCE/ BPCL.

5.13 Excise duty, sales tax, service tax, VAT and Works Contract Tax shall not be included in the quoted prices and shall be payable extra at actual. Work contract tax shall be included in the quoted prices and no variation shall be payable by BPCL. Further, the amount of excise duty, service tax and VAT shall be payable only against submission of cenvatable/ vatable invoices and in case of non-submission, will not be paid.

5.14 If it is stipulated that octroi, terminal taxes and entry taxes are to be

borne by BPCL, the Vendor shall arrange for the transporter to pay the octroi, terminal taxes and/or entry taxes, if any leviable and claim reimbursement thereof from BPCL against proof of payment.

5.15 If it is stipulated that dispatch shall be on “freight to pay basis”, the

Vendor shall advise the transporter to collect the freight from BPCL after the full quantity of the Material(s) has/have been delivered in good condition to the Project Site.

5.16 Unless otherwise stipulated, the price of Imported Material(s) shall be the

FOB /FCA price of Material(s) and shall be inclusive of sea/air worthy water-proof packing and forwarding charges and loading of Material(s) below deck of vessel and all taxes upto delivery of Material(s) at stipulated Indian Port, shipped through Indian flag vessels, but shall be exclusive of marine/air insurance and ocean/air freight. Except for stipulations to the contrary in the Contract, the provisions of FOB (INCOTERMS-2000) shall apply to ocean shipments and the provisions of FCA (INCOTERMS-2000) shall apply to air shipments.

6.0 FREIGHT, TAXES AND DUTIES

6.1 Subject to the provisions of Clause above, Excise duty and Sales tax/VAT payable on the sale and delivery of Material(s) pursuant to the Contract will be paid in the case of Sales tax and reimbursed in the case of VAT and Excise duty at actual within the contractual delivery date. Any increase in the rates of Excise Duty & VAT beyond the contractual completion date or approved extended contractual completion date will be borne by BPCL to the extent CENVATABLE documents passed on to BPCL and BPCL is in a position to get the CENVAT claim from the authorities. However, the benefit of any reduction must be passed on to BPCL

6.2 Taxes and duties payable or reimbursable by BPCL to the Vendor on the

supply of Indigenous Material(s) shall be included in and shown




separately in the Vendor’s invoice for the Material(s). However, the Vendor shall not be entitled to claim payment from the bankers or BPCL of CENVATABLE or VATABLE taxes or duties on which BPCL would be entitled to other credits (presently Excise Duty, Value Added Tax (VAT) and Service Tax) without furnishing BPCL the documents required for BPCL to avail of the full CENVAT / VAT or other tax benefits available to BPCL against the payment of the tax. The Vendor shall prior to despatch of the Material(s) obtain from BPCL a list of the documents required by BPCL to enable it to avail of the relative benefits. Payment or reimbursement of the CENVATABLE / VATABLE / other taxes and duties on which credit is available to BPCL shall be made upon the Vendor furnishing the relevant documents.

6.3 Freight and/or octroi and entry and/or terminal taxes, if any, payable or

reimbursable by BPCL shall be invoiced separately and shall be paid/re-imbursed by BPCL after receipt of the Material(s) at the Project Site and satisfactory proof of payment of the relative octroi, entry and/or terminal taxes, as the case may be.

6.4 The statutory variation in customs duty shall be subject to the following

guidelines and the supplier shall confirm the following in their bid:

(b) Maximum CIF value of import content shall be furnished in the bid. (c) The material to be imported covering the above CIF value to be

indicated in the bid. (d) Any increase in price due to increase in customs duty rate beyond

two-third of the quoted delivery period will be to supplier’s account. However, any decrease in price due to decrease in customs duty rate at the time of actual clearance of imported materials shall be passed on to BPCL.

(e) Variation in price due to customs duty rate will be dealt with

separately after receipt of materials at site against documentary evidence.

6.5 Freight, taxes and duties are not intended to operate as a profit centre

but are intended only to meet the relevant costs incurred on this account. If any reimbursement or collection of the taxes or duties by the Vendor from BPCL is in excess of the freight, taxes and/or duties actually paid by the Vendor, the Vendor shall forthwith refund such excess to BPCL together with interest thereon at 1% (one percent) per annum above the Prime Lending Rate of the State Bank of India from the date of collection until the date of refund.




7.0 EARNEST MONEY

7.1 A bid is liable to be rejected unless it is supported by earnest money of a value as provided in the Purchase Requisition/ Request for Quote/ Special Conditions of Purchase.

7.2 Earnest Money by the tenderers shall be accepted either in the form of

Crossed Demand Draft or Bank Guarantees from any Indian scheduled bank which includes Indian branch of foreign bank recognized as scheduled bank by RBI of DD or BG in favour of BPCL) . Foreign Bidders may also submit bank guarantee from an international bank of repute having a branch in India or having correspondent banking relationship with an Indian scheduled bank, in which case the Bank Guarantee shall be countersigned by their Indian Branch or by any Scheduled Indian Bank. The bid security shall be in US Dollars for foreign bidders and in Indian Rupees for domestic bidders. The Bank Guarantees shall be valid for a period of 9(nine) months from the date of submission of bid including 3 months claim period.

7.3 If the Earnest Money is in the form of a Bank Guarantee, the validity of

the Bank Guarantee shall be extended by the Vendor at the Vendor’s cost and initiative for a period of 3 (three) months beyond the date of the acceptance of bid by BPCL, failing which the Bank Guarantee may be encashed by BPCL and the proceeds held as security for the performance of Vendor’s obligation and the due discharge of Vendor’s liability under the resultant Contract until the Vendor acknowledges the acceptance of the Purchase Order and furnishes the Performance Guarantee. Should the Vendor fail to accept the Purchase Order and/or furnish the Performance Guarantee within the time specified in this behalf, or specifically permitted by BPCL for the purpose, BPCL may encash the Bank Guarantee furnished by the Vendor by way of Earnest Money Deposit and/or forfeit such proceeds or other encashable Earnest Money Deposit held by it in cash without prejudice to any other right or remedy available to it.

7.4 The Earnest Money paid by the unsuccessful bidder(s) shall be

refunded/returned within 15 days of the finalization of the Tender by BPCL.

7.5 Earnest Money furnished by a tenderer may also be forfeited in the

following circumstances: (a) If the tenderer alters or modifies or withdraws their bid prior to

opening of the price bid and within the specified validity period of the Tender; or

(b) If the tenderer withdraws their bid after the Tender is opened.

7.6 EMD for limited tender is not required in case of

a) Small Scale Units registered with the National Small Industries Corporation. The exemption shall, however, be only to the items




for which the small-scale industries hold the registration with National Small Industries Corporation. The certificate issued by the National Small Industries Corporation should be valid on the date of opening of the tender.

b) Govt. organization & Public Sector Undertaking of the Central/

State Government

c) BPCL’s registered vendors

7.7 EMD for public/press tender is not required in case of

Small Scale Units registered with the National Small Industries Corporation. The exemption shall, however, be only to the items for which the small-scale industries hold the registration with National Small Industries Corporation. The certificate issued by the National Small Industries Corporation should be valid on the date of opening of the tender.

8.0 VENDORS’ DRAWINGS AND DATA REQUIREMENT

The Vendor shall submit drawings, data and documentation in accordance with (but not limited to) what is specified in the Purchase Requisition/Tender documents and/or Vendor’s drawing and data form attached to the Purchase Order, within 15 (fifteen) days of the Purchase Order. The types, quantities and time limits for submitting these must be respected by the Vendor and the Material(s) shall be deemed not to have been delivered for all purposes (including payment) until completion of the said submissions to the satisfaction of BPCL.

9.0 FREE ISSUE MATERIALS (for incorporation in the Indigenous supply)

If the Purchase Order involves the incorporation of any Free Issue Material(s):

(f) The Vendor shall prior to taking delivery of the Free Issue Material(s) arrange for a Bank Guarantee for the full value of the Free Issue Material as per BPCL format valid from the date of the receipt of the Free Issue Material(s) until delivery of the Material(s) in which the Free Issue Material(s) has/have been incorporated.

(g) The Vendor shall inspect the Free Issue Material(s) at the time of

taking delivery thereof and satisfy itself of the quality, quantity and condition of the Free Issue Material(s). BPCL shall not be liable for any claims or complaints whatsoever in respect of the quality, quantity or condition of the Free Issue Material(s) once the Vendor has taken delivery thereof.

(h) All Free Issue Material(s) shall be taken delivery of, transported, held,

stored and utilized by the Vendor as trustee of BPCL, and delivery of the Free Issue Material to the Vendor shall constitute an entrustment




thereof by BPCL to the Vendor with the intent that any transportation, utilization, application or disposal thereof by the Vendor otherwise than for incorporation in the Indigenous Material(s) shall constitute a breach by the Vendor.

(i) The Vendor shall transport the Free Issue Material(s) only by such

transportation as is suitable and shall hold and store the Free Issue Material(s) only at such place and/or premises that are air and water tight and otherwise suitable for the storage of the Free Issue Material(s) so as to prevent damage or deterioration or theft or other loss, and shall arrange such watch and ward as shall be necessary to ensure the safety thereof.

(j) Notwithstanding the Bank Guarantee mentioned in sub-paragraph (a)

above, the Vendor shall replace any Free Issue Material(s) which is/are lost, damaged, misused, stolen or deteriorated with other Material(s) of equivalent quantity and quality and condition, and the same shall be deemed to constitute Free Issue Material(s) and the provisions of sub-paragraphs (a) to (f) hereof shall apply thereto in the same manner as to the originally supplied Free Issue Material(s).

(k) Unused Material(s) from the Free Issue Material(s) shall be returned

by the Vendor to BPCL and if BPCL so directs, the Vendor shall dispose of the same by sale or otherwise on such terms and conditions as BPCL may stipulate or approve and the Vendor shall pay to BPCL the sale proceeds of the Material(s) so disposed of by sale.

10.0 THE BILL OF MATERIAL(S)

10.1 Where the price of Material(s) is a lump sum price and pro-rata payment is envisaged in the Purchase Order, the Vendor shall within 7 (seven) days of the issue of the Purchase Order furnish to BPCL for approval, a priced and detailed Bill of Material(s)/ Billing Schedule as required covering all Material(s), which shall conform to the price break-up and Total Contract Value given in the Purchase Order. The Bill of Material(s) shall operate as the Billing Schedule for payment of the price of the Material(s). In preparing the Bill of Material(s), the Vendor shall ensure that all contracted Material(s) are included in the Bill of Material(s) so as to ensure that BPCL is not required, due to any oversight or omission, to pay any taxes and duties on a value in excess of the total Value indicated in the Contract.

10.2 The Material Safety Data Sheets in the case of catalysts and chemicals and other items where ever applicabe shall also be submitted within 7 (seven) days after receipt of the Purchase Order.




11.0 MODIFICATION

11.1 BPCL shall have the right to request changes or modifications in the technical documents and/or specifications comprised in the Contract, subject to the Vendor’s approval thereto. BPCL shall bear any additional cost and shall be entitled to the benefit of any reduced cost resultant upon any such change or modification.

11.2 As soon as possible after receipt of a written request from BPCL for

change(s), the Vendor shall furnish in writing to BPCL an estimate of the additional cost or benefit for the change(s) and/or modification(s) requested and its effect on the delivery date. On agreement with respect to the enhanced/reduced cost and modified delivery time, which shall be finalized within 10 (ten) days of the request for the modification, BPCL shall issue an amendment to the Purchase Order, and the Vendor shall promptly proceed with the change(s)/modification(s) contemplated by the amended Purchase Order / Contract.

12.0 SUB-CONTRACTS

12.1 The Vendor shall not assign the Sub-Contract in whole or part without obtaining the prior written consent of BPCL.

12.2 The Vendor shall, notwithstanding the consent and assignment, remain

jointly and severally liable and responsible to BPCL together with the assignee, for and in respect of the due performance of the Contract and the Vendor’s obligations there under.

13.0 EXPEDITING

13.1 BPCL/TCE may appoint a Procurement Coordinator to manage,

expedite and coordinate the manufacture, shipment and/or despatch of Material(s) covered by the Contract.

13.2 The Vendor shall furnish to the Procurement Coordinator within 7

(seven) days of receiving the Purchase Order, the required number of copies of documents including but not limited to Schedule of manufacture/PERT chart, unpriced copies of sub-orders, phased programme of item-wise manufacturing, testing and delivery and any other information and/or documents as may be called for by the Procurement Coordinator.

13.3 The Procurement Coordinator shall have free access to the Vendor’s

shop and sub-suppliers’ shop during normal working hours and shall be provided all the necessary assistance and information to help him perform his job.




14.0 RESPECT FOR DELIVERY DATES AND PRICE DISCOUNT / DELAYED

DELIVERIES

14.1 The time and date of Delivery of Material(s) as stipulated in the Contract shall be adhered to on the clear understanding that the Price(s) of the Material(s) has/have been fixed with reference to the said Delivery date(s).

14.2 If any delay is anticipated by the Vendor in the delivery of the Material(s)

or any of them beyond the stipulated date(s) of Delivery, the Vendor

shall forthwith inform BPCL/TCE in writing of such anticipated delay and

of the steps being taken by the Vendor to remove or reduce the anticipated delay, and shall promptly keep BPCL informed of all subsequent developments.

14.3 In the event of delay beyond the contractual progressive delivery date for

reasons not attributable to BPCL and not constituting conditions of force majeure, it will be at BPCL’s discretion, without prejudice to his other rights under the contract, to accept delayed delivery, but at the prices reduced at the rate of 1% (one percent) of the order value of delayed goods / supplies per week of delay or part thereof, subject to a maximum of 10% (ten percent) of the total order value.

The above price reduction schedule for delay in delivery shall be applicable for delay in delivery for all indigenous/imported items required for the project.

Further, in case of delay in delivery, the vendor shall calculate the applicable price reduction for delayed delivery and raise their invoices net of the same.

14.4 Without prejudice to its rights under Clause above hereof and to entitlement to discount(s) accrued in terms thereof and in addition thereto, BPCL may at any time after the expiry of the stipulated date(s) of Delivery in respect of any Material(s), at its discretion terminate in whole or part the Contract in respect of the undelivered Material(s) or any of them and either purchase such Material(s) from any other available source at the risks and costs of the Vendor and recover from the Vendor any additional cost incurred by it on such purchase or recover from the Vendor without such purchase the difference between the market and contract price of such Material(s) on the date of termination of Contract relative thereto.




15.0 DELAYS DUE TO FORCE MAJEURE

In the event of causes of Force Majeure occurring within the contractual delivery period and if they impede the performance of contract, the delivery dates shall be extended on receipt of application from the Vendor / Owner without imposition of penalty. Only those causes which depend on natural calamities, civil wars, fire and national strikes which have a duration of more than seven consecutive calendar days are considered the causes of force Majeure. The decision of Owner shall be final and binding on Vendor. The Vendor must advise the Owner by a registered letter duly certified by Local Chamber of Commerce or statutory authorities and Owner must advise the Vendor by a letter, the beginning and the end of the delay immediately, but in no case later than within 10 days of the beginning and end of such causes of Force Majeure condition as defined above. Provided further that if the performance in whole or part of any obligation under this contract is prevented or delayed by reason of any such event for period exceeding 60 days either party may at its option terminate the contract.”

16.0 WARRANTY OF TITLE

16.1 The Vendor warrants that the Material(s) sold and supplied by it to BPCL

pursuant to the Contract shall be free from any and all defects in title including but not limited to any charge, third party claim, mortgage, hypothecation, foreclosure, lien, restriction, injunction, attachment or encumbrance whatsoever and shall hold and keep BPCL indemnified from and against any and all contrary claims, demands, actions and proceedings and all costs (including legal costs), charges, expenses and losses suffered or incurred by BPCL as a consequence thereof and/or to defend any such claim, demand, action or proceeding.

16.2 The Vendor shall be understood to have represented to BPCL that the

use by BPCL of the Material(s) supplied by the Vendor will not infringe any third party patent rights or pending patent applications or other intellectual property rights. Accordingly, the Vendor will hold harmless

and indemnify BPCL & TCE against all costs (including legal costs),

charges and expenses incurred or any damages or other sums that may be assessed or become payable under any decree or judgment of any court or under any settlement resulting from any suit, claim or action for infringement of third party patents or other third party intellectual property.




17.0 INSPECTION AND TESTING

17.1 Third Party Inspection Agency where ever applicable shall be nominated by BPCL. In general the following TPIA’s are in the approved list viz. Lloyds, DNV, BV. However the bidder has option to specify in his bid the choice of the TPIA.

17.2 In addition to any tests to be conducted by the Vendor under the

Contract or any applicable codes or standards, the Material(s) shall be subject to inspection and/or testing by Inspector(s) (including Third Party Inspector(s)) at any time prior to shipment and/or despatch and to final inspection within a reasonable time after arrival at the Project Site. The Inspector(s) shall have the right to carry out the inspection or testing, which will include inspection and testing of the raw materials at manufacturers shop, at fabricators shop and at the time of actual despatch before and/or after completion of packing.

17.3 In addition to testing and inspection by Inspectors, BPCL may nominate

an institutional agency like Boiler-Inspectorate for official testing of coded equipment. The Vendor shall ensure that all procedures for preparation and performance of tests prescribed by such institution shall be scrupulously complied and observed.

17.4 Unless otherwise specified in the Contract, the inspection shall be

carried out as per the relevant standards/scope of inspection provided along with the Tender Enquiry/Purchase Order. All charges for Third Party Inspectors shall be borne by the Vendor and BPCL shall reimburse these charges at actual against documentary proof of payment (limited to the amount indicated in the Contract towards third party inspection,) unless such inspection has become infructuous for any cause.

17.5 All manufacturers’ mill test certificates and analytical reports from

material laboratories in respect of raw materials employed and components incorporated shall have to be presented by the Vendor.

17.6 Before shipping or despatch, the Material(s) will have to be checked and

stamped by the Inspector(s) who may forbid the use and dispatch of any equipment and/or Material(s) which during tests and inspection fail(s) to comply with the specifications, codes and testing or other contractual requirements applicable thereto, and the Vendor shall not tender such rejected Material(s) for supply to BPCL nor shall incorporate the same in any Material(s) to be tendered for supply to BPCL.

17.7 The Vendor will inform BPCL at least eight (8) days in advance of the

exact place, date and time of tendering the Material(s) for required inspection and provide free access to the Inspector(s) during normal working hours at Vendor’s or his/its sub-Suppliers’ works, and place at the disposal of the Inspector(s) all useful means for undertaking the Inspection, checking the results of tests performed, marking the




Material(s), getting additional tests conducted and final stamping of the Material(s).

17.8 All tests will be performed at the Vendors’ expense and if required by the

Inspector(s), shall be conducted in accordance with the Inspector’s instructions. The Vendor shall also bear the expense for the preparation and rendering of tests required by the Boiler Inspectorate or other statutory testing or certifying agencies/institutions.

17.9 Unless otherwise specified, all charges for the Inspection shall be borne

by the Vendor.

17.10 BPCL may, at its own expense, have its representative(s) witness any

test or inspection. In order to enable BPCL’s / TCE’s representative(s) to

witness the tests/inspections, the Vendor shall notify BPCL/TCE at least

15 (fifteen) days in advance, of the schedule of all inspection hold points prior to the initiation of equipment fabrication. BPCL shall be notified eight (8) calendar days in advance of any changes in the schedule of inspection. BPCL will advise the Vendor in advance whether it intends to have its representative(s) be present at any of the inspections.

17.11 Even if the inspection and tests are fully carried out, the Vendor shall not

be absolved from its responsibilities to ensure that the Material(s), raw materials, components and other inputs are supplied strictly to conform and comply with all the requirements of the Contract at all stages, whether during manufacture and fabrication, or at the time of Delivery as on arrival at site and after its erection or start up or consumption, and during the defect liability period. The inspections and tests are merely intended to prima facie satisfy BPCL that the Material(s) and the parts and components comply with the requirements of the Contract.

17.12 The Vendor’s responsibility shall also not be anywise reduced or

discharged because BPCL or BPCL’s representative(s) or Inspector(s) shall have examined or commented on the Vendor’s drawings or specifications or shall have witnessed the tests or required any chemical or physical or other tests or shall have stamped or approved or certified any Material(s).

17.13 Unless otherwise specifically permitted by the Contract, no Material(s)

shall be dispatched for delivery or delivered under the Contract without being stamped or otherwise approved for delivery by the Inspector(s).

17.14 Notwithstanding approval by the Inspector(s), if on testing and/or

inspection after receipt of the Material(s) at Project Site, any Material(s) is/are found not to be in strict conformity with the contractual requirements or specifications, BPCL shall have the right to reject the same and hold the Vendor liable for non-performance of the Contract.




18.0 ACCEPTANCE OF MATERIALS & GUARANTEES

18.1 The Vendor acknowledges that notwithstanding the provision or approval of any drawings, designs, specifications, source of supply or other data relative thereto by BPCL and/or the testing of Material(s) in accordance with the requirements of the Contract or any applicable code or specification and/or any inspection of the input or Material(s) by the Inspector(s) or issue of an Inspection Certificate relative thereto and/or any other act, matter or thing done or required by BPCL to satisfy itself of the quality, quantity, sufficiency or efficiency of the Material(s) prior to delivery thereof and/or the transfer of title and/or risks in relation to the Material(s), shall not be deemed or understood to constitute acceptance of the Material(s) by BPCL nor shall BPCL be understood to have accepted any Material(s) other than plant, machinery, equipment and parts and components unless such Material(s) have been received at the Project Site of BPCL and found to be acceptable as evidenced by a

Certificate of Acceptance issued by BPCL/TCE, and in case of plant,

machinery, equipment and parts and components, unless they have been incorporated into the relative Project Unit and the said Unit has been tested and the relative plant, machine, equipment, part or component has successfully functioned without patent defect.

18.2 To this end, the Vendor guarantees that:

(i) All materials used in the execution of the Contract and all Material(s) used in performance thereof shall be in strict compliance and conformity to the characteristics, requirements and specifications of the Contract and suitable for the purpose for which such Material(s) are intended to be used if such purpose has been disclosed or is/are suitable for use to which such Material(s) are ordinarily put to use, if such purpose has not been disclosed.

(ii) In the case of machinery, plant or equipment with rated capacities, outputs or other characteristics, that the machinery, plant or equipment as the case may be, shall function to such capacities and/or outputs and shall meet the other characteristics required in respect thereof.

18.3 The Vendor further undertakes to replace any Material(s) if found not to

conform to the guarantees aforesaid at any time during the defect liability period applicable thereto. BPCL shall give written notice of the defect to the Vendor and of the rejection of the defective Material(s).

18.4 If the defect can be rectified or repaired without diminishing the quality,

utility, efficiency or life of the Material(s) (of which BPCL / TCE shall be

the sole judge), instead of outright rejection of the Material(s) BPCL may at its discretion permit the Vendor to rectify the defect(s) within a period to be specified by BPCL in this behalf in the notice. Should the Vendor fail to take action satisfactory to BPCL to rectify the defect(s) within the period specified, BPCL may at its option, at the risk and cost of the




Vendor in all respects, rectify or repair or cause to be rectified or repaired the defect(s) either by itself or through any other source or agency, or to reject the defective Material(s).

18.5 Should BPCL, notwithstanding the endeavour to do so, be unable to

rectify or repair or get rectified or repaired the defect(s) within a reasonable time, BPCL may, notwithstanding such endeavour reject the defective Material(s).

18.6 The Vendor shall repair, rectify and/or replace, as the case may be, the

defective and rejected Material(s) without entitlement to any extra payment. DDP (INCOTERMS 2000) shall apply for such replacement parts or components or Material(s) at Project Site with respect to imported parts or components or materials.

18.7 The Vendor shall at its own risk and cost remove any rejected Material(s)

from the Project Site, and in case of plant, machinery, equipment, parts or components which have been installed, cause the same to be dismantled and removed from the Project Site subject to the Vendor in all cases prior to the removal of the rejected Material(s) from the Project site: (i) furnishing a bank guarantee to BPCL from a Scheduled bank in

India (including an Indian branch of a foreign bank acceptable to BPCL) and in a BPCL format for the value paid by BPCL on the Material(s) rejected; and

(ii) undertaking to replace the rejected Material(s) with other Material(s) conforming to the Vendor’s guarantees aforesaid applicable thereto.

18.8 The Vendor shall not without the prior written consent of BPCL utilize

any rejected Material(s) in the re-supply.

18.9 The Defect Liability Period with respect to any Material(s) replaced, repaired and/or rectified shall be reckoned from the date of such replacement, repair and/or rectification as the case may be.

18.10 Should the Vendor fail to dismantle and/or remove any rejected

Material(s) from the Project Site within the time specified in the notice of rejection, BPCL may without prejudice to any other right or remedy, at the risk and cost of the Vendor cause the rejected Material(s) to be dismantled and sold by public auction or private treaty as it deems fit and hold or adjust the sale proceeds for the recovery of the cost of dismantling, sale and removal of the rejected Material(s) and any amount paid by BPCL towards the price of the rejected Material(s). In so doing, BPCL shall not act as a trustee or constructive trustee of the Vendor and shall be entitled to act solely on the basis of its best judgment without being accountable or liable to the Vendor in any manner except for the proceeds of the sale.




18.11 The time taken for the repair, rectification or replacement of Material(s) will not be added to the stipulated Delivery date for the purpose of calculating price discount, and delivery of such Material(s) shall be the date of Delivery of the repaired, rectified or replaced Material(s).

18.12 As security for the due performance of its obligations and the due

discharge of its liabilities under the Contract, the Vendor shall within 15 (fifteen) days of the issue of the Purchase Order furnish to BPCL a Bank Guarantee issued by a Scheduled Bank in India acceptable to BPCL, in the BPCL format. The Bank guarantee shall remain in force for the entire period required for the performance of the contract and the defect liability period plus a 3 (three) months claim period thereafter. Any shortfall in the value of the Bank Guarantee, as a result of encashment by BPCL either in full or in part, shall be made good by the Vendor within 7 (seven) days of notice by BPCL to the Vendor in this behalf. Any failure by the Vendor to furnish the Bank Guarantee or to enhance the Value of the Bank guarantee as stated above shall constitute a default by the Vendor for which BPCL shall, without prejudice to any other right or remedy available to it, be entitled to terminate the Contract with consequences as indicated in clause 12.4, the provisions whereof shall mutatis mutandis apply.

19.0 WEIGHTS AND MEASUREMENTS

19.1 The shipping documents, invoices, packing lists and all other relevant documents shall contain the same units of weights and measurements as given in the Contract Documents, in respect to the following data:

a. Unit net weight b. Unit gross weight (including packing) c. Dimensions of packing

19.2 All weights and measurements recorded by the Procurement Co-

ordinator or Inspector(s) on receipt of the Material(s) at the Project site will be treated as final.

20.0 PACKING & MARKING

20.1 All Material(s) shall be suitably packed in weatherproof seaworthy/ airworthy packing for ocean/air transport under tropical conditions and/or for rail and road or other appropriate transport within India. The Vendor shall ensure that the packing is strong enough to ensure safety and preservation of the Material(s) upto the Project Site or other point of final destination.

20.2 Material(s) shall be protected by a suitable coat of paint and all bright

parts shall be protected from rust by application of rust preventives as may be necessary. All machinery surfaces shall be suitably protected.




20.3 For uniform Material(s) when packed in several cases/crates, progressive serial numbers shall be indicated on each end. In case of bundles, the shipping marks shall be embossed on metal tag and wired securely on each end.

20.4 A distinct colour splash in say red-black around each package/ crate/

bundle shall be given for identification.

20.5 All nozzle holes and openings as also all delicate surfaces shall be carefully protected against damage and bad weather. Flange faces of all nozzles shall be protected by blanks. All manufactured surfaces shall be painted with rust proof paint or as specified in the specification.

20.6 All threaded fittings shall be greased and provided with a plastic cap. All

pipes and sheets shall be marked with strips bearing progressive numbers.

20.7 All small pieces shall be packed in cases. All fragile and exposed parts

will be packed with care and packages will bear the words “HANDLE WITH CARE” in English and in the case of Indigenous Supply, in Hindi also.

20.8 The Vendor shall be held liable for all damages or breakages to the

Material(s) due to defective or insufficient packing as well as for corrosion due to insufficient greasing/protection.

20.9 On three sides of the packages, the Vendor shall affix or cause to be

affixed the following marks clearly visible in indelible paint

FROM: VENDOR TO: BHARAT PETROLEUM CORPORATION LTD. [Address] INDIA

PROJECT NO. TCE-6758APROJECT NAME: BLENDING FACILITY

CONSULTANT: TATA CONSULTING ENGINEERS LIMITED

PURCHASE ORDER NO.: [ ] Rev. No.:[ ] ITEM CODE : [ ] EQUIPMENT NOMENCLATURE: [ ] NET WEIGHT: [ ]kg/lb GROSS WEIGHT: [ ]kg/lb CASE NO.: [ ]OF [ ] TOTAL CASES [ ] DIMENSIONS: [ ] IMPORT LICENCE NO.[ ] NOTE:Marking shall be bold with a minimum letter height of 5 cm.




20.10 For every shipment, packages must be marked with serial progressive

numbering. The numbering will be progressively continued for each subsequent shipment covering the Contract.

20.11 All packages will bear warning signs on the outside denoting the center

of gravity and sling marks. Packages that require special handling and transport shall have their centers of gravity and points at which they may be gripped clearly indicated and marked “Attention Special Load Handle With Care” in English Language. Any other direction for handling shall also be clearly indicated on the package.

20.12 Top heavy containers will be marked either “TOP HEAVY” or “HEAVY

ENDS’.

20.13 When packing is clean and light colored, a dark black stencil paint shall be acceptable. However, where packing is soiled or dark, a coat of flat Zinc white paint shall be applied and allowed to dry before applying the specific marking(s).

20.14 Colour codification shall be used to identify different items e.g, IBR,

NACE, Fire Safety Items etc.

20.15 In case of large equipments like vessels, heat exchangers etc., documents contained in a waterproof envelope shall be fastened inside a shell connection with an identifying arrow sign “DOCUMENTS” applied with indelible paint.

21.0 SHIPMENT AND SHIPMENT NOTICES

For Indigenous Material(s)

21.1 Unless otherwise advised by BPCL or the Procurement Co-ordinator in

writing, Material(s) shall not be despatched without prior inspection and/or testing and Release Order/Material(s) Acceptance Certificate issued by the Inspector(s).

21.2 The Vendor shall exercise due care to ensure that the consignment is

booked under appropriate railway classification, failing which any additional freight incurred by BPCL due to the Vendor booking the Material(s) under a wrong railway classification shall be borne by the Vendor.

21.3 The Material(s) shall be consigned in the name of the consignee viz.

BHARAT PETROLEUM CORPORATION LTD., [Site address]

21.4 The Material(s) shall be transported only through bank approved

transporters by the most economical and expeditious mode of transport




to the destination as applicable for respective mode of despatches as follows :

(a) By Rail in wagon load consignment to : [Name and address of Site /

Project to be specified] (b) By road transport to : [Name and address of Site / Project to be

specified]

BPCL and the Procurement Coordinator shall have the right to advise any change in despatch point or destination and/or mode of transport in respect of any Material(s). Any extra expenditure incurred by the Vendor on this account supported by satisfactory documentary evidence, will be reimbursed to the Vendor by BPCL.

21.5 Immediately after shipment, the Vendor shall inform despatch particulars to BPCL/ Procurement Coordinator hereunder:

1 copy to CEM (E & P)-WEST, BPCL, Sewree Office [Address & Fax no]

1 copy to Project Leader, BPCL, Uran Office [Address & Fax no.]

1copy to Resident Construction Manager,TCE at BPCL Uran addressed

to: [Address & Fax no.]

1 copy to Project Manager, TCE, Mumbai office

For Imported Material

21.6 The Vendor shall make shipment only after prior approval of the

Inspector(s) unless otherwise specifically authorized in writing by BPCL or the Procurement Coordinator. As soon as any shipment is made, the Vendor shall send advance information by way of FAX message to the

[Fax No +91 022 24168001] to the CHIEF ENGINEERING Manager (E&P)-WEST,

BHARAT PETROLEUM Corporation Ltd.,, giving particulars of the shipments, vessel’s name, port of shipment, Bill of Lading number and date for ocean shipment and Airway Bill number & Date & Flight details for air consignment, total FOB and freight value with confirmation copy to BPCL, addressed to [designation and address]

21.7 For import items Shipping Corporation of India shall be given first preference as a carrier

22.0 MARINE AND TRANSIT RISK INSURANCE

22.1 Marine/Air and Transit Risk Insurance shall be covered by BPCL against its Open General Policy.

22.2 The Vendor shall send BPCL information of the proposed

shipment/consignment well in advance by telegram/fax/e-mail/courier to enable BPCL to take necessary action for the marine/air/transit insurance of the shipment/consignment.




22.3 The Vendor shall advise the despatch particulars of the shipment/consignment to the Insurance Company by fax / email under advice to the Procurement Coordinator promptly after shipment to ensure that the consignment is fully covered by insurance. Any failure by the Vendor to do so shall place the consignment at the Vendor’s risk.

23.0 SHIPPING AND SHIPPING DOCUMENTS

23.1 For Imported Materials(s)

(a) The Vendor shall arrange with Vessel owner(s) or Forwarding Agent(s) specified in the Contract Documents for proper storage of the Material(s) in a manner so as to facilitate the handling and off-loading at the port of destination and to avoid any over carriage on discharge. All shipment by ocean vessel shall be under deck.

(b) The Bill(s) of Lading/Airway Bill shall be made out in favor of “BHARAT PETROLEUM Corporation Ltd.” E & P, Western Region, Sewree office or to the order of the L/C opening bank, and the notify

column should indicate [CEM, E&P-WEST] BHARAT PETROLEUM

Corporation Ltd., Western Region, Sewree (c) All columns in the body of the Bill of Lading/Airway Bill namely marks

and Numbers, material description, weight particulars, etc. should be completed accurately and such statement should be uniform in all the shipping documents. The freight particulars should mention the basis of freight tonnage, heavy lift charges, if any, surcharge, discount, etc. clearly and separately and the net total freight payable, shown at the bottom.

(d) The Bill of Lading/Airway Bill shall be free of any liability of BPCL to the carrier for demurrage.

(e) The Bill of Lading/Airway Bill shall indicate the following: Consignee : BHARAT PETROLEUM Corporation Limited [Name of Project]

(f) All documents viz. Bill of Lading/Airway Bill, invoices, packing list,

freight memos, country of origin certificate, Third Party Inspection Release Certificate, inspector’s certificate, Export certificate (wherever applicable), test certificates, drawings and catalogues should be in the English language.

(g) In addition to the Bill of Lading/Airway Bill, which should be obtained in 3 (three) stamped originals plus as many copies as required, invoices, packing lists, freight memos (if the freight particulars are not shown in the Bill of Lading), country of origin certificate(s), Third Party Inspection Release Certificate, inspector’s certificate, Export certificate (wherever applicable) and test/composition certificate, shall be made out against each shipment in as many number of copies as are shown in Clause below.

(h) The Bill of Lading/Airway Bill, invoice and packing list must specifically show uniformly, the marks and numbers, material description, contents case-wise, country of origin, consignee’s name,




port of destination and all other indicated particulars. The invoice must show the unit rates and net total FOB price. The invoice must cover also items packed separately and the value shown accordingly.

(i) The packing list must show, apart from other particulars, the actual contents in each case, net and gross weights and dimensions and the total number of packages.

(j) All documents must be duly signed by an authorized representative of the Vendor.

23.2 In case of FOB contracts:

(i) Shipping Arrangements shall be made through nominated freight

forwarders (in the country of exit) as detailed in the Purchase Order and freight will be accordingly paid by BPCL in Indian Rupees.

(ii) The Vendor shall furnish to the respective nominated freight forwarder, the full details of consignment such as outside dimensions, weights (both gross and net), No. of packages, technical description and drawings, name of the supplier, ports of loading etc. two weeks prior to the proposed date of shipment to enable the concerned agency to arrange the shipping space.

23.3 The Vendor shall obtain the shipping documents in required number of

sets including three original stamped copies of the Bill of Lading/Airway Bill immediately after the shipment is made and airmail the shipping documents in the manner stipulated hereunder to ensure that the documents so forwarded are received at least one week before the vessel’s arrival. The Vendor shall be fully responsible for any delay and/or demurrage in clearance of the consignment at the port due to delay in forwarding the shipping documents. If in terms of the Letter of Credit , the complete original set of documents are required to be sent to BPCL through the bank, the distribution indicated below will be confined to obtaining copies of documents only.

Documents BPCL

(Sewree Office that issued the PO)

BPCL (Uran Project Site)

TCE

(Project Site)

Bill of lading/Airway Bill 3 (including 1 original) 1 1

Invoice 2 1 1

Packing List 2 1 1

Certificate of Origin 2 1 1

Test/Composition Certificate 2 1 1

Third Party Inspection Release Certificate

1 1 (original) 1

(original)

Drawing/Catalogue 1 1 1

Invoice of Third Party/Lloyds for Inspection Charges, wherever

applicable. 2 1 1

Export Certificate (where applicable)

1 1 1




24.0 ARBITRATION “Any dispute or difference of any nature whatsoever, any claim, cross-claim, counter-claim or set off of Owner / Vendor against omission or account of any of the parties hereto arising out of or in related to this Contract shall be referred to the Sole Arbitration of Director (Marketing) of BPCL or to some officer of BPCL who may be nominated by the Director (Marketing). In the event the Arbitrator being unable or refusing to act for any reason whatsoever, the Director (Marketing) of BPCL shall designate another person to act as an Arbitrator in accordance with the terms of the said Agreement. The Arbitrator newly appointed shall be entitled to proceed with the reference from the point at which it was left by his predecessor. It is known to the parties herein that the Arbitrator appointed hereunder is an employee of the Corporation and may be Share holder of the Corporation. The award of the Arbitrator so appointed shall be final, conclusive and binding on all the parties to the contract and the law applicable to arbitration proceedings will be the Arbitration and Conciliation Act, 1996 or any other enactment in replacement thereof. The language of the proceedings will be English and the place of proceedings will be Mumbai The parties hereby agree that the Courts in the city of Mumbai alone shall have jurisdiction to entertain any application or other proceedings in respect of anything arising under this Agreement and any Award or Awards made by the Sole Arbitrator hereunder shall be filed, if required, in the concerned Courts in the City of Mumbai alone.”


ANNEXURE- I

PROFORMA OF BANK GUARANTEEE (EARNEST MONEY DEPOSIT)

(On Non-Judicial Stamp paper for appropriate value) BANK GUARANTEE NO. : BANK GUARANTEE AMOUNT: EXPIRY DATE : 6 MONTHS CLAIM DATE : (FROM EXPIRTY DATE) TENDER NO. /DATE : JOB DESCRIPTION/ LACATION : In consideration of the Bharat Petroleum Corporation Ltd’ (hereinafter called “the Corporation”) having agreed to exempt M/s. __________________________ (hereinafter called “the said Contractor(s)” ) from the payment of Earnest Money against Tender No,_____________ dated _____________ issued by corporation on production of a Bank Guarantee for Rs._________________ (Rupees_______________ ) only. We (Bank’s name ) ___________________________, bank do hereby undertake to indemnify and keep indemnified the Corporation by reason of any breach by the said Contractor(s) of any of the terms and conditions contained in the Tender Notice/documents. We, __________________________________ further agree that the guarantee herein contained shall remain in the full force and effect during the period that would be taken for the finalization of the said Tender and that it shall continue to be enforceable till the Tender is finally decided and order placed on the successful Tenderer.. We, ________________________________, further agree that the Corporation shall be the sole judge of and as to whether the said Contractor has committed any breach or breaches of any of the terms and conditions of the tender/or the contract and the extent of loss, damage, costs, charges and expenses caused to or suffered by or that may be caused to or suffered by the Corporation on account thereof to the extent of the earnest money required to be deposited by the contractor in respect of the said tender or the contract and the decision of the Corporation that the said Contractor has committed such breach or breaches and as to the amount or amounts of loss, damage, costs, charges and expenses


caused to or suffered by or that may be caused to or suffered by the Corporation from time to time shall be final and binding on us.

Contd…2/-

-2- Notwithstanding anything contained in forgoing, our liability under this guarantee is restricted to Rs__________________. The Guarantee shall remain in force till ________________ Months i.e. ________________. Unless a claim under this guarantee is made within six months from the expiry date herein before mentioned the Corporation shall have not rights under these presents. We, _________________, lastly undertake not to revoke this Guarantee during its currency except with the previous consent of the Corporation in writing/. Dated the _________________ day of ______________________200

Yours faithfully For ………………………………………….. Signature

Name & Designation

Name of the Branch


ANNEXURE- II

PROFORMA OF BANK GUARANTEE

(SECURITY DEPOSIT ) (On Non-Judicial Stamp paper for appropriate value)

BANK GUARANTEE NO. : BANK GUARANTEE AMOUNT : EXPIRY DATE : (last date of completion as per LOI) 6 MONTHS CLAIM DATE : (from the date of expiry date) LOI/AGREEMENT NO./ : JOB DESCRIPTION : In consideration of the Bharat Petroleum Corporation Limited ( hereinafter called “ the Owner’s which expression shall include its successors and assigns ) having awarded certain work for and relative to M/s………………… ……………(name and address of the Contractor ) upon certain terms and conditions interalia mentioned in the Owner’s Letter of Intent No………………. dated……………………..for the job …………………………………………… (hereinafter collectively called the “the contractor” expression shall include any formal contract entered into between the Owner and Contractor in suppression of the said Letter of Intent and all amendments and/or modifications in the contract) inclusive of the condition that the Owner may accept a Bank Guarantee of a Scheduled Bank in India in lieu of Cash Deposit of the Initial Security Deposit as provided for in Clause 13 (a) of the General Conditions of Tender : We, …………………………………………… (Name of the Bank) ………………… Having registered and head office at ………………………… (herein after called “The Bank”) at the request of the Contractor and with the intent to bind the Bank and its successors and permitted assigns, do hereby unconditionally and irrevocably guarantee payment to the Owner at New Delhi of the unpaid balance of the initial Security Deposit upto and aggregate limit of Rs. ………………………….. (Rupees ……………………………………………). And


Contd..2

-2- undertake to pay the Owner on demand and without protect or demur the unpaid balance of said initial Security Deposit subject to the aggregate limit of aforesaid of Rs……………………………….. (Rupees ……………………..only ) And The Bank does hereby further agree as follows : 1) The guarantee/undertaking herein contained shall remain in full force

And effect during the period that would be taken for the performance of the said Contract and the claims of the Owner relative thereto satisfied and/or discharged and the Owner accordingly discharges this Guarantee/undertaking subject. However, that the Owner shall have claim under this Guarantee./undertaking after expiry date………………..200 , unless a notice of the claim under this Guarantee/undertaking has been served on the Bank before the expiry of the claim date, in which event the same shall be enforceable against the Bank notwithstanding that the same is enforced till………………… after the expiry date, namely ( claim date). The claim date shall be valid for six months from the expiry date .

2) The Owner shall have the fullest liberty without reference to the Bank and

without affecting in any way the liability of the Bank under this Guarantee/undertaking, at any time and/or from time to time to anywise vary the said contract and/or any of the terms and conditions therefore or of or relative to the said initial Security Deposit or to extend time of performance of the said Contract in whole or part or to postpone for any time and/or from time to time any of obligations of the Contract and/or power exercisable by the Owner against the Contractor and either to enforce or for bear from enforcing any of the terms and conditions of or governing the said Contract or the said initial Security Deposit or the securities available to the Owner or any of them and the Bank Shall not be released from its liability under these presents and the liability of the Bank shall remain in full force and affect notwithstanding any exercise by the owner of the liberty with reference to any or/all the matters aforesaid or by reason of time being given to the Contractor or any other forbearance, act or omission on the part of the Owner or any indulgence by the Owner to the contractor or of any other act, matter or thing whatsoever which under the law relating to sureties would, but for this provision, have the effect of releasing the Bank from its liability hereunder or any part.


Contd…3/- 3-

3) It shall not be necessary for the Owner to proceed against the Contractor

before proceeding against the Bank and the Guarantee/ Undertaking herein contained shall be enforceable against the Bank notwithstanding the existence of any other security for any indebtedness of the Contractor to the Owner (including relative to the said initial security deposit) and notwithstanding any such security deposit) and notwithstanding any such security shall at the time when claim it made against the Bank or proceeding taken against the Bank hereunder, be outstanding or unreels.

4) The amount stated by the Owner in any demand, claim or notice as the

unpaid balance of the said initial security deposit for the time being shall be between the Bank and the Owner for the purpose of these presents be conclusive of the said balance.

5) The liability of the Bank to the Owner under this Guarantee/undertaking shall

remain in full force and effect notwithstanding the existence of any difference or dispute between the Contractor and the Bank/and or the Bank and the Owner, or otherwise howsoever touching or effecting these presents or the liability of the Contractor to the Owner and notwithstanding the existence of any instructions or purported instructions by the Contractor or any other person to the Bank not to pay or for any cause withhold or defer payment to the Owner under these presents, with the intent that notwithstanding the existence of such difference, dispute or instruction, the Bank shall be and remain liable to make payment to the Owner in terms hereof.

6) The Bank shall not revoke this Guarantee/undertaking during its currency

except with the previous consent of the Owner in writing and also agreed that any change in the constitution of the Contractor or the Bank or the Owner shall not discharge the Bank’s liability hereunder.

7) The Bank does hereby declare that ……………….. Name of the person

signing on behalf of the Bank) …………..who is ……………………….., is authorized to sign this Guarantee/undertaking on behalf of the Bank and to bind the Bank thereby.

Dated this …………………….day of ……………………..2007 Yours faithfully. For ……………………………………….. Signature

Name & Designation Name of the Branch


ANNEXURE-III

PROFORMA OF BANK GUARANTEE (PERFORMANCE )

(On Non-Judicial Stamp paper for appropriate value)

BANK GUARANTEE NO. : BANK GUARANTEE AMOUNT : EXPIRY DATE : (12 months defect liability period from the completion date) 6 MONTHS CLAIM PERIOD : (FROM EXPIRTY DATE) LOI/AGREEMENT NO./ : JOB DESCRIPTION : In consideration of the Bharat Petroleum Corporation Limited ( hereinafter called “ the Owner’s which expression shall include its successors and assigns ) having awarded to M/s………………… ……………(name of the constitution)………………………………………………….. …………………….(address)…………………………………………………………… …………………………………………………………………………………….. (hereinafter referred to as “ the supplier/contractor” which expression shall wherever the subject or context so permits include its successors and assigns) a supply contract in terms inter-alia, of the Owner’s Purchase Order/LOI/Agreement No……………………………date………………….. and the General Purchase Conditions of the Owner and upon the condition of Supplier’s furnishing security for the performance of the supplier’s liability under and/or in connection with the said supply contract upto a sum of Rs……………………………….. (Rupees……………………………………………. amounting to 10% (ten percent) of the total contract value. We,………………(name)………………………..(constitution)…………………………………… (hereinafter called “ the Bank which expression shall include its successors and assigns) hereby jointly and severally undertake the guarantee to pay to the Owner in Rupees forthwith on demand in writing and without protest or demur of any and all moneys anywise payable by the supplier to the Company under,


-2-- inclusive of all the Owner’s losses and damages and costs (inclusive between attorney and client), charges and expenses and other moneys anywise payable in respect of the above and specified in any notice of Demand made by the Owner to the Bank with reference to this Guarantee up to and aggregate limit of Rs………………………(Rupees…………………………..) And the Bank hereby agrees with the Owner that :

The guarantee/undertaking herein contained shall remain in full force And effect during the period that would be taken for the performance of the said Contract and the claims of the Owner relative thereto satisfied and/or discharged and the Owner accordingly discharges this Guarantee/undertaking subject. However, that the Owner shall have claim under this Guarantee./undertaking after expiry date………………..200 , unless a notice of the claim under this Guarantee/undertaking has been served on the Bank before the expiry of the claim date, in which event the same shall be enforceable against the Bank notwithstanding that the same is enforced till………………… after the expiry date, namely ( claim date). The claim date shall be valid for six months from the expiry date .

(i) This Guarantee/Undertaking shall be in addition to any other guarantee or

security what-so-ever that the Owner may now or at any time anywise have in relation to the Supplier’s obligations/liabilities under and /or in connection with the said contract, and the Owner shall have full authority to take recourse to or reinforce this security in preference to the other security (ies) at its sole discretion, and no failure on the part of the Owner in enforcing or requiring enforcement of any other security shall have the effect of releasing the Bank from its full liability hereunder.

(ii) The Owner shall be a liberty without reference to the Bank and without

affecting the full liability of the Bank hereunder to take any other security in respect of the supplier'’ obligations and/or liabilities under or in connection with the said supply contract and to vary the terms vis-à-vis the supplier of the said supply contract or to grant time and/or indulgence to the supplier of the said supply contract or to grant time and/or indulgence to the supplier of the said supply contract or to grant time and/or indulgence to the supplier or to reduce or to increase or otherwise vary the prices of the total contract value or to release or to forebear from enforcement of all or any of the obligations of the supplier under the said supply contract and/or the remedies of the Owner under and other security(ies) now or here-after held by the Owner and no such dealing(s), variation(s), reductin9s), increase(s) or their indulgence(s), or arrangement (s) with the supplier or


release or forbearance what-so--ever shall have the effect of releasing the Bank from its full liability to the Owner hereunder or of prejudicing rights of the Owner against the Bank.

(iii) This Guarantee/Undertaking shall not be determined or affected by the liquidation or winding up, dissolution, or change of constitution or insolvency of the supplier but shall in all respect s and for all purposes be binding and operative until payment of all moneys payable to the Company in terms hereof.;

(iv) The Bank hereby waives all rights at any time inconsistent with the terms

of this Guarantee/Undertaking and obligations of the Bank in terms hereof shall not be anywise affected or suspended by reason of any dispute or disputes having been raised by the supplier (whether or not pending before any Arbitrator, Officer, Tribunal or Court) or any denial or liability by the Supplier or any other order or communication whatsoever by the by the supplier or preventing or purporting to stop or prevent any payment by the Bank to the owner in terms hereof.

(v) The amount stated in any notice of demand addressed by the Owner to

the Guarantor As liable to be paid to the owner by the supplier or as suffered or incurred by Owner on account of any losses or damages of costs, charges and/or expenses shall as between the Bank and the Owner be conclusive of the amount so liable to be paid to the Owner or suffered or incurred by the Owner, as the case may be, and payable by the Guarantor to Owner in terms hereof.

For ……………………………………….. Signature

Name & Designation Name of the Branch


ANNEXURE – IV

National Electronic Fund Transfer (NEFT) Mandate Form

(Mandate for receiving payments through NEFT from Bharat Petroleum Corporation Ltd)

1 Vendor Name

2 Vendor Code

3 Permanent Account Number (PAN)

4 Particulars of the Bank

A. Name of the bank

B. Name of the Branch

C. Branch Code

D. Address

E. City Name

F. Telephone No.

G. NEFT IFSC Code (11 digits)

H. 9 digit MICR code appearing on the cheque book

I. Type of Account (10/11/13)

J. Account No.

5 Vendor’s e-mail id

6 Date of effect

7 PAN No.of the Vendor

(Please enclose a photocopy of the cancelled cheque to enable us to verify the details

mentioned above)

We hereby declare that the particulars given above are correct and complete. If the

transaction is delayed or lost because of incomplete information, we would not hold the

company responsible.

_________________________

Signature of the Vendor


Bank Certificate

We certify that ____________________________ has a Account No.

_______________with us and we confirm that the details given above are correct as per

our records.

Date:

______________________

Place:

Authorized Official of the

Bank



SPC: MECHANICAL WORKS Page 1 of 11

Special Purchase Conditions (SPC) RFQ. No.: 6758A_BPCL/TCE_RFQ_003 Item: MECHANICAL TENDER

Project No.: TCE-6758A

BLENDING UNIT AT URAN LPG PLANT

Client: Bharat Petroleum Corporation Limited

TABLE OF CONTENTS

1.0 DUE DATE FOR SUBMISSION OF BIDS AND PREBID MEETING2.0 BID OPENING PROCEDURE

3.0 TECHNO-COMMERCIAL UNPRICED BID OPENING TIME & DATE

4.0 REQUIRED DELIVERY PERIOD

5.0 BID VALIDITY 6.0 BID SECURITY / EARNEST MONEY DEPOSIT (EMD) 7.0 DEFECT LIABILITY PERIOD

8.0 FORCE MAJEURE

9.0 ARBITRATION CLAUSE

10.0 PERFORMANCE BANK GUARANTEE (PBG) / CONTRACT PERFORMANCE BANK GUARANTEE (CPBG)

11.0 PAYMENT TERMS 12.0 PRICE REDUCTION CLAUSE FOR DELAY IN DELIVERY

13.0 FORMAT FOR SUBMITTING PRICE 14.0 BID EVALUATION 15.0 TECHNICAL AND COMMERCIAL LOADING




1.0 Due Date for Submission of Bids.: 15.00 hrs of 03/09/2012 and Pre bid meeting will be held at TCE, Mumbai Office on 24/08/2012 at 10.30 hrs. Considering the tight schedule of the Project, no extension will be given for submission of bids. 2.0 Bid Opening Procedure: Both the techno commercial and Priced bid shall be opened on the specified dates at BPCL Sewree office in presence of the bidder’s representatives. Only

the final bid cost and EMD details will be read before the bidder’s representatives.

3.0 Techno-Commercial Unpriced Bid Opening Time & Date: 16.00 Hrs. of 03/09/2012.

4.0 Required Delivery Period: Within 3 months at site from the placement of Fax

/ letter of Intent. 5.0 Bid Validity: Bidders shall confirm the bid validity of 6 Months from the bid due

date of RFQ / Tender. 6.0 Bid Security / Earnest Money Deposit (EMD):

a) Indian Bidders shall furnish EMD of Rs. 5,00,000/- along with the bids.

b) Foreign Bidders shall furnish EMD of USD 10,000/- along with the bids.

c) A bid is liable to be rejected unless it is supported by earnest money.

d) EMD shall be accepted either in the form of Crossed Demand Draft or

Bank Guarantee. e) The earnest money deposit shall be returned to the unsuccessful bidder/s

within one month after due date for opening of the tender. The earnest money deposit of the successful bidder will be retained till the receipt of order acceptance and security deposit. No interest shall be payable on earnest money deposit.

f) EMD for limited tender is not applicable in case of

i) Small Scale Units registered with the National Small Industries

Corporation. The exemption shall, however, be only to the items for which the small-scale industries hold the registration with National Small Industries Corporation. The certificate issued by the National Small Industries Corporation should be valid on the date of opening of the tender.

ii) Govt. organization & Public Sector Undertaking of the Central/ State

Government




iii) BPCL’s registered vendors. However bidders must furnish vendor registration letter issued by BPCL.

7.0 “Defect Liability Period” in respect of:

(i) Bulk Consumables shall be the date of delivery plus 6 (six) months (ii) In the case of other Material(s) shall be 18 (eighteen) months from

the date of delivery or 12 (twelve) months after the same have been put in service or commissioned, whichever is earlier;

(iii) In the case of altered or replaced Material(s):

(a) With respect to Bulk Consumables, shall be 6 (six) months from the date of alteration, repair or replacement as the case may be; and

(b) With respect to other Material(s), shall be 12 (twelve) months from the date of alteration, repair or replacement as the case may be.

8.0 “Force Majeure:

In the event of causes of Force Majeure occurring within the contractual delivery period and if they impede the performance of contract, the delivery dates shall be extended on receipt of application from the Vendor / Owner without imposition of penalty. Only those causes which depend on natural calamities, civil wars, fire and national strikes which have a duration of more than seven consecutive calendar days are considered the causes of force Majeure. The decision of Owner shall be final and binding on Vendor.

The Vendor must advise the Owner by a registered letter duly certified by Local Chamber of Commerce or statutory authorities and Owner must advise the Vendor by a letter, the beginning and the end of the delay immediately, but in no case later than within 10 days of the beginning and end of such causes of Force Majeure condition as defined above. Provided further that if the performance in whole or part of any obligation under this contract is prevented or delayed by reason of any such event for period exceeding 60 days either party may at its option terminate the contract.”

9.0 Arbitration clause:

“Any dispute or difference of any nature whatsoever, any claim, cross-claim, counter-claim or set off of Owner / Vendor against omission or account of any of the parties hereto arising out of or in related to this Contract shall be referred to the Sole Arbitration of Director (Marketing) of BPCL or to some officer of BPCL who may be nominated by the Director (Marketing).

In the event the Arbitrator being unable or refusing to act for any reason whatsoever, the Director (Marketing) of BPCL shall designate another person to act as an Arbitrator in accordance with the terms of the said Agreement. The Arbitrator newly appointed shall be entitled to proceed with the reference from the point at which it was left by his predecessor.




It is known to the parties herein that the Arbitrator appointed hereunder is an employee of the Corporation and may be Share holder of the Corporation.

The award of the Arbitrator so appointed shall be final, conclusive and binding on all the parties to the contract and the law applicable to arbitration proceedings will be the Arbitration and Conciliation Act, 1996 or any other enactment in replacement thereof.

The language of the proceedings will be English and the place of proceedings will be Mumbai

The parties hereby agree that the Courts in the city of Mumbai alone shall have jurisdiction to entertain any application or other proceedings in respect of anything arising under this Agreement and any Award or Awards made by the Sole Arbitrator hereunder shall be filed, if required, in the concerned Courts in the City of Mumbai alone.”

10.0 Performance Bank Guarantee (PBG) / Contract Performance Bank Guarantee

(CPBG):

Performance Bank Guarantee in Indigenous enquiries and Contract Performance

Bank Guarantee (for 10% of order value) in Foreign & Global enquiries and NITs

shall be furnished by successful vendors in BPCL format. However, for order value

upto Rs. 1 lakh, PBG/CPBG shall not be applicable.

11.0 Payment Terms:

Indigenous Vendors:

a) Supply: 90% payment within 30 days of receipt & acceptance of material at

site and submission of all test certificates, final documents. Balance 10% shall be against submission of Performance Bank Guarantee.

b) Supervision Charges: 100% of supervision charges plus applicable taxes

shall be payable after successful commissioning of the equipment, duly certified by Site-in-Charge.

Foreign Vendors: 100% payment will be made by the owner against an irrevocable letter of credit with

45 days credit period against submission of dispatch documents. The letter of credit shall be established after seller furnishes a performance Bank guarantee of 10% of order value along with the Purchase Order Acceptance. The Seller shall furnish, for release of payment, following documents to the Purchase, through the Purchase’s Banker.

a) Negotiable bill of lading or Airway Bill as the case may be, evidencing

shipment. b) Invoice for the shipment: Four copies c) Certificate of country of origin: Two copies d) Packing list: Four copies




e) Inspection Release Note from TCE in 4 copies. f) Certificate of Quality including works certificate / certificate of chemical

analysis, where applicable: Two copies. g) Certificate from Seller that, in case of delay in delivery, price reduction for

the same has been applied in the invoice submitted for payment. Payment will be made by the owner against an irrevocable letter of credit against submission of dispatch documents. Payment of Indian Agent Commission: It is not the policy of BPCL per se to look

for, encourage or engage agents. BPCL shall not be liable for any payment on account of commission to supplier or his agents.

Commission, if any, needs to be settled by the supplier directly to his agents.

12.0 PRICE REDUCTION CLAUSE FOR DELAY IN DELIVERY

In the event of delay beyond of the contractual progressive delivery date for reasons not attributable to BPCL and not constituting conditions of force majeure, it will be at BPCL’s discretion, without prejudice to his other rights under the contract, to accept delayed delivery, but at the prices reduced at the rate of 1% (one percent) of the order value of delayed goods / supplies per week of delay or part thereof, subject to a maximum of 10% (ten percent) of the total order value.

The above price reduction schedule for delay in delivery shall be applicable for delay in delivery for all indigenous/imported items required for the project.

Further, in case of delay in delivery, the vendor shall calculate the applicable price reduction for delayed delivery and raise their invoices net of the same.

13.0 FORMAT FOR SUBMITTING PRICE

The price should be submitted in the format given below on your Company’s letterhead.

A) FOR INDIGENOUS VENDORS:

Sr. No.

Description Qty. Unit Rate

Total Price

1 Item wise price on ex-your works basis. 2 Charges for packing & forwarding 3 Third Party Inspection Charges (if applicable)

4 CENVAT (Excise Duty) @ _____% 5 Sales Tax / MVAT @ _________% 6 Octroi Not applicable 7 Transportation charges for delivery at the plant site by road 8 Charges for erection (if applicable)

9 Charges for commissioning (if applicable) 10 Charges for testing at site (if applicable) 11 Per Diem Rate for supervision of erection & commissioning

(if applicable)

12 Price for commissioning spares. Itemized with unit costs and




Sr. No.


Total Price

relevant part no(s). 13 Price for spares for 5 year’s trouble free operation –

Itemized with unit costs and relevant part no(s).

14 Price for Insurance spares. Itemized with unit costs and relevant part no(s).

15 Price for special tools and tackles, if any 16 Any other charges (if applicable)

B) FOR FOREIGN VENDORS:

Sr. No.


Total Price

1 Item wise price on FOB, port of shipment basis as per INCO terms 2000.

2 Freight charges up to Mumbai (India) Sea / Air ports 3 Third Party Inspection Charges (if applicable) 4 Charges for erection (if applicable) 5 Charges for commissioning (if applicable) 6 Charges for testing at site (if applicable) 7 Per Diem Rate for supervision of erection & commissioning

(if applicable)

8 Price for commissioning spares. Itemized with unit costs and relevant part no(s).

9 Price for spares for 5 year’s trouble free operation – Itemized with unit costs and relevant part no(s).

10 Price for Insurance spares. Itemized with unit costs and relevant part no(s).

11 Price for special tools and tackles, if any 12 Any other charges (if applicable), not covered herein above.

The bidder shall include in his price, the cost of all documentation as per the enquiry specifications. All necessary statutory Licensed, approvals, etc. for the manufacture and supply, including transportation of goods / equipment, items quoted shall be vendor’s responsibility at no extra cost to the purchaser. 14.0 Bid Evaluation:

14.1 Where only Indian Bids are under comparison

Bids shall be evaluated on the basis of landed cost at Site including third party inspection charges (if applicable) by third party inspection agency as nominated by BPCL.

14.2 Where only Foreign Bids are under comparison




Bids shall be evaluated on CFR basis including third party inspection charges by third party inspection agency (nominated by BPCL) if applicable, and considering sea freight as under:

Packages/equipments/pipes & plates: Firm freight as quoted by bidders

In case vendor/bidder does not quote for freight charges then following loading will apply Bulk items – piping (other than pipes) / instruments: Europe / Japan / Asia : 6% of FOB price Australia / American Continent : 9% of FOB price

14.3 Where Indian as well as Foreign Bids are under comparison

Domestic Bidders:

Bids shall be evaluated on the basis of landed cost at Site including third party inspection charges by third party inspection agency (nominated by BPCL) if applicable

Foreign Bidders:

Bids shall be evaluated on the basis of landed cost at Site including third party inspection charges by third party inspection agency (nominated by BPCL) if applicable

a) F.O.B. price quoted by the bidder (including stowage charges in case

of pipes) b) Ocean freight as under: Packages/equipments/pipes & plates: Firm freight as quoted by bidders

In case vendor/bidder does not quote for freight charges then following loading will apply Bulk items – piping (other than pipes) / instruments: Europe / Japan / Asia : 6% of FOB price Australia / American Continent : 9% of FOB price

c) Marine insurance @0.25% of FOB price d) Prevailing rate of Customs duty calculated with Landing Charges @

1% of CIF Value e) Port handling charges @ 2% of FOB value f) Inland freight charges from Mumbai port(India) to project site(s) @2%

of landed cost, i.e., sl.no.(a )to (e)


105802

Highlight

105802

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g) In case of pipes, in case a foreign bidder has not quoted or not included stowage charges, the same shall be loaded @ 10% of bidder’s quoted Ocean Freight.

14.4 SPARES

a) Vendors shall quote for vendor recommended mandatory spares. All such prices of mandatory spares shall be considered for evaluation and ordering with the main equipment.

b) Commissioning spares and special tools and tackles, if specifically

required and mentioned in the enquiry / offer, will be considered for price evaluation and placement of order. However, suppliers shall be fully responsible and no additional cost shall be paid by BPCL in case commissioning spares/special tools and tackles over and above those quoted by suppliers are required.

c) Bidders are requested to quote for their recommended five years

operation and maintenance spares but the same will not be considered for price evaluation. These will be selected and ordered by BPCL.

14.5 Third Party Inspection Charges:

Foreign bidders shall quote third party inspection charges separately if applicable as indicated in technical specifications. Third party inspection charges shall be considered for evaluation while arriving at Suppliers’ landed prices. TPI charges shall not be applicable for Indian vendors as

the materials supplied by Indian vendors shall be inspected by TCE.

14.6 Other Conditions Related To The Bid Evaluation: i. Canvassing in any form will make the bid liable for rejection. ii. Unsolicited clarifications to the offer and/or change in prices during its validity period would render the bid liable for outright rejection. iii. Bidders are advised to ensure that their bids are complete in all respects and conform to our terms, conditions and Bid Evaluation criteria of RFQ. Bids not complying with Owner’s requirement may be rejected without seeking any clarifications. iv. Bidders will not be allowed to revise their price/bid for any subsequent clarification compliance to RFQ conditions after submission of bid. v. Bid should be complete covering the individual item wise total scope of work indicated in the Bid documents. vi. OWNER reserves the right to split the quantities of the PO as required among the bidders. vii. OWNER also reserves the right to consolidate the quantities of PO where it is commercially prudent to place single order.




14.7 Foreign suppliers’ bid shall be compared considering Bill collection selling market rate of foreign exchange declared by the State Bank of India one day prior to opening of Price Bids.

15.0 Technical and Commercial Loading

i) Basis of Loading

The Foreign Bids shall be loaded on FOB Port of Exit prices and the Indian Bids shall be loaded on FOT Dispatch Point prices.

ii) Differential Payment Terms

Any differential payment terms offered by a supplier as against the terms specified in the RFQ/ GPC shall be loaded @ 15.75% simple interest per annum for the applicable period. In case a supplier asks for release of final payment (due after receipt and acceptance of materials) along with dispatch documents, loading for one month will be considered.

iii) In case of foreign suppliers, no advance payment shall be allowed

iv) In case supplier insists for liquidated damages or indicates penalty clause in place of Price Reduction Clause, the supplier shall be loaded by 10%.

v) Performance Bank Guarantee (PBG) / Contract Performance Bank

Guarantee (CPBG):

Performance Bank Guarantee by Indian vendors and Contract Performance Bank Guarantee (for 10% of order value) by foreign vendors shall be furnished. However, for order value upto Rs. 1.00 lakh, PBG/CPBG will not be applicable. In case a supplier offers to give a PBG/CPBG for less than 10% of order value, or for a lesser period than what is provided in GPC / SPC, loading shall be done for the differential amount and/ or the differential period.

For differential period/ amount loading, the following example will amplify the methodology (if GPC / SPC specifies 10% PBG/CPBG for 18 months) : For differential period : 10% for 18 months - No loading 10% for 12 months - 10% x 6/18 = 3.3% 10% for 6 months - 10% x 12/18 = 6.7% No PBG - 10 %

In case of Differential Amount Amount Offered by Bidder Loading a) 10% Nil b) Less than 10% Differential between the offered percentage and 10%




vi) PRICE REDUCTION CLAUSE FOR DELAY IN DELIVERY

a) In case a Supplier does not accept the price reduction clause or takes

exception to the percentage rate , loading shall be done to the extent of maximum of 10% of the order value or the differential percentage not agreed by the supplier.

b) In case supplier takes an exception that price reduction in case of

delayed delivery should be restricted to 10% of delayed portion only and not on total order value, then price loading @ 5% shall be done.

c) In case supplier insists for liquidated damages or indicates penalty

clause in place of Price Reduction Clause, the supplier shall be loaded by 10%.

vii) Price variation :

In case Supplier quotes variable price and indicates the price variation

formula and a ceiling, then prices will be loaded with the ceiling so indicated by the supplier. Bids with Price Variation Clause (PVC) but without price variation formula and/or without any ceiling shall be rejected and such price bids shall not be opened.

In case, price variation clause is incorporated within the enquiry, in such cases, Suppliers quoting firm prices shall be considered at par with other suppliers and shall not be given any advantage in price evaluation.

viii) Freight charges:

Indian Suppliers shall quote firm freight charges up to destination by road transport. If a vendor does not quote freight charges, his offer shall be loaded with maximum freight charges as quoted by the other bidders or prorated (with respect to approx. distance) on maximum freight charges as quoted by the other bidders whichever is more.

Foreign vendors shall quote firm sea freight charges from international port of exit to port of destination (Mumbai Port) separately. In case vendor/bidder does not quote for sea freight charges then following loading will apply

Europe / Japan / Asia : 6% of FOB price Australia / American Continent : 9% of FOB price

ix) Any differential in taxes and duties will be cost loaded on case to case

basis. However, if a supplier states that taxes/duties are not applicable at present and will be charged as applicable at the time of delivery then his bid shall be loaded by the maximum rate of taxes/duties applicable as on the date of price evaluation.

x) Delivery:

Delivery longer than required in enquiry shall be loaded @1% per week

upto a maximum of ten weeks. In case a supplier quotes delivery




longer than ten weeks from required, the bid may be rejected. One month shall be construed as equal to four weeks for the purpose of such evaluation

xi) Cost loading in respect of utilities etc. if applicable shall be considered as

per respective technical specification stipulation.

xii) Foreign Exchanage Rate Variation/Custom Duty Variation For Indian Bidders (On Built-In Import Content):

Prices shall remain firm and fixed without any escalation except for

statutory variation in customs duty rate. However, the prices shall be firm and fixed on account of FE variation.

The statutory variation in customs duty shall be subject to the following

guidelines and the supplier shall be asked to confirm the following in their bid:

(a) Maximum CIF value of import content shall be furnished in the bid. (b) The material to be imported covering the above CIF value to be

indicated in the bid. (c) Any increase in price due to increase in customs duty rate beyond

two-third of the quoted delivery period will be to supplier’s account. However, any decrease in price due to decrease in customs duty rate at the time of actual clearance of imported materials shall be passed on to BPCL.

(d) Variation in price due to customs duty rate will be dealt with

separately after receipt of materials at site against documentary evidence.


SPEC NO.

TATA CONSULTING ENGINEERS LIMITED SECTION : F

TCE.6758A-954 APPROVED VENDOR LIST SHEET 1 OF

13 OF 4

PIPING

1. PIPES ERW CS

1.1. JINDAL PIPES LTD., MUMBAI

1.2. MAHARASHTRA SEAMLESS LTD., MUMBAI

1.3. RATNAMANI METALS & TUBES LTD., AHMEDABAD

1.4. WELSPUN GUJARAT STAHL ROHREN LTD., MUMBAI

1.5. ISMT LIMITED, PUNE

1.6. SURINDRA ENGINEERING CO. PVT. LTD., MUMBAI

1.7. LALIT PIPES

1.8. EUROTUBE LTD., ITALY

1.9. ESCO LTD., JAPAN

1.10. VALLOUREC & MANNESHMAN

1.11. TENARIS ( DALMINE, TAMSA, SIDERCA, SILCOTUB)

1.12. JFE STEEL CORPORATION GERMANY

1.13. SUMITOMO PIPE CO & TUBE CO. LIMITED.

1.14. BENTLER AG

2. PIPES EFW CS

2.1. JINDAL SAW LTD. (FORMERLY SAW PIPES LTD), MUMBAI

2.2. LALIT PROFILES & STEEL INDUSTRIES LTD., NAVI MUMBAI

2.3. PSL LIMITED, MUMBAI


2.5. SURINDRA ENGINEERING CO. PVT. LTD., MUMBAI

2.6. WELSPUN GUJARAT STAHL ROHREN LTD., MUMBAI

2.7. MAN INDUSTRIES

2.8. MUKAT PIPES

2.9. LALIT PIPES





2.14. VALLOUREC & MANNESHMAN


3. PIPES SEAMLESS CS

3.1. DALMINE S.P.A., ITALY (ONLY FOR 16” AND ABOVE SIZE)

3.2. HORST KURVERS GMBH, GERMANY (ONLY FOR 16” AND ABOVE SIZE)

3.3. INOXTECH S.P.A, ITALY (ONLY FOR 16” AND ABOVE SIZE)





SPEC NO.



13 OF 4

3.7. TUBOS REUNIDOS, S.A., SPAIN (ONLY FOR 16” AND ABOVE SIZE)

3.8. VAN LEEUWEN BUIZEN, BELGIUM (ONLY FOR 16” AND ABOVE SIZE)



3.11. BHARAT HEAVY ELECTRCAL LTD.




3.15. RATNADEEP METAL & TUBES PVT. LTD

4. PIPES SS SEAMLESS & WELDED

4.1. HORST KURVERS GMBH, GERMANY

4.2. INOXTECH S.P.A, ITALY



4.5. SANDVIK ASIA LTD., PUNE

4.6. VAN LEEUWEN BUIZEN, BELGIUM

4.7. PEERAJ GENERAL TRADING CO.LLC

4.8. IGAWARA TRADING, SINGAPORE

4.9. METAL INDIA

4.10. P. B. METAL CORPORATION

4.11. KWALITY TUBES

4.12. ARISTO METAL INDUSTRIES



4.15. RAJENDRA MECHANICAL INDUSTRIES LTD (FOR SS/ AL SEAMLESS & WELDED)

4.16. PRAKASH STEELAGE LTD, SILVASA (FOR SS WELDED)


4.18. RATNADEEP METAL & TUBES PVT.LTD.

5. PIPES ALLOY STEEL(SEAMLESS)






5.6. JINDAL PIPES LTD.

5.7. PEERAJ GENERAL TRADING CO.LLC


5.9. ARISTO METAL INDUSTRIES

5.10. ARDH METAL AGENCIES


SPEC NO.



13 OF 4

5.11. KWALITY TUBES



5.14. BENTLER AG

5.15. SANDVIK ASIA LTD., PUNE

6. PIPES - CPVC

6.1. ASTRAL POLYTECHNIK LIMITED

6.2. GEORG FISCHER PIPING SYSTEMS PVT LIMITED

7. BARE TUBES

7.1. HEAVY METALS AND TUBES MUMBAI 7.2. SAINEST TUBES AHMEDABAD 7.3. RATNADEEP METALS AND TUBES, KHETWADI LANE, MUMBAI 7.4. SHIN HAN METAL

7.5. SALZGITTER MANNESMANN

7.6. RATHGIBSON, INC

7.7. RONCONI

7.8. VALLOUREC PRECISION

7.9. RATHGIBSON, INC

7.10. RAJENDRA MECHANICAL INDUSTRIES, GOREGAON E

7.11. HART B V

7.12. DMV FRANCE

7.13. BENTELER AKTIENGESELLSCHAFT, GERMANY

7.14. DALMINE SPA, ITALY

7.15. INTERNATIONAL EXTRUDED PRODUCTS, USA

7.16. KAWASAKI STEEL CORPORATION, JAPAN

7.17. MANNESMANN ROHRENWERKE AG

7.18. NIPPON STEEL CORPORATION, JAPAN

7.19. NKK CORPORATION, JAPAN

7.20. SUMITOMO METAL INDUSTRIES LTD., JAPAN

7.21. VALLOUREC INDUSTRIES, FRANCE

7.22. TUBOS DEACERODE. MEXICO, SA, UK

8. TUBE STUDDED

8.1. BHEL (TRICHY) INDIA

8.2. BIRAGHI S.A. France

8.3. FINTUBE LTD. PARTNERSHIP, CANADA

8.4. JORD ENGINEERS INDIA LTD., INDIA

8.5. LPA SPA, ITALY


SPEC NO.



13 OF 4

8.6. SUMITOMO METAL INDUSTRIES LTD., JAPAN

9. FITTINGS WROUGHT / FORGED FITTINGS(CS/AS/SS)

9.1. EBY FASTENERS, TALOJA

9.2. GUJARAT INFRAPIPES PVT. LTD., VADODARA

9.3. TECNOFORGE S.P.A, ITALY

9.4. TEEKAY TUBES PVT.LTD., NAVI MUMBAI

9.5. TUBE PRODUCTS INCORPORATE, VADODARA


9.7. PIPEFIT ENGINEERS

9.8. SAWAN ENGINEERS

9.9. AMFORGE INDUSTRIES

9.10. FIT TECH INDUSTRIES PVT. LTD.

9.11. ECHJAY INDUSTRIES PVT. LTD. MUMBAI.(M) 9.12. PARAMOUNT FORGE, PANVEL.(M) (UPTO 1.5 INCH) 9.13. PARMAR TECHNOFORGE,PUNE(M) (UPTO 6 INCH) 9.14. ASIAN BOILER ENGINEERS,MUMBAI.9M)(PIPE FITTINGS - IBR) 9.15. RACCORTUBI

9.16. ERNE GMBH

9.17. FITTINOX, ITALY

9.18. PHOCEENNE - GENOYER S.A. FRANCE

9.19. MUNRO & MILLER FITTINGS, UK

10. INCONEL 600 / 625 PIPES, FITTINGS AND FLANGES

10.1. CORROTHERM INTERNATIONAL LTD., UK

10.2. FITTINOX, ITALY, ITALY



10.5. MANNESMANN DMV STAINLESS GMBH, GERMANY

10.6. PEERAJ GENERAL TRADING CO. LLC, U.A.E

10.7. RACCORTUBI, ITALY, ITALY

10.8. TEEKAY TUBES PVT.LTD., NAVI MUMBAI



11. FLANGE- FORGED/ PLATE (CS/AS/SS)

11.1. C.D. INDUSTRIES LTD., MUMBAI

11.2. ECHJAY INDUSTRIES LTD., RAJKOT

11.3. J.K. FORGINGS, NEW DELHI

11.4. SHREE GANESH FORGINGS LTD., MUMBAI

11.5. SANGHVI FORGING


SPEC NO.



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11.6. PARAMOUNT FORGE

11.7. BRITEX ENGINEERING

11.8. FIVEBROS FORGINGS PVT. LTD.

11.9. FERROSTAAL AG

11.10. METALFAR PRODOTTI INDUSTRIALI S.P.A.

11.11. AMFORGE INDUSTRIES


11.13. PIPEFIT ENGINEERS PVT. LTD

11.14. PARMAR TECHNOFORGE

12. BLIND, SPACERS & SPECTACLE BLINDS

12.1. C.D. INDUSTRIES LTD., MUMBAI

12.2. ECHJAY INDUSTRIES LTD., RAJKOT

12.3. J.K. FORGINGS, NEW DELHI

12.4. SHREE GANESH FORGINGS LTD., MUMBAI

12.5. SANGHVI FORGING


12.7. BRITEX ENGINEERING

12.8. FIVEBROS FORGINGS PVT. LTD.

12.9. FERROSTAAL AG

12.10. METALFAR PRODOTTI INDUSTRIALI S.P.A.

13. VALVES-GATE,GLOBE,CHECK(CAST/FORGED)-CS/AS/SS

13.1. BDK ENGINEERING INDUSTRIES PVT.LTD., PUNE

13.2. KSB PUMPS LTD., PUNE

13.3. LARSEN & TOUBRO LTD., MUMBAI

13.4. NITON VALVE INDUSTRIES LTD., MUMBAI

13.5. OSWAL INDUSTRIES LTD, GANDHINAGAR

13.6. BHEL

13.7. TYCO VALVES & CONTROLS ITALIA SRL

13.8. VELAN, GMBH

13.9. AUTOCAP INDUSTRIES CHENNAI (0.5 INCH TO 1.5 INCH NB CLASS 800)

13.10. NSSL Limited

14. VALVE GATE(GUNMETAL/BRASS/BRONZE)

14.1. BOMBAY METAL & ALLOYS MFG. CO. PVT. LTD., MUMBAI

14.2. LEADER VALVES LTD., JALANDHAR

14.3. SANT VALVES PVT.LTD., JALANDHAR

14.4. GG VALVES PVT. LTD.

14.5. A. V. VLAVES LTD.

14.6. FLUID CONTROLS PVT. LTD.


SPEC NO.



13 OF 4

14.7. PEMTO-VALVES INDUSTRIE ARMATUREN GMBH

14.8. TAKAMISAWA VALVE CO. LTD.

15. VALVES - CPVC

15.1. ASTRAL POLYTECHNIK LIMITED

15.2. GEORG FISCHER PIPING SYSTEMS PVT LIMITED

16. Y-TYPE-ANGLE STOP CHECK VALVES

16.1. B.F.E. S.P.A., ITALY

16.2. BABCOCK POWER ESPANA, SPAIN

16.3. EDWARD VOGT VALVE CO, UNITED STATES OF AMERICA

16.4. PETROL VALVES SRL, ITALY

16.5. TAKAMISAWA VALVE CO.,LTD, JAPAN

16.6. VELAN INC, CANADA

16.7. Z&J TECHNOLOGIES GMBH, GERMANY

17. VALVE CHECK(DUAL PLATE WAFER TYPE) CS


17.2. CRANE PROCESS FLOW TECHNOLOGIES, INDIA

17.3. MICROFINISH VALVES PVT. LTD.

17.4. ADVANCE VALVES PVT. LTD.

17.5. VALVES INDUSTRIES

17.6. GOODWIN INTERNATIONAL LTD., U.K.

17.7. NITON VALVES

17.8. LARSEN & TOUBRO


17.10. BPCL CATEGORY :GLOBE/GATE/CHECK VALVES - CS(A-105)

17.11. AUTOCAP INDUSTRIES.CHENNAI.(M).(1/2" TO 1.1/2" NB CLASS 800)

18. VALVE BALL FIRE SAFE(CAST CARBON STEEL)

18.1. BELGAUM AQUA VALVES PVT LTD, BELGAUM

18.2. FLOW CHEM INDUSTRIES, AHMEDABAD


18.4. MICROFINISH VALVES PVT. LTD., MUMBAI

18.5. REYNOLD VALVES LTD, MUMBAI

18.6. VIRGO ENGINEERS LTD., NAVI MUMBAI

18.7. WEIR VALVES & CONTROL UK LTD.

18.8. XOMOX INTERNATIONAL GMBH & CO.

18.9. B.D.K.ENGINEERING INDUSTRIES LTD. MUMBAI.(M)

18.10. BHARAT HEAVY ELECTRICALS LTD. TIRUCHIRAPPALLI.(M)

18.11. KSB PUMPS LTD. MUMBAI.(M)


SPEC NO.



13 OF 4

18.12. TYCO VALVES & CONTROLS INDIA PVT. LTD. MAGHASAR.(M)

18.13. AKAY INDUSTRIES. MUMBAI.(M) 18.14. EL-O-MATIC (I) PVT.LTD.PUNE

19. VALVE BUTTERFLY(CARBON STEEL)


19.2. CRANE PROCESS FLOW TECHNOLOGIES (I) LTD., PUNE

19.3. INSTRUMENTATION LTD., MUMBAI


19.5. TYCO VALVES & CONTROLS INDIA PVT LTD, NAVI MUMBAI

19.6. ARMATUREN VERTRIEB ALMS GMBH


19.8. WEIR VALVES & CONTROL UK LTD.

19.9. ADVANCE VALVES PVT. LTD.NOIDA.(M) 19.10. BHARAT HEAVY ELECTRICALS LTD. TIRUCHIRAPPALLI.(M) 19.11. FOURES ENGG. (I) PVT. LTD. MUMBAI.(M) 19.12. DEMBLA VALVES LTD

20. VALVE BUTTERFLY(STAINLESS STEEL)

20.1. CRANE PROCESS FLOW TECHNOLOGIES (I) LTD., PUNE

20.2. INSTRUMENTATION LTD., MUMBAI


20.4. TYCO VALVES & CONTROLS INDIA PVT LTD, NAVI MUMBAI

20.5. ARMATUREN VERTRIEB ALMS GMBH


20.7. ADVANCE VALVES PVT. LTD.NOIDA.(M) 20.8. BHARAT HEAVY ELECTRICALS LTD. TIRUCHIRAPPALLI.(M) 20.9. FOURES ENGG. (I) PVT. LTD. MUMBAI.(M) 20.10. DEMBLA VALVES LTD

21. MOTORISED OPERATED VALVES (FLANGED /B.W END GATE/GLOBE/CHECK VALVE C.S./S.S./A.S.)


21.2. ECONO VALVES PVT. LTD., CHENNAI

21.3. KSB PUMPS LTD., PUNE


21.5. NITON VALVE INDUSTRIES LTD., MUMBAI


21.7. VALVA ITALIA

21.8. TYCO VALVES & CONTROLS ITALIA SRL

21.9. ROTORK CONTROLS (INDIA) LTD. MUMBAI.(M)


SPEC NO.



13 OF 4

22. TILT DISC CHECK VALVES

22.1. CRISPIN VALVES, INDIA


22.3. FRUILCO, ITALY

22.4. PACIFIC VALVES, U.S.A

22.5. POYAM VALVES ( AMPO, S.COOP), SPAIN

22.6. VELAN INC, CANADA

22.7. XANIK SPECIALITY VALVES S.A.DE.C.V, MEXICO

23. FASTENERS(INDIGENOUS) (FOR CS/LTCS ONLY)

23.1. ASHCROFT INDIA PVT LTD (FORMERLY PRECISION IND.), MUMBAI

23.2. FASTENERS & ALLIED PRODUCTS PVT.LTD., HUBLI

23.3. HARDWIN FASTENERS PVT. LTD., MUMBAI

23.4. J.J. INDUSTRIES, MUMBAI

23.5. MULTI FASTENERS PVT.LTD., VADODARA

23.6. PACIFIC FORGING & FASTENERS PVT. LTD, MUMBAI

23.7. PRECISION AUTO ENGINEERS, LUDHIANA

23.8. SANDEEP ENGINEERING WORKS, MUMBAI

23.9. SUNDARAM FASTENERS, CHENNAI

23.10. SYNDICATE ENGINEERING INDUSTRIES, MUMBAI

23.11. UDEHRA FASTENERS LIMITED. LUDHIANA.(M)

23.12. BOLTMASTER (INDIA) PVT. LTD. THANE.(M)

23.13. FIX FIT FASTENERS MFG PVT. LTD. CALCUTTA.(M)

23.14. MEGA ENGINEERING PVT. LTD. NAVI MUMBAI.(M) 23.15. F.E.DARUKHANAWALA 23.16. BPCL CATEGORY - SS BOLTS / STUDS / NUTS

23.17. GUPTA WORKSHOP. MUMBAI.(M)

23.18. KUNDAN ENGINEERING WORKS. MUMBAI.(M)

23.19. UDEHRA FASTENERS LIMITED. LUDHIANA.(M)

24. FASTENERS(IMPORTED) (FOR AS ONLY)

24.1. BECK CRESPEL, FRANCE

24.2. KADDAS OILFIELD SERVICES & TRADING COMPANY LLC, U.A.E

24.3. MEZON TECHNICAL TRADING L.L.C., U.A.E

24.4. OME METALLURGICA ERBESE S.R.L, ITALY

24.5. PEERAJ GENERAL TRADING CO. LLC, U.A.E

24.6. PROSPER ENGINEERING LTD, UNITED KINGDOM

24.7. ROLLSTUD LTD, UNITED KINGDOM

24.8. SANWA BYORA SEISAKUSYO CO LTD, JAPAN

24.9. STAINLESS STEEL FASTENERS LTD, ENGLAND


SPEC NO.



13 OF 4

25. GASKETS (ASBESTOS/ ASBESTOS FREE / RUBBER / PTFE /ELASTOMER / SPIRAL WOUND / JACKETED / METALLIC)

25.1. CHAMPION JOINTINGS PVT.LTD., MUMBAI

25.2. IGP ENGINEERS LTD., CHENNAI

25.3. MADRAS INDUSTRIAL PRODUCTS, CHENNAI

25.4. STARFLEX SEALING INDIA PVT. LTD. (FLEXITALLIC), MUMBAI

25.5. UNIQUE INDUSTRIAL PACKINGS, MUMBAI

25.6. UNIKLINGER LTD., PUNE

25.7. VIRCAP SEALINGTECH PVT. LTD., CHENNAI

25.8. EUROGUARCO S.P.A.

25.9. KEMPCHEN & CO.

BPCL CATEGORY – CAF GASKET

25.10. SEIMAR ENGINEERING PVT. LTD.MUMBAI..(M)

25.11. SUPER GASKET INDUSTRIES.MUMBAI.(M)

25.12. UNITED ENTERPRISES.MUMBAI.(M)

25.13. HINDUSTAN COMPOSITES LTD.MUMBAI.(M) BPCL CATEGORY – (CORRU GASKET, SOFT STEEL,SS,CU)

25.14. PACKINGS & JOINTINGS GASKETS P.LTD. CHENNAI.(M) 25.15. SPIRASEAL GASKETS PRIVATE LIMITED. MADRAS.(M)

25.16. BPCL CATEGORY – (JACKETTED GASKETS NON FERROUS) 25.17. GOODRICH GASKET PRIVATE LIMITED.CHENNAI.(M)

25.18. PACKINGS & JOINTINGS GASKETS P.LTD. CHENNAI.(M)

25.19. SPIRASEAL GASKETS PRIVATE LIMITED.MADRAS.(M)

25.20. SUPER GASKET INDUSTRIES.MUMBAI.(M)

25.21. BPCL CATEGORY – (SPIRAL WOUND METALLIC GASKETS)

25.22. PACKINGS & JOINTINGS GASKETS P.LTD .CHENNAI.(M)

25.23. SPIRASEAL GASKETS PRIVATE LIMITED. MADRAS.(M)

25.24. TEEKAY METAFLEX PVT. LTD. MUMBAI.(M)

BPCL CATEGORY (HOSES - FIRE SERVICES)

25.25. INDIAN RAYON AND INDUSTRIES LTD..(M)

25.26. NEW AGE HOSE MANUFACTURING CO..(M)

25.27. CHHATARIYA FIRETECH INDUSTRIES.(M)

25.28. ZENITH FIRE SERVICES (INDIA) PVT.(M)

25.29. RM APPLIED ENG.

26. GRATINGS

26.1. ALLIED ENGINEERING CORPORATION

26.2. GREATWELD STEEL GRATINGS PVT.

26.3. INDIANA ENGINEERING WORKS (BOMBAY) PVT. LTD.

26.4. KEMROCK INDUSTRIES AND EXPORTS LTD.

26.5. SWATHI ENGINEERS


SPEC NO.



13 OF 4

26.6. WEST COAST ENGINEERING WORKS PVT. LTD.

BPCL CATEGORY -(GRATINGS GALVANISED) 26.7. GUPTA WORKSHOP.MUMBAI.(M) 26.8. ERCON COMPOSITES.JODHPUR.(M) 26.9. INDUSTRIAL PLASTICS.MUMBAI(M)

27. PRIMARY SUPPORTS

27.1. BARODA EQUIPMENT AND VESSELS PVT LTD

27.2. KINAM ENGINEERING INDUSTRIES

27.3. SPRING SUPPORTS MFG. COMPANY

27.4. SUPREME ENGINEERING WORKS

27.5. SWATHI ENGINEERS

27.6. TINITA ENGINEERING PVT. LTD.

27.7. TECHNO INDUSTRY

27.8. DOLPHIN ENGINEERING

28. SPECIAL SUPPORTS

28.1. KINAM ENGINEERING INDUSTRIES

28.2. PIPE HANGERS & SUPPORTS PRIVATE LTD.

28.3. PIPING & ENERGY PRODUCTS PVT. LTD

28.4. RAJ ENGINEERING CO.

28.5. SARATHI ENGINEERING ENTERPRISE

28.6. SPRING SUPPORTS MFG. COMPANY

28.7. TINITA ENGINEERING PVT. LTD.

TECHNO INDUSTRY

29. EXPANSION BELLOWS

29.1. CORI ENGINEERS PVT. LTD.

29.2. D. WREN INDUSTRIES PVT.LTD.

29.3. DIP-FLON ENGINEERING & CO.

29.4. FLEXICAN BELLOWS & HOSES PVT.LTD

29.5. FLUOROPOLYMER PACKINGS & SEALS PVT.LTD.

29.6. LONESTAR INDUSTRIES

29.7. MIL INDUSTRIES LTD.

29.8. METALLIC BELLOWS (I) PVT. LTD.

29.9. RM APPLIED ENGINEERS

29.10. KELD ELLENTOFT INDIA PVT. LTD.MUMBAI.(M) 29.11. SUR INDUSTRIES PVT LTD.CALCUTTA.(M)

30. NON-SLAM CHECK VALVES

30.1. CRANE ENERGY FLOW SOLUTIONS, USA

30.2. CAMERON VALVES AND MEASUREMENT, USA


SPEC NO.



13 OF 4

PROCESS / MECHANICAL

31. ELECTRODES / WELDING CONSUMABLES

31.1. ADVANI – ORLIKON LTD.

31.2. ANAND ARC ELECTRODES PVT. LTD.

31.3. D&H SECHERON ELECTRODES PVT. LTD.

31.4. ESAB INDIA LTD.

31.5. HONAVAR ELECTRODES LTD.

31.6. MAILAM INDIA LTD.

31.7. MODI ARC ELECTRODES CO.

31.8. WELDCRAFT PVT. LTD.

31.9. GEE LIMITED.THANE.(M)

31.10. BOHLER THYSSEN

31.11. OERLIKON

31.12. TASETO

31.13. AVESTA

31.14. SANDVIK

32. INSULATION (HOT & COLD)

32.1. ASSOCIATED INSULATION CO.

32.2. G.J. INSULATIONS PVT.LTD.

32.3. LEAR INSULATION PVT. LTD.

32.4. LLOYD INSULATIONS (INDIA) LTD.

32.5. NAVBHARAT INSULATION & ENGINEERING CO

32.6. NEWKEM INDUSTRIES

32.7. KAFER PUNJ LLOYD

32.8. ROCKWOOL INSULATION (I) PVT.LTD.

32.9. SHREEJI INSULATIONS PVT LTD

32.10. THERMAL INSULATIONS

BPCL CATEGORY -(BONDED MINERAL WOOL/CROWN WOOL)

32.11. MINWOOL ROCK FIBRES LTD.HYDERABAD.

32.12. ROCKWOOL (INDIA) LIMITED.MUMBAI.(M)

32.13. LLOYD'S ROCKFIBRES LTD. MUMBAI

33. INDUSTRIAL PAINTS

33.1. GOODLASS NEROLAC PAINTS PVT. LTD.MUMBAI.(M)

33.2. ALKALI & CHEMICALS CORPN. OF INDIA LTD.MUMBAI.(T)

33.3. ASIAN PAINTS (I) LIMITED.MUMBAI.(T)

33.4. BERGER PAINTS INDIA LTD.MUMBAI.(T)

33.5. ESDEE PAINTS PVT. LTD.MUMBAI.(T)

33.6. JENSON & NICHOLSON (I) LTD.MUMBAI.(T)

33.7. MERCURY PAINTS & VARNISHES LTD.MUMBAI.(T)

33.8. SHALIMAR PAINTS LTD.MUMBAI.(T)


SPEC NO.



13 OF 4


34. PLATES (CS / SS / LAS / CLAD)

34.1. ACRONI

34.2. DILLINGER HUTTE GTS (MILL), GERMANY

34.3. DMV FRANCE

34.4. DUFERCO S A

34.5. EXPLO HUNGARY KFT.

34.6. INDUSTEEL,BELGIUM

34.7. JACQUET NEDERLAND

34.8. VOESTALPINE GROBBLECH GMBH, AUSTRIA

34.9. ESSAR STEEL, INDIA

34.10. STEEL AUTHORITY OF INDIA, INDIA

34.11. LLOYDS STEEL INDUSTRIES LTD, INDIA

34.12. SALZGITTER INTERNATIONAL, GERMANY

34.13. POSCO, KOREA

34.14. NIPPON STEEL, JAPAN

34.15. RUKKI METALS, FINLAND

34.16. THYSSENKRUPP

34.17. KOBE STEEL, JAPAN

35. FORGINGS

35.1. BAYFORGE

35.2. BRIGHTEX

35.3. BUKWANG

35.4. CD ENGINEERING COMPANY GAZIABAD

35.5. CD INDUSTRIES, GAZIABAD

35.6. CHAUDHARY HAMMER WORKS

35.7. DAE HWA METAL CO. LTD, KOREA

35.8. ECHJAY FORGINGS PVT. LTD.

35.9. GALPERTI, ITALY

35.10. GOLDEN IRON AND STEEL WORKS

35.11. GOVA GMBH

35.12. HANWHCORPORATION, KOREA

35.13. HYUNDAI FORGINGS CO, KOREA

35.14. JAC FORGINGS

35.15. JK FORGINGS

35.16. KOFCO KOREA

35.17. KUNJ FORGINGS,

35.18. MELESI, ITALY

35.19. METSTEEL, BUSAN KOREA

35.20. MS FITTINGS

35.21. MYSCO CO LTD.

35.22. O SUNG KOREA


SPEC NO.



13 OF 4


35.23. OFFICINE NICOLA


35.25. PRADEEP METALS

35.26. PUNJAB STEEL WORKS PVT. LTD.

35.27. RP ENGINEERING PVT. LTD.

35.28. SANGHVI FORGINGS & ENGINEERING PVT. LTD


35.30. TAEWOONG CO LTD

35.31. ULMA SPAIN

36. BOLT TIGHTNER

36.1. HYTORC MUMBAI

SL.NO FIRE PROTECTION

EQUIPMENT

APPROVED VENDORS

1.0 HYDRANT VALVE NEWAGE/SUKAN/SBJ

2.0 BRANCH PIPES & NOZZLE NEWAGE/SUKAN/SBJ

3.0 HOSE PIPE NEWAGE/INDIAN

RAYON/JAYSHREE/CHATTRIYA/NIRMAL

4.0 GATE VALVES/NRV(CS) L&T/KSB

5.0 FIRE EXTINGUISHERS ZENITH/SUPRIMAX/SAFEX/NITIN FIRE

6.0 PIPES TATA/ZENITH/JINDAL

7.0 HOSE BOX SBJ/NITIN FIRE/KIDDE INDIA

8.0 WATER MONITOR HD/VIJAY/NEWAGE/VIMAL/VISHAL


1

Commercial Questionnaire (FOR INDIGENOUS MATERIALS AND EQUIPMENT)

Project No.: TCE-6758A BLENDING UNIT AT URAN LPG PLANT

Client: Bharat Petroleum Corporation Limited Vendor Name: M/s. ____________________________________________________________

Enquiry No.__________________________________________________________________

Vendor’s Offer Ref. No. : ________________________________________________________

Tel No. ____________________________________ Fax No._________________________ Contact Person : ___________________________E-Mail _____________________________

1. DULY SIGNED & STAMPED COPIES OF THIS “QUESTIONNAIRE”, WITH ALL THE

CLAUSES DULY CONFIRMED/ PRECISELY REPLIED TO BY THE VENDOR, SHALL BE ENCLOSED WITH EACH AND EVERY SET OF VENDOR'S UNPRICED QUOTATION.

2. FAILURE ON THE PART OF VENDOR IN NOT RETURNING THIS DULY FILLED-UP "QUESTIONNAIRE WITH ALL THE SETS OF UNPRICED QUOTATION AND/OR SUBMITTING INCOMPLETE REPLIES MAY LEAD TO REJECTION OF VENDOR'S QUOTATION”.

Sr. No.

DESCRIPTION VENDOR’S CONFIRMATION

1 Bid rejection criteria: Bidders shall note that the following provisions of the bidding document must be adhered to without any deviations, failing which the bid shall be considered to be non-responsive and may be rejected. Please confirm the acceptance of these clauses:

Noted

1.1 Earnest Money Deposit: (if applicable) : Confirm mode (BG / DD) of submission and details of EMD as per SPC EMD waiver: If applied for, confirm the waiver clause applicable as indicated in SPC, and confirm the supporting documents submitted. Please note that, for BPCL registered vendors, submission of vendor registration letter issued by BPCL is a must.

Submitted BG / DD No.:_______________________ EMD value: USD_____________ OR Not Applicable Supporting document submitted:__________________ OR Not submitted. Refer deviation sheet.

1.2 Bid Validity period: Confirm Offer validity of SIX MONTHS from final bid due date.

Confirmed / Not Confirmed refer deviation sheet Validity: _______Months from bid due date.

1.3 Defects Liability Period: Confirm acceptance of defect liability period clause as indicated in Special Purchase Conditions.

Accepted / Not accepted refer deviation sheet


2

1.4 Performance Bank Guarantee: Confirm acceptance of performance guarantee clause as indicated in Special Purchase Conditions & General Purchase Conditions.


1.5 Delivery Period: In case a supplier quotes delivery longer than ten weeks from required as indicated in SPC, the bid may be rejected. One month shall be construed as equal to four weeks for the purpose of such evaluation. Please confirm shortest delivery period from the date of Fax of Acceptance only

Noted Quoted delivery period: _______ delivered at site from the date of fax of acceptance

2. Technical and Commercial Loading: Bidders shall note that the following provisions of the bidding document must be adhered to without any deviations, failing which the quoted prices shall be loaded as indicated in special purchase conditions. The Foreign Bids shall be loaded on FOB Port of Exit prices and the Indian Bids shall be loaded on FOT Dispatch Point prices. Loading maximum up to 10% of the quoted price shall be taken. Please confirm the acceptance of these clauses:

Noted

2.1 Payment Terms: Confirm acceptance of payment terms as indicated in special purchase conditions.


2.2 Firmness of prices: Quoted prices shall remain firm and fixed till complete execution of the order.


2.3 Freight charges : Bidders to quote freight charges in terms of % of basic quoted price

Quoted in terms of % / Included in basic price

2.4 Taxes and Duties : Any differential in taxes and duties will be cost loaded on case to case basis. However, if a supplier states that taxes / duties are not applicable at present and will be charged as applicable at the time of delivery then his bid shall be loaded by the maximum rate of taxes/duties applicable as on the date of price evaluation


2.5 Delivery : Delivery longer than required in enquiry shall be loaded @1% per week up to a maximum of ten weeks. One month shall be construed as equal to 4 weeks for the purpose of such evaluation


2.6 Foreigh exchange rate variation/custom duty variation for Indian bidders (On built in import content) : Prices shall remain firm and fixed and without any escalation except for statutory variation in customs duty rate. However, the prices shall be firm and fixed on account of FE variation. The statutory variation in customs duty shall be subject to the guidelines as indicated in SPC


3 PRICE REDUCTION CLAUSE FOR DELAY IN DELIVERY: In the event of delay beyond the contractual



3

progressive delivery date for reasons not attributable to BPCL and not constituting conditions of force majeure, it will be at BPCL’s discretion, without prejudice to his other rights under the contract, to accept delayed delivery, but at the prices reduced at the rate of 1% (one percent) of the order value of delayed goods / supplies per week of delay or part thereof, subject to a maximum of 10% (ten percent) of the total order value.

4 Force Majeure Clause : Confirm acceptance of Force Majeure Clause as indicated in Special Purchase Conditions (GPC).


5 Arbitration Clause: Confirm acceptance of Arbitration Clause as indicated in Special Purchase Conditions (GPC).


6 Prices have been furnished as per “Format For Submitting Price” indicated in Special Purchase Conditions (SPC)

Furnished / Not furnished refer deviation sheet

7 Confirm that Prices quoted are on FOT dispatch point basis

Confirmed / Not confirmed

8 Specify Despatch Point Material shall be dispatched from : ___________. State : __________

9 Confirm that the prices quoted are inclusive of packing & forwarding charges

Confirmed / Quoted separately

10 Transit risk insurance shall be covered by BPCL and the same has not been included in the quoted prices.

Noted and confirmed

11 Excise Duty : Tarrif sub heading No. Present rate of excise duty payable extra on finished products including spares Maximum rate applicable (if present rate is nil or concessional)

12 Please indicate the following break-up

a. Cenvatable excise duty b. Non cenvatable excise duty

13 Only statutory variations, if any, in the present rate of excise duty, upto the contractual delivery period shall be to Owner’s account subject to documentary evidence to be furnished by the vendor

Accepted

14 Any variation in excise duty at the time of supplies for any reasons, other than statutory including variations due to turnover, shall be borne by vendor

Accepted

15 Material supplied will be eligible for CENVAT Credit and vendor shall furnish all documents as required to avail the same

Accepted

16 Sales tax payable extra, specify CST/MVAT and the present rate applicable

CST : ______% against C form MVAT : ______%

17 In case of CST, C form shall be provided. Noted


4

In case of MVAT, no concessional form shall be provided

18 Only statutory variations, if any, in the present rate of CST/MVAT, upto contractual delivery period shall be to Owner’s account subject to documentary evidence to be furnished by the vendor

Accepted

19 If CST/MVAT is not applicable at present due to any reason, the same shall be borne by vendor if it becomes applicable later

Accepted

20 Any new or additional taxes/duties and any increase in the existing taxes/duties imposed after contractual delivery shall be to Vendor’s account whereas any corresponding decrease shall be passed on to the Owner

Accepted

21 Repeat Order: Confirm acceptance of repeat order if ordered within 12 months from the date of placement of original purchase order with same unit price(s) and terms & conditions


22 Testing and Inspection charges : Goods and services are subject to stage wise and final inspection by Owner / TCE for which no extra charges shall be payable by Owner. Travel, living and personnel expenses of Owner’s inspectors shall be borne by Owner. Travel living and personnel expenses of TCE’s inspectors shall be borne by TCE. All built in import content shall be subjected to inspection by Third Party Inspection Agency nominated by BPCL for which charges are included in quoted prices and no additional charges will be paid by Owner

Noted & accepted

23 Quoted prices are inclusive of all testing and inspection charges

Confirmed

24 Acceptance of all other terms & conditions as per attached : a) General Purchase Conditions. b) Special Purchase Conditions c) Instructions to bidders. d) Terms & Conditions for Supervision of Erection & Commissioning (if applicable) e) Terms & Conditions for Site work(if applicable) Bidder to submit above documents duly signed & stamped along with deviation sheet (if any) as token of acceptance.

Accepted OR Accepted with deviation as indicated in separate deviation sheet Submitted

25 Whether any of the Directors of Vendor is a relative of any Director of BPCL/TCE or the vendor is a firm in which any Director of BPCL/TCE or his relative is a Partner or the vendor is a private company in which any director of BPCL/TCE is a member or Director.

Yes / No

26 Please confirm you have not been banned or delisted by any Government or Quasi Government agencies or PSUs. If you have been banned, then this fact must be

Not banned Banned as indicated in


5

clearly stated. This does not necessarily be cause for disqualification. However if this declaration is not furnished the bid shall be rejected as non-responsive. Please confirm that you have filled in, signed and attached the enclosed "Proforma of Declaration of Black Listing / Holiday Listing" along with your unpriced offer

Declaration of Black Listing / Holiday Listing Furnished / Not applicable

27 Confirm that all deviations to Technical Specifications have been indicated on a separate deviation sheet. Any deviation indicated in bid elsewhere other than Deviation Sheet shall not be considered.

Separate Technical Deviations Sheet submitted

28 Confirm that all commercial deviations to Tender Conditions, GPC, SPC have been indicated on a separate commercial deviation sheet. Any deviation indicated in bid elsewhere other than Deviation Sheet shall not be considered.

Separate Commercial Deviations Sheet submitted

29 All commercial deviations to Tender Conditions, GPC, and SPC will result in loading of the quoted price as indicated in special purchase conditions.

Noted

30 Any claim arising out of order shall be sent to Owner in writing with a copy to TCE within 3 months from the date of last despatch. In case the claim is received after 3 months, the same shall not be entertained by Consultant/ Owner.

Accepted

31 Printed terms and conditions, if any, appearing in quotation, shall not be applicable in the event of order. In case of contradiction between the confirmations given above and terms & conditions mentioned elsewhere in the offer, the confirmation given herein above shall prevail.

Confirmed & Accepted

32 Confirm readiness for signing of integrity pact in the event of placement of order.

Confirmed

(Signature of Vendor with Company seal)

Name of the Authorised Signatory :

Designation :

Date :


SPEC. NO. TCE.M4-903

TATA CONSULTING ENGINEERS LIMITED SECTION: E

DRAWINGS, ENGINEERING DOCUMENTS AND INSTRUCTION MANUALS SHEET 1 OF 6

ISSUE R5

TCE FORM NO. 329 R5 FILE NAME: M4903R5.DOC

1.0 SCOPE This specification covers the requirements to be followed by the VENDOR/

CONTRACTOR while submitting Drawings, Engineering Documents and Instruction Manuals

2.0 DRAWINGS AND DOCUMENTS 2.1 All drawings and documents submitted by the VENDOR/CONTRACTOR

including those submitted at the time of bid shall be with sufficient detail to indicate the type, size, arrangement, weight of each component, breakdown for packing and shipment, the external connections, fixing arrangements required, the dimensions required for installation and interconnection with other equipment and materials, clearance and spaces required between various portions of equipment and any other information specifically requested in the enquiry document.

2.2 Each drawing and document submitted by the VENDOR/CONTRACTOR shall

be clearly marked with the following details. (a) Name of the PURCHASER (b) Name of the CONSULTANT (c) Project Title including (if applicable) number of units and unit numbers (d) Purchase Order Number/Contract Number (e) Title of the Drawing or Document clearly identifying the system,

equipment or part (f) Drawing or Document Revision Number and Date of Revision (g) Space for PURCHASER/CONSULTANT's Drawing Number (h) Name of the VENDOR/CONTRACTOR (i) In case of SUB-VENDOR/SUB-CONTRACTOR or MANUFACTURER's

drawing, name of the SUB-VENDOR/SUB-CONTRACTOR or MANUFACTURER shall be incorporated.

(j) Drawings and documents shall be duly signed in ‘checked’ and

‘approved’ columns. (k) Scale to which the drawing is drawn (l) Cross references to all relevant drawings and documents (m) All relevant notes to the drawings and documents. All notes necessary

for understanding and execution of work shown on a drawing or document shall be presented on the same drawing or document.





ISSUE R5


(n) All legends to all notations (o) Details of revisions carried out as mentioned in para 2.13 below (p) Bill of materials shall be tabulated, wherever required. (q) All titles, notings, markings and writings on the drawing shall be in

English. (r) All the dimensions shall be in metric units. (s) If standard catalogues are submitted, the applicable items shall be

highlighted therein. 2.3 CATEGORISATION OF DRAWINGS AND DOCUMENTS 2.3.1 The drawings and documents submitted by the VENDOR/CONTRACTOR are

generally categorised under the following three heads: (a) Drawings and documents which are to be reviewed and approved

(Category FA) (b) Drawings and documents which are to be reviewed and commented

but are not for approval (Category FR). (c) Drawings and documents which are for information and records only

(Category FI) 2.3.2 The category of each drawing and document shall be decided by the

PURCHASER/CONSULTANT. 2.4 LIST OF DRAWINGS AND DOCUMENTS On the issue of Purchase Order or Award of Contract, the VENDOR/

CONTRACTOR shall furnish a detailed drawing and document schedule with descriptive title and expected dates of submission within the time as specified in the enquiry document. The categorisation of drawings and documents as per para 2.3.1 above shall be marked by the PURCHASER/CONSULTANT on the Drawing and Document Schedule. The VENDOR/CONTRACTOR shall incorporate these details and submit revised schedules. This schedule shall be revised and drawings and documents added, as necessary, during the progress of work with the concurrence of the PURCHASER/CONSULTANT.

2.5 QUALITY OF DRAWINGS AND DOCUMENTS 2.5.1 The VENDOR/CONTRACTOR shall prepare all necessary detailed drawings,

documents and designs etc., giving full and complete information to enable the PURCHASER/CONSULTANT to properly review the design of work.

2.5.2 Drawings and documents shall be fully legible and drawn in ink and all writing

shall be clearly printed or stencilled.





ISSUE R5


2.5.3 Reproduced drawings shall be clear and legible with no background shade. Sections and details of points of the work shall be shown on the same drawing of the work to which these relate.

2.5.4 Drawings and their title blocks shall be properly drawn, prepared and printed to

the approval of the PURCHASER/CONSULTANT. 2.5.5 Drawings poorly drafted or engineered or without signatures in checked and

approval columns will be returned to the VENDOR/CONTRACTOR without review, for necessary action.

2.6 DRAWINGS AND DOCUMENTS BY SUB-VENDORS/SUB-CONTRACTORS Drawings and documents provided by the SUB-VENDORS/SUB-

CONTRACTORS shall be checked thoroughly by the VENDOR/ CONTRACTOR with special regard to measurements, size of components, material and details to satisfy himself that they conform to the requirements and to the intent of the enquiry document and the VENDOR/CONTRACTOR shall place thereon his signature and the date of his approval before submitting the same to the PURCHASER/CONSULTANT. Drawings and documents found to be inaccurate or otherwise in error shall be returned to the VENDOR/ CONTRACTOR for corrections.

2.7 DESIGN CALCULATIONS The VENDOR/CONTRACTOR shall generally furnish the following information. 2.7.1 Manual Design Calculations (a) Input data and source of information (b) Design criteria to satisfy statutory requirements (c) Formulae used and references for the same (d) Assumptions made. Assumptions made based on experience shall be

clearly mentioned. (e) Latest applicable National/International Codes and Standards. The

Codes and Standards shall be referred to with year of publication, revision number, amendment/addenda.

(f) Reference drawings and documents along with their revision numbers (g) Final results, conclusions and recommendations. 2.7.2 Analysis and Design Calculations using Computers (a) VENDOR/CONTRACTOR shall use accredited and validated software

and the same shall be indicated.





ISSUE R5


(b) Modelling, wherever applicable (c) All information as called for in para 2.7.1 above 2.8 SEQUENCE OF SUBMISSION OF DRAWINGS AND DOCUMENTS 2.8.1 Drawings and documents shall be submitted without delay in line with the

agreed schedule as per para 2.4 above. Number of copies submitted to the PURCHASER/CONSULTANT shall be as per the distribution schedule in Section-F of the enquiry document.

2.8.2 The sequence of submission of drawings and documents shall be such that all

information or data is available for reviewing each drawing and document when it is received.

2.8.3 Revised drawings and documents shall be immediately re-submitted for

approval unless directed otherwise by the PURCHASER/CONSULTANT. 2.8.4 Drawings and documents submitted out of sequence will be returned to the

CONTRACTOR without review for re-submission as per the sequence of drawing and document submission.

2.9 The PURCHASER/CONSULTANT shall have the right at all reasonable times to

see at the work place of the VENDOR/CONTRACTOR, all drawings and documents of any portion of the work.

2.10 The drawings and documents submitted by the VENDOR/CONTRACTOR shall

be reviewed by the PURCHASER/CONSULTANT as far as practicable within four (4) weeks and shall be marked up with comments, if any.

One print of such drawings and documents shall be returned to the VENDOR/

CONTRACTOR duly signed by the PURCHASER/CONSULTANT clearly identifying the review status of the drawing or document.

The VENDOR/CONTRACTOR shall incorporate such modifications and/or

corrections and submit the final drawings and documents for approval. If the VENDOR/CONTRACTOR is unable to incorporate comments in his

drawings or documents, he shall clearly state in his forwarding letter such non-compliance along with valid reasons.

Any delays arising out of failure by the VENDOR/CONTRACTOR to rectify the

drawings and documents to the satisfaction of the PURCHASER/ CONSULTANT in good time shall not alter the CONTRACT completion date.

2.11 Further work by the VENDOR/CONTRACTOR shall be in strict accordance

with these drawings and documents and no deviations shall be permitted without the written approval of the PURCHASER/CONSULTANT.





ISSUE R5


2.12 The PURCHASER/CONSULTANT's approval of the VENDOR/ CONTRACTOR’s and SUB-VENDOR’s/CONTRACTOR’s drawings and documents shall not relieve the VENDOR/CONTRACTOR from his responsibility for errors or omissions which may exist, even though work is done in accordance with such approved drawings and documents. When such errors or omissions are discovered later, these shall be made good by the VENDOR/ CONTRACTOR at his expense irrespective of any approval of the PURCHASER/CONSULTANT.

2.13 REVISION OF DRAWINGS AND DOCUMENTS 2.13.1 For all revisions of the drawings and documents, the VENDOR/CONTRACTOR

shall ensure that all revisions are clearly encircled with revision numbers marked on the drawings and documents.

2.13.2 The VENDOR/CONTRACTOR shall also ensure that general details of revisions

are indicated for each revision in the revision block of the drawing or document along with the date and signed by the approving authority.

2.14 Any manufacturing and fabrication work carried out prior to the approval of the

drawings and documents shall be at the VENDOR’s/CONTRACTOR's own risk and expenses.

2.15 Final drawings and documents of the work as completed ('As-Built' drawings)

shall be prepared by the VENDOR/CONTRACTOR and forwarded to the PURCHASER/CONSULTANT.

'As-Built' drawings and documents shall be submitted within three (3) months of

the issue of the Provisional Acceptance Certificate. 2.16 REPRODUCIBLES 2.16.1 Reproducibles, where called for in the distribution schedule in Section F of the

Enquiry Document shall be submitted after the approval of drawings and documents.

2.16.2 Upon completion of the installation, the VENDOR/CONTRACTOR shall furnish

a complete set of drawings and documents on reproducible tracing. The VENDOR/CONTRACTOR shall make in a neat and accurate manner, a complete record of all changes and revisions to the original design, as installed in the completed work. These drawings and documents shall be submitted to the PURCHASER/CONSULTANT for records and these become the property of the PURCHASER.

2.16.3 In case the drawings and documents are prepared using drafting software,

original floppy or compact disc shall be submitted. In addition drawings and documents on Kilburn reproducible tracings film or equivalent shall be submitted as called for in the enquiry document.





ISSUE R5


3.0 ENGINEERING DATA 3.1 The furnishing of engineering data by the VENDOR/CONTRACTOR shall be in

accordance with the schedule for each set of equipment as specified in the technical specifications and the same shall be in English Language and in metric units unless specified otherwise. The review of these data by the PURCHASER/CONSULTANT will cover only general conformance of the data to the specifications and documents interfaces with the equipment provided under the specifications, external connections, and of the dimensions which might affect plant layout. This review by the PURCHASER/CONSULTANT may not indicate a thorough review of all dimensions, quantities and details of the equipment, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by the PURCHASER/ CONSULTANT shall not be construed by the VENDOR/CONTRACTOR, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these specifications and documents.

3.2 All engineering data submitted by the VENDOR/CONTRACTOR after final

process including review and approval by the PURCHASER/CONSULTANT shall form part of the CONTRACT documents and the entire works covered under these specifications shall be performed in strict conformity, unless expressly advised otherwise by the PURCHASER/CONSULTANT in writing.

4.0 INSTRUCTION MANUALS 4.1 The VENDOR/CONTRACTOR shall submit to the PURCHASER/

CONSULTANT for their review, the preliminary instruction manuals for all the equipment, covered under the CONTRACT within the time agreed upon between the PURCHASER/CONSULTANT and the VENDOR/CONTRACTOR. The final instruction manuals complete in all respects shall be submitted by the VENDOR/CONTRACTOR within thirty (30) days before the first shipment of the equipment. The instruction manuals shall contain full details and As-Built drawings for all the equipment furnished, the erection procedures, testing procedures, operation and maintenance procedures of the equipment and the same shall be written in English Language unless specified otherwise in the enquiry document. Each manual shall also include a complete set of approved/as-built drawings together with performance/rating curves of the equipment and test certificates where applicable. These instruction manuals shall be submitted in the form of one (1) reproducible original and number of copies shall be as per Section F of the Enquiry Document.

4.2 If, after the commissioning and initial operation of the plant, the instruction

manuals require any modification/additions/changes, the same shall be incorporated and the updated final instruction manuals shall be submitted in the form of one (1) reproducible original and number of copies shall be as per Section-F of the enquiry document.




PROGRESS SCHEDULE AND REPORTS SHEET 1 OF 3

ISSUE R7


1.0 SCOPE This specification covers general requirements of planning and scheduling of

work and progress reporting by the VENDOR/CONTRACTOR. 2.0 PLANNING AND SCHEDULING OF WORK 2.1 Within a period of two weeks from the date of issue of LETTER OF

INTENT/PURCHASE ORDER/AWARD OF CONTRACT the VENDOR/ CONTRACTOR shall furnish documents as indicated at para 2.2 below, to the PURCHASER/CONSULTANT. The VENDOR/CONTRACTOR shall furnish the dates of manufacture, testing, despatch, completion of erection and commissioning or stages of work. Work shall be divided into parts and items, showing the order to be adopted for the execution and ensuring that periods do not exceed the periods indicated in the LETTER OF INTENT/PURCHASE ORDER/CONTRACT.

2.2 NETWORK SCHEDULE OR LINKED BAR CHART The VENDOR/CONTRACTOR shall submit the Network Schedule or Linked Bar

Chart for his portion of supply or erection work to the PURCHASER/ CONSULTANT showing the logic and period of execution of activities for review and approval.

2.2.1 EQUIPMENT SUPPLY (a) Commencement and completion of submission of final design data,

specifications and calculations (b) Commencement and completion of submission of drawings of various

categories (c) Procurement of raw materials and bought out items (d) Manufacturing process indicating all major stages (e) Shop inspection and testing indicating all inspection and tests (f) Shipment indicating each planned shipment (g) Other major key activities considered to be critical to the progress of the

PURCHASE ORDER 2.2.2 EQUIPMENT SUPPLY AND ERECTION CONTRACT (a) Commencement and completion of submission of final design data,


categories





ISSUE R7


(c) Procurement of raw materials and bought out items (d) Manufacturing process indicating all major stages (e) Shop inspection and testing indicating all inspection and tests (f) Shipment indicating each planned shipment (g) Other major key activities considered to be critical to the progress of

the PURCHASE ORDER/CONTRACT (h) Commencement of preliminary works (i) Detailed stages of construction and erection for each equipment,

structure and system (j) Resources such as labour, material and equipment etc. planned to be

mobilised (k) Commissioning of all major systems 2.2.3 WORKS CONTRACT (a) Commencement and completion of submission of final design data,


categories (c) Procurement of raw materials and bought out items (d) Manufacturing process indicating all major stages (e) Shop inspection and testing indicating all inspection and tests (f) Shipment indicating each planned shipment (g) Other major key activities considered to be critical to the progress of

the PURCHASE ORDER/CONTRACT (h) Commencement of preliminary works (i) Detailed stages of construction and erection for each equipment,

structure and system (j) Resources such as labour, material and equipment etc. planned to be

mobilised (k) Commissioning of all major systems (l) Phased requirement of bulk materials, if supplied by the PURCHASER





ISSUE R7


(m) Cash flow, if required by the PURCHASER/CONSULTANT 2.3 Appropriate time shall be allocated for the approval of the documents and

inspection of the equipment by the PURCHASER/CONSULTANT. Such time periods shall be indicated in the Network Schedule or Linked Bar Chart.

2.4 Work shall be carried out in line with the Network Schedule or Linked Bar Chart

approved by the PURCHASER/CONSULTANT. The Network Schedule or Linked Bar Chart shall be updated every month or at a frequency mutually agreed upon.

2.5 Major milestones and completion dates as indicated in the approved Network

Schedule or Linked Bar Chart shall not be amended unless the consent of the PURCHASER/CONSULTANT has been obtained.

2.6 Progress meetings shall be held at regular intervals and latest updated and

approved Network Schedule or Linked Bar Chart shall be the basis for discussion. Responsible representatives of the VENDOR/CONTRACTOR and the PURCHASER/CONSULTANT shall attend the meeting.

3.0 PROGRESS REPORTS 3.1 During manufacture or the execution of the PURCHASE ORDER/CONTRACT

the VENDOR/CONTRACTOR shall furnish monthly progress reports to the PURCHASER/CONSULTANT in a format as specified by the PURCHASER/ CONSULTANT. The report shall indicate the progress achieved during the month and total progress up to the month as against scheduled progress. Anticipated completion dates in respect of key phases of work such as release of drawings for fabrication, procurement of raw material, fabrication, inspection, testing and shipment shall be indicated.

3.2 Corrective action for the slippage, if any, in the schedule shall be highlighted in

the progress report. 3.3 After the site work or erection has commenced, the VENDOR/CONTRACTOR

shall provide the PURCHASER/CONSULTANT, at regular intervals, the detailed reports on the progress of all works under the CONTRACT. In case of erection, of critical items, VENDOR/CONTRACTOR shall submit a document indicating the proposed erection scheme with complete details of erection planning and resources proposed to be used for review and approval by PURCHASER/ CONSULTANT. The VENDOR/CONTRACTOR shall submit photographs showing the progress of work at the time and in the manner specified by the PURCHASER/CONSULTANT. The VENDOR/CONTRACTOR shall provide the PURCHASER/CONSULTANT, with daily reports giving the number of labourers, skilled workers, supervisory staff and major construction equipment - his own as well as the SUB-VENDOR’s/SUB-CONTRACTOR’s employed by him, in addition to their locations at the work site.


SPEC NO.


TCE.6758A-954 SCHEDULE OF DISTRIBUTION OF DRAWINGS AND

DOCUMENTS SHEET 1 OF 2 OF 4

ISSUE

R0

Document Description BPCL TCE

TCE Site

Supplier / Contractors

TCE Progress Reports, General Correspondence 2 S 1 -

TCE Site Progress Reports 1 1 S -

Concept Notes Preliminary Final

2 2

S S

- -

- -

Design Drawings from TCE to BPCL Preliminary 'P' issues 'R' issues for Site execution / installation As-Built‟ drawings

2

2 (**) 3 +

1CD

S

S S

2

1(**) -

2 2(**) -

Tender Specification Draft Final

3 5

S S

- -

- -

Purchase order from BPCL to contractors Final

S

1

1

2

General Correspondence from contractors Commercial Technical

1 1

1 1

1 1

S S

General Correspondence to Contractor From TCE From BPCL

1 S

S 1

1 1

1 1

General Correspondence from TCE site to Site Contractor BPCL

1 1

1 1

S S

1 -

Vendor Documents / drawings 1st Submission Subsequent revisions Final approved drawings As-built drawings

2(*) 2(*) 4# 2

3(*) 3(*) 2 1

- - - -

S S S S

Operation / Maintenance Manuals by Preliminary Final

3(*) 3

3 (*)

1

1 1

S S

Inspection / Expediting Reports 3 S 1 -


SPEC NO.


TCE.6758A-954 SCHEDULE OF DISTRIBUTION OF DRAWINGS AND

DOCUMENTS SHEET 2 OF 2 OF 4

ISSUE

R0

Document Description BPCL TCE

TCE Site

Supplier / Contractors

Test & Evaluation reports and Commissioning Reports

3 S 1 -

Marked up for As-Built drawings from contractor

- - 2 S

NOTES * - TCE shall review the drawings and stamp with comments and send the commented copies to BPCL and Vendor. * * - BPCL will send one copy of signed and stamped drawing released to site for construction to TCE design office, one copy to TCE site and two copies to Cotnractor. # Vendor shall provide 4 hard copies and 2 soft copies (editable version) of the final drawings and documents for BPCL‟s reference and records. LEGENDS S = Source, CD = compact disc


1.0 Price of Supply items as per FORM SOR-1 a) Section - I : Cost of supply items for Mechanical, Fire

Protection , & Process Piping 0.00b) Excise Duty @ 12.36% of a) 0.00c) CST @ 2% of (a+b) 0.00d) Freight Charges @ 5% of a 0.00e) Total for Supply (a+b+c+d) 0.002.0 Price of works/Services items as per FORM S0R-2 f) Section - II : Cost of works/services for Mechanical, Fire

Protection , & Process Piping 0.00g) Service Tax @ 12.36% of f) 0.00h) Total for Services (f+g) 0.00

TOTAL AMOUNT IN NUMERIC (1.0+2.0) 0.00

NOTE FOR SOR-1 :

NOTE FOR SOR-2 :

PRICE BID - SCHEDULE OF RATES - FORM SOR-0SUB : SUPPLY & DESIGN OF BOUGHT OUT ITEMS/EQUIPMENTS, FIELD ENGINEERING, FABRICATION, INSTALLATION,CONSTRUCTION, INSPECTION,TESTING FOR LPG BLENDING FACILITY AT BPCL (URAN).

Item No. Description

Total amount ( in `)

SOP-0 : PRICE SUMMARY

TOTAL AMOUNT IN WORDS : Two Crores forty lakhs four thousand four hundred twenty one only

1. Import of any item is not envisaged.2. In case bidder plans to import, Customs duty / Countervailing duty and any other special duty related to Customs is to the account of Bidder

3. The prices in SOR-1 are inclusive of supply of material/equipment including supply of - Erection & commissioning spares,tools & tackles. The rates are also inclusive of Packing & forwarding, transportation to site, insurance , loading and unloading / handling etc and excluding taxes.

4. If CST is applicable in any of the above items, the same is to be indicated in SOR-1 form5. Bidder to indicate CST in form SOR-1 against the line items of SOR-1 for which they are planning to source from inter state sale. BPCL will provide ‘C’ Form for these items. Such amount shall be calculated at the current rate of 2% of the central sales tax value of such sale. Bidder to

note that the Form C against Central Sales tax (CST) will be given only to the items indicated in SOR-1. During execution, if the bidder decides to procure any item not indicated in SP-1 from inter state sale, Form C will not be provided by BPCL & CST shall be borne by the bidder. For remaining line items for which contractor has not indicated their option for CST in SOR-1 , BPCL shall reimburse VAT/Local sales tax against those item to Contractor if applicable.6. Excise Duty, VAT will be reimbursed on bidder submitting documents

1. In SOR-2 prices/rates are quoted for works/services like fabrication, erection, testing and commissioning etc. The prices in SOR-2 includes cost for installation/fabrication, testing, commissioning including cost of supply of materials as required , machineries, transport, supervision, , insurance, overheads, profits, etc. Service tax shall only be reimbursed to the contractor/tenderer at prevailing rate on production of documentary evidences. Contractor/Tenderer should have valid Maharashtra sales tax, Central sales tax & service tax registration in India. No C FORM shall be issued for SOR-2.


BHARAT PETROLEUM CORPORATION LTD.,(MARKETING DIVISION), MUMBAI,

LPG ENGG DEPARTMENT PRICE BID - SCHEDULE OF RATES

ESTIMATES

FORM SP - 1

IMPORTANT:1) Bidders shall not alter the contents of this schedule of prices. If the bidderwants any additions / alterations, these shall be brought out separately.2) Basic Price shall be on FOR site basis inclusive of Packing & ForwardingCharges.3)In case of any discrepancy arises out in unit rates & total prices , unit rate will beconsidered final for evaluation.4)In case of any discrepancy arises out in unit rates & total prices , unit rate will beconsidered final for evaluation.

A PART A - PIPES- SUPPLY

1.0 Supply of Pipe as per mentioned material standard & dimensional standard.

1.1 PIPE 15-40NB ASTM A 333 GR.6, ASME-B36.10 PE, SEAMLESS1.1.1 20 NB BE55C m 21.1.2 25 NB BE55C m 201.1.3 20 NB BE57C m 2

SECTION - I - MECHANICAL, FIRE PROTECTION AND PROCESS PIPING

PIPING GRADE

NAME OF THE WORK: SUPPLY & DESIGN OF BOUGHT OUT ITEMS/EQUIPMENTS, FIELD ENGINEERING, FABRICATION, INSTALLATION,CONSTRUCTION, INSPECTION,TESTING FOR LPG BLENDING FACILITY AT BPCL, URAN

SP-1 – PRICE SCHEDULE -SUPPLIES INCLUDING SUPPLY OF ERECTION & COMMISSIONING SPARES , SPARES & SPECIAL TOOLS /TACKLES AS LISTED IN SPECIFICATION/DATA

SHEET.

SCHEDULE OF PRICEItem No.

Description UnitSUPPLY

Qty. Unit price (in Rs) in numeric

Unit price (in Rs) in

words

Total amount (Rs) Bidder to Indicate CST / VAT & Percentage of Tax

SEAL

Tenderer's Signature Page 2 OF 8




ESTIMATES

FORM SP - 1

PIPING GRADE





words


PIPE 50-150NB ASTM A 333 GR.6, ASME-B36.10 BE, SEAMLESS1.1.4 150 BE57C m 11.1.5 200 BE57C m 5001.1.6 300 BE57C m 160

PIPE <=150NB CS, IS 1239 PT-1 (GALVANISED), IS 1239 PT-1, ERW, BLACK, 40 – PE

1.1.7 25NB GA m 2251.1.8 50NB GA m 551.1.9 65NB GA m 701.2.0 80NB GA m 100

PIPE <=150NB IS 1239 PT.1 , IS1239, ERW BLACK, <=40-PE, >= 50-BE1.2.1 100NB CT m 701.2.2 150NB CT m 40

PIPE >=200NB IS 3589 Gr. FE410, IS3589 BE, ERW/EFW, BLACK1.2.3 400NB CT m 100

PIPE 15-20NB ASTM A 312 Gr. TP 304, ASME-B36.19, PE, SEAMLESS1.2.4 15NB SA1 m 100

2.0 Supply of Pipe Fittings as per mentioned material standard & dimensional standard.

Elbow 90 Deg, 1.5D, SW, ASTM A 350 GR LF2 CLASS 1, ASME B-16.112.1.1 20 NB BE55C Nos 52.1.2 25 NB BE55C Nos 20

Elbow 90 Deg, 1.5D, BW, ASTM A 420 GR. WPL 6, ASME B-16.9, BW (THK. TO MATCH PIPE THK.)

2.1.3 200 NB BE57C Nos 1052.1.4 300 NB BE57C Nos 15

Elbow 90 Deg, 1.5D, SW, ASTM A 105 (GALVANISED), ANSI B 16.11, 3000 CL.

2.1.5 25 NB GA Nos 402.1.7 50NB GA Nos 62.1.8 65NB GA Nos 62.1.9 80NB GA Nos 20

Elbow 90 Deg, 1.5D, SW, ASTM A 182 Gr. F304, ANSI B-16.11, 3000 CL2.1.6 15NB SA1 Nos 20

Elbow 90 Deg, 1.5D, BW, ASTM A 234 GR. WPB, ANSI B-16.9, BW SCH 40, SMLS

2.2.0 100NB CT Nos 152.2.1 150NB CT Nos 5

Elbow 45 Deg, 1.5D, BW, ASTM A 420 GR. WPL 6, ASME B-16.9, BW (THK. TO MATCH PIPE THK.)


Elbow 45 Deg, 1.5D, BW, ASTM A 234 GR. WPB, ANSI B-16.9, BW SCH 40, SMLS

2.2.3 80NB CT Nos 22.2.4 100NB CT Nos 6

150NB CT Nos 3

CONCENTRIC REDUCER, ASTM A 420 GR. WPL 6, ASME B-16.9, BW (THK. TO MATCH PIPE THK.)

2.2.5 200 X 150 NB BE57C Nos 1

CONCENTRIC REDUCER, ASTM A 234 GR. WPB(GALVANISED), ANSI B-16.9, BW SCH 40, SMLS

2.2.6 100 X 65 GA Nos 22.2.7 80 X 50 GA Nos 2

EQUAL TEE, ASTM A 420 GR. WPL 6, ASME B-16.9, BW (THK. TO MATCH PIPE THK.)


EQUAL TEE, SW, ASTM A 105 (GALVANISED), ANSI B 16.11, 3000 CL.2.3.0 25 NB GA Nos 7

REDUCING TEE, SW, ASTM A 105 (GALVANISED), ANSI B 16.11, 3000 CL.

2.3.1 25 X 15NB GA Nos 35

UNEQUAL TEE, ASTM A 420 GR. WPL 6, ASME B-16.9, BW (THK. TO MATCH PIPE THK.)

2.3.2 300 X 200NB BE57C Nos 5

NIPPLE ASTM A 333 GR.6, ASME-B36.10 PBE, SEAMLESS, SCH80,2.3.3 15 NB BE57C Nos 62.3.4 25 NB BE57C Nos 302.3.5 40 NB BE57C Nos 5

NIPPLE IS 1239 PT.1(GALVANISED), PBE2.3.6 15 NB GA Nos 35

SOCKOLET, ASTM A 350 GR LF2 CLASS 1, ASME B-16.11

SEAL





ESTIMATES

FORM SP - 1

PIPING GRADE





words


2.3.7 200 X 15NB BE57C Nos 22.3.8 200 X 20NB BE57C Nos 22.3.9 200 X 25NB BE57C Nos 222.4.0 200 X 40NB BE57C Nos 12.4.1 300 X 25NB BE57C Nos 10

FLANGES, SW, 300, RF / 125 AARH, ASTM A 350 GR LF2 CLASS 1, ASME B-16.5 FOR BE55C

2.4.2 20 NB BE55C Nos 62.4.3 25 NB BE55C Nos 62.4.4 15 NB BE57C Nos 62.4.5 20 NB BE57C Nos 52.4.6 25 NB BE57C Nos 302.4.7 40 NB BE57C Nos 2

FLANGES, WN, 300, RF / 125 AARH, ASTM A 350 GR LF2 CLASS 1, ASME B-16.5

2.4.8 150 NB BE57C Nos 12.4.9 200 NB BE57C Nos 602.5.0 300 NB BE57C Nos 25

FLANGES, WN, 300, RF / 125 AARH, ASTM A182 Gr. F304, ASME B-16.5

2.5.1 15 NB SA1 Nos 5

FLANGES, SO, 150 CL, RF / CONN SERR FINISH, ASTM A 105 (GALVANISED), ANSI B16.5


FLANGES, <=150NB, SO, 150 CL, RF / CONN SERR FINISH, ASTM A 105, ANSI B16.5

2.5.6 100NB CT Nos 24

FLANGES, >=350NB, SO, 150 CL, RF / CONN SERR FINISH, ASTM A 105, ANSI B16.5

2.5.7 400NB CT Nos 4

BLIND FLANGES, <=150NB, 150 CL, RF / CONN SERR FINISH, ASTM A 105, ANSI B16.5

2.5.8 100NB CT Nos 2

BLIND FLANGES, 300, RF / 125 AARH, ASTM A 350 GR LF2 CLASS 1, ASME B-16.5

2.5.9 25 NB BE57C Nos 302.6.0 200 NB BE57C Nos 152.6.1 300 NB BE57C Nos 2

GASKETS, SP. WND SS304 + GRAFIL, ASME B 16.20 – ASME B 16.5,

4.5MM THK, SPIRAL, 3002.6.2 20 NB BE55C Nos 122.6.3 25 NB BE55C Nos 122.6.4 15 NB BE57C Nos 122.6.5 20 NB BE57C Nos 102.6.6 25 NB BE57C Nos 1102.6.7 40 NB BE57C Nos 42.6.8 150 NB BE57C Nos 22.6.9 200 NB BE57C Nos 1302.7.0 300 NB BE57C Nos 50

GASKETS, SP. WND SS304 + GRAFIL, ASME B 16.20 – ASME B 16.5,

4.5MM THK, SPIRAL, 3002.7.1 15 NB SA1 Nos 10

GASKETS, BLACK RUBBER, ANSI B 16.5, CL150, 3MM THICK RING, SELF CENTERING TYPE100NB CT Nos 52400NB CT Nos 8

GASKETS, ASBESTOS FREE NBR DULY REINFORCED WITH ARMID FIBRES, ANSI B 16.21 CL.150, SELF-CENTERING RING, 2 MM THK


FULL COUPLING, ASTM A 105 (GALVANISED), ANSI B 16.11, 3000 CL

2.7.6 25 NB GA Nos 30

FULL COUPLING, ASTM A 350 Gr. LF2 CLASS1, ASME B-16.11, SW 2.7.7 25 NB BE55C Nos 10

FULL COUPLING, ASTM A 182 Gr. F304, ASME B-16.11, SW 30002.7.8 15 NB SA1 Nos 25

STUD BOLTS & HEAVY HEX NUTS, ASTM A 320 GR.L7, ASME B-18.2.1, ASTM A 194 GR.4, ASME B-18.2.2

2.7.9 20 NB-5/8" M16 X 75 LONG-4 NOS BE55C SETS 482.8.0 25 NB-5/8" M16 X 80 LONG-4 NOS BE55C SETS 482.8.1 15 NB-1/2" M14 X 70 LONG-4 NOS BE57C SETS 482.8.2 20 NB-5/8" M16 X 75 LONG-4 NOS BE57C SETS 402.8.3 25 NB-5/8" M16 X 80 LONG-4 NOS BE57C SETS 2402.8.4 40 NB-3/4" M20 X 95 LONG-4 NOS BE57C SETS 162.8.5 150 NB-3/4" M20 X 130 LONG-12 NOS BE57C SETS 242.8.6 200 NB-7/8" M24 X 150 LONG-12 NOS BE57C SETS 1440

SEAL





ESTIMATES

FORM SP - 1

PIPING GRADE





words


2.8.7 300 NB-1 1/8" M30 X 185 LONG-16 NOS BE57C SETS 800

STUD BOLTS & HEAVY HEX NUTS, ASTM A 193 GR.B7 , ASME B-18.2, ASTM A 194 GR.2H, ASME B-18.2

2.8.8 15 NB-1/2" M14 X 70 LONG-4 NOS SA1 SETS 40

STUD BOLTS & HEAVY HEX NUTS, ASTM A307 Gr. B, ASTM A563 Gr. A

2.9.2 100NB-3/4" M16 X 90 LONG-8 NOS CT SETS 3842.9.3 400NB-1" M27 X 150 LONG-16 NOS CT SETS 96

MACHINE BOLTS & HEAVY HEX NUTS, ASTM A 307 GR.B (GALVANISED), ANSI B 18.2.1, CL. 2A, ASTM A 563, Gr.A (GALVANISED), ANSI B 18.2.2, CL.2B

2.9.4 25 NB-1/2" M14 X 70 LONG-4 NOS GA SETS 482.8.9 50NB-5/8" M16 X 85 LONG-4 NOS GA SETS 642.9.0 65NB-5/8" M16 X 90 LONG-4 NOS GA SETS 642.9.1 80NB-5/8" M16 X 90 LONG-4 NOS GA SETS 32

3.0 BALL VALVE, 15 – 40, A350 GR LF2 CLASS 1, SW, 800, B 16.11 DMN.

STD :- ISO-17292, WITH 100MM PIPE PIECE ON EITHER SIDES FOR BE55C

3.1.1 20 NB BE55C Nos 23.1.2 25 NB BE55C Nos 23.1.3 15 NB BE57C Nos 43.1.4 25 NB BE57C Nos 30

BALL VALVE, 150 – 400, A352 GR LCB, FLGD, 300, B 16.5, RF/125AARH,

DMN. STD :- ISO-17292, WITH GEAR OPERATOR WITH ADEQUATE TORQUE


BALL VALVE, 15, ASTM A 216 Gr.WCB , 150, RF, TWO PIECE,REGULAR PORT TYPE WITH PTFE

3.1.7 25 NB GA Nos 5

CHECK VALVE, 15-40, ASTM A 182 Gr. F304, SS304, SW 800, B-16.11

3.1.8 15 NB SA1 Nos 1

CHECK VALVE, 50 – 400, A352 GR LCB, FLGD, 300, B 16.5, RF/125AARH,

DMN. STD :- BS-1868, SWING TYPE3.1.9 200 NB BE57C Nos 33.2.0 300 NB BE57C Nos 2

GLOBE VALVE, 50 – 250, A352 GR LCB, FLGD, 300, B 16.5, RF/125AARH,

DMN. STD :- BS-1873, WITH GEAR OPERATOR WITH ADEQUATE TORQUE

3.2.1 200 NB BE57C Nos 1

SEAL





ESTIMATES

FORM SP - 1

PIPING GRADE





words


GATE VALVE >=50NB, ASTM A216 Gr. WCB, TRIM BRONZE SS304, RF ENDS

3.2.2 80NB CT Nos 13.2.3 100NB CT Nos 43.2.4 400NB CT Nos 2

4.0 Equipments and Accessories for Hydrant System

4.1.1 Fire Hydrants Valves (As per data seets & Specifications)4.1.2 Double headed hydrant valves as per IS : 5290 Type A complete with 100 NB

stand post. Nos 2

4.1.3 Water Monitor Type : Hand Controlled monitor with NozzleRotation Angle : 360o continous locking deviceElevation Angle : -45o to + 80o with locking device

Nos 1

4.1.5 Hose cabinets with 2 nos. 15 mtr long hoses and 2 no. branch pipe with nozzle for Double headed Hydrant valve

Nos2

4.1.7 Quartzoid Bulb DetectorsUL Approved & as per IS 9972

Nos 35

4.1.8 Spray Nozzles K22 NPT ASME B 1.20.115 NB Nos 35Fire Extinguisher- As per IS 15683 5KG Capacity ABC Type Stored Pressure Nos 10

5.0 WRAPPING, COATING FOR U/G PIPING

5.1.1 Supply and application of corrosion tape coating for Underground Piping IS-1239 / 3589 - Cleaning of external pipe surface by wire brush- Application of primer and allow it to touch dry- Heat the primer coated pipe and the bottom surface of 4mm tape- Wrap the 4mm tape (Tar based polymeric mix supported on a fabric of hightensile strength fibre glass

5.1.2 400 NB - 20 m m2 30

6.0 SUPPLY OF PIPE SUPPORT & AUXILIARY STRUCTURAL STEEL FORCS PIPING :- Supply of pipe support components such as shoes,saddles, hanger rods pipe clamps, U-bolts, platforms, structural steelsections as per drawings / norms

MT 3

7.2 COLD INSULATION:Providing insulation including supply of all insulating and ancillary material,weather protective covering, consumables and the other necessary materials,testing of the material as required including transportation of the material to work sites.150NB-(THICKNESS=150mm) BE57C SQM 1200NB-(THICKNESS=200mm) BE57C SQM 350300NB-(THICKNESS=200mm) BE57C SQM 180

7.0 Supply of Paints for piping, Pipe supports & equipment as per Painting Specification

SQM 100

SUB-TOTAL OF PART - A IN RUPEES

TOTAL OF SECTION - I (MECHANICAL + FIRE PROTECTION SYSTEM)

SEAL



SCHEDULE OF PRICE

B PART B - PIPES- ERECTION

Erection of Butane Air Pre-heater Nos 1Overall Size=14Mtr X 10 Mtr X 10 Mtr Height.Approx Erection Weight=90MTAssembly/Erection of Pre-Fabricated Bolted Structures-50Mt(Approx)Minor Cutting/ Welding is to be carried to suite site conditions if necessaryAssembly/Erection of Miscellaneous Structures like Loads, Plenums & Side Frames-12MT(Approx)Assembly/ Erection of 4 Nos of Tube Bundles-13 MT( Approx)

Assembly/ Erection of Bought Out Items like 4 Nos Fan (13 ft dia), 4 Nos of 37KW Motor, Belt, Pulley, Instruments etc.Fabrication & Erection of Approx 40Mts of 8" LTCS Pipes with 16 Nos of 8" Ball Valves & FittingsInsulation of 40 Mts of 8" Pipes, 16 Nos of 8" Ball Valves & Fittings

Erection of Blending Skid Nos 1Approx Erection Weight=25MTApprox Size=14MT X 8MT X 3MT HeightThe skid will be a single assembled unit. Only erection, no assembly or welding is envisaged

1.0

Fabrication and Erection of Pipe as per mentioned material standard & dimensional standard. This rate includes fabrication and erection of pipe fittings, gaskets, nuts and bolts. Separate erection rate will not be paid for them. The approximate quantity of fittings, gaskets, nuts and bolts are given in SOR-1

1.1 PIPE 15-40NB ASTM A 333 GR.6, ASME-B36.10 PE, SEAMLESS1.1.1 20 NB BE55C Inch M 21.1.2 25 NB BE55C Inch M 201.1.3 20 NB BE57C Inch M 2

PIPE 50-150NB ASTM A 333 GR.6, ASME-B36.10 BE, SEAMLESS1.1.4 150 NB BE57C Inch M 61.1.5 200 NB BE57C Inch M 40001.1.6 300 NB BE57C Inch M 1920

PIPE <=150NB CS, IS 1239 PT-1 (GALVANISED), IS 1239 PT-1, ERW, BLACK, 40 – PE

1.1.7 25NB GA Inch M 2251.1.8 50NB GA Inch M 1101.1.9 65NB GA Inch M 1751.2.0 80NB GA Inch M 300

PIPE <=150NB IS 1239 PT.1 , IS1239, ERW BLACK, <=40-PE, >= 50-BE1.2.1 100NB CT Inch M 2801.2.2 150NB CT Inch M 320

PIPE >=200NB IS 3589 Gr. FE410, IS3589 BE, ERW/EFW, BLACK1.2.3 400NB CT Inch M 1600

PIPE 15-20NB ASTM A 312 Gr. TP 304, ASME-B36.19, PE, SEAMLESS1.2.4 15NB SA1 Inch M 100

1.3 Fabrication and Erection of Pipe Fittings as per mentioned material standard & dimensional standard.

MITRES 90 DEG, >=200, MATERIAL SAME AS PIPE, R=1.5D1.4.2 400 NB CT Nos 6

MITRES 45 DEG, >=200, MATERIAL SAME AS PIPE, R=1.5D1.4.8 400NB CT Nos 8

3.0 BALL VALVE, 15 – 40, A350 GR LF2 CLASS 1, SW, 800, B 16.11 DMN. STD :- 3.1.1 20 NB BE55C Nos 23.1.2 25 NB BE55C Nos 23.1.3 15 NB BE57C Nos 43.1.4 25 NB BE57C Nos 30

BALL VALVE, 150 – 400, A352 GR LCB, FLGD, 300, B 16.5, RF/125AARH, 3.1.5 200 NB BE57C Nos 143.1.6 300 NB BE57C Nos 5

BALL VALVE, 15, ASTM A 216 Gr.WCB , 150, RF, TWO PIECE,REGULAR PORT TYPE WITH PTFE

3.1.7 25 NB GA Nos 5

CHECK VALVE, 15-40, ASTM A 182 Gr. F304, SS304, SW 800, B-16.11

3.1.8 15 NB SA1 Nos 1

CHECK VALVE, 50 – 400, A352 GR LCB, FLGD, 300, B 16.5, RF/125AARH,

DMN. STD :- BS-1868, SWING TYPE3.1.9 200 NB BE57C Nos 33.2.0 300 NB BE57C Nos 2

GLOBE VALVE, 50 – 250, A352 GR LCB, FLGD, 300, B 16.5, RF/125AARH,

DMN. STD :- BS-1873, WITH GEAR OPERATOR WITH ADEQUATE TORQUE

3.2.1 200 NB BE57C Nos 1

Total amount (Rs)

SP-2 – PRICE SCHEDULE - WORKS / SERVICES (Works / Services like Handling, fabrication,Non-destructive testing, inspection & testing, erection /

installation, mechanical completion, calibration, Commissioning , specification to the complete satisfaction of the Engineer-In-Charge including supply of all labours, consumables & hardwares etc. as required)

NAME OF THE WORK: SUPPLY & DESIGN OF BOUGHT OUT ITEMS/EQUIPMENTS, FIELD ENGINEERING, FABRICATION, INSTALLATION,CONSTRUCTION, INSPECTION, TESTING FOR LPG BLENDING FACILITY AT BPCL, URAN

SECTION - II - MECHANICAL, FIRE PROTECTION AND PROCESS PIPING

ERECTIONItem No.

Description PIPING GRADE Unit Qty. Unit price (in Rs) in numeric

Unit price (in Rs) in words


GATE VALVE >=50NB, ASTM A216 Gr. WCB, TRIM BRONZE SS304, RF ENDS

3.2.2 80NB CT Nos 13.2.3 100NB CT Nos 43.2.4 400NB CT Nos 2

4.0 Equipments and Accessories for Hydrant System

4.1.1 Fire Hydrants Valves4.1.2 Double headed hydrant valves as per IS : 5290 Type A complete with 100 NB

stand post.Nos 2

4.1.3 Water MonitorType : Hand Controlled monitor with NozzleRotation Angle : 360o continous locking deviceElevation Angle : -45o to + 80o with locking device

Nos 1

4.1.5 Hose cabinets with 2 nos. 15 mtr long hoses and 2 no. branch pipe with nozzle for Double headed Hydrant valve

Nos 2

4.1.7 Quartzoid Bulb DetectorsUL Approved & as per IS 9972

Nos 35

4.1.8 Spray Nozzles K22 NPT ASME B 1.20.115 NB Nos 35Fire Extinguisher- As per IS 15683 5KG Capacity ABC Type Stored Pressure Nos 10

5.0 WRAPPING, COATING FOR U/G PIPING

5.1.1 Supply and application of corrosion tape coating for Underground Piping IS-1239 / 3589 - Cleaning of external pipe surface by wire brush- Application of primer and allow it to touch dry- Heat the primer coated pipe and the bottom surface of 4mm tape- Wrap the 4mm tape (Tar based polymeric mix supported on a fabric of hightensile strength fibre glass

5.1.2 400 NB - 20 m m2 30

6.0 ERECTION OF PIPE SUPPORT & AUXILIARY STRUCTURAL STEEL FORCS PIPING :- Erection of pipe support components such as shoes,saddles, hanger rods pipe clamps, U-bolts, platforms, structural steelsections as per drawings / norms

MT 3

7.0 Sandblasting and Application of Painting as per Painting Specification SQM 100STRUCTURAL PAINTING: Applying paint including storage, surface preparation,degreasing, cleaning, drying, touching up of shop primer coat, providing temporary staging,scaffolding, testing etc., for steel strucres at all levels and locations, all complete as speficied.

MT 5

7.1 DISMANTLING OF FIRE WATER PIPINGDismantling of Fire Water piping system:Disconnecting all the Piping connections (as per Marked P&ID and instructions of Engineer in charge). Spading/ Despading of connected piping, removal of insulation, removal of pipes, valves, fittings, instruments on piping etc and placing them in sorted manner at designated place as per instructions of Engineer in charge. Dismantling of electrical cables. Providing all required tools and tackles, crane etc, scaffolding as per requirements to complete the work in all respects as per instructions of Engineer in Charge. Adequate care shall be taken by the contractor not to damage the existing equipment /piping system while dismantling. The Contractor shall rectify any damage caused without any implication to the Owner.

400NB MT 40

200NB MT 107.2 COLD INSULATION: Applying insulation on surfaces as specified, including all preparatory

works thereon, all binding, tying, lacing, stiching and/or otherwise securing, providing vapour barrier, inishing with plain/ corrugated sheet cladding or as specified, providing bolts, rivets, self tapping screws wherever specified, providing inspection windows etc., providing necessary scaffolding, all tools and tackles, equip-ments,apparatus etc.,labour and supervision and completing the work in all respect at all heights as per specifications, drawings, equipment details for painting and direction of Engineer-in-charge

150NB-(THICKNESS=150mm) BE57C SQM 1200NB-(THICKNESS=200mm) BE57C SQM 350300NB-(THICKNESS=200mm) BE57C SQM 180

7.3 RADIOGRAPHY :- Performance of radiographic inspection on piping of all types & thicknessesincluding providing or hiring of all necessary equipment and whatever else even though notexpressly mentioned but required to perform the work as per specifications and instructions ofEngineer-inCharge. Radiographs shall be submitted to the Engineer-in-Charge. (RepeatRadiography due to defective radiograph on repaired joints due to Contractor's fault and foradditional radiography necessitated due to poor performance of contractor's welders shall bedone at contractor's cost) Note: Unit for radiography quantity is 'Nos of circumferencial weldjoints'.FOR JOINTS THK. <= 8MM (FOR CS)NB 1.000 INCHES Nos 30NB 2.000 INCHES Nos 10NB 2.500 INCHES Nos 12NB 3.000 INCHES Nos 5NB 4.000 INCHES Nos 12NB 8.000 INCHES Nos 95NB 12.000 INCHES Nos 28

FOR JOINTS THK. >= 8MM (FOR CS)NB 16.000 INCHES Nos 18

FOR JOINTS THK. <= 8MM (FOR AS/SS)NB 0.500 INCHES Nos 18

7.4 MISC ITEMSCHEMICAL CLEANING: Cleaning and pickling of pipeline including preparation of circulationloop, supply of temporary piping, gaskets, valves, test coupons, spares,safety accessories andalso providing or having all necessary equipments and whatever else even though not expresslymentioned herein and in specification but required to perform the work as per specification andinstruction of Engineer in Charge.Chemical cleaning of all welds (Joints) and post cleaning passivation of SS 304 pipingNB UPTO 1.5 INCH Meters 100

7.5 Commissioning assistance: Providing commissioning assistance to Owner by providingmanpower (Rigger, fitter, helper etc, one Manday = 12hrs working) on two 12 hr shift round theclock for spading, despading, air blowing, cardboard blasting, control valve dismantling / erectionetc with hand tool and tackles, as per the directions of Engineer-in-Charge.

MANDAY

15

SUB-TOTAL OF PART - B IN RUPEES

TOTAL OF SECTION - II (MECHANICAL + FIRE PROTECTION SYSTEM)


TENDER. NO. TCE.6758A-B-300-003


Master Index SHEET i OF iii

ISSUE

R0

MASTER INDEX

TO

BIDDING DOCUMENT FOR MECHNICAL WORKS

BHARAT PETROLEUM CORPORATION LIMITED, URAN, MUMBAI

(BIDDING DOCUMENT NO: TCE-6758A-B-300-003)


SPEC. NO. BHARAT PETROLEUM CORPORATION LIMITED

LPG-ENGINEERING DEPARTMENT PROJECT: PMC SERVICES FOR BLENDING UNIT AT BPCL,

URAN.


VOLUME - 2

TCE.6758A-B-300-003

SECTION:CONTENTS

SHEET 1 OF 2

CONTENTS

‘

ISSUE R0 Bidder’s signature & seal



C 6758A-TCE/BPCL-RFQ-003

R0 Scope of work – Process / Mechanical / Piping and fire protection

8

B3 TCE.6758A-B-300-003 R0 Painting Specification 3


D

TCE.M4-111-02

--

R6

R6

R6

Hydrant valves

Data Sheet-A

Data Sheet-B

Data Sheet-C

--

2

1

1

D TCE.M4-111-04

--

R4

R4

R4

Branch pipe and nozzles

Data Sheet-A

Data Sheet-B

Data Sheet-C

--

1

1

1

D TCE.M4-111-05 --

R4

R5

Fire Hoses

Data Sheet-A

data Sheet-C

1

1

D TCE. M4-111-08 --

R7

R7

R7

Hose cabinets

Data Sheet-A

Data Sheet-B

Data Sheet-C

--

2

1

1

D TCE. M4-111-16 --

R5

R5

R5

Fire Extinguishers

Data Sheet-A

Data Sheet-B

Data Sheet-C

--

3

2

1

D TCE. M4-111-23 --

R5

Fixed Spray System

Data Sheet-A

4

2

D TCE. M4-111-03 --

R4

R4

R3

Water Monitors

Data Sheet-A

Data Sheet-B

Data Sheet-C

--

2

1

1


SPEC. NO. BHARAT PETROLEUM CORPORATION LIMITED

LPG-ENGINEERING DEPARTMENT PROJECT: PMC SERVICES FOR BLENDING UNIT AT BPCL,

URAN.


VOLUME - 2

TCE.6758A-B-300-003

SECTION:CONTENTS

SHEET 2 OF 2

CONTENTS

‘

ISSUE R0 Bidder’s signature & seal



D TCE.M4-134-102 R5

R0

Underground Protection for Piping

Data Sheet A & C

5

1

D TCE.6758A-B-300-003 R0 Thermal Insulation for Cold Surfaces-Datasheet 2

D TCE.M4-134-06 R2 Fabrication, Erection & Testing Of

Piping Systems

13

PIPING

D TCE.6758A-590-LS-1001

R0 Piping Material Specification 13

D TCE.6758A-E-590-003 R0 Insulation Specification 7

D TCE.6758A-B-300-003 R0 Welding Specification - Equipment and Piping 23

D TCE.6758A-E-590-001 R5 Structural Steel Fabrication 8

D TCE.6758A-E-590-002 R0 Structural Steel Erection 3

SHOP INSPECTION REQUIREMENTS

E TCE.M4-904 R9 Shop Inspection and Tests 7

D TCE.M4-186-04 R2 Valves – Metallic 1

D TCE.M4-186-05 R2 Pipes & Pipe Fittings – Metallic 1

D TCE.M4-186-30 R2 Fire Protection Equipment 2

D TCE.M4-186-35 R2 Structural Fabrication 1

ANNEXURE-I

TCE.6758A-590-PP-8701

R0 OVERALL PIPING PLAN FOR BLENDING UNIT 1

6457-PE-UPI-002,005,006

P2 P & ID FOR BLENDING UNIT 3

TCE.6758A-300-PI-8601

P3 P & ID FOR BLENDING SKID 1

OISD-GDN-192 SAFETY PRACTICES DURING CONSTRUCTION 1


FILE NAME: DB11102R6.DOC

NOTES TO BIDDER SIGNATURE OF BIDDER AND DATE ISSUE

R6 1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHALL

BE MARKED WITH ASTERISK (*) AND DETAILS SHALL BE GIVEN IN SCHEDULE OF DEVIATIONS.

2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

TCE FORM NO. 294 R4

SPECIFICATION NO. TCE.M4-111-02

TATA CONSULTING ENGINEERS LIMITED SECTION: D

DATA SHEET B FIRE PROTECTION EQUIPMENT HYDRANT VALVES

SHEET 1 OF 1

ENQUIRY NO. BIDDER:

SL. NO. ITEM UNIT

GEN

ERAL

1. SUB VENDOR'S NAME / MAKE /

2.

3.

4.

5.

6.

7.

8.


FILE NAME: DA11102R6.DOC

SPECIFICATION NO.

TCE.M4-111-02 TATA CONSULTING ENGINEERS LIMITED SECTION: D

ENQUIRY NO.

TCE.6758A-B-300-003

DATA SHEET A FIRE PROTECTION EQUIPMENT HYDRANT VALVES

SHEET 1 OF 2

REV. NO. JOB NO.

6758A

CLIENT: BPCL, URAN ISSUE

R6 PPD. BY SG

CHD. BY RR PROJECT: PMC SERVICES FOR BLENDING UNIT AT URAN

DATE 06-08-2012

TCE FORM NO. 330 R4

GE

NE

RA

L

1. TYPE: SINGLE HEADED-63 mm SIZE CONF

MA

TE

RIA

LS

OF

CO

NS

TR

UC

TIO

N (

CO

NT

D.)

17. HAND WHEEL: CS AS PER IS 1030 OR CI

TO IS 5290 TYPE A WITH / WITHOUT AS PER IS 210

STAND POST OF 80 mm NB 18. SEAT WASHER:

2. TYPE: DOUBLE HEADED- CONF TO IS:5290 RUBBER AS PER IS 937 OR LEATHER

TYPE B / TWO VALVES AS ABOVE AS PER IS 581

3. LUG TYPE: PULL OUT / TWIST 19. GLAND PACKING: ASBESTOS THREAD

4. FLANGE DRILLING STANDARD: ANSI AS PER IS 4687 /

B16.5 / IS:_ _ _ _ / 20. SPRING: PHOSPHOR BRONZE WIRE

5. COMPANION FLANGE AT STAND POST AS PER IS 7608 FOR Cu ALLOY HYDRANT

REQUIRED: YES/NO VALVE OR SS WIRE AS PER IS 6528 FOR

6. SIZE: 63 mm Al ALLOY/SS HYDRANT VALVE

7. SCOPE INCLUDES STAND POST - YES/NO 21. BLANK CAP: SAME AS BODY MOC/ ABS

PLASTICS

8. STANDPOST SIZE: 80 mm/ 100 mm 22. STAND POST: SAME AS FIREWATER PIPE

9. WATER: ORDINARY/ SEA WATER 23. COMPANION FLANGE AT STAND POST:

10. HYDRANT VALVE SHALL BEAR ISI MARK ASTM A 105

11. 24.

12. 25.

13. 26.

MA

TE

RIA

LS

OF

CO

NS

TR

UC

TIO

N

14. VALVE BODY, BONNET, STOP VALVE, 27.

CHECKNUT AND INSTANTANEOUS FEMALE 28.

OUTLET 29.

14.1 LEADED TIN BRONZE AS PER GR LTB2 30.

OF IS 318 OR

PA

INT

ING

31. VALVE TOP EXCEPT FACE OF FLANGE

14.2 Al ALLOY AS PER DESIGNATION AND INSTANTANEOUS OUTLET:

4225, 4450, 4600 OF IS 617 OR FIRE RED, SHADE NO. 536 OF IS 5

14.3 SS AS PER GRADE 1 / 4 OF IS 3444 32. HAND WHEEL: BLACK AS PER IS 2932

15. VALVE SPINDLE: BRASS ROD AS PER IS

SP

AR

ES

AN

D

MA

INT

EN

AN

CE

TO

OL

S A

ND

TA

CK

LE

S

33. REFER TCE.M4-907

319 OR IS 320 FOR BODY OF LEADED TIN 34. ESSENTIAL SPARES

BRONZE OR SS AS PER IS 6603 FOR BODY 34.1

OF Al OR SS 34.2


FILE NAME: DA11102R6.DOC

SPECIFICATION NO.


ENQUIRY NO.

TCE.6758A-B-300-003

DATA SHEET A FIRE PROTECTION EQUIPMENT HYDRANT VALVES

SHEET 2 OF 2

REV. NO. JOB NO.

6758A


R6 PPD. BY SG


DATE 06-08-2012

TCE FORM NO. 330 R4

16. 34.3

TE

ST

S A

ND

IN

SP

EC

TIO

N

35. TEST PRESSURE FOR:

AP

PR

OV

ED

SU

B-V

EN

DO

RS

41.

35.1 WATER TIGHTNESS: 14 Kg/cm2g 42.

35.2 VALVE BODY AND GLAND: 21 Kg/cm2g 43.

36. FLOW TEST: 900 LPM @ 7.0 Kg/cm2g 44.

37. AS PER TCE.M4-904 AND/OR TCE.M4- 45.

185-01, AND TCE.M4-185-75 OR 46.

TCE.M4-186-30 AND TAC REGULATIONS 47.

(NOTE 1) 48.

38. 49.

39. 60.

40. 51.

NOTE

1. ADDITIONAL TESTS INDICATED AS 'B' IN TCE.M4-186-30 SHALL ALSO BE CARRIED OUT WHEN TCE.M4-186-

30 IS APPLICABLE.


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D

TCE. M4-111-02 FIRE PROTECTION EQUIPMENT HYDRANT VALVES SHEET 1 OF 1

FILENAME: M411102R6.DOC TCE FORM NO. 329R5

ISSUE R6

DATA SHEET C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACT

1. List of drawings and documents to be submitted for review, approval and

information along with scheduled submission dates 2. Quality Assurance Plan (QAP) 3. Descriptive catalogues 4. Dimensional drawings 5. Cross-sectional drawing of hydrant valve assembly with part list and material

of construction of each part 6. Material test certificates 7. Current ISI certificates


ISS

UE

NO

. R

4

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D

TCE.M4-111-04 DATA SHEET B

SHEET: 1 OF 1 FIRE PROTECTION EQUIPMENT

BRANCH PIPES AND NOZZLES

ENQUIRY / SPECIFICATION NO.

SL.

NO.

BIDDER

ITEM

1. SUB VENDOR'S NAME/MAKE /

2.

3.

4.

5.

NOTES TO BIDDER

1.DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN

REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE FROM

DATA SHEET-A, BIDDER SHALL BRING OUT THE SAME IN

SCHEDULE OF DEVIATIONS, FAILING WHICH IT SHALL BE

CONSTRUED THAT BIDDER COMPLIES WITH THE

REQUIREMENTS STIPULATED IN DATA SHEET-A.

2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF

BIDDER

DATE

FILE NAME: DB11104R4.DOC TCE FORM NO. 294 R1


I

SS

UE

NO

. R

4


ENQ. SPEC. NO. DATA SHEET A

SHEET: 1 OF 1 TCE.6758A-B-300-003

FIRE PROTECTION EQUIPMENT

BRANCH PIPES AND NOZZLES

GE

NE

RA

L 1. STANDARD: IS 903

SP

AR

ES

AN

D M

AIN

TE

NA

NC

E

TO

OL

S A

ND

TA

CK

LE

S


2. 14. ESSENTIAL SPARES

3. 14.1

4. 14.2

MA

TE

RIA

LS

OF

CO

NS

TR

UC

TIO

N

5.1 Cu ALLOY AS PER SAND CASTINGS: 14.3

GR LTB2 OF IS 318 OR GR HTB1 OF IS 304 14.4

DIE CASTING: GR 3 OF IS 292 14.5

HOT FORGINGS: DCB 1 OF IS 291

TE

ST

S A

ND

IN

SP

EC

TIO

N

15. TAC APPROVAL REQUIRED: -NA-

GRAVITY DIE CASTINGS: IS 1264 16. TEST PRESSURE: 21 Kg/cm2g

- OR - 17. AS PER TCE.M4-904 AND/OR TCE.M4-185-

5.2 Al ALLOY AS PER DIE CASTINGS: 01 OR TCE.M4-185- OR TCE.M4-186-30

DESIGNATIONS 4450, 4600 OF IS 617 AND TAC GUIDELINES (NOTE 1)

- OR- 18.

5.3 SS GR 1 AS PER IS 3444 19.

AP

PR

OV

ED

SU

B-V

EN

DO

RS

20.

6. WASHER: TYPE B OF IS 937 21.

7. NOZZLE SPANNER: GR 35C4 OR 40C8 OF 22.

IS 1570 (PART 2/SECTION 1) 23.

8. 24.

DIM

EN

SIO

NS

9. BRANCH PIPE INLET SIZE: 63 mm 25.

10. NOZZLE BORE: 20 / 25 / 30 26.

11. 27.

12. 28.

NOTES

1. ADDITIONAL TESTS INDICATED AS 'B' IN TCE.M4-186-30 SHALL ALSO BE CARRIED OUT WHEN

TCE.M4-186-30 IS APPLICABLE.

2. BRANCH PIPE WITH NOZZLE SHALL BE ISI MARKED.

REV. NO. PPD. BY:SG JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY:RR 6758A PROJECT: PMC SERVICES FOR

BLENDING UNIT AT URAN

REV. BY DATE: 06-08-12

FILE NAME: DA11104R4.DOC TCE FORM NO. 330 R1



TCE.M4-111-04 FIRE PROTECTION EQUIPMENT

BRANCH PIPES AND NOZZLES SHEET 1 OF 1 OF 4


ISSUE

R4

TITLE

DATA SHEET C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE

AWARD OF CONTRACT

1. Quality Assurance Plan (QAP)

2. Descriptive catalogues

3. Dimensional drawings

4. Cross-sectional drawing of branch pipe and nozzles with part list and material

of construction of each part

5. Material test certificates

6. Current ISI certificates



ISS

UE

NO

.

R4


SHEET: 1 OF 1 TCE.6758A-B-300-003


FIRE HOSES

ST

AN

DA

RD

S

1. HOSE: IS 8423 OR IS 636 (TYPE A) OR

DIM

EN

SIO

NS

7. DIAMETER: 63 mm

IS 636 (TYPE B) OR IS 4927 8. LENGTH FOR:

2. DELIVERY COUPLING: 8.1 INTERNAL/ FIRE ESCAPE

HYDRANT: 7.5 M / 15 M

INSTANTANEOUS SPRING LOCK TYPE 8.2 EXTERNAL HYDRANT: 15

M

AS PER IS 903 (NOTE 1) 9.

3.

SP

AR

ES

AN

D M

AIN

TE

NA

NC

E

TO

OL

S A

ND

TA

CK

LE

S 10. REFER TCE.M4-907

MA

TE

RIA

LS

OF

CO

NS

TR

UC

TIO

N

4. HOSE: RUBBERLINED HOSE (TYPE A) 11. ESSENTIAL SPARES

5. DELIVERY COUPLINGS: 11.1

5.1 Cu ALLOY AS PER SAND CASTINGS: 11.2

GR LTB2 OF IS 318 OR GR HTB1 OF IS 304 11.3

DIE CASTINGS: GR 3 OF IS 292 11.4

HOT FORGINGS: DCB 1 OF IS 291

TE

ST

S A

ND

IN

SP

EC

TIO

N

12. PROOF PRESSURE: 21.4

Kg/cm2(g)

GRAVITY DIE CASTINGS: IS 1264 13. BURSTING PRESSURE:

35.7 Kg/cm2(g)

- OR - 14. TAC APPROVAL

REQUIRED: NA

5.2 Al ALLOY AS PER DIE CASTINGS: 15. AS PER TCE.M4-904

AND/OR TCE.M4-185-01

IS DESIGNATIONS OF 4450, 4600 OF IS 617 AND TCE.M4-185- OR

TCE.M4-186-30

AND TAC GUIDELINES

(SEE NOTE 2)

- OR -

AP

PR

OV

ED

SU

B-V

EN

DO

RS

16.

5.3 SS AS PER GR 1 OF IS 3444 17.

18.

6. 19.

NOTES

1. EACH HOSE SHALL HAVE ONE MALE HALF COUPLING AT ONE END AND ONE

FEMALE HALF COUPLING AT THE OTHER END WITH JOINING METHOD AS PER TAC

2. ADDITIONAL TESTS INDICATED AS 'B' IN TCE.M4-186-30 SHALL ALSO BE CARRIED

OUT WHEN TCE.M4-186-30 IS APPLICABLE.

3. HOSES & COUPLING SHALL BE ISI MARKED

REV. NO. PPD. BY:SG JOB NO. CLIENT: BPCL, URAN

DATE CHD.BY:RR 6758A PROJECT: PMC SERVICES FOR





TCE.M4-111-05 FIRE PROTECTION EQUIPMENT

FIRE HOSES SHEET 1 OF 1


ISSUE

R5

TITLE

DATA SHEET C


AWARD OF CONTRACT



3. Dimensional drawings


5. Hose proof pressure and bursting pressure test certificates



FILE NAME:DB11108R7.DOCX



DATA SHEET B FIRE PROTECTION EQUIPMENT

HOSE CABINETS

SHEET 1 OF 1

ENQUIRY NO. 6758A-TCE/BPCL-RFQ-003 BIDDER:

NOTES TO BIDDER SIGNATURE OF BIDDER AND DATE ISSUE

R7 1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHALL BE

MARKED WITH ASTERISK (*) AND DETAILS SHALL BE GIVEN IN SCHEDULE OF DEVIATIONS.


TCE FORM NO. 294 R4

SL. NO.

ITEM

UNIT

GEN

ERAL

1. SUB-VENDOR’S NAME / MAKE /

2. DIMENSIONS L B D

2.1 SUITABLE FOR HYDRANTS mm x x

2.3 SUITABLE FOR HYDRANT AND HOSE REEL

ASSEMBLY mm x x

3. WHETHER TAC APPROVED -NA- 4. 5. 6. 7. 8. 9. 10.

DO

CU

ME

NTS

11. DIMENSIONAL DRAWINGS OF CABINETS TO BE

WHETHER ENCLOSED : YES/NO

ENCLOSED

12. CROSS-SECTIONAL DRAWINGS OF WHETHER ENCLOSED : YES/NO

CABINETS TO BE ENCLOSED

13.

14.

15.

16.


FILE NAME:DA211108R0.DOCX

SPECIFICATION NO. TCE.M4-111-08 TATA CONSULTING ENGINEERS LIMITED SECTION: D

ENQUIRY NO. 6758A-TCE/BPCL-RFQ-003

DATA SHEET A2 FIRE PROTECTION EQUIPMENT

HOSE CABINETS

SHEET 1 OF 1

REV. NO. JOB NO. 6758A


R0 PPD. BY SG


DATE 06-08-12 TCE FORM NO. 330 R4




ENQUIRY NO. TCE.6758A-B-300-003


HOSE CABINETS

SHEET 1 OF 2


CLIENT:BPCL, URAN ISSUE

R7 PPD. BY SG

CHD. BY RR PROJECT:PMC SERVICES FOR BLENDING UNIT AT URAN

DATE 06-08-12

TCE FORM NO. 330 R4

GE

NE

RA

L

1. WALL / FLOOR MOUNTED HOSE

CO

NS

TRU

CTI

ON

FE

ATU

RE

S (C

ON

TD.)

SUPPORT LEGS COMPLETE WITH

CABINETS SUITABLE FOR 2 NOS.63 mm

FOUNDATION BOLTS, NUTS ETC.:

DIA x 15 M / 7.5 M LONG HOSES AND YES / NO

ACCESSORIES : (NOTE 1,2) 12. PAINTING FOR GI CRCA MOC: (NOTE 10)

( REFER DATA SHEET A2 ) 12.1 EXTERNAL (SPRAY PAINT):

2. WALL / FLOOR MOUNTED HOSE

a. ONE COAT OF RED OXIDE PRIMER

CABINETS SUITABLE FOR 2 NOS.63 mm

b. TWO COATS OF SYNTHETIC ENAMEL

DIAx 15 M / 7.5 M LONG HOSES, ACCESSORIES

FINESH PAINT PO RED SHADE 538 AS

AND HOSE REEL AS PER IS 884 :

PER IS-5.

SIZE: _____ H x ______ W x _____ D IN mm. 12.2 INTERNAL (SPRAY PAINT):

(NOTE 1, 2)

a. ONE COAT OF RED OXIDE PRIMER

3. SPECIAL HOSE CABINET:- b. TWO COATS OF SYNTHETIC ENAMEL

FINESH PAINT. SHADE WHITE

13.

SIZE: _____ H x ______ W x _____ D IN mm.

SP

AR

ES

&

MA

INTE

NA

NC

E

TOO

LS &

TA

CK

LES


(NOTE 1, 2) 14.1 ESSENTIAL SPARES

4. CANOPY REQUIRED: YES / NO

( ALSO SEE NOTE-3)

5.

CO

NS

TRU

CTI

ON

FE

ATU

RE

S

6. MATERIAL OF CONSTRUCTION OF

TES

TS A

ND

IN

SP

EC

TIO

N

15. AS PER TCE.M4-904 AND / OR

CABINET BODY : FRP / GI CRCA AS PER TCE.M4-185-01 AND TCE.M4-185-74

IS 277 & BASE METAL CONFORMING OR TCE.M4-186-30 (NOTE 11)

TO IS 513 16.

7. THICKNESS OF BODY IF MATERIAL OF 17.

CONSTRUCTION IS GI CRCA : 16/18/20 SWG & 18.

GRADE OF ZINC COATING 200 AS PER IS 277

AP

PR

OV

ED

SU

B-V

EN

DO

RS

19.

8. THICKNESS OF GLASS PANEL: 3mm 20.

9. HAMMER WITH CHAIN: 1 SET CHROME PLATED 21.

10. LOCK WITH DUPLICATE SET OF KEYS 22.

FOR EACH CABINET: YES 23.

11. MOUNTING CLAMPS, STRUCTURAL 24.




ENQUIRY NO. TCE.6758A-B-300-003


HOSE CABINETS

SHEET 2 OF 2


CLIENT:BPCL, URAN ISSUE

R7 PPD. BY SG

CHD. BY RR PROJECT:PMC SERVICES FOR BLENDING UNIT AT URAN

DATE 06-08-12

TCE FORM NO. 330 R4

NOTES

1. FOLLOWING ACCESSORIES SHALL BE MADE AVAILABLE INSIDE THE HOSE BOX AFTER INSTALLATION AT SITE

a. 2 NOS. 63 mm DIA x 15 M / 7.5M LONG HOSES WITH COUPLING

b. 1 NO. BRANCH PIPE

c. 1 NO. NOZZLE

d. 1 NO. NOZZLE SPANNER

2. FLOOR MOUNTED HOSE CABINETS SHALL BE PROVIDED WITH MINIMUM 1 M HIGH STRUCTURAL SUPPORT LEGS.

3. CANOPY IS REQUIRED FOR HOSE CABINETS TO BE LOCATED OUTDOORS.

4. SCOPE OF SUPPLY WITH HOSE CABINETS SHALL NOT INCLUDE HOSES, HOSE REELS, BRANCH PIPES AND NOZZLES.

5. THE WORD “FIRE”, IN 150 mm LETTER SIZE IN RED, SHALL BE PAINTED ON THE CABINET GLASS.

6. THE CABINET SHALL BE PROVIDED WITH CLAMPS FOR HOLDING BRANCH PIPE, NOZZLE AND HOSE REEL WHERE APPLICABLE.

7. PROVISION TO KEEP ONE KEY AND ONE HAMMER IN GLASS COVERED RECESS ON THE SIDE OF THE CABINET SHALL BE MADE.

8. THE CABINET SHALL BE SUPPLIED WITH A SMALL CONTAINER HAVING A SET OF SPARE RUBBER RINGS PACKED IN FRENCH CHALK.

9. MAKING OF POCKETS IN THE WALL, GROUTING OF BOLTS, FINISHING THE WALL AS BEFORE, AND MOUNTING OF CABINETS ON TO THE WALL OR THE STRUCTURAL SUPPORTS SHALL BE IN CONTRACTOR’S SCOPE.

10. COLOUR SHADE SCHEME FOR FRP HOSE BOX SHALL BE SAME AS THAT MENTIONED FOR GI CRCA MOC – HOWEVER THE COLOUR SHALL BE UV RESISTANT FADE PROOF INTEGRAL TYPE SUITABLE FOR EXTERNAL ATMOSPHERE.

11. ADDITIONAL TESTS INDICATED AS 'B' IN TCE.M4-186-30 SHALL ALSO BE CARRIED OUT WHEN TCE.M4-186-30 IS APPLICABLE.




FIRE PROTECTION EQUIPMENT HOSE CABINETS SHEET 1 OF 1

TCE FORM NO. 329 R5 FILE NAME: DC 11108R7.DOCX

ISSUE R7

DATA SHEET C


AWARD OF CONTRACT

1. Technical Data Sheet 2. Quality Assurance Plan (QAP) 3. Dimensional outline drawing indicating plan, elevation and end views showing

arrangement of accessories, Part list with material specifications. 4. Cabinet supporting arrangement


ISS

UE

NO

. R

5

TCE.M4-111-16 TATA CONSULTING ENGINEERS LIMITED SECTION : D


SHEET: 1 OF 3 TCE.6758A-B-300-003


PORTABLE FIRE EXTINGUISHERS.

SL.

NO. TY

PE

CAPACITY STANDARD

TAC

GUIDE

LINES

QUANTITY REQUIRED

SP

AR

E

RE

FIL

LS

RE

MA

RK

S

FLOOR WALL COLOUMN TROLLEY

TO

TA

L

MOUNTED

1.

SA

ND

/

WA

TE

R

BU

CK

ET

10 LIT IS 2546 YES

2.1

CA

RB

ON

DIO

XID

E

2.0 Kg IS 2878 YES/NO -- -- -- --

2.2 3.0 Kg IS 2878 YES/NO -- -- -- --

2.3 4.5 Kg IS 2878 YES -- -- -- --

2.4 6.5 Kg IS 2878 YES/NO -- -- -- --

2.5 9.0 Kg IS 2878 YES/NO -- -- -- --

2.6 22.5 Kg IS 2878 YES/NO -- -- -- --

2.7 6 TO 7 Kg

2 Nos. IS 8149 YES/NO -- -- -- --

2.8

2.9

3.1

CH

EM

ICA

L F

OA

M

9.0 LIT IS 940 YES -- -- -- --

3.2 50.0 LIT YES/NO -- -- -- --

3.3 150.0 LIT YES/NO -- -- -- --

3.4

3.5

3.6

3.7

3.8

3.9

4.1

ME

CH

AN

ICA

L F

OA

M

9.0 LIT IS 10204 YES -- -- -- --

4.2 135.0 LIT IS 14951 YES/NO -- -- -- --

4.3

4.4

4.5

4.6

4.7

4.8

4.9

REV NO PPD. BY: SG JOB NO. CLIENT: BPCL, URAN

DATE CHD.BY: RR 6758A PROJECT: PMC SERVICES FOR LPG





IS

SU

E N

O.

R5



SHEET: 2 OF 3 TCE.6758A-B-300-003


PORTABLE FIRE EXTINGUISHERS

SL.

NO. TY

PE

CAPACITY STANDARD

TAC

GUIDE

LINES

QUANTITY REQUIRED

SP

AR

E

RE

FIL

LS

RE

MA

RK

S

FLOOR WALL COLOUMN TROLLEY

TO

TA

L

MOUNTED

5.1

SO

DA

AC

ID 9.0 LIT YES/NO -- -- -- --

5.2 50.0 LIT YES/NO -- -- -- --

5.3 -- -- -- --

5.4 -- -- -- --

6.1

DR

Y C

HE

MIC

AL

PO

WD

ER

0.5 Kg IS 13849 YES/NO -- -- -- --

6.2 1.0 Kg IS 13849 YES/NO -- -- -- --

6.3 2.0 Kg IS 13849 YES/NO -- -- -- --

6.4 5.0 Kg IS 15683 YES -- 10 -- --

6.5 10.0 Kg IS 13849 YES/NO -- -- -- --

6.6 1.0 Kg IS 2171 YES/NO -- -- -- --

6.7 2.0 Kg IS 2171 YES/NO -- -- -- --

6.8 5.0 Kg IS 2171 YES/NO -- -- -- --

6.9 10.0 Kg IS 2171 YES/NO -- -- -- --

6.10 25.0 Kg IS 10658 YES -- -- -- --

6.11 50.0 Kg IS 10658 YES/NO -- -- -- --

612 75.0 Kg IS 10658 YES/NO -- -- -- --

6.13

6.14

7.1

HA

LO

N 1

21

1

1.25 Kg IS 11108 YES/NO -- -- -- --

7.2 2.5 Kg IS 11108 YES/NO -- -- -- --

7.3 4.0 Kg IS 11108 YES/NO -- -- -- --

7.4 5.0 Kg IS 11108 YES/NO -- -- -- --

7.5 6.5 Kg IS 11108 YES/NO -- -- -- --

7.6

7.7

7.8

7.9







IS

SU

E N

O.

R5



SHEET: 3 OF 3 TCE.6758A-B-300-003 FIRE PROTECTION EQUIPMENT

PORTABLE FIRE EXTINGUISHERS

SL.

NO. TY

PE

CAPACITY STANDARD

TAC

GUIDE

LINES

QUANTITY REQUIRED

SPARE

REFILLS REMARKS FLOOR WALL COLOUMN TROLLEY

TO

TA

L

MOUNTED

8.1

WA

TE

R

(GA

S C

AR

TR

IDG

E)

9.0 LIT IS 940 YES --

8.2

8.3

8.4

8.5

SP

AR

ES

AN

D M

AIN

TE

NA

NC

E

TO

OL

S A

ND

TA

CK

LE

S

9. REFER TCE.M4-907

AP

PR

OV

ED

SU

B-V

EN

DO

RS

11.

10. ESSENTIAL SPARES 12.

10.1 13.

10.2 14.

10.3 15.

10.4 16.

10.5 17.

10.6 18.

NOTES

1. ALL ITEMS CONFORMING TO IS SHALL BE ISI MARKED.

2. TESTS AND INSPECTION SHALL BE AS PER TCE.M4-904 AND/OR TCE.M4-185-01 AND TCE.M4-185-

OR TCE.M4-186-30 AND APPLICABLE INDIAN STANDARDS AND TAC REGULATIONS.

ADDITIONAL TESTS INDICATED AS 'B' IN TCE.M4-186-30 SHALL ALSO BE CARRIED OUT WHEN


3. MOUNTING CLAMPS AND STRUCTURAL SUPPORT LEGS COMPLETE WITH NUTS AND BOLTS ETC.

SHALL BE PROVIDED BY THE VENDOR FOR FLOOR, WALL AND COLUMN MOUNTED PORTABLE

FIRE EXTINGUSHERS.








TATA Consulting Engineers Limited SECTION: D


PORTABLE FIRE EXTINGUISHERS SHEET 1OF 2

ENQUIRY/SPECIFICATION NO.:

SL. NO.

BIDDER ITEM

NOTES TO BIDDER SIGNATURE OF BIDDER & DATE 1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS.


ISSUE R0


SL

NO

TYPE CAPACITY MAKE ISI

MARKED

CATALOUGE FOR EACH

TYPE TO BE

ENCLOSED. WHETHER

ENCLOSED

1. SAND/WATER

BUCKET

10.0 LIT YES/NO YES/NO

2.1

CARBON

DIOXIDE

2.0 Kg

YES/NO YES/NO

2.2 3.0 Kg YES/NO YES/NO





2.7 6 TO 7 Kg 2 Nos. YES/NO YES/NO

2.8

2.9

3.1 CHEMICAL

FOAM 9.0 LIT

YES/NO YES/NO

3.2 50.0 LIT YES/NO YES/NO


3.4

4.1 MECHANICAL

FOAM 9.0 LIT

YES/NO YES/NO


4.3

5.1 SODA ACID 9.0 LIT YES/NO YES/NO




TATA Consulting Engineers Limited SECTION: D


PORTABLE FIRE EXTINGUISHERS SHEET 2OF 2

ENQUIRY/SPECIFICATION NO.:

SL. NO.

BIDDER ITEM

NOTES TO BIDDER SIGNATURE OF BIDDER & DATE 1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS.


ISSUE R0


SL NO TYPE CAPACITY MAKE ISI

MARKED

CATALOUGE FOR EACH

TYPE TO BE ENCLOSED.

WHETHER ENCLOSED

6.1

DRY

CHEMICAL

POWDER

0.5 Kg

YES/NO YES/NO











612 75.0 Kg YES/NO YES/NO

YES/NO YES/NO

7.1 HALON 1211 1.25 Kg YES/NO YES/NO





8.1 WATER(GAS

CARTRIDGE)

9.0 LIT YES/NO YES/NO

8.2



TCE. M4-111-16 FIRE PROTECTION EQUIPMENT

PORTABLE FIRE EXTINGUISHERS SHEET 1 OF 1


ISSUE

R5

TITLE

DATA SHEET C


AWARD OF CONTRACT

1. List of drawings and documents to be submitted for review, approval and

information along with scheduled submission dates

2. Quality Assurance Plan (QAP)a

3. Descriptive catalogues for each type of extinguisher

4. Detailed dimensional drawings for each type of extinguisher with trolley

(wherever applicable)

5. Cross-sectional drawing of hydrant valve assembly with part list and material

of construction of each part

6. Dimensional drawing of supporting stand for each type of floor mounted

extinguisher

7. Fixing detail for each type of wall mounted and column mounted extinguisher



10. TAC approval certificates


ISS

UE

NO

. R

5




MVWS SPRAY SYSTEM

DE

SIG

N D

AT

A

1. STANDARD: NFPA/OISD/TAC

CO

NS

TR

UC

TIO

N F

EA

TU

RE

S (

CO

NT

D.)

(A) HEAT DETECTOR TYPE:

2. TAG NUMBERS OF EQUIPMENT/AREA FIXED TEMPERATURE/RATE OF RISE

TO BE PROTECTED: PREHEATER & TEMPERATURE-CUM-FIXED

BLENDING SKID TEMPERATURE

3. QUALITY OF WATER: FIRE WATER (B) SMOKE DETECTOR TYPE:

IONISATION/OPTICAL

4. TYPE OF SYSTEM: MANUAL/AUTOMATIC (PHOTOELECTRIC)

MEDIUM VELOCITY/HIGH VELOCITY 12.3.2 LINE DETECTOR TYPE:

5. TYPE OF ACTUATION: MANUAL OR LHS CABLE – DIGITAL TYPE

AUTOMATIC - HYDRAULIC/PNEUMATIC/ 13. DELUGE VALVE:

ELECTRICAL 13.1 SIZE: AS PER SPECIFICATION

6. PRESSURE AT DELUGE VALVE INLET: 13.2 END CONNECTION: FLANGED TO

ASME B 16.5

7. DESIGN DENSITY OF DISCHARGE: M

AT

ER

IAL

S O

F C

ON

ST

RU

CT

ION

14. DELUGE VALVE FOR:

3 / 10.2 / 12.2 LPM/M2 FIRE WATER/

8. MINIMUM RESIDUAL PRESSURE AT 14.1 BODY: CI TO IS 210 GR. FG 200/

HYDRAULICALLY MOST UNFAVOURABLE

NOZZLE: 1.4 / 2.8 / 3.5 BAR 14.2 SEAT RING: BRONZE TO IS 318

MOST FAVOURABLE NOZZLE: 3.5 / 5 BAR GR. LTB2/

9. 14.3 CLAPPER: BRONZE TO IS 318

CO

NS

TR

UC

TIO

N F

EA

TU

RE

S

10. TYPE OF DETECTOR: GR. LTB2/

Q B DETECTOR/ELECTRICAL DETECTOR 14.4 CLAPPER FACING: BRONZE TO IS 318

11. SPRINKLER-Q B DETECTOR GR. LTB2/

11.1 STANDARD: IS 9972 /UL APPROVED 14.5 HANDHOLE COVER: CI TO IS 210

11.2 NOMINAL TEMPERATURE RATING: GR. FG 225/

AS PER DWG 14.6 CLAPPER/HANDHOLE GASKET:

12. ELECTRICAL DETECTOR NEOPRENE RUBBER/

12.1 STANDARD: IS 2189 15. SPRINKLER-Q B DETECTOR: BRASS

12.2 NOMINAL TEMPERATURE RATING: AS PER IS 319/BRONZE AS PER IS 318

0C GR. LTB2 CHROME PLATED

12.3 TYPE: SPOT DETECTOR/LINE DETECTOR 16. NOZZLES: BRASS AS PER IS 319/

12.3.1 SPOT DETECTOR TYPE: HEAT DETECTOR BRONZE AS PER IS 318 GR. LTB2

/SMOKE DETECTOR CHROME PLATED

REV.NO. PPD.BY: SG JOB NO. CLIENT: BPCL, URAN

DATE CHD.BY: RR 6758A PROJECT: PMC SERVICES FOR BLENDING

UNIT AT URAN




ISS

UE

NO

. R

5 TCE.M4-111-23 TATA CONSULTING ENGINEERS LIMITED SECTION : D



MVWS SPRAY SYSTEM

CO

MP

AN

ION

SP

EC

IFIC

AT

ION

S

17. P&I DIGRAM:

AP

PR

OV

ED

S

UB

-VE

ND

OR

S

28. DELUGE VALVE:

28.1

18. GA DRAWING: 28.2

28.3

19. PUMP: 28.4

20. PIPING: AS PER TCE.M4-111-60 , TCE-6159A- 29. SPRINKLER- QB:

C-617-030-CT AND TCE.6159A-C-617-030-GA 29.1

21. INSTRUMENTS: AS PER 29.2

29.3

22. CONTROL PANEL: AS PER 29.4

30. ELECTRICAL DETECTOR:

23. 30.1

TE

ST

S A

ND

IN

SP

EC

TIO

N 24. AS PER TCE.M4-904 AND/OR TCE.M4-185-01 30.2

AND TCE.M4-185- OR TCE.M4-186-30 AND 30.3

APPLICABLE NFPA, AND TAC 30.4

REGULATIONS (NOTE 1) 31. SPRAY NOZZLE:

25. FOC/UL/FM APPROVAL CERTIFICATES 31.1

FOR IMPORTED ITEMS 31.2

26. 31.3

27. 31.4

NOTE

1. ADDITIONAL TESTS INDICATED AS ‘B’ IN TCE.M4-186-30 SHALL ALSO BE CARRIED OUT WHEN


2. SPRAY NOZZLE SHALL BE UL LISTED OR FM APPROVED.

REV.NO. PPD.BY: SG JOB NO. CLIENT: BPCL, URAN

DATE CHD.BY: RR TCE. PROJECT: PMC SERVICES FOR BLENDING

REV. BY DATE: 06-08-

2012

6758A UNIT AT URAN


PLS REFER SECTION C


ISS

UE

NO

. R

4

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D

TCE.M4-111-03 DATA SHEET B

SHEET: 1 OF 1 FIRE PROTECTION EQUIPMENT

WATER MONITORS

ENQUIRY/SPECIFICATION NO. 6758A-TCE/BPCL-RFQ-003

SL.

NO.

BIDDER

ITEM

GE

NE

RA

L

1. SUB-VENDOR'S NAME/MAKE /

2. STANDARD

3. INLET SIZE/NOZZLE BORE mm /

4. CAPACITY LPM

5. INLET FLANGE RATING

6. WHETHER TAC APPROVED YES/NO

7. WHETHER ISI MARKED YES/NO

8.

CO

NS

TR

UC

TIO

N

FE

AT

UR

ES

9. ROTATION MECHANISM

HANDLE BAR WITH LOCK/WORM

AND WORM WHEEL WITH SELF

LOCKING ARRANGEMENT

10.

11.

DO

CU

ME

NT

S

12. CATALOUGES TO BE ENCLOSED WHETHER ENCLOSED: YES/NO

13. CHARACTERISTIC CURVES TO BE

ENCLOSED FOR WHETHER ENCLOSED

13.1 FLOW vs HORIZONTAL RANGE FOR

VARIOUS ANGLES OF INCLINATION YES/NO

13.2 FLOW vs REACTION THRUST YES/NO

14.

15.

NOTES TO BIDDER

1.DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN REPRODUCED

IN DATA SHEET-B. IN CASE OF DEPARTURE FROM DATA SHEET-A,

BIDDER SHALL BRING OUT THE SAME IN SCHEDULE OF

DEVIATIONS, FAILING WHICH IT SHALL BE CONSTRUED THAT

BIDDER COMPLIES WITH THE REQUIREMENTS STIPULATED IN

DATA SHEET-A.

2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF

BIDDER

DATE

FILE NAME: DB11103R4.DOC TCE FORM NO. 294 R1


I

SS

UE

NO

. R

4



SHEET: 1 OF 2 TCE.6758A-B-300-003


WATER MONITORS

GE

NE

RA

L

1. STANDARD: IS 8442/MFR’S STD.

MA

TE

RR

IAL

S

OF

CO

NS

TR

UC

TIO

N (

CO

NT

D.)

15. SWIVEL JOINTS: Cu ALLOY

2. INLET SIZE/NOZZLE BORE: 16. LOCKS: BRASS AS PER IS 291

63/32 OR 75/38 OR 100/45/ mm 17. WATER BARREL: CS SEAMLESS AS

3. TYPE: WATER MONITOR PER IS 1239 (PART 1)/BRASS AS PER

4. ISOLATION VALVE REQUIRED: YES/NO IS 407 OR Al AS PER IS 1285

5. STAND POST SIZE: 100/150 mm 18. NOZZLE: Cu ALLOY

6. COMPANION FLANGES AT STAND POST: OR Al ALLOY AS PER IS 617

YES/NO 19. HANDLE: CS AS PER IS 1732

7. 20. WORM AND WORM WHEEL:

PE

RF

OR

MA

NC

E

RE

QU

IRE

ME

NT

S

8. HORIZONTAL THROW AT 30O

ABOVE Cu ALLOY

HORIZONTAL PLANE AT 7 Kg/cm2g 21. HAND WHEEL: CI AS PER IS 210 GR 200

INLET MINIMUM MINIMUM 22.

SIZE (mm) DISCHARGE HORIZONTAL 23.

CAPACITY (LPM) THROW (M) 24.

63 1750 53

CO

NS

TR

UC

TIO

N F

EA

TU

RE

S

25. WATER BARREL: EXTERNAL

75 2580 60 THREADS AS PER IS 2643 (PART 1)

100 3500 64 26. NOZZLE: EXTERNAL THREADS FOR

9. HORIZONTAL ROTATION ANGLE IN

CONNECTING SMALLER NOZZLE/

EITHER DIRECTION: 3600

FOG TIP

10. MINIMUM VERTICAL TRAVERSE

27. HORIZONTAL AND VERTICAL

ANGLES: (-) 450 TO (+) 90

0 TRAVERSING MECHANISM WITH

11. SINGLE HANDLE BAR OR WORM AND

MA

TE

RIA

LS

O

F C

ON

ST

RU

CT

ION

12. BASE FLANGE: CS AS PER ASTM A 105/ WORM WHEEL WITH POSITIVE

IS 6392 LOCKING ARRANGEMENT. WORM

13. REDUCER: CS AS PER IS 1239 (PART 2) AND WORM WHEEL GEARED UNIT

14. BODY, ELBOWS, BENDS: AS PER IS 4310 SHALL BE SELF LOCKING TYPE

OR Cu ALLOY AS PER SAND CASTINGS: 28. DRAIN NIPPLE: REQUIRED

GR LTB 2 OR LTB 3 OF IS 318 OR GR3 OF 29. FLANGE DRILLING STANDARDS:

IS 304, DIE CASTING: GR3 OF IS 292 ANSI B16.5

HOT FORGINGS: GR1 OF IS 291 30. PAINTING: P.O. RED AS PER SHADE

HIGH TENSILE CASTING: GR3 OF IS 304 NO. 538 OF IS 5

REV. NO. PPD. BY: SG JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY: RR TCE.6758A PROJECT: PMC SERVICES FOR


REV. BY DATE:06-08-2012



ISS

UE

NO

. R

4




WATER MONITORS

CO

NS

TR

UC

TIO

N

FE

AT

UR

ES

(C

ON

TD

.) 31. ANTI-CORROSIVE TREATMENT:

TE

ST

S A

ND

IN

SP

EC

TIO

N

39. TAC APPROVAL REQUIRED: YES/NO

(NOTE 1) 40. TEST PRESSURE: 23 Kg/cm2g

32. 41. AS PER TCE.M4-904 AND/OR TCE.M4-

33. 185-01 AND TCE.M4-185- OR TCE.M4-

34. 186-30 AND TAC GUIDELINES (NOTE 2)

35. 42.

36. 43.

SP

AR

ES

AN

D

MA

INT

EN

AN

CE

TO

OL

S

AN

D T

AC

KL

ES


AP

PR

OV

ED

SU

B-V

EN

DO

RS

44.

38. ESSENTIAL SPARES 45.

38.1 46.

38.2 47.

38.3 48.

38.4 49.

38.5 50.

NOTES

1. ALL STEEL COMPONENTS SUBJECTED TO DIRECT WATER CONTACT SHALL BE HOT DIP

GALVANIZED TO THICKNESS NOT LESS THAN 0.03 mm. THE ALUMINIUM PARTS SUBJECT TO DIRECT

WATER CONTACT SHALL BE HARD ANODIZED TO A MINIMUM THICKNESS OF 0.015mm.

2. ADDITIONAL TESTS INDICATED AS 'B' IN TCE.M4-186-30 SHALL ALSO BE CARRIED OUT WHEN


3. MONITOR SHALL BE ISI MARKED.

REV. NO. PPD. BY: SG JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY: RR TCE.6758A PROJECT: PMC SERVICES FOR


REV. BY DATE:06-08-

2012

FILE NAME: DA11103R4.DOC TCE FORM NO. 330 R


SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D TCE.M4-111-09 FIRE PROTECTION EQUIPMENT

WATER MONITORS SHEET OF 1 OF 4

1

ISSUE

R3

TITLE

FILENAME:M411109R3.DOC TCE FORM NO. 329R3

DATA SHEET C


AWARD OF CONTRACT

1. Schedule of drawings and documents to be submitted along with submission

dates



4. Dimensional drawings of monitor assembly

5. Cross-sectional drawing of monitor assembly with part list and material of

construction of each part

6. Performance characteristics, flow vs horizontal range for various angles of

inclination and flow vs reaction thrust




IS

SU

E N

O. R

0 TCE.M4-134-102 TATA CONSULTING ENGINEERS SECTION : D

ENQ.SPEC.NO. DATA SHEET A & C SHEET : 1 OF 1 TCE.6758A-B-300-003 UNDERGROUND PROTECTION FOR PIPING

GEN

ER

AL A

ND

MAT

ERIA

LS

1. SUPPLY OF ALL COATING AND BY CONTRACTOR/ PURCHASER WRAPPING MATERIALS 2. SOIL RESISTIVITY (Refer Civil Section) ohm-m 3. TYPE OF UNDERGROUND PROTECTION 3.1 3 COATS AND 3 WRAPS OF COAL TAR COATING / 3 LAYERS OF WRAPPING TAPE 3.2 2 COATS AND 2 WRAPS OF COAL TAR COATING / 2 LAYERS OF WRAPPING TAPE 4.

APPL

ICAT

ION

5. APPLICATION METHODOLOGY AS PER THE WRITE-UP OF TCE.M4-134-102

6.

TEST

ING

7. COATING THICKNESS REQUIRED 8. BOND/ ADHESION TEST FOR COATING / REQUIRED WRAPPING TAPES 9. HOLIDAY TEST REQUIRED

DO

CU

MEN

TS 10. DOCUMENTS REQUIRED AFTER THE 10.1 MATERIAL TEST CERTIFICATES

AWARD OF CONTRACT 10.2 MANUFACTURER'S INSTALLATION INSTRUCTIONS FOR STORAGE, PREPARATION AND APPLICATION OF COATING MATERIALS

NOTES :

REV.NO. PPD.BY: DVK JOB NO. CLIENT: BPCL, URAN

DATE CHD.BY : DSJ TCE.6758A PROJECT: PMC SERVICES FOR

REV. BY DATE: 06-08-12 BLENDING UNIT AT URAN FILE NAME : DA134102.DOC TCE FORM NO. 330 R2


TATA CONSULTING ENGINEERS LIMITED SECTION : D8

. DATA SHEET A

TCE.6758A-B-300-003

THERMAL INSULATION FOR COLD SURFACES SHEET : 1 OF 2

(CARBON STEEL EQUIPMENT & PIPING)

1. AMBIENT TEMPERATURE : 45 OC 13.

2. 14.

3. 15.

4. 16.

5. 17.

6. INSULATION MATERIALS 18.

6.1 EQUIPMENT: EP/PUR/PIR/PF/LRG/U150 19.

6.2 PIPING SYSTEMS : EP/PUR/PIR/PF/LRG/ 20.

PSG/U150 21.

6.3 AIR-CONDITIONING DUCT : EP/PUR/ 22.

PIR/PF/LRG/U150 23.

6.4 24.

6.5 25.

7. INSULATION ADHESIVES : BIT/CPRX/ 26.

MAS 83 27.

8. VAPOUR BARRIERS : VB1/ALF/MAS 130 28.

9. FINISHING MATERIALS 29.

9.1 EQUIPMENT : FC/AL1/GS1/MAS 134

9.2 PIPING SYSTEMS:FC/AL1/GS1/MAS 134 30. TEST CERTIFICATES FOR ALL

9.3 AIR-CONDITIONING DUCT : FC/AL1/ MATERIALS REQUIRED : YES/NO

GS1/MAS 134 31.

9.4 32.

9.5 33.

10. INSULATING CEMENT MATERIAL: 34.

SAME AS THE BASIC INSULATION 35.

MATERIAL 36.

11. 37.

12. 38.

NOTES

1.

REV. NO. PPD. BY : BSR JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY : KR TCE. PROJECT: PMC SERVICES FOR

BLENDING UNIT AT URAN REV. BY DATE : 30-03-12 6758A

GE

NE

RA

L

CO

MP

AN

ION

SP

EC

IFIC

AT

ION

S (

NO

TE

-1)

ISS

UE

NO

. R

4

MA

TE

RIA

LS

TE

ST

S A

ND

IN

SP

EC

TIO

N


TATA CONSULTING ENGINEERS LIMITED SECTION : D8

DATA SHEET A1

TCE.6758A-B-300-003

THERMAL INSULATION FOR COLD SURFACES SHEET : 2 OF 2

(CARBON STEEL EQUIPMENT & PIPING)

INSULATION THICKNESSES IN mm FOR INSULATION MATERIALS

PUR,PIR AND PF

OPERATING

TEMP. oC AMB.

TO 19 TO

9 TO -1 TO

-11 TO

-21 TO

-31 TO

-41 TO

-51 TO

-61 TO

-71 TO

PIPE SIZE

MmNB 20 10 0 -10 -20 -30 -40 -50 -60 -70 -80

15 20 20 30 40 40 50 65 75 75 100 125

20 20 20 30 40 40 65 65 75 75 100 125

25 20 20 30 40 50 65 75 75 100 100 125

40 20 30 40 50 65 75 75 75 100 100 125

50 20 30 40 50 65 75 75 75 100 125 150

65 30 30 40 65 65 75 75 100 100 125 150

80 30 30 40 65 65 75 75 100 100 125 150

100 30 40 40 65 75 75 100 100 125 125 150

125 40 40 40 65 75 75 100 125 125 150 175

150 40 40 65 65 75 100 100 125 125 150 175

200 AND ABOVE AND

FLAT SURFACES

40 50 75 100 125 150 150 150 175 200 225

NOTES

1. INSULATION THICKNESSES SPECIFIED DO NOT INCLUDE THICKNESS OF FINISHING

MATERIALS SUCH AS CEMENT SAND PLASTER, ALUMINIUM OR GS SHEET, BINDING AND

LACING WIRES, WIRE NETTING AND BANDS ETC.

2. FOR INSULATION THICKNESS FOR TAIL END AIR-CONDITIONING DUCT AND EVAPORATIVE

COOLING SYSTEM ETC. REFER SECTION C OF THE ENQUIRY DOCUMENT.

REV. NO. PPD. BY : BSR JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY : KR TCE. PROJECT: PMC SERVICES FOR

BLENDING UNIT AT URAN REV. BY DATE : 30-03-12 6758A

ISS

UE

NO

. R

4


SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D

TCE.M4-134-06 FABRICATION, ERECTION AND TESTING OF

PIPING SYSTEMS FOR

CHEMICAL AND INDUSTRIAL PLANTS

SHEET 1 OF 13 OF 4

ISSUE

R1

TITLE

FILE NAME : M413406R1.DOC TCE FORM NO.329 R3

1.0 SCOPE

This specification covers the technical requirements and essential particulars for

the fabrication, erection and testing of piping systems for chemical and industrial

plants. It also includes any commissioning assistance that the PURCHASER may

require the CONTRACTOR to provide. The CONTRACTOR shall demonstrate

that the piping meets the requirements of the specification and applicable codes

and standards.

2.0 CODES AND STANDARDS

2.1 All the piping systems shall comply with all the currently applicable statues,

regulations and safety codes in the locality where the systems would be installed.

The piping systems shall also conform to the latest editions of the following codes

and standards as applicable:

(a) ASME Code for Pressure Piping, Code for Process Piping, ASME B31.3.

(b) The Indian Boiler Regulations (IBR)

(c) All applicable state laws

(d) Relevant Indian Standards

(e) Relevant British Standards

(f) Relevant MSS-SP Standards

(g) Pipe Fabrication Institute (PFI) Standards

(h) Any other applicable International Standards

2.2 In case of conflict between this specification and any of the codes or standards,

the CONTRACTOR shall bring the same to the attention of the PURCHASER for

resolution.

3.0 SCOPE OF SUPPLY

3.1 The scope of supply of pipes, fittings, gaskets, studs/bolts and nuts, valves and

specialities and other items shall be as described in Section C of the enquiry

specification.

3.2 The CONTRACTOR shall supply the following materials unless otherwise

mentioned in Section C.




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3.2.1 Piping support materials such as pipe clamps, shoes, U-bolts, hanger rods etc. but

excluding spring box assemblies.

3.2.2 Auxiliary structural steel, such as angles, I-beams, channels etc., for pipe

supports.

3.2.3 Miscellaneous materials for weather hoods, pipe sleeves, funnels, anchor

fasteners and similar items.

4.0 SCOPE OF ERECTION

4.1 For all materials supplied by him, the CONTRACTOR shall unload them from

carriers at plant site, handle, check, receive, transport, store, take to places of

fabrication and/or erection as required to complete the scope of work as per the

specification.

4.2 For "free issue" items, the CONTRACTOR shall collect the "free issue" items

from the PURCHASER's store or any other designated place of storage and take

the items to places of fabrication and/or erection.

4.3 The CONTRACTOR shall regularly check all materials supplied by him as well

as "free issue" items issued to him. All items shall be checked by the

CONTRACTOR for dimensional consistencies and freedom from damage, and

any deviations/defects shall be promptly reported to the PURCHASER for

remedial action.

4.4 The CONTRACTOR shall install all the systems identified to be in his scope

based on piping plans and sections, isometrics and for, field-run piping, based on

relevant P&I Ds, plot plan, equipment layout drawings etc.

4.5 The scope of erection shall include the following:

(a) All piping including all fittings, flanges, gaskets, studs/bolts and nuts - of

all sizes

(b) All valves and specialities

(c) All in-line instrumentation items

(d) Stubs for thermowells and stubs and small bore piping items for pressure

and other instrumentation

(e) All integral piping and instrumentation of equipment identified to be in

the CONTRACTOR'S scope




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(f) Internal machining of piping for installation of instrumentation items such

as flow nozzles

(g) Supply, fabrication and installation of pipe support items such as clamps,

hanger rods, U-bolts etc. and installation of spring supports, if any

(h) Supply, fabrication and installation of auxiliary steel for pipe supports

(pipe racks and pipe sleepers will be by OTHERS unless otherwise stated

in Section-C)

(i) Supply, fabrication and installation of miscellaneous items such as

funnels, weather hoods and anchor fasteners for pipe supports

(j) Supply and installation of small pedestals for pipe supports (major

sleepers are by OTHERS)

4.6 Unless noted otherwise, piping 40 mm and smaller shall be considered as field-

run. The CONTRACTOR shall study the relevant P&I Ds, equipment layout

drawings, equipment and other relevant drawings and develop routing for such

piping based on good engineering practice, keeping in mind the following

requirements:

(a) Head room

(b) Interference with other piping, equipment, structures, cable trays, ducting

etc.

(c) Accessibility for valves and specialities, in-line instrument items and

instruments

(d) Provision for thermal expansion in the form of expansion loops or through

flexible routing

(e) Adequate support (generally every 3000 mm but using as far as possible

existing structures or other large diameter pipes)

(f) Fabrication of wrinkle-free bends for piping 40 mm and smaller

(g) Clearance from access ways, equipment openings, maintenance areas,

crane movement areas, etc.

The CONTRACTOR shall obtain the approval of the PURCHASER for the

routing developed by him. Any routing of 40 mm and smaller shown on the

PURCHASER's drawings shall be considered for guidance only.




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5.0 WELDING

All welding shall conform to the requirements given in the companion

specification, TCE.M4-134-01, "Welding Specification for Chemical and

Industrial Plant Piping Systems". Any specific requirements given in Section-C

shall also govern.

6.0 STATUTORY REQUIREMENTS

6.1 For piping falling under the purview of IBR, the PURCHASER shall furnish

isometric drawings showing the piping configuration, locations and details of

supports, piping specifications, bills of materials, design and test conditions. The

CONTRACTOR shall submit the isometrics to the concerned IBR authority and

obtain approval for fabrication and installation. Statutory fees shall be paid by the

CONTRACTOR.

6.2 For IBR piping, the CONTRACTOR shall use IBR - approved welders and carry

out all the formalities for approval for fabrication, installation and testing.

6.3 The CONTRACTOR is responsible for getting the approval of the local IBR

inspector for all fabrication and erection work done by him. All certificates of

approvals shall be in proper IBR forms.

6.4 The CONTRACTOR shall carry out all IBR activities in his scope within the

quoted unit rates. For statutory fees for drawing approval, refer para 6.1.

7.0 BURIED PIPING

7.1 The CONTRACTOR shall provide protection against soil corrosion for buried

piping as per TCE.M4-134-102, "Underground Protection for Piping".

7.2 The CONTRACTOR shall carry out the necessary excavation for installation of

buried piping and, after satisfactory completion of leak tests, complete the back-

filling to achieve the original grade level.

7.3 Unless noted otherwise in Section-C, the soil resistivity shall be taken as being

less than 1000 ohm-cm and protection by the use of wrapping tapes shall be

considered.

8.0 MATERIAL SPECIFICATION

8.1 The Piping Material Specifications enclosed with the enquiry specification and

the bill of materials enclosed shall form the basis for the supply of materials,

wherever supply is in the scope of the CONTRACTOR.




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8.2 The scope of inspection for materials supplied by the CONTRACTOR shall be as

defined in Section-C.

8.3 For materials supplied by him, the CONTRACTOR shall supply six (6) copies of

certified physical and chemical test reports and any other test certificate as

required by the applicable material standard. The certificates shall include the

following information as applicable :

(a) Chemical composition

(b) Tensile strength, yield/proof stress and percentage elongation

(c) Results of other tests, such as, flattening, bending, hardness, impact as

applicable

(d) Heat treatment procedure

(e) Hydrostatic test results as applicable

(f) Dimensions

(g) IBR approval

(h) Any other test such as inter-granular corrosion test

9.0 FABRICATION AND ERECTION

9.1 The type of piping connections to be used, whether butt welding, socket welding,

threaded, flanged or sleeved shall be strictly in accordance with the Piping

Material Specifications. At equipment connections, the method of attachment

shall be as given on the equipment drawings. The final equipment connection, by

any method of joining, shall be in the CONTRACTOR'S scope of work.

9.2 Mitres shall be fabricated from straight pipes wherever mitres are specified.

Unless otherwise specified 900 mitres elbows shall be 3-weld mitres of 15

0, 30

0,

300 and 15

0 angles and 45

0 mitre elbows shall be 2-weld mitres of 11¼

0, 22½

0 and

11¼0 angles. The "radius" shall be 1.5 times the nominal size (in inch units)

unless the layout drawing requires other dimensions.

9.3 Site-fabricated reducers shall be fabricated by the cut-and-shut method using

proper mandrels. Included angle shall be 300.

9.4 The CONTRACTOR shall use the bench mark provided by the PURCHASER

and transfer levels as required accurately using his own surveying equipment. The

Purchaser’s bench mark shall, in no way, be disturbed.




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9.5 Tolerances on fabricated assemblies shall generally conform to the following:

9.5.1 Tolerances on linear dimensions, intermediate and overall (these tolerances are

not cumulative) :

Sizes 250 mm, 3.0 mm

Sizes 300 to 600 mm, 5.0 mm

Sizes 650 to 900 mm, 6.0 mm

For sizes over 900 mm, the tolerance is 6.0 mm increasing by 2.0 mm for

each 300 mm increase over 900 mm.

9.5.2 Due to cumulative effects of tolerances on fittings and flanges, when joined

without intervening pipe segments, deviations in excess of those specified in para

9.5.1 are permissible.

9.5.3 Alignment of flange facings or welding ends shall not deviate from the indicated

position, measured across any diameter, by more than 1.0 mm per 25 mm or 1

mm whichever is greater.

9.5.4 The axes of flange gasket surfaces shall not be more than 2.0 mm from their

indicated positions.

9.6 Flange bolt holes of vertical flanges shall straddle the vertical axis and bolt holes

of horizontal flanges shall straddle the north-south axis.

9.7 In making flanged joints, gaskets and flange faces shall be cleaned and free of

weld spatter burns etc. Gaskets shall be properly centred and bolting shall be well

lubricated. The lubricant shall be supplied by the CONTRACTOR as a part of his

unit rates. All flanged joints shall be brought up flush until the entire flange face

or groove bears on the gasket and then made up with uniform bolt tension.

Tightening sequence shall assure uniform distribution of bolt loading.

9.8 The following wastages are the maximum permissible on pipe lengths :

Irrecoverable 1.5%

Recoverable 3.0%

Returnable pipes shall be at least 500 mm long or five (5) times the nominal size

whichever is higher.

9.9 Steam tracers shall be clamped to the parent pipes by using 16 SWG galvanised

steel wire at intervals of 300 mm for horizontal pipes and 500 mm for vertical




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pipes. The supply and installation of the galvanised steel wire are included in the

scope of the CONTRACTOR as a part of erection scope of steam-traced pipe.

9.10 Alignment of piping connected to equipment shall be achieved without bending

or springing the pipe under any circumstances. Alignment shall be checked and

approved by the PURCHASER prior to final connection.

9.11 The CONTRACTOR shall provide adequate spools in all the directions to take

care of tolerances in erection of structures, equipment etc. Final adjustments shall

be made so as to achieve the desired connection locations after installation, but

before final welding. This fact shall be considered while carrying out

prefabrication of piping assemblies.

9.12 For piping carrying flammable fluids like LPG, natural gas etc. the

CONTRACTOR shall supply, fabricate and install aluminium strips at every

flanged joint to provide electrical continuity. The strips shall be 15 mm wide and

1 mm thick. At the end of each section of piping, the CONTRACTOR shall

supply and install earthing straps on piping to facilitate connection to plant

earthing grid. The above requirements shall form a part of unit rates for

fabrication and erection.

9.13 Effective precautions shall be taken to protect ends and faces of pipes, fittings,

valves, specialities, in-line instrumentation items and other items in the custody of

the CONTRACTOR to prevent mechanical damage and ingress of foreign matter.

10.0 PIPE SUPPORTS

10.1 For piping for which layouts are furnished by the PURCHASER, the

CONTRACTOR shall install pipe supports in accordance with the details

supplied by the PURCHASER. During erection, piping shall be provided with

adequate temporary supports until the final supports are installed. Temporary

supports shall rest on paving, or in direct or indirect contact with concrete or

structural beams. Platform grating or scaffolding shall not be used for temporary

supports. The CONTRACTOR shall supply the necessary materials for the

temporary supports as a part of his scope of work and remove the same after

completion of site work.

10.2 For field-routed piping the CONTRACTOR shall provide supports based on good

engineering practice.

10.3 Pipe supports shall generally conform to TCE.M6-ME-590-441 "Standard Pipe

Supports for Chemical and Industrial Plants".

10.4 SPRING SUPPORTS




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Great care shall be exercised in the installation of spring support assemblies.

These shall be installed strictly as per the manufacturer's recommendation.

Normally, the spring box assembly will be received locked in the cold-set

condition. The assembly shall be installed in this condition and after successful

completion of leak tests, the spring shall be unlocked by loosening the upper and

lower nuts on either side of the piston plate or as per the manufacturer's

instructions. The turnbuckle or the load flange shall be adjusted to transfer the

load to the spring and the adjustment continued until the scale pointer is at the

cold load mark. Simultaneous adjustment of adjacent supports may be required to

achieve the desired results. For liquid-carrying lines which may be emptied after

hydrotest, the pipe may sag or bow as the pipe may be either over-supported or

under-supported at this stage. This is to be considered as normal.

11.0 EXPANSION JOINTS

11.1 As the function of an expansion joint is greatly affected by inaccuracies in

installation, the CONTRACTOR shall exercise great care in the installation of

piping, piping supports and expansion joints in piping systems having such joints.

The manufacturer's instructions regarding installation, removal of shipping bars

etc. are to be strictly followed.

11.2 Due care shall be taken to prevent any damage to the thin bellows section, such as

dents, scores, arc strikes and weld spatter.

11.3 The expansion joint shall not be used to absorb piping installation misalignment.

The expansion joint shall be positioned only after the ends of pipe which are to

connect the expansion joint are properly aligned.

11.4 Any preset required shall be carefully implemented.

11.5 Expansion joints with internal sleeves shall be positioned with the proper

orientation with respect to flow direction (as per the marked direction).

11.6 The expansion joint shipping devices shall be removed only after the anchors or

other fixed points are in place and the piping is properly supported and guided.

11.7 A careful inspection of the system shall be made to ensure the following :

11.7.1 Proper installation of anchors, guides and supports in accordance with the

drawings.

11.7.2 Proper expansion joint at the proper location.

11.7.3 Flow direction for expansion joints with internal sleeves.

11.7.4 Proper orientation of hinges and tie bars etc.




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11.7.5 Removal of shipping devices.

11.7.6 Freedom of pipe movement at guides and supports.

11.7.7 Removal of hydrotest water after completion of test.

11.7.8 Checking for damage to the expansion joint during handling, installation and

testing and for any evidence of instability during the test.

11.7.9 Misalignment of the expansion joint not accounted for.

11.8 The PURCHASER shall be immediately notified if any damage or abnormality is

noticed and further advice sought.

12.0 LEAK TESTING

12.1 All installed piping systems shall be subject to leak tests to ensure integrity of the

erected system. The test medium used and the test pressure shall be in accordance

with the project Line Designation Schedule. The Test pressure shall be 1.3 times

the operating pressure in case of hydro testing and holding time should be 30

minutes or the time required for inspecting all the joints (whichever is higher).

The test pressure shall be 1.1 times the operating pressure in case of pneumatic

testing.

12.2 Suitable precautions shall be taken during pressure tests to eliminate hazards to

personnel in case piping under test ruptures. Provision for release of excess

pressure due to thermal expansion of the test fluid shall be made.

12.3 Pressure testing shall be carried out only after the completion of postweld heat

treatment and non destructive testing of welds.

12.4 Equipment which do not form a part of the pressure test shall be disconnected or a

blank used at the equipment connection. Valves may be used for the purpose after

checking with the PURCHASER that the valve closure is suitable for the

proposed test pressure.

12.5 The core pipe in a jacketed piping system shall be tested before the jacket is

completed unless the core welds are permanently exposed.

12.6 Where pneumatic testing is involved particular care shall be taken as the testing

involves the hazard of stored energy of compressed air. A pressure relief device

shall be provided, by the CONTRACTOR, having a set pressure not higher than

the test pressure plus the lesser of 3.5 kg/cm2 or 10% of the test pressure. The test

pressure shall be first raised to one-half the final test pressure or 1.75 kg/cm2g

whichever is less, at which time a preliminary check shall be made of the system.




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Thereafter, the pressure shall be gradually increased in steps until the test pressure

is reached, holding the pressure at each step long enough to equalize piping

strains. The pressure shall then be reduced to design pressure before examining

for leakage.

12.7 After satisfactory completion of the leak test, the system shall be gradually

depressurised and the test liquid completely drained. High point vents and low

point drains shall be used during the filling and draining operations of hydrotest.

12.8 The following items shall be removed from the systems to be pressure tested :

(a) Relief valves and rupture discs

(b) Orifice plates, flow nozzles or other similar restrictions

(c) Flanged venturi type flowmeters

(d) Flanged control valves (for welded control valves internals shall be

removed)

(e) Flanged check valves

(f) All instruments

(g) All items not designed to withstand the test pressure. (In lines with

expansion joints, system test pressure shall not exceed expansion joint test

pressure).

(h) Internals of strainers and filters

12.9 In lines with untied expansion joints, all anchors, guides, directional anchors and

supports shall be installed prior to hydrotest.

12.10 In lines with tied expansion joints, the tie rods and nuts shall be in proper position

prior to hydrotest.

12.11 Piping open to atmosphere, such as relief valve discharge piping need not be leak

tested.

13.0 CLEANING AND FLUSHING OF PIPING

13.1 During fabrication and installation, the CONTRACTOR shall prevent foreign

materials such as oil, grease, sand, dirt, scale, loose particles from cutting,

grinding, etc., from entering the pipe or pipe component. If foreign materials have

entered the pipe or pipe component, they shall be removed immediately before

the assembly of the parts by a suitable cleaning method such as wire-brushing,




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blowing through with air or degreasing using a suitable cleaning agent or solvent.

Before cleaning with a solvent, the PURCHASER shall be consulted regarding

suitability of the agent especially when alloy or stainless steels are involved. Wire

brushes used on stainless steel parts shall be of stainless steel.

13.2 Cleaning of erected piping systems shall be accomplished by one of the following

methods :

13.2.1 All air lines and all lines which are pneumatically tested shall be blown with clean

dry air.

13.2.2 All steam lines which have been successfully hydrotested and completely drained

and dried shall be steam blown. Steam traps shall be bypassed during this

operation in order to prevent damage to trap internals. Drip leg blow-off

connections shall be used. Steam lines connected to sensitive equipment like

steam turbines shall have temporary pipes connected close to the turbine end of

the steam line. Quality of the cleanliness of the blown pipe shall be checked using

aluminium and stainless steel target plates in the temporary piping. Care shall be

taken to adequately brace the temporary piping against large reaction forces

developed during blowing. Specific project guidelines shall be followed.

13.2.3 All fuel oil piping shall be cleaned by blowing with clean dry air.

13.2.4 All other water and liquid lines shall be flushed with water.

13.3 Cleaning and flushing operations shall be done through open pipe ends or

branches and not through equipment or pumps. The cleaning and flushing

operations shall be carried out until all trash and construction debris are removed

from the piping systems.

13.4 Stainless steel piping systems shall be flushed with clean water with chloride

content not exceeding 100 ppm. Potable water is considered acceptable for this

purpose.

13.5 Following the flushing operations, the lines shall be dried and all equipment/items

isolated or removed during flushing operations shall be connected or reinstated.

14.0 EQUIPMENT FOR TESTING AND FLUSHING OPERATIONS

14.1 The CONTRACTOR shall supply all equipment, tools and tackles and manpower

required to carry out and successfully complete the testing and flushing

operations, as a part of his scope of work for erection. These shall include but not

be limited to the following :

(a) Equipment for testing such as pumps, compressors, tanks, etc.




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(b) All temporary piping, supports, valves etc.

(c) All instrumentation such as pressure gauges, temperature measuring

instruments etc.

(d) Necessary manpower assistance

(e) Tools and tackles required

(f) Blanks, gaskets, fasteners etc.

14.2 After successful completion of testing and flushing operations, the

CONTRACTOR shall dismantle all the temporary items and restore the

permanent piping to its final condition ready for other activities.

14.3 All temporary items supplied by the CONTRACTOR for testing and flushing

operations shall be taken back by the CONTRACTOR.

15.0 DOCUMENTATION

15.1 The CONTRACTOR shall maintain necessary written records of all work carried

out by him.

15.2 The records shall include names and identification of welders, details of welds

made, details of NDT, leak testing, flushing operations etc.

15.3 The records shall also include all documentation as required by statutory authority

such as IBR.

15.4 For all materials supplied by him, the CONTRACTOR shall submit all test

certificates as per the applicable standards and of any other tests as specified in

Section-C. Also refer para 8.3.

15.5 Weekly and monthly progress reports.

16.0 EXECUTION OF CONTRACT

16.1 Upon receipt of the letter of intent, the CONTRACTOR shall take immediate

steps to establish his site organisation and to procure materials in his scope after

release for procurement has been given by the PURCHASER.

16.2 Before commencement of fabrication/erection of piping systems, the

CONTRACTOR shall ensure that the drawings available with him are the latest

issues as on date.




PIPING SYSTEMS FOR


SHEET 13 OF 13 OF 4

ISSUE

R1

TITLE


16.3 No work shall be carried out in areas indicated to be under "HOLD" in the

PURCHASER's drawings until such time the "HOLDS" are released by the

PURCHASER.

16.4 Any rework necessitated due to non-compliance of the above clauses shall be to

the CONTRACTOR'S account.

16.5 Within two (2) weeks of award of the Contract, the CONTRACTOR shall prepare

and submit a detailed bar chart indicating the sequence of various activities along

with their durations. Every effort shall be made by the CONTRACTOR to

execute his work as per this bar chart. The bar chart is subject to review and

approval of the PURCHASER. Where, in the judgement of the PURCHASER,

the CONTRACTOR's work is slipping beyond the time schedule as agreed, the

PURCHASER may direct the CONTRACTOR to deploy additional manpower to

achieve the desired progress of work. In the case of non-compliance of the

directive by the CONTRACTOR, the PURCHASER may arrange for execution

of any work or a part thereof to meet the schedule through OTHERS. All costs

thereof will be recovered from the CONTRACTOR.

16.6 The CONTRACTOR shall submit monthly progress reports on the progress of

work at site. The report shall include monthly and cumulative progress of work.

16.7 On completion of site work, all excess materials out of the items supplied by the

PURCHASER shall be returned by the CONTRACTOR to the PURCHASER in a

neat package with proper reconciliation. These materials shall be delivered to the

PURCHASER at a place identified by the PURCHASER within the plot

premises. The CONTRACTOR shall take back all excess materials brought to site

by him. He shall handover to the PURCHASER the site allotted to him for

storage/ fabrication work/temporary quarters in a clean condition after

dismantling and removing all materials and debris.

17.0 AS-BUILT DRAWINGS

The CONTRACTOR shall maintain a set of relevant drawings with site changes

duly marked and submit to the PURCHASER at the end of the project as 'As Built

Mark-Up'. This activity is a part of the scope of the CONTRACTOR'S work.


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up

TCE.6758A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE : BE57C SHEET : 1 OF 13

SERVICE :- PROPANE, BUTANE AND LPG

P-T

R

ATI

NG

TEMP. ºC -45 -29 CA (mm) :- 1.5

PR. kg/cm2 g 35.32 35.32 FLANGE FACING:- RF, 125 RA

NOM. PIPE SIZE NB 15 20 25 40 50 80 100 150 200 250 300 350

OUTSIDE DIA. mm 21.3 26.7 33.4 48.3 60.3 88.9 114.3 168.3 219.0 273.0 323.9 355.6

THICKNESS MM 3.73 3.91 4.55 5.08 3.91 5.49 6.02 7.11 6.35 6.35 6.35 7.92

NOM. PIPE SIZE NB 400

OUTSIDE DIA. mm 406.4

THICKNESS mm 7.92

LINE JOINT 40 NB & BELOW :- SW COUPLING

50 NB & ABOVE:- BUTT WELDED

ITEM

NOMINAL PIPE

SIZE RANGE NB

MATERIAL SPECIFICATION

DIMENSIONAL STANDARD

REMARKS

PIPES

15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PE, SEAMLESS, SCH 80

50 – 150 ASTM A 333 GR. 6 ASME B-36.10 BE, SEAMLESS, SCH 40


NIPPLES 15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PBE, SEAMLESS, SCH 80

BW

FI

TTIN

GS ELBOWS (90°/ 45°-

1.5D), CAPS, REDUCERS (ECC. / CONC.), TEES (EQUAL / RED.)

50 – 350 ASTM A 420 GR. WPL 6 ASME B-16.9 BW (THK. TO MATCH PIPE THK.)

SW

FI

TTIN

GS ELBOWS (90°/ 45°),

TEES (EQUAL / RED.), COUPLING (FULL / HALF/RED.)

15 – 40 ASTM A 350 GR LF2 CLASS 1 ASME B-16.11 SW

BRANCH CONNECTION 15 – 350 --- --- REFER BRANCH CONNECTION CHART

FLANGES

15 – 40 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 SW, 300, RF / 125 AARH, SCH 80

50 – 150 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 WN, 300, RF / 125 AARH, SCH 40

200 – 400 ASTM A 350 GR LF2 CLASS 1 ASMB B-16.5 WN, 300, RF / 125 AARH, SCH 20

BLIND FLANGES 15 – 400 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 300, RF / 125 AARH

STUD BOLTS 15 – 400 ASTM A 320 GR.L7 ASME B-18.2.1

REV. NO. PPD. BY: DVK JOB NO. CLIENT: BPCL, Uran ISSUE DATE CHD. BY: DSJ TCE. PROJECT: PMC SERVICES FOR R0 REV. BY DATE: 06-08-12 6758A BLENDING UNIT AT URAN

TCE FORM NO. 087 R5 FILE NAME: 6758APP1551R0.DOC


SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up


ITEM NOMINAL PIPE SIZE RANGE

NB



REMARKS

HEAVY HEX. NUTS 15 – 400 ASTM A 194 GR. 4 ASME B 18.2.2 NUTS TO BE PROVIDED ALONG WITH

WASHER

GASKETS 15 – 400 SP. WND SS304 + GRAFHITE

ASME B 16.20 – ASME B 16.5 4.5MM THK, 300 # AS PER ASME B16.5

THREADED FITTINGS :- CAPS

15 – 40 ASTM A 333 GR. 6 ASME B-16.11 SCREWED

TYPE OF VALVE

SIZE RANGE MATERIAL PR.

RATING TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

NB BODY TRIM ANSI

GLOBE VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 T63 DMN. STD :- API-602

Note 1

GLOBE VALVE 50 – 250 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH T33

DMN. STD :- BS-1873 NOTE 2 for valves greater than 100NB


FLGD, 300, B-16.5, RF /125

AARH T33 DMN. STD :- B-16.34,

Note 2

CHECK VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 C63

DMN. STD :- API-602 PISTON LIFT TYPE

CHECK VALVE 50 – 400 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH C33

DMN. STD :- BS-1868 SWING TYPE

BALL VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B 16.11 B63 DMN. STD :- ISO-

17292, Note 1

BALL VALVE 50-100 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH B33 DMN. STD :- ISO-

17292


FLGD, 300, B-16.5, RF /125


17292, NOTE 2

TYPE OF SPECIALITY

SIZE RANGE

NB

MATERIAL PR. RATING

ANSI

TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

BODY TRIM & INT

STRAINER - 15 – 40 A350 GR

LF2 CLASS 1

INT: SS304 800 SW SY63 Y-TYPE

STRAINER – 50 – 150 A 352 GR LCB INT: SS304 300 WN, RF SY33 Y – TYPE

STRAINER – 200 – 400 A 350 GR LF2 CL 1 INT: SS304 300 WN, RF SY33 Y – TYPE

NOTES:- 1. With 100 mm pipe piece on each side of the valve. 2. With Gear Operator with adequate torque. 3. All valves shall be full bore, trunion mounted, fire safe design(API 607) and with anti-static features. 4. 20% of valve casting shall undergo radiographic examination. All cast steel valves shall be subjected to radiography as per ASME

B 16.34. 5. Valves shall be tested with API 598/ BS EN 12266-1 as applicable. 6. Valves shall be provided with extended stem wherever required considering insulation. 7. Valve stems shall be of Forged Construction. Castings are not acceptable.





TCE.6758A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE :

BE57C SHEET: 3 OF 13

BRANCH CONNECTION CHART

SIZE

BRANCH inch/mm

RUN 15 20 25 40 50 80 100 150 200 250 300 350 400

15 T

20 RT T

25 RT RT T

40 RT RT RT T

50 SL RT RT RT T

80 SL SL SL SL RT T

100 SL SL SL SL RT RT T

150 SL SL SL SL WL RT RT T

200 SL SL SL SL WL WL RT RT T

250 SL SL SL SL WL WL RT RT RT T

300 SL SL SL SL WL WL WL RT RT RT T

350 SL SL SL SL WL WL WL RT RT RT RT T

400 SL SL SL SL WL WL WL RT RT RT RT RT T

LEGEND : T - STRAIGHT TEE RT - REDUCING TEE C - HALF COUPLING TL -THREADOLET SL - SOCKOLET WL - WELDOLET P - PIPE TO PIPE N - NIPOLET

R - REINFORCED


FILE NAME: 6758APP1551R0.DOC TCE FORM NO. 088 R3




SERVICE :- PROPANE, BUTANE AND LPG

P-T

R

ATI

NG

TEMP. ºC -45 -29 CA (mm) :- 1.5

PR. kg/cm2 g 20.04 20.04 FLANGE FACING:- RF, 125 RA

NOM. PIPE SIZE NB 15 20 25 40 50 80 100

OUTSIDE DIA. mm 21.3 26.7 33.4 48.3 60.3 88.9 114.3

THICKNESS MM 3.73 3.91 4.55 5.08 3.91 5.49 6.02

NOM. PIPE SIZE NB

OUTSIDE DIA. mm

THICKNESS mm



ITEM

NOMINAL PIPE

SIZE RANGE NB



REMARKS

PIPES

15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PE, SEAMLESS, SCH 80



NIPPLES 15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PBE, SEAMLESS, SCH 80

BW

FI

TTIN



50 – 350 ASTM A 420 GR. WPL 6 ASME B-16.9 BW (THK. TO MATCH PIPE THK.)

SW

FI

TTIN

GS ELBOWS (90°/ 45°),

TEES (EQUAL / RED.), COUPLING (FULL / HALF/RED.)

15 – 40 ASTM A 350 GR LF2 CLASS 1 ASME B-16.11 SW


SOCKOLET 50-350 ASTM A 350 GR LF2 CLASS 1 MSS SP 97 SW

FLANGES

15 – 40 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 SW, 300, RF / 125 AARH, SCH 80

50 – 150 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 WN, 300, RF / 125 AARH, SCH 40

200 – 400 ASTM A 350 GR LF2 CLASS 1 ASMB B-16.5 WN, 300, RF / 125 AARH, SCH 20

BLIND FLANGES 15 – 400 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 300, RF / 125 AARH

STUD BOLTS 15 – 400 ASTM A 320 GR.L7 ASME B-18.2.1







NB



REMARKS

HEAVY HEX. NUTS 15 – 400 ASTM A 194 GR. 4 ASME B 18.2.2 NUTS TO BE PROVIDED ALONG WITH

WASHER

GASKETS 15 – 400 SP. WND SS304 + GRAFHITE

ASME B 16.20 – ASME B 16.5 4.5MM THK, 300 # AS PER ASME B16.5

THREADED FITTINGS :- CAPS

15 – 40 ASTM A 333 GR. 6 ASME B-16.11 SCREWED

TYPE OF VALVE


RATING TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

NB BODY TRIM ANSI

GLOBE VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 T63 DMN. STD :- API-602

Note 1


FLGD, 300, B-16.5, RF /125

AARH T33

DMN. STD :- BS-1873 NOTE 2 for valves greater than 100NB


FLGD, 300, B-16.5, RF /125

AARH T33 DMN. STD :- B-16.34,

Note 2

CHECK VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 C63

DMN. STD :- API-602 PISTON LIFT TYPE

CHECK VALVE 50 – 400 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH C33

DMN. STD :- BS-1868 SWING TYPE

BALL VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B 16.11 B63 DMN. STD :- ISO-

17292, Note 1


FLGD, 300, B-16.5, RF /125


17292


FLGD, 300, B-16.5, RF /125


17292, NOTE 2

TYPE OF SPECIALITY

SIZE RANGE

NB

MATERIAL PR. RATING

ANSI

TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

BODY TRIM & INT

STRAINER - 15 – 40 A350 GR

LF2 CLASS 1

INT: SS304 800 SW SY63 Y-TYPE

STRAINER – 50 – 150 A 352 GR LCB INT: SS304 300 WN, RF SY33 Y – TYPE

STRAINER – 200 – 400 A 350 GR LF2 CL 1 INT: SS304 300 WN, RF SY33 Y – TYPE

NOTES:- 1. With 100 mm pipe piece on each side of the valve. 2. With Gear Operator with adequate torque. 3. All valves shall be full bore, trunion mounted, fire safe design(API 607) and with anti-static features. 4. 20% of valve casting shall undergo radiographic examination. All cast steel valves shall be subjected to radiography as per ASME

B 16.34. 5. Valves shall be tested with API 598/ BS EN 12266-1 as applicable. 6. Valves shall be provided with extended stem wherever required considering insulation.

Valve stems shall be of Forged Construction. Castings are not acceptable.





TCE.6758A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE :

BE55C SHEET: 6 OF 13


SIZE

BRANCH inch/mm

RUN 15 20 25 40 50 80 100 150 200 250 300 350 400

15 T

20 RT T

25 RT RT T

40 RT RT RT T

50 SL RT RT RT T

80 SL SL SL SL RT T

100 SL SL SL SL RT RT T

150 SL SL SL SL WL RT RT T

200 SL SL SL SL WL WL RT RT T

250 SL SL SL SL WL WL RT RT RT T

300 SL SL SL SL WL WL WL RT RT RT T

350 SL SL SL SL WL WL WL RT RT RT RT T

400 SL SL SL SL WL WL WL RT RT RT RT RT T

LEGEND : T - STRAIGHT TEE RT - REDUCING TEE C - HALF COUPLING TL -THREADOLET SL - SOCKOLET WL - WELDOLET P - PIPE TO PIPE N - NIPOLET

R - REINFORCED




SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6758A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE :GA SHEET 7 OF 13

RATING : 150 # SERVICE : : COMPRESSED AIR FOR PROCESS,INSTRUMENT AIR, POTABLE WATER, FIRE WATER SPRAY SYSTEM (AT

DOWNSTREAM OF DELUGE VALVE)

DE

SIG

N

TEMP. º F / º C 60 CORR. ALL. inch/ mm 1.5

PR. psig/ kg/ cm2 g 10 FLANGE FACING RF, CONC. SERR. FINISH (NOTE-5)

NOM. PIPE SIZE inch

15 20 25 32 40 50 65 80 100 mm

OUTSIDE DIA. inch

21.34 26.7 33.4 42.16 48.3 60.3 73.03 88.9 114.3 mm

CLASS/ THICKNESS

inch 3.2 3.2 4.0 4.0 4.0 4.5 4.5 4.8 5.4

mm

NOM. PIPE SIZE inch

mm

OUTSIDE DIA. inch

mm

THICKNESS inch

mm

LINE JOINT 40 < 40 - SW TO ANSI B16.11

50 > 50 - BW TO ANSI B16.25

MAINTENANCE JOINTS ALL FLANGED. TO BE KEPT MINIMUM


inch / mm



REMARKS

PIPES < 150 CS, IS 1239 PT-1 (GALVANISED) IS 1239 PT-1 ERW, BLACK, 40 – PE, 50 -

BE

> 150 CS, IS 3589 Gr. FE 410 (GALVANISED) IS 3589 ERW, EFW,BLACK, BE

PIPE NIPPLE 15 TO 40 CS, IS 1239 PT-1 (GALVANISED) IS 1239 PT-1 TYPE-E, POE-TOE,PBE,TBE,SCH

TO MATCH PIPE

B.W

. FI

TTIN

GS

ELBOWS, CAPS, REDUCERS,TEES > 40 TO 150 ASTM A 234 Gr. WPB

(GALVANISED) ANSI B 16.9 SCH 40, SMLS

ELBOWS, CAPS, REDUCERS,TEES > 150 ASTM A 234 Gr. WPBW

(GALVANISED) ANSI B 16.9 SCH MATCH TO PIPE THICKNESS, WELDED (SEE NOTE –1)

S.W . FITTINGS 40 ASTM A 105 (GALVANISED) ANSI B 16.11 3000CL.

SWAGES( ECC/CONC) 15 TO 100 ASTM A 234 Gr. WPB (GALVANISED) MSS SP 95 PSE & BLE,THICKNESS TO

MATCH PIPE

BRANCH CONNECTION ALL SEE BRANCH CONNECTION CHART

FLANGES 150 ASTM A 105 (GALVANISED) ANSI B 16.5 SO, 150 CL

BLIND FLANGES 150 ASTM A 105 (GALVANISED) ANSI B 16.5 150 CL

REV.NO. PPD.BY:DVK JOB NO. CLIENT: BPCL, URAN ISSUE

DATE CHD.BY:DSJ TCE.6059A PROJECT: PMC SERVICES FOR BLENDING UNIT AT URAN

R0





TCE.6059A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE GA SHEET 8 OF 13


Inch / mm



REMARKS

MACHINE / STUD BOLTS ALL ASTM A 307 GR.B

(GALVANISED) ANSI B 18.2.1 CL. 2A

HEAVY HEX. NUTS ALL

ASTM A 563, Gr.A (GALVANISED)

ANSI B 18.2.2 CL.2B REF NOTE 3

GASKETS ALL NOTE-4 ANSI B 16.21 CL.150 SELF-CENTERING RING, 2 MM THK. (NOTE-5)

UNIONS

< 40 ASTM A 105 (GALVANISED) ANSI B 16.11 SW 3000 CL

THREADED FITTINGS

40 ASTM A 105 (GALVANISED) ANSI B 16.11 3000 CL

NPT / IS 554 ( TAPER) AS REQUIRED

TYPE OF VALVE

SIZE RANGE MATERIAL PRESSURE

RATING

TYPE OF

ENDS

SPECIFICATION OR REMARKS

inch./ mm. BODY TRIM ANSI/ IS TAG NUMBER

CHECK (PISTON TYPE) GATE GLOBE

40

ASTM A 105

13% Cr. STEEL

800

SW

C63 G63 T63

GATE 50 ASTM A 216 Gr.WCB

13% Cr. STEEL 150 RF G23

BALL 15 ASTM A 216 Gr.WCB SS 304 150 RF B23

CHECK (DUAL PLATE) 50 ASTM A216

Gr. WCB SEAT-EPDM 150 WAFER C23

STRAINER (Y-TYPE) < 150 ASTM A 216

GR WCB SS 304 150 RF SY23 MESH 40

STRAINER (T-TYPE) > 200 IS 1239 PT-1 /

IS 2062 Gr.B SS 304 150 RF ST23 MESH 40

NOTES:

1. USE FLAT END COVERS INSTEAD OF CAPS FOR SIZE 200 mm.

2. NUT SHALL BE ALONG WITH WASHER. 3. GASKETS SHALL BE OF ASBESTOS FREE NBR DULY REINFORCED WITH ARMID FIBRES 4. USE FLAT FACE FLANGES & FULL FACE GASKETS WITH CAST IRON FLANGED VALVES. 5. BALL VALVES SHALL BE GEAR OPERATED FOR 150 NB & ABOVE



R0





TCE.6059A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE GA SHEET 9 OF 13


SIZE BRANCH

inch / mm

RUN 15 20 25 32 40 50 65 80 100 150 200 250 300 350

15 T

20 RT T

25 RT RT T

32 RT RT RT T

40 RT RT RT RT T

50 H H H H H T

65 H H H H H S T

80 H H H H H S S T

100 H H H H H S S S T

LEGEND : T - EQUAL TEE RT - REDUCING TEE H - HALF COUPLING TL -THREADOLET SL - SOCKOLET WL - WELDOLET S - STUB –IN N - NIPOLET

SR - STUB-IN WITH R-PAD



R0




ENQ. SPEC. NO.

TCE. 6758A-590-LS-1001

TATA CONSULTING ENGINEERS LIMITED SECTION : D


PIPING MATERIAL SPECIFICATION

GRADE CT SHEET 10 OF 13

SERVICE : FIRE WATER (FRESH WATER)

DE

SIG

N TEMP. º F / º C 50 CORR. ALL. inch/ mm 1.5

PR. psig/ kg/ cm2 g 8.8 / 10.5 FLANGE FACING RF, CONC.SERR.

(NOTE -1)

NOM. PIPE SIZE inch

< 150 200 250 300 350 400 mm

OUTSIDE DIA. inch

219 273 324 356 406 mm

THICKNESS inch HEAVY

CL 6.3 6.3 7.1 8.0 8.8

mm

NOM. PIPE SIZE inch

mm

OUTSIDE DIA. inch

mm

THICKNESS inch

mm

LINE JOINT < 40 - SW TO ANSI B16.11

> 50 - BW TO ANSI B16.25

ITEM

NOMINAL PIPE

SIZE RANGE

inch / mm

MATERIAL

SPECIFICATION

DIMENSIONAL

STANDARD REMARKS

PIPES < 150 IS 1239 PT.1 IS 1239 PT.1 ERW, BLACK, < 40 - PE, > 50 - BE

> 200 IS 3589 Gr. FE 410 IS 3589 ERW / EFW, BLACK, BE

B

.W.

FIT

TIN

GS

ELBOWS, CAPS,

REDUCERS ,TEES

50 TO 150 ASTM A234 Gr. WPB ANSI B16.9 SCH40, SMLS ( NOTE -2 )

STUB ENDS

S.W.FITTINGS < 40 ASTM A105 ANSI B16.11 3000CL

FABRICATED REDUCERS

> 200 SAME AS PIPE INCLUDED ANGLE =300,

SITE FABRICATED

MITRES > 200 SAME AS PIPE R=1.5 D 15 0 , 30 0 , 30 0, 15 0,

SITE FABRICATED

BRANCH CONNECTIONS ALL SAME AS PIPE USE STUB-IN TYPE

FLANGES ALL ASTM A105 ANSI B 16.5 SO , 150 CL

BLIND FLANGES ALL ASTM A105 ANSI B 16.5 150 CL

MACHINE / STUD BOLTS ALL ASTM A 307 GR.B ANSI B 18.2.1


PROJECT: PMC SERVICES FOR BLENDING

UNIT AT URAN

ISSUE

DATE CHD.BY: DSJ TCE.

6758A R0

REV BY. DATE: 06-08-12



ENQ. SPEC. NO.

TCE. 6758A-590-LS-1001

TATA CONSULTING ENGINEERS LIMITED SECTION : D


PIPING MATERIAL SPECIFICATION

GRADE CT SHEET 11 OF 13

ITEM

NOMINAL PIPE

SIZE RANGE

inch / mm

MATERIAL

SPECIFICATION

DIMENSIONAL

STANDARD REMARKS

HEAVY HEX. NUTS

ALL ASTM A 563, Gr.A ANSI B 18.2.2

GASKETS ALL BLACK RUBBER ANSI B16.21

CL150

3mm THICK RING , SELF CENTERING TYPE

(NOTE-1) SHORE HARDNESS 60

THREADED FITTINGS

< 40 ASTM A105 ANSI B 16.11 3000 / 2000 CL, NPT / IS 554 TAPER AS REQUIRED

TYPE OF VALVE SIZE

RANGE MATERIAL

PRESSURE RATING

TYPE OF ENDS

SPECIFICATION OR

REMARKS

inch / mm BODY TRIM ANSI/ IS TAG NUMBER

GATE

GLOBE

CHECK

< 40 ASTM A105 SS304 PN 1.6 NPT/

IS 554 TAPER

GATE (NOTE- 4)

> 50 ASTM A216

Gr. WCB SS304 150 RF

GLOBE (NOTE- 4)

CHECK

NOTES

1. USE FLAT FACE FLANGES AND FULL FACE GASKETS WITH CAST IRON FLANGED VALVES.

2. USE FLAT END COVERS INSTEAD OF CAPS FOR SIZES > 200 mm.

3. LIGHT WEIGHT FLANGES SHALL BE RING TYPE AS PER CLASS D OF TABLE 1 OR HUB TYPE AS PER CLASS D OF TABLE 2 OF AWWA C207.

4. FOR SIZES > 150 mm , BUTTERFLY VALVES SHALL BE USED IN PLACE OF GATE AND GLOBE VALVES FOR SERVICES OTHER THAN

THOSE COVERED IN NOTE-5.

5 BUTTERFLY VALVES SHALL NOT BE USED IN FIRE WATER RESERVOIR OUTLET AND PUMP SUCTION LINE.

6. HYDROTEST PRESSURE OF INSTALLED PIPING: 19 / 22 kg/cm2g.

7. BURIED PIPING SHALL BE COATED AND WRAPPED AS PER TCE.M4-134-102 AND REQUIREMENTS OF TAC.


PROJECT: PMC SERVICES FOR BLENDING UNIT AT URAN

ISSUE

DATE CHD.BY: DSJ TCE. 6758A

R0

REV BY. DATE: 06-08-12




TCE.6758A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE : SA1 SHEET : 12 OF 13

SERVICE :- MERCAPTAN

P-T

R

ATI

NG

TEMP. ºC -29 38 93 149 204 260 316 343 371 CA (mm) :- 0

PR. kg/cm2 g 19.33 19.33 16.17 14.41 13.35 11.95 9.84 8.78 7.73 FLANGE FACING:- RF, 125 RA

NOM. PIPE SIZE NB 15 20 25 40 50 80 100

OUTSIDE DIA. mm 21.3 26.7 33.4 48.3 60.3 88.9 114.3

THICKNESS MM 3.73 3.91 4.55 5.08 3.91 5.49 6.02

NOM. PIPE SIZE NB

OUTSIDE DIA. mm

THICKNESS mm



ITEM

NOMINAL PIPE

SIZE RANGE NB



REMARKS

PIPES

15 – 20 ASTM A 312 TP 304 ASME B-36.19 PE, SEAMLESS, SCH 80S

25 - 40 ASTM A 312 TP 304 ASME B-36.19 PE, SEAMLESS, SCH 40S

50 ASTM A 312 TP 304 ASME B-36.19 BE, SEAMLESS, SCH 40S

NIPPLES 15 – 40 ASTM A 312 TP 304 ASME B-36.19 PBE, SEAMLESS

BW

FI

TTIN



50 – 200 ASTM A 403 GR.WP304-S ASME B-16.9 BW (THK. TO MATCH PIPE THK.)

SW

FI

TTIN

GS

ELBOWS (90°/ 45°), TEES (EQUAL / RED.), COUPLING (FULL / HALF/RED.)

15 – 40 ASTM A 182 GR. F304 ASME B-16.11 SW, 3000

SWAGE (CONC. / ECC.) 15 – 80 ASTM A 182 GR. F304 BS-3799 PBE (THK. TO MATCH PIPE THK.)

UNIONS 15 – 40 ASTM A 182 GR. F304 BS-3799 SW


FLANGES 15 – 40 ASTM A 182 GR. F304 ASME B-16.5 WN, 300, RF / 125 AARH

BLIND FLANGES 15 – 600 ASTM A 182 GR. F304 ASME B-16.5 300, RF / 125 AARH

STUD BOLTS 15 – 600 ASTM A 193 GR.B7 ASME B-18.2





TCE.6758A-590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE : SA1 SHEET : 13 OF 13


NB



REMARKS

HEAVY HEX. NUTS 15 – 600 ASTM A 194 GR. 2H ASME B 18.2

GASKETS 15 – 600 SP. WND SS316 + GRAPHITE

ASME B 16.20 – ASME B 16.5 4.5MM THK, SPIRAL, 300

TYPE OF VALVE


RATING TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

NB BODY TRIM ANSI

GLOBE VALVE 15 – 40 ASTM A 182 GR. F304 SS 304 800 SW, 800, B-

16.11 T63 DMN. STD :- BS-5352 Note 1

CHECK VALVE 15 – 40 ASTM A 182 GR. F304 SS 304 800 SW, 800, B-

16.11 C63 DMN. STD :- BS-5352 PISTON LIFT TYPE

BALL VALVE 15 – 40 ASTM A 182 GR. F304 SS 304 300

FLGD, 300, B-16.5, RF /125

AARH B33 DMN. STD :- BS-

5351, Note 1

TYPE OF SPECIALITY

SIZE RANGE

NB

MATERIAL PR. RATING

ANSI

TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

BODY TRIM & INT

STRAINER - 15 – 40 ASTM A 182 GR. F304 INT: SS304 800 WN SY63 Y-TYPE

NOTES:- 1. With 100 mm pipe piece on each side of the valve. 2. With Gear Operator with adequate torque. 3. All ball valves shall be full bore, trunion mounted, fire safe design(API 607) and with anti-static features. 4. 20% of valve casting shall undergo radiographic examination. All cast steel valves shall be subjected to radiography as per ASME

B 16.34. 5. Valves shall be tested with API 598/ BS EN 12266-1 as applicable. 6. Valves shall be provided with extended stem wherever required considering insulation.

Valve stems shall be of Forged Construction. Castings are not acceptable.



TCE.6758A-E-590-003

TATA CONSULTING ENGINEERS LIMITED SECTION: D SUBSECT D8

INSULATION SPECIFICATION FOR COLD INSULATION

SHEET 1 OF 7

ISSUE

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1.0 SCOPE

1.1 This specification covers the technical requirements and essential particulars for

the supply, application and finishing of the complete thermal insulation for cold

equipment, piping systems, air-conditioning ducts etc. for temperatures between

ambient and (-) 80oC and also for dual temperatures (both hot and cold) service

with hot temperature above ambient and up to 230oC. Unless specified otherwise

in section C and/or data sheet A, the scope of supply of the CONTRACTOR shall

include, but not be limited to, the following items :

(a) Insulation materials of all types as specified and required

(b) Insulation adhesives, vapour barriers and finishing materials of all types as

specified and required

(c) Auxiliary materials such as binding and lacing wires, wire netting, bands,

screws, pop rivets etc., as specified and required

(d) Angles, clamps, lugs etc. for supporting insulation

(f) Any other material as may be required for making the insulation complete

2.0 CODES AND STANDARDS

2.1 The supply and application of thermal insulation and finishing covered under this

specification shall comply with all currently applicable statutes, regulations and

safety codes in the locality where it is to be applied. The materials and application

shall also conform to the latest editions of the codes and standards listed. Nothing

in this specification shall be construed to relieve the CONTRACTOR of this

responsibility.

2.2 The following are some of the codes and standards relevant to this specification :

IS 737 Wrought Aluminium and Aluminium Alloy Sheet and Strip for

General Engineering Purposes

IS 3144 Mineral Wool Thermal Insulation Materials - Method of Test

IS 14164 Industrial Application and Finishing of Thermal Insulation

Materials at Temperatures above (-) 800C and up to (+) 750

0C

BS 5608 Preformed Rigid Polyurethane (PUR) and Polyisocyanurate

(PIR) Foams for Thermal Insulation of Pipework and Equipment

BS 5970 Thermal Insulation of Pipework and Equipment (in the

Temperature Range (-) 1000C to (+) 870

0C )

3.0 MATERIALS

3.1 GENERAL


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3.1.1 All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-

hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically

inert, non-corrosive to steel and aluminium (even if soaked in water for extended

periods) and shall be guaranteed to withstand continuously and without

deterioration the minimum and maximum temperatures to which these shall be

subjected to under the specified applications.

3.1.2 The insulation materials and any component of the finished insulation job shall

not react chemically, singly or in combination, with water or moisture to form

substances that are more actively corrosive to applied surface than water or

moisture alone.

3.1.3 In order to protect the workers from the hazards of insulation materials, suitable

protective gadgets shall be provided. Required safety precautions shall be taken

during handling and application of insulation.

3.1.4 The insulation material shall be kept dry at all times during transport, storage and

installation. Decking and covering tarpaulins alone are not adequate for any

length of time and shall not be allowed except in extreme emergencies and only

for short period. Stacking of insulation materials directly on ground shall not be

done. No wet insulation shall be installed. If wet insulation is present, it shall be

removed and replaced with new dry insulation. The insulation may be protected

with plastic film but shall be vented to prevent sweating.

3.2 INSULATION MATERIALS

The insulation material shall be one or more of the following types as specified in

data sheet A.

SL.

NO.

INSULATION MATERIAL STANDARD DENSITY,

Kg/M3

TEMP. RANGE, 0C

MATERIAL

CODE

1. Rigid polyurethane / Polyisocyanurate foam BS 5608 32 (-)80 to 110 PUR/ PIR

3.3 INSULATION ADHESIVES

The insulation adhesive shall be one or more of the following types as specified

in data sheet A.

Material Description Material Code

3.3.1 Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall

be uniformly applied at 1.5 Kg/M2 on the surface to be insulated.

A similar layer shall also be applied on the inside surface of the

insulation. This material shall not be used for stainless steel

surfaces.

BIT

3.3.2 MAS 83 with 0.5 mm wet film thickness shall be uniformly

applied at 0.5 lit/M2 by trowelling. MAS 83 shall not be used

with polystyrene as insulation material. MAS 83 can be used

MAS 83


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only between (-) 46 and (+) 149oC.

3.4 VAPOUR BARRIERS

The vapour barrier shall be one or more of the following types as specified in data

sheet A.


3.4.1 MAS 130 with 1.02 mm wet film thickness primer coat at 1.0

lit/M2 and 2.25 mm wet film thickness finish coat at 2.5 lit/M

2

shall be uniformly applied over the insulation by spatula or

trowelling. MAS 130 shall not be used with polystyrene as

insulation material. MAS 130 can be used only between (-) 40

and (+) 60oC.

MAS 130

3.5 FINISHING MATERIALS

The finishing material shall be one or more of the following types as specified in

data sheet A.


3.5.1 Aluminium sheet as per IS 737, designation 31000, condition

H3.

AL1

(a) Insulation outside diameter 150 to 450 mm - sheet

thickness 20 SWG

(b) Insulation outside diameter below 150 mm - sheet

thickness 22 SWG

(c) Equipment - sheet thickness 18 SWG

3.6 AUXILIARY MATERIALS

3.6.1 Binding and Lacing Wires

Binding and lacing wire shall be annealed GS 24 SWG.

3.6.2 Wire Netting

Wire netting shall be with GS 24 SWG wire and 20 mm hexagonal opening.

3.6.3 Bands

(a) For securing insulation material : 24 SWG GS, 20 mm wide

(b) For securing aluminium and GS : 24 SWG anodised


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sheets aluminium or

SS 304, 20 mm wide

3.6.4 Screws

Screws shall be of self-tapping type and shall be of aluminium or stainless steel

for aluminium sheets and GS for GS sheets.

3.6.5 Pop Rivets

Pop rivets shall be of aluminium or stainless steel for aluminium sheets and GS

for GS sheets.

4.0 APPLICATION

4.1 GENERAL

4.1.1 The application of insulation shall be made in a professional manner. The

insulation shall be applied to all surfaces when these are at ambient temperature.

Ample provision shall be made for the maximum possible thermal movement and

the insulation shall be applied in a manner which shall avoid breaking or

telescoping due to alternate periods of contraction and expansion. A single layer

of insulation shall not be more than 75 mm thick.

4.1.2 Insulation shall be applied after all leak tests on equipment and piping are over

and the section of the plant has been specifically released by the PURCHASER

for such work. If insulation has to be applied before the leak test, all welded and

flanged joints shall be left exposed and insulated after satisfactory completion of

the leak test.

4.1.3 All surfaces to be insulated shall be clean and dry before the insulation is applied.

The surfaces shall be cleaned of all foreign material such as scale, dirt, rust and

paint, by the use of steel wire brushes and steel scrapers, where necessary. Where

a surface is not free of paint the CONTRACTOR shall notify the PURCHASER

of the condition for remedial action. The insulation shall be applied after remedial

action, suggested by the PURCHASER, has been taken by the CONTRACTOR.

One coat of primer paint shall be applied and allowed to dry before application of

insulation.

4.1.4 After cleaning and application of one coat of primer paint on the surface to be

insulated, the insulation adhesive shall be applied for fluid operating temperatures

between 200C and (-) 20

0C. Insulation material of required thickness shall be

stuck to the surface with joints staggered. The adjoining sections shall be tightly

pressed together. All the joints shall be sealed with adhesive material. Voids, if

any, shall be packed with suitably cut pieces of insulation material. Vapour

barrier and insulation finish shall be applied as per paras 3.4 and 3.5 or 4.5

respectively.


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4.1.5 Where multilayer insulation is provided, insulation adhesive shall be used

between two layers, based on temperature criterion given in para 4.1.4.

4.1.6 If aluminium or GS sheet is specified as finishing material, all joints shall be

sealed with bitumastic paint and made effectively weather and water-proof. For

temperatures between (-) 40 and (+) 120oC, MAS 94 may also be used as sealant.

MAS 94 shall, however, not be used with polystyrene as insulation material. All

flat surfaces shall be adequately sloped to prevent pools of water collecting. The

sheet shall be protected internally with 2 coats of bitumastic paint.

4.1.7 All actions shall be taken to complete the application of finishing on exposed

surfaces covered with insulation before closing the day's work. If this is not

practicable, adequate precautions shall be taken to protect the insulation from

weather, for example by wrapping it with polythene sheet, roofing felt or other

approved material.

4.2 PIPES, PIPE FITTINGS, VALVES AND SPECIALITIES

4.2.1 All vertical pipes shall be provided with suitable insulation supports to prevent

the insulation from collapsing due to its own weight. Any welding required,

shall be carried out by the CONTRCATOR with the prior permission of the

PURCHASER and only under his direct supervision. Where welding is not

permitted, suitable clamped supports shall be used. The insulation shall be

applied starting from bottom up. Mattress type insulation materials shall be

clamped from top.

4.2.2 All pipe fittings, valves and specialities shall be covered with the same type and

thickness of insulation as specified for the adjoining pipe. On pipe fittings,

insulation outside diameter shall be same as the outside diameter of adjacent pipe

insulation. Unless specified otherwise in section C, valves and specialities of 100

mm NB and larger sizes shall be provided with removable box type insulation.

Box shall be fabricated from sheet material specified for adjoining pipes. Pipe

insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm

before flange to permit removal of the bolts and nuts. The insulation shall be

applied after the finish has been applied over insulation on the adjacent piping.

Flanged joints shall also be insulated with removable type of boxes. Arrangement

shall be similar to that for valves.

4.2.3 The sheets shall be installed with the longitudinal lap joints at 450 below the

horizontal for horizontal pipes and the joints sealed with bitumastic paint.

4.2.4 On vertical pipes the sheets shall be applied working from bottom up. Each

section of sheets shall have a minimum overlap of 50 mm longitudinally and

circumferentially. Each circumferential joint shall be made weather-proof by

securing with a band of sheet material and sealing with bitumastic paint.

Longitudinal lap joints shall be fixed with screws or pop rivets at approximately

150 mm centres.


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4.2.5 Valves shall be insulated up to and including their bonnet flange.

4.3.1 Weather hoods shall be provided for insulated piping passing through roof and

external walls.

4.3.2 EQUIPMENT

4.3.3 Where the insulation material is in the mattress form, cleats in the form of wire

nails or nuts or angles and flats for supporting the insulation material, shall be

welded to the equipment by others. If wire nails are to be used as insulation

cleats, these shall be bent and secured with the metal fabric of the mattress, after

the insulation has been applied. Where insulation cleats are in the form of M6

and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable

length for fixing the insulation. The insulation applied to equipment shall be

reinforced with wire netting. One course of wire netting shall be applied to the

surface of the equipment and each layer of insulation shall be backed up with

wire netting. All irregularities of the surface shall be filled and levelled over with

insulating cement. All mattress joints shall be butted tightly and the mattresses

shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centres. After

banding, all mattress edges shall be laced tightly.

4.3.4 All equipment, unless specified otherwise, shall have a smooth aluminium or GS

sheet finish as specified in data sheet A, applied in a manner similar to that

specified for piping. For fixing of aluminium or GS sheets, wooden spacer rings

at 1000 mm centres shall be fixed to the equipment by the CONTRACTOR. All

vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The

lapped joints of adjoining sections of sheets shall be secured with screws or pop

rivets. On all equipment above 2500 mm diameter and flat surfaces, the sheet

shall be further secured by circumferential bands at approximately 1000 mm

centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections

shall overlap the side walls to prevent water seepage between insulation and the

equipment wall. Side wall sheets shall be securely banded at intersections of the

side wall and roof sections.

4.3.3 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends

etc. shall have removable box type insulation, with same thickness of insulation

as for adjacent surfaces. Insulation adjoining such equipment openings shall be

tapered towards these openings to permit removal of bolts, screws, heads, covers

or plates with no damage to adjacent surface insulation or cover.

4.3.4 Nozzles and other connections on tanks and other equipment shall be insulated in

the same manner as the pipes.

4.3.5 Pump casing shall be completely insulated with removable type of boxes

fabricated from the specified sheet material. Proper care shall be taken to

maintain continuity of vapour barrier between static and removable portion of

insulation.


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4.3.6 Name plates on equipment shall not be insulated. Proper care shall be taken to

eliminate seepage of moisture from such un-insulated portions into the insulating

material.

4.4 CONTRACTION JOINTS IN INSULATION

Depending on the type of insulation material used and the operating temperature,

contraction joints shall be provided for equipment or pipes to prevent rupturing or

buckling when the cold surface contracts.

5.0 MEASUREMENT

5.1 Measurement of insulation over equipment and piping shall be as per IS 14164.

6.0 MISCELLANEOUS

Approval of the PURCHASER shall be obtained of samples of all materials and

necessary test certificates of approved national laboratories, before despatching

these to site. Insulation shall not be applied until specific release is given by the

PURCHASER.


SPEC. NO.

TATA CONSULTING ENGINEERS LIMITED SECTION: D TCE.6758A-B-300-003

WELDING SPECIFICATION FOR EQUIPMENT AND PIPING SYSTEM

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TCE FORM NO.329 R3 FILE NAME: 6165APP1568R0.DOC

1.0 SCOPE 1.1 This specification shall apply to site fabrication of all welded joints in

carbon steel, low alloy steel and stainless steel for LPG Marketing Terminal Project. Site fabrication also covers any fabrication in a shop set-up at site.

1.2 The welded joints include the following:

(a) All butt welding joints of the longitudinal and circumferential type for attachments in piping, castings and forgings of all components

(b) Socket welding and fillet joints

(c) All types of branch welds

(d) Any other joints not specifically covered above

1.3 For welding of materials not covered by this specification, reference shall

be made to specific project requirements covered in other section of enquiry specification.

2.0 CODES AND STANDARDS 2.1 The welding of all piping systems including equipment, welding

consumables, preheating, postweld heat treatment, other auxiliary functions and welding personnel shall comply with all currently applicable statutes, regulations and safety codes in the locality where the systems are to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. Specifically, the latest editions of the codes and standards listed in following paragraphs shall apply :

(a) ASME B31.3 - Pressure Piping Code for Process Piping (b) Indian Boiler Regulations (IBR) (c) ASME Boiler and Pressure Vessel Code (BPV Code), Section II

Part C - Material Specifications for Welding Rods, Electrodes and Filler Materials

(d) ASME Boiler and Pressure Vessel Code (BPV Code), Section V -

Non-Destructive Examination (e) ASME Boiler and Pressure Vessel Code (BPV Code), Section IX -

Welding and Brazing Qualifications (f) Standards of the Pipe Fabrication Institute


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(g) BS 2633-Specification for Class I Arc Welding of Ferritic Steel Pipe

work for Carrying Fluids (h) Any other codes and standards specified in Section C of enquiry

specification. 2.2 The codes and standards listed in para 2.1 form an integral part of this

specification. In the event of conflict between this specification and the codes and standards, the more stringent shall govern.

2.3 If no specific requirements are given in this specification, the requirements

of the applicable code shall govern. 3.0 WELDING PROCESSES 3.1 The following welding processes shall be used for shop-fabricated and

field- fabricated piping systems:

(a) Gas Tungsten Arc Welding (GTAW)

(b) Shielded Metal Arc Welding (SMAW) Welding by oxyacetylene process shall not be used. 3.2 GTAW process shall be used for the following:

(a) On butt welds in carbon steels, in sizes 40 mm and smaller in all passes for 300 class and higher systems (in case butt welds are required) and for steam tracers. Also refer Table 1.

(b) On butt welds in alloy steels for the root pass in all sizes (c) On butt welds in stainless steels for the root pass in all sizes 3.3 SMAW process shall be used for the following:

(a) On butt welds in carbon steel, in sizes 50 mm and larger, for the filler passes

(b) On butt welds in low alloy steel for the filler passes in all sizes (c) On butt welds in stainless steel for the filler passes in all sizes 3.4 For carbon steel piping, in sizes 40 mm and smaller, where butt welding is

required, the entire butt welding including root pass may be carried out by SMAW process in 150 class piping systems except for steam tracers.


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3.5 For IBR systems, all processes used shall be as approved by the IBR inspector.

3.6 Other welding processes such as submerged arc welding are also

acceptable provided the process is properly qualified and approval obtained from the PURCHASER.

3.7 All butt welds shall be considered as full penetration welds. 3.8 Table 1 gives recommendations for welding procedures to be used for

carbon, low alloy and austenitic stainless steels. Welding from inside of the pipe after back gouging and chipping is not envisaged. However, if the CONTRACTOR proposes to use such a method, a detailed written procedure shall be submitted for the PURCHASER’s approval.

4.0 WELDING CONSUMABLES 4.1 The CONTRACTOR shall provide, at no additional cost, all the welding

consumables such as electrodes, filler wires, oxygen, acetylene, argon etc., in order to complete the welding in all respects. The consumables shall be from reputed and approved manufacturers. All the consumables shall be approved by the PURCHASER.

4.2 The electrodes and filler wires shall be of the class specified in the

welding electrode chart. 4.3 Electrode qualification test records shall be submitted for PURCHASER’s

approval. The CONTRACTOR shall also submit batch test certificates from the electrode manufacturer for physical and chemical tests.

4.4 Electrodes shall be in sealed containers and adequate care shall be taken

for storage, strictly in accordance with the manufacturer’s recommendations.

4.5 Electrodes, which have been removed from the original containers, shall

be kept in ovens as per the manufacturer’s recommendations and, once these are taken out, shall be consumed within the time limits stipulated by the manufacturer. Care shall be taken in handling the electrodes to prevent any damage to the flux covering. Portable ovens shall be used for carrying the electrodes from the main oven to the field.

4.6 The electrodes, filler wires and flux used shall be free from

contaminations such as rust, oil, grease and such foreign matter. 4.7 Low hydrogen electrodes shall be used for weld joints in carbon steel if

the wall thickness exceeds 19 mm, except that non-low hydrogen electrodes shall be permitted for the root pass.


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4.8 E 6010 electrodes may be used for root pass of butt welds and for fillet

welds in carbon steel. 4.9 Refer Table 1 for welding specifications and electrodes. 5.0 WELDING QUALIFICATIONS 5.1 Qualification of the welding procedures to be used and the performance of

welders and welding operators shall conform to the requirements of the BPV Code, Section IX. For IBR systems, these shall also meet the requirements of IBR.

5.2 No production welds shall be undertaken until the qualification

requirements are completed to the satisfaction of the PURCHASER. 5.3 When impact testing is required by the code or by the specification, these

requirements shall be met in qualifying welding procedures. 5.4 The CONTRACTOR shall be responsible for qualifying any welding

procedure and welders intended to be used. The CONTRACTOR shall submit the Welding Procedure Specification (WPS) for acceptance by the PURCHASER. After approval by the PURCHASER, the procedure qualification test shall be carried out by the CONTRACTOR, at his own expense, duly witnessed by the PURCHASER. A complete set of test results shall be submitted to the PURCHASER for approval immediately after successful completion of procedure qualification test. All tests as required by the BPV code Section IX or IBR shall be carried out. The WPS shall require re-qualification if any of the essential variables or supplementary variables is altered.

5.5 Welders shall be qualified in accordance with BPV Code, Section IX or

IBR, as applicable. The qualification shall be carried out in the presence of the PURCHASER. Only those welders who are qualified and approved by the PURCHASER shall be used on the job. For IBR systems, approval of the local IBR inspector shall be obtained by the CONTRACTOR.

5.6 Welders shall always keep their identification cards with them and shall

produce them on demand. The CONTRACTOR shall issue the identity cards after the same are duly certified by the PURCHASER. Welder, who is not in possession of the identity card, shall not be allowed to work.

5.7 The CONTRACTOR shall use forms as per BPV code, section IX, form

QW-482, form QW-483 and form QW-484. Other forms are also acceptable subject to approval by the PURCHASER.


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5.8 Unless agreed otherwise, the CONTRACTOR shall advise the PURCHASER, in writing, at least three (3) weeks before any welder is employed on the work, the names and qualifications of the proposed welders and welding supervisors. It shall be the CONTRACTOR’s responsibility to ensure that all welders employed by him or his SUB-CONTRACTORS, on any part of the CONTRACT either in the CONTRACTOR’s/his SUB-CONTRACTOR’s works or at site are fully qualified as required by the code. Each welder shall qualify for all types of welds, positions and materials or material combinations he may be called upon to weld.

5.9 Should the PURCHASER require to test or retest any welder, the

CONTRACTOR shall make available, at no extra cost to the PURCHASER, the men, equipment and materials for the tests. The cost of testing the welds shall be borne by the CONTRACTOR.

5.10 Welding supervisors shall have qualifications such as engineering degree

or engineering diploma in welding technology with adequate knowledge of non-destructive testing and a minimum of five (5) years of experience in supervising welding of pipe joints.

5.11 All welding, including the tacking up of all welds shall be carried out by

approved welders. Any weld made by other than an approved welder shall be cut out and re-welded.

5.12 For purposes of identification and to enable tracing full history of each

joint, each welder employed on the work shall be given a designation. The welder’s designation and the date on which the joint was made, shall be stamped on the relevant piping and marked on the relevant drawings also. Copies of the drawings so marked shall be furnished to the PURCHASER for record purposes. For austenitic stainless steels, welder’s designation shall be applied with water-proof paint that is not detrimental to the pipe. Alternatively, record charts may be used.

5.13 For each welder, a record card shall be maintained showing the

procedures for which he is qualified. These cards shall note the production welds, the date of the welding done, the type of defects produced and their frequency. The record shall be reviewed once in a week by the PURCHASER and those welders whose work required a disproportionate amount of repair shall be disqualified from welding. Requalification of welders disqualified more than three (3) times shall be entirely at the discretion of the PURCHASER.

6.0 PREPARATION FOR WELDING 6.1 Surfaces to be welded shall be smooth, uniform and free from fins, tears

and other defects, which would adversely affect the quality of the weld.


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All welding faces and adjoining surfaces, for a distance of at least 150 mm from the edge of the welding groove or 12 mm from the toe of the fillet in the case of socket welded or fillet welded joints shall be thoroughly cleaned of rust, scale, paint, oil or grease, both inside and outside.

6.2 Joints for welding, whether socket welding or butt welding shall be as per

the project piping material specifications. 6.3 Butt joints shall be prepared as per ANSI B16.25 unless specified

otherwise. For piping under the purview of IBR, these shall be as per IBR. Any other end preparation which meets the WPS is acceptable.

6.4 Internal misalignment shall be reduced by trimming but such trimming

shall not reduce the finished wall thickness below the required minimum wall thickness. Root opening of the joint shall be within the tolerance limits of the WPS.

6.5 Fillet welds, socket welds and welded - on branch connections shall be as

per ASME B31.3 or in accordance with IBR for IBR systems. 6.6 Reinforcing pads and saddles shall have a good fit with the parts to which

they are attached. A vent hole shall be provided on the side of any pad or saddle to reveal leakage in the weld and to allow venting during welding and heat treatment. Pad or saddle shall be added after the branch weld has undergone examination and necessary repairs.

6.7 The ends shall be prepared by machining, grinding or flame cutting.

Where flame cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration. Flame cutting of alloy steel pipes is not allowed. However, flame cutting of carbon steel pipes is permitted. Wherever practicable, flame cutting shall be carried out by machine. Machine flame-cut edges shall be substantially as smooth and regular as those produced by edge planing and shall be cleaned free of slag. Manual flame cutting shall be permitted only where machine flame cutting is not practicable and with the approval of the PURCHASER, and such surfaces shall be ground or dressed to a smooth finish as required by the specification and to the satisfaction of the PURCHASER. Slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area.

6.8 Thermal cutting of carbon steel piping shall be performed under the same

conditions of preheating and postweld heat treatment as for the welding of each class of material. However, post-weld heat treatment is not required when :

(a) The heat affected zone produced by thermal cutting is removed by

mechanical means immediately after cutting. However, in any case,


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all remaining slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area, or

(b) Thermal cutting is part of fabrication, manufacturing or erection

sequence leading to a weld end preparation where welding immediately follows.

6.9 On austenitic stainless steels, plasma cutting, machining or grinding

methods may be used for edge preparation. Cut surfaces shall be machined or ground smooth after plasma cutting.

6.10 Before fitting up the weld joint, the profile and dimensions of the weld end

preparation shall be checked by the PURCHASER. If the specified tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining or any other method acceptable to the PURCHASER.

6.11 Fit-ups shall be examined by the PURCHASER prior to welding the root

pass. 7.0 TECHNIQUE AND WORKMANSHIP 7.1 Components to be welded shall be aligned and spaced as per the

requirements of the code and WPS. Special care is required when GTAW process is employed.

7.2 Alignment and spacing shall be achieved using suitable wires to maintain

the gap. These shall be removed after tack welding. The ends to be welded shall be held using suitable clamps, yokes or other devices which will not damage the surfaces in any manner. It shall be ensured that welding operations do not result in distortions.

7.3 Tack welds at the root joint, for maintaining joint alignment, shall be made

only by qualified welders or welding operators and with filler metal equivalent to that used in the root pass. Tack welds shall be fused with the root pass weld, except that those which have cracked shall be removed. Peening is prohibited on the root and final passes of a weld. The required preheat shall be maintained prior to tack welding.

7.4 No welding shall be carried out if there is any impingement in the weld

area of rain, snow, excessive wind or if the weld area is wet. 7.5 Irrespective of the class of steel, root runs shall be made without

interruption other than for changing the electrodes or to allow the welder to reposition himself. Root runs made in the shop may afterwards be allowed to cool by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos blanket. Welds made at site shall not be


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allowed to cool until the thickness of weld metal deposited exceeds one third of the final weld thickness or 10 mm, whichever is greater.

7.6 When welding alloy steels, it is strongly recommended that interruption of

welding be avoided. Where such interruption is unavoidable, either the pre-heat shall be maintained during the interruption or the joint shall be wrapped in dry asbestos blankets to ensure slow cooling. Before recommencing welding, preheat shall be applied again.

7.7 Welded-on bridge pieces and temporary attachments shall preferably be

avoided. Where approved by the PURCHASER, these may be used. Material of these shall be compatible with material with which they are temporarily welded. All such pieces shall be removed after welding of pipe joints and the weld area ground flush. These areas shall be subject to liquid penetrant or magnetic particle examination for high yield strength materials (YS > 3200 kg/cm2) or when the component thickness exceeds 20 mm or for P3 and P4 group materials. These pieces shall be welded by qualified welders and with electrodes compatible with the parent pipe material. The preheating requirements of pipe material shall be applied and maintained during the welding of attachments. These temporary attachments shall be removed by grinding, chipping, sawing or by arc or flame gouging. When arc or flame gouging is used, at least three (3) mm of metal shall be left around the pipe surface which shall be removed by grinding.

7.8 The arc shall be struck only on those parts of parent metal where weld

metal is to be deposited. When inadvertent arc-strikes are made on the base metal surfaces outside the joint groove, the arc-strikes shall be removed by grinding and shall be examined by liquid penetration or magnetic particle examination procedures.

7.9 Oxides shall not be permitted to form during welding or heat treatment or

both, on the internal surfaces of pipes which will not be subsequently cleaned. Inert gas purging is an acceptable method to prevent such oxidation. All joints in materials which contain more than 1¼% chromium shall be purged to assure that less than 1% of oxygen is present on the joint underside before initiation of the welding. The purging operation shall be maintained for a minimum of two (2) passes.

7.10 Argon gas used in GTAW process for shielding and purging shall be at

least 99.95% pure. Purging shall be carried out at a flow rate depending on diameter of pipe until at least five (5) times the volume between dams is displaced. In no case shall the initial purging period be less than 10 minutes. After initial purging, the flow of the backing gas shall be reduced to a point where only a slight positive pressure prevails. Any dams used in purging shall be fully identified and removed after welding and accounted


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for in order to avoid leaving them in the system. The rate of flow for shielding purposes shall be established in the procedure qualification.

7.11 Thorough check shall be exercised to maintain the required inter-pass

temperature. 7.12 All equipment necessary to carry out the welding, for supporting of the

work, for preheating and post weld heating including thermal insulation for retaining the heat and for the protection of the welder shall be provided by the CONTRACTOR at no extra cost. All necessary precautions shall be taken during cutting and welding operations. It shall be ensured that proper ventilation is available in the welding area and adequate protective gear such as goggles, masks, gloves, protection for the ears and body are used at all times. For guidelines refer ANSI standard Z49.1, “Safety in Welding and Cutting”.

7.13 After deposition, each layer of weld metal shall be cleaned with a wire brush to remove all slag, scale and defects, to prepare for the proper deposition of the next layer. The material of wire brush shall be compatible with pipe material. Stainless steel materials shall be cleaned with grinding wheels or stainless steel brushes which have not been used on other materials. Either aluminium oxide or silicon carbide grinding wheels shall be used. Special care shall be taken to secure complete and thorough penetration of the fusion zone into the bottom of the weld. It is recommended that the root run be checked by liquid penetrant or magnetic particle procedures for critical process piping.

7.14 Upon completion of welding, the joints shall be wrapped in dry asbestos

blankets to ensure slow cooling, unless post-weld heat treatment is applied immediately.

7.15 No welding or welded parts shall be painted, plated, galvanised or heat

treated until inspected and approved by the PURCHASER. Welds shall be prepared and ground in such a way that the weld surfaces merge smoothly into the base metal surface.

7.16 Except where necessary to grind flush for non-destructive examination,

reinforcement for butt welds may be provided. The height of such reinforcement shall meet the requirements of the code. The reinforcement shall be crowned at the centre and tapered on each side of the joined members. The exposed surface of the weld shall be ground where required to present a workmanlike appearance and shall be free from depressions below the surface of the joined members. The exposed surface of the butt welds shall be free from undercuts greater than 0.5 mm in depth, overlaps or abrupt ridges or valleys and shall merge smoothly into the pipe surface at the weld toe. However, undercuts shall not encroach on the minimum section thickness.


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7.17 Repair of weld metal defects shall meet the requirements of the code. 7.18 Any weld repair shall be subject to the approval of the PURCHASER. 7.19 In the event of several unsuccessful repair attempts or if the

PURCHASER feels that a satisfactory repair is not feasible, the joint shall be completely remade.

7.20 IDENTIFICATION OF WELDS Wherever code symbol stamps are required on carbon steel and ferritic

alloy steel piping they shall be applied directly to the pipe with low stress dotted design metal die stamps or to a small stainless steel plate especially provided for such marks. These plates shall be lightly tack welded to the pipe using electrodes, of diameter three (3) mm or less, of the type specified for the material. Before making the required tack weld, the pipe material in the immediate surrounding area shall be preheated, as required, by electric means or propane or natural gas burners. Cooling shall take place under asbestos insulation in a draft-free area. Stress relieving of these welds is not required. Steel stamping directly on the surface of alloy steel piping with other than low stress die stamps shall not be used.

7.21 SEAL WELDS 7.21.1 Seal welding shall be carried out by qualified welders and in accordance

with approved drawings. 7.21.2 Threaded joints that are to be seal welded shall be made without the use

of thread lubricating compound. Seal weld shall cover all exposed threads.

7.22 WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN

WELDS 7.22.1 Welded joints, more specifically longitudinal welds, shall be placed not

closer than 50 mm to opening or branch welds, reinforcements, attachment devices or from supports, etc. In case of deviation, the PURCHASER may specify additional non-destructive examination.

7.22.2 The longitudinal welds of two adjacent pipes or components shall be

staggered by at least 30o. The minimum distance between welds shall be 50 mm or three (3) times the wall thickness, whichever is greater. Longitudinal welds shall not be situated at the bottom of the pipe. Intersection of welds shall be avoided as far as possible. If such welds are present, they shall be subject to suitable Non-Destructive Testing (NDT) at the discretion of the PURCHASER.


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8.0 PREHEATING 8.1 Preheating prior to tack welding, welding and thermal cutting shall be used

as a means of crack prevention and improving weld reliability. The general requirements of post-weld heat treatment also apply to preheating.

8.2 Preheating shall be used as per the recommendations of ASME B31.3,

Table 330.1.1. For IBR systems, the requirements of IBR shall govern. Preheating of austenitic stainless steels is not required, except at low ambient temperatures, in which case a minimum preheat temperature of 10oC is recommended. Table 2 gives the requirements of preheating for commonly used materials.

8.3 The preheating zone shall extend 75 mm or a distance equal to four (4)

times the material thickness, whichever is greater, beyond the edge of the weld.

8.4 The preheat temperature shall be measured at least 75 mm away from

the weld preparation. 8.5 Where preheating is specified, welding shall continue without interruption.

In case interruption cannot be avoided, preheating shall be continued for at least thirty (30) minutes after interruption. Also refer para 8.9.

8.6 Oxy-acetylene preheating shall not be applied. 8.7 For preheating, fuel gas/air torches, burner systems (high velocity gas or

oil burners) or electrical heating may be used either locally or in a furnace. For preheating above 250oC, electric heating (resistance or inductive heating) is preferred.

8.8 Approved temperature - indicating crayons, thermocouples or digital

contact pyrometers shall be used to measure preheat and interpass temperatures. A calibration report of the pyrometers and thermocouples shall be available.

8.9 When the preheat temperature is 150oC or higher, the metal shall be

maintained at or above the preheat temperature until the weld is completed.

8.10 The welding of groove welds in low alloy steels of P-3 to P-5 groups with

wall thickness of 19 mm or greater may only be interrupted, provided at least 10 mm of weld metal is deposited, or 25% of the welding groove is filled, whichever is greater. If the welding is interrupted prior to the above, the weld area shall be adequately covered with insulating material to ensure slow cooling. After cooling and before welding is resumed, visual


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examination of the weld shall be performed to assure that no cracks are formed. Required preheat shall be applied before welding is resumed.

9.0 POSTWELD HEAT TREATMENT Post-weld heat treatment shall meet the requirements of para 331 of

ASME B31.3. For IBR systems, post-weld heat treatment shall be as per IBR. Table 3 summarises the post-weld heat treatment requirements for commonly used materials.

9.1 GENERAL REQUIREMENTS 9.1.1 A complete automatic temperature recording shall be made of preheating

and stress relieving operations. Where propane gas burners or electrical resistance coils are employed, a complete temperature record of the preheating and stress relieving operation shall be made by means of a box type potentiometer. Other means of recording temperatures are permissible subject to the PURCHASER’S approval.

9.1.2 Stress relief may be local or full furnace. Local stress relief shall be

performed with electric induction or electric resistance coils. Suitable gas burning equipment using natural gas or propane may be employed.

9.1.3 At no time during a stress relieving/preheating cycle shall any water or liquid cooling medium be employed.

9.1.4 Where members being joined are unequal in thickness, the dimension of

the heavier section shall govern the selection of width of the heated band and the duration of the holding period.

9.1.5 For local stress relief, using electrical methods, a minimum of two (2)

thermocouples tack-welded to the surface and potentiometers shall be used on the pipe under at least four (4) layers of asbestos paper. The hot junctions of the thermocouples shall be located on either side of the joint at least 12 mm from the edge of the joint but no further away than 100 mm. When employing induction heating, at least six (6) turns of induction cable shall be used on each side of the weld. Induction coils shall be wrapped on top of the asbestos paper protecting the thermocouples with the first turn approximately 150 mm from the centre of the weld.

9.1.6 Local stress relief using gas torches or ring burners may be employed.

However, the procedure shall be limited to pipes below 100 mm NPS and shall be approved by the PURCHASER.

9.1.7 The stress relieving temperature shall be maintained for a period of time

proportioned on the basis of one (1) hour per 25 mm of wall thickness of the thickest section at the joint, but in no case less than one (1) hour.


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9.1.8 For tubing joints and socket welded joints, pads, bosses, branch welds and couplings, one (1) thermocouple shall be positioned at a minimum distance of two (2) pipe wall thicknesses from the weld.

9.1.9 Piping on both sides of any joint shall be adequately supported throughout

the preheating, welding and stress relieving operations to prevent distortion. When a butt welded joint is to be post-weld heat treated and the piping is cold-sprung, the forces required to position the pipes shall be maintained by external means until the completion of the heat treatment procedure.

9.1.10 All heating and cooling must be performed in still air. 9.1.11 The governing thickness for the post-weld heat treatment shall be the

thicker of the two components joined by welding. For deviations from this requirement for branch welds, fillet welds etc., reference shall be made to the applicable paragraph of ASME B 31.3.

9.1.12 The CONTRACTOR shall submit a detailed written procedure for the post-

weld heat treatment for the approval of the PURCHASER. 9.2 CARBON STEEL 9.2.1 Welded joints in carbon steel piping systems shall be stress relieved,

upon completion of the welding operation, in accordance with Table 3. 9.2.2 When local stress relief is employed, the welded joint shall be heated to a

temperature of not less than 625°C the temperature level shall be maintained between 625°C and 675°C, one (1) hour per 25 mm of wall thickness but in no case less than one (1) hour. The weld area shall then be allowed to cool undisturbed in still air to a temperature not exceeding 315°C. All welded joints in pipe sizes 100 mm and larger, shall be heated by means of electric induction coils or resistance heating. Welded joints in pipes smaller than 100 mm shall be stress relieved by means of electrical resistance coils or suitable propane or natural gas torches only.

9.2.3 Heating and Cooling Carbon steels, after having reached their specific stress relief

temperatures, may be cooled in the furnace or under wraps, i.e., leaving the induction coils or resistance heaters and insulation in place. This means that, at the stress relief temperatures, the power to the furnace or heating coils may be shut off and cooling takes place in the furnace or with all insulation and coils remaining on the pipe. For furnace stress relief, the doors of the furnace may be opened after the power is shut off, at or below 315°C. Thermocouples controlling the temperatures shall remain during the cooling cycle so that excessive cooling, if it occurs, can


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be observed and immediately corrected. The stress relieving coils and insulation shall only be removed after the piping has cooled to below 315°C or if stress relieved in a furnace the pipe may be removed from the furnace and permitted to cool in still air at a temperature not below 10°C.

9.3 ALLOY STEEL 9.3.1 All welds in alloy steel piping shall be stress relieved after the welding

operation in accordance with Table 3. Immediately after welding, the material shall be wrapped in asbestos and allowed to cool.

9.3.2 Local Stress Relief All welded joints in pipes 100 mm size and larger shall be locally stress

relieved by means of electric induction coils or resistance heating. Welded joints in smaller pipe sizes shall be stress relieved by means of electric resistance coils or suitable propane or natural gas torches only.

9.3.3 For full furnace stress relief of a welded assembly, the entire fabricated

section shall be heated uniformly to the temperature specified. The temperature shall be maintained for a period of time proportioned on the basis of one (1) hour per 25 mm of wall thickness of the piece having the greatest wall thickness in the furnace charge, but, in no case, less than one (1) hour.

9.4 AUSTENITIC STAINLESS STEEL Welded joints in austenitic stainless steel piping need not be stress

relieved after welding. 9.5 The rate of heating and cooling during stress relieving operations shall not

exceed 315°C per hour up to a thickness of 50 mm at the weld. 10.0 ELECTRODES 10.1 The specification and size of the electrodes, voltages and amperages,

thickness of beads and number of passes shall be as specified in the approved welding procedure or otherwise agreed in writing. Only basic coated electrodes shall be used, which will deposit weld metal having the same or higher physical properties and similar chemical composition to the members being joined. For each batch of approved brand, certificate showing compliance with the specification shall be submitted to the PURCHASER for review before being released for use. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. All low hydrogen electrodes, after baking as per the manufacturer’s recommendations, shall be stored in ovens kept at 80 to 100°C before being used. Recommendations of the electrode


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manufacturer shall be strictly followed. Until the electrodes are taken out for welding, they shall be stored in portable ovens. The electrodes shall not be exposed to open atmosphere.

10.2 For welding of all grades of steel and alloys by the GTAW process, a 2%

thoriated tungsten electrode conforming to SFA-5.12-86 EWTh-2 (AWS-A5.12-80, EWTh-2) classification shall be used.

10.3 All electrodes to be used on alloy and carbon steel shall conform to BPV

Code Section II Part C or any other equivalent code. 10.4 As welding electrodes deteriorate under adverse conditions of storage

leading to dampness in the electrode coating, they shall normally be stored in dehumidified air-conditioned rooms or in hot boxes or ovens in their original sealed containers whose temperatures shall be maintained within specified limits. The condition of electrodes shall be frequently inspected. Electrodes with damage to coating shall not be used. Electrodes shall remain identified until consumed. It is preferable to procure low hydrogen electrodes in hermetically sealed containers and preserve them without damage to the containers.

10.5 The type of electrodes used shall be only those recommended by the

manufacturer for the use in the position in which the welds are to be made. Electrodes which have the areas of flux covering broken away or damaged shall not be used.

10.6 Table 1 gives recommendations on electrodes to be used for carbon, low

alloy and austenitic stainless steels. 11.0 INSPECTION AND TESTING 11.1 The PURCHASER shall have free access to inspect welding or any other

related operations at any time and at any stage of fabrication. 11.2 The PURCHASER may require non-destructive testing of any weld for

reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the PURCHASER and the CONTRACTOR.

11.3 The CONTRACTOR shall inform the PURCHASER when the weld

preparation and setting up for welding of various members selected by the PURCHASER is in progress so that the PURCHASER can inspect the assembly before welding starts.

11.4 The responsibilities of the PURCHASER’s representative shall in no way

reduce the CONTRACTOR’s responsibilities to ensure that the work is carried out in accordance with the specification.


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11.5 Any examination by non-destructive methods on low alloy steels shall be performed after post-weld heat treatment.

11.6 For a welded branch connection, the examination of and any necessary

repairs shall be completed before any reinforcing pad is added. 12.0 EXAMINATION OF WELDS 12.1 Examination refers to the quality control functions performed by the

CONTRACTOR during fabrication, erection and testing. 12.2 As a minimum, the following shall be examined by visual examination :

(a) Materials and components to ensure that these are as per the specification and are free from defects. If defects are noticed on “free-issue” items, these shall be brought to the notice of the PURCHASER without delay.

(b) Joint preparation and cleanliness (c) Preheating as applicable (d) Fit-up, joint clearance, and internal alignment prior to joining

(e) Variables specified by the welding procedure, including filler

material, position and electrode (f) Condition of the root pass after cleaning - external and where

accessible, internal (g) Slag removal and weld condition between passes (h) Appearance of the finished joint

12.3 Acceptance for the visual examination shall be as per ASME B 31.3 or IBR as applicable.

12.4 Other types of examination shall be as defined in Tables 4 and 5, unless

otherwise mentioned in section C of enquiry specification. For the purpose of examination, fluids are categorised, in accordance with ASME B 31.3, as Category D, Normal Service and Category M and supplemented by other requirements.


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13.0 QUALIFICATION AND CERTIFICATION OF NON-DESTRUCTIVE EXAMINATION PERSONNEL

13.1 The CONTRACTOR’s examining personnel shall have training and

experience commensurate with the needs of the specified examinations. NDT supervisors/ examiners shall be qualified at level II or above.

13.2 The CONTRACTOR shall make available to the PURCHASER copies of

certificates of qualification of the examiners he proposes to use for the PURCHASER’s approval.

14.0 METHODS OF EXAMINATION The methods of examination used, radiographic (RT), liquid penetrant

(PT) or magnetic particle (MT), shall be in accordance BPV Code, Section V.

15.0 ACCEPTANCE STANDARDS 15.1 Levels of acceptance of defects in welds shall be in accordance with

ASME B 31.3. 15.2 For IBR piping, the levels of acceptable defects shall be as per IBR. 16.0 REPAIR WELDING 16.1 All defects in welds requiring repair shall be removed by flame or arc

gouging, grinding, chipping or machining. The major repairs may involve :

(a) Cutting through the weld (b) Cutting out a length of pipe containing the weld, or (c) Removing the weld metal down to the root depending upon the

magnitude of the defects.

16.2 After removing the defect, the welds shall be examined by the same non-destructive testing methods as specified for the original weld and the same acceptance criteria shall hold good.

16.3 All the repair welds shall be made using the same or other specified

welding procedures as those used in making the original welds including preheating and stress relieving if originally required.


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TABLE 1

WELDING SPECIFICATION CHART

SL. NO.

BASE MATERIAL P. NO.

WELDING PROCESS FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING

SHIELDING

1.0 CARBON STEELS

1.1

SIZES 40 mm AND/OR 3 mm THK

1 GTAW GTAW ER 70S2 OR

ER 70S3

ER 70S2 OR

ER 70S3

- - 1

1.2

SIZES 50 mm THK 19 mm

1 SMAW SMAW E 6010 E 6013 - -

1.3

SIZES 50 mm THK 19 mm

1 GTAW SMAW ER 70S2 OR

ER 70S3

ER 7018 OR

ER 7016

- - 2

2.0 LOW ALLOY STEELS

2.1

1¼% Cr ½% Mo

4 GTAW SMAW ER 80S B2

E8016/E 8018-B2

- -

2.2

2¼% Cr 1% Mo

5 GTAW SMAW ER90S B3

E9015/ E 9016/ E 9018-B3

ARGON ARGON 3 to 8

3.0 AUSTENITIC STAINLESS STEELS

3.1

TYPE 304 (304L)

8 GTAW GTAW for THK 4.5 mm

ER 308 (ER 308L)

ER 308 (ER 308L)

ARGON ARGON 3 to 8

SMAW for THK > 4.5mm

E 308 (E 308L)

3.2

TYPE 316 (316L)

8 GTAW GTAW for THK 4.5 mm

ER 316 (ER316L)

ER 316 (ER 316L)

ARGON ARGON 3 to 8


E 316 (E 316L)

3.3 TYPE 321 8 GTAW GTAW for

THK 4.5mm

ER 321/ ER 347

ER321/ ER 347

ARGON ARGON 3 to 8


E321/E347


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TABLE 1 (CONTD.)

SL. NO.

BASE MATERIAL

P. NO.

WELDING PROCESS

FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING SHIELDING 4.0 STAINLESS

STEEL TO CARBON STEEL

4.1 SS 304/321 8 to 1

GTAW/ SMAW

SMAW ER309

ER309

- -

4.2 SS 316 8 to 1

ER310Mo E310Mo - -

NOTES 1. For 300 and higher class systems. For 150 class systems, refer para 3.4. For

fillet welds SMAW process with E6013 can be used. 2. Low hydrogen electrodes shall also be used for critical systems such as

chlorine, hydrogen, caustic and similar toxic inflammable fluids and also whenever the wall thickness exceeds 19 mm.

3. The argon shielding gas flow rate shall not be less than 0.34 m3/hr. 4. Nitrogen can be used as an alternative to argon for purging purpose only. 5. For fillet welds, electrode can be used instead of filler wire. 6. For GTAW process, electrode shall be 2% thoriated tungsten. 7. Initial purging prior to welding process shall be a minimum of five (5) times the

volume between dams or ten minutes minimum whichever is higher. When welding commences, the purge gas flow shall ensure that the gas pressure is only marginally higher than atmospheric pressure to ensure no roof concavity.

8. Back purging using argon/nitrogen shall be maintained for a minimum of two

passes. 9. Electrodes / filler wires manufactured by reputed firms duly approved by the

PURCHSER shall only be used. 10. Electrodes shall have at least the same or higher physical properties and

similar chemical composition to the members being joined. 11. Read the table in conjunction with para 3.0


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TABLE - 2

PREHEAT REQUIREMENTS

SL. NO.

BASE MATERIAL P. NO. NOMINAL WALL

THICKNESS , mm

SPECIFIED MINIMUM TENSILE

STRENGTH, MPa

RECOMMENDED MINIMUM PREHEAT

TEMPERATURE, ° C

1. CARBON STEEL 1 25 490 10

2. LOW ALLOY STEEL - 1¼% Cr ½% Mo

4 ALL ALL 149

3. LOW ALLOY STEEL - 2¼%Cr 1% Mo

5 ALL ALL 177


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TABLE 3

POSTWELD HEAT TREATMENT REQUIREMENTS

SL. NO

.

BASE MATERIAL P. NO.

NOMINAL WALL

THICKNESS,

mm

SPECIFIED MINIMUM TENSILE

STRENGTH, MPA

METAL TEMPERATURE

RANGE ° C

BRINELL

HARDNESS

MAX.

1. CARBON STEEL 1 19 ALL NONE -

2. CARBON STEEL 1 > 19 ALL 625-675 -

3. LOW ALLOY STEEL 1¼% Cr ½% Mo

4 13 490 NONE -


4 > 13 ALL 704 to 746 225


5 13 490 NONE -


5 > 13 ALL 704 to 760 241

7. AUSTENITIC STAINLESS STEELS

8, 9 ALL ALL NONE -

NOTES 1. In IBR systems, in carbon steels, postweld heat treatment is also required,

when the carbon percentage exceeds 0.25%, at the temperature range of 600 +/- 20°C.

2. All low alloy steel welds in IBR systems shall be postweld heat treated at the

temperature range of 620 to 660° C for 1 1/4% Cr 1/2% Mo steels and at a range of 660 to 750°C for 2 1/4% Cr 1% Mo steels.


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TABLE 4 WELD EXAMINATION (OTHER THAN ‘IBR’)

SL. NO.

FLUID SERVICE CATEGORY AS PER

ASME B 31.3

TYPE OF EXAMINATION

EXTENT OF EXAMINATION

GIRTH BUTT WELD

SOCKET AND FILLET WELDS

BRANCH WELDS (FABRI-CATED)

FABRICATED MITRES /

REDUCERS

ATTACH MENT

WELDS

1.0 CATEGORY D VISUAL 100% 100% 100% 100% 100%

LT/MT - - 5% - -

RT (ABOVE GROUND)

10% - - 10% -

RT (UNDER GROUND)

100% - - - -

2.0 NORMAL VISUAL 100% 100% 100% 100% 100%

RT 10% - - 10% -

LT/MT - 10% 10% - 10%

3.1 CATEGORY M & PIPING GRADE – BE57C (Propane / Butane / LPG SERVICE)

VISUAL

RT

LT/MT

100%

100%

100% (FOR ROOT RUN)

100%

-

100%

100%

-

100%

100%

100%

100% (FOR ROOT RUN)

100%

-

100%

3.2 HIGH PRESSURE (ASME 600 CLASS AND HIGHER)

3.3 CRITICAL SERVICES SUCH AS CHLORINE, CAUSTIC, HYDROGEN AND OTHERS AS DEFINED IN SECTION-C

3.4 LOW TEMPERATURE [<(-)80°C]

3.5 SEVERELY CYCLIC AS PER ASME B 31.3

NOTES Fluid services are categorised as follows (as per ASME B 31.3) 1. Category D: Fluid is non-flammable, non-toxic, and not damaging to human

tissues, and design pressure is 1.035 M Pa g(150 psig) and design temperature is 186°C and not below (-) 20°C.

2. Category Normal: Not Category D, not category M, not “high pressure” as per ASME B31.3 and not subject to severe cycling as defined in ASME B 31.3.


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3. Category M: Toxic Services which can damage human tissue after a single exposure even if prompt remedial measures are taken.

TABLE 5

WELD EXAMINATION (IBR PIPING)

SL. NO.

ANSI PRESSURE CLASS

NOM PIPE SIZE, mm

TYPE OF EXAMINATION

EXTENT OF EXAMINATION

GIRTH BUTT WELD

SOCKET AND

FILLET WELDS

BRANCH WELDS

FABRICATED

ATTACHMENT WELDS

1. ALL ALL VISUAL 100% 100% 100% 100%

2. 150 AND 300

100 RT 10% - - -

50 to 80 RT 2% - 2% -

40 LT/MT - 2% - -

3. 600 AND HIGHER

50 RT 100% - - -

40 LT/MT NOTE 2

100% 100% 10%

NOTES

1. The extent of examination shown above is minimum and any additional requirement as required by ‘IBR’ shall also be considered.

2. For root runs of butt welds in sizes 50 mm (100%)



SUBSECT D5

D5

TCE.6758A-E-590-001 STRUCTURAL STEEL FABRICATION

SHEET 1 OF 8

TCE FORM NO. 329 R3

ISSUE

R5

CONTENT

1. SCOPE .............................................................................................................................. 2

2. APPLICABLE CODES & SPECIFICATIONS ..................................................................... 2

3. STEEL MATERIALS .......................................................................................................... 3

4. DRAWINGS PREPARED BY THE OWNER ...................................................................... 3

5. DRAWINGS PREPARED BY THE CONTRACTOR ........................................................... 4

6. FABRICATION .................................................................................................................. 4

7. INSPECTION ..................................................................................................................... 6

8. TESTS ON WELDS ........................................................................................................... 7

9. MARKING OF MEMBERS ................................................................................................. 7

10. METHOD OF MEASUREMENT ......................................................................................... 7



SUBSECT D5

D5


SHEET 2 OF 8

TCE FORM NO. 329 R3

ISSUE

R5

1. SCOPE

1.1 This specification covers the general requirements for supply where specified, fabrication and delivery at site of structural steel.

1.2 This specification also covers design of all connections and substituted members, preparation of all shop fabrication drawings, inspection and shop painting of structures.

2. APPLICABLE CODES & SPECIFICATIONS

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

2.2 In case of discrepancy between this specification and other documents referred to herein, this specification shall govern.

a) Materials

IS:808 Dimensions for Hot Rolled Steel sections

E 7018 Covered Electrodes for Manual Metal Arc Welding of Carbon and Carbon Manganese Steel

E 309 For SS304 to CS welding

IS:1161 Steel Tubes for structural purposes

IS:1852 Rolling and Cutting Tolerances for Hot Rolled Steel Products

IS:2062 Steel for General Structural Purposes

Codes Of Practice

IS:800 Code of Practice for General Construction in Steel

IS:806 Code of practice for use of steel tubes in general building construction

ASME SECTION IX

Welding and Brazing Qualifications



SUBSECT D5

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SHEET 3 OF 8

TCE FORM NO. 329 R3

ISSUE

R5

IS:1200 Method of Measurement in Building Civil Engineering Works

IS:3658 Code of Practice for Liquid Penetrant Flaw Detection

IS:7215 Tolerances for Fabrication of Steel Structures

IS:9595 Recommendations for Metal Arc Welding of Carbon and Carbon Manganese Steel

3. STEEL MATERIALS

3.1 Steel materials shall comply with the specifications laid down under clause 2.0 and/or as called for on the design drawings.

3.2 All materials used shall be new, unused and free from defects.

4. DRAWINGS PREPARED BY THE OWNER

4.1 Design drawings will be furnished to the CONTRACTOR and all drawings so furnished shall form a part of this specification. These design drawings prepared by the ENGINEER will show all the, levels, forces on members where shall necessary, size and orientation of each member, location/size of openings, to enable the CONTRACTOR to prepare drawings for fabrication and erection. It shall be clearly understood that these drawings are not intended to show connection details, thickness of members, cuts, notches, bends and such other details.

4.2 The ENGINEER reserves the right to make changes. Revisions to drawings, even after release for preparation of shop drawings, are very likely to be made to reflect additional data/details received and updated requirements. Revisions to drawings and any new drawings made to include additional work by the CONTRACTOR shall be considered a part of this specification and contract. The PURCHASER shall not entertain IS any extra claims on this account.

4.3 Where the fabrication drawings are to be furnished by the ENGINEER, he will issue to the CONTRACTOR the required copies of such drawings in the sequence required for the fabrication of the components in the order they will be required to be erected at site. Such drawings will be issued in such numbers as required for the CONTRACTOR to adhere to the project schedule.

4.4 Should the CONTRACTOR during the execution of his work, find discrepancies in the information furnished by the ENGINEER, he shall refer such discrepancies to the ENGINEER before proceeding with such work.



SUBSECT D5

D5


SHEET 4 OF 8

TCE FORM NO. 329 R3

ISSUE

R5

5. DRAWINGS PREPARED BY THE CONTRACTOR

5.1 GA drawing with typical details will be provided by TCE. Based on the same, CONTRACTOR shall prepare all fabrication and erection drawings for the entire work. All the drawings for the entire work shall be prepared in metric units. The drawings shall preferably be of one standard size and the details shown there in shall be clear and legible.

5.2 The CONTRACTOR shall not commence detailing unless ENGINEER's design drawings are officially released for preparation of shop drawings. The CONTRACTOR shall be responsible for the correctness of all fabrication drawings. Fabrication drawings shall be revised by the CONTRACTOR to reflect all revisions in design drawings as and when such revisions are made by the ENGINEER.

5.3 All fabrication drawings shall be submitted to the ENGINEER for approval.

5.4 No fabrication drawings will be accepted for ENGINEER's approval unless checked and approved by the CONTRACTOR's qualified structural engineer and accompanied by an erection plan showing the location of all pieces detailed. The CONTRACTOR shall ensure that connections are detailed to obtain ease in erection of structures and in making field connections.

5.5 Fabrication shall be started by the CONTRACTOR only after ENGINEER's approval of fabrication drawings. Approval by the ENGINEER of any of the drawings shall not relieve the CONTRACTOR from the responsibility for correctness of engineering & design of connections, workmanship, fit of parts, details, material, errors or omissions of any and all work shown thereon. The ENGINEER's approval shall constitute approval of the size of members, dimensions and general arrangement but shall not constitute approval of the connections between members and other details.

5.6 The drawings prepared by the CONTRACTOR and all subsequent revisions etc. shall be at the cost of the CONTRACTOR for which no separate payment will be made.

6. FABRICATION

6.1 General

All workmanship and finish shall be of the best quality and shall conform to the best approved method of fabrication. All materials shall be finished straight and shall be machined/ground smooth true and square where so specified. All holes and edges shall be free of burrs. Shearing and chipping shall be neatly and



SUBSECT D5

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SHEET 5 OF 8

TCE FORM NO. 329 R3

ISSUE

R5

accurately done and all portions of work exposed to view shall be neatly finished. Unless otherwise directed/ approved, reference may be made to relevant IS codes for providing standard fabrication tolerance. Material at the shops shall be kept clean and protected from weather.

6.2 Welding

6.2.1 Welding procedure shall be submitted to ENGINEER for approval. Welding shall be entrusted to only qualified and experienced welders who shall be periodically tested and graded as per ASME Sec. IX.

6.2.2 Welding specification shall be as follows

Note 1 The argon shielding gas flow rate shall not be less than 0.34 m3/hr.

Note 2 For GTAW process, electrode shall be 2% thoriated tungsten.

6.2.3 While fabricating plated beams and built up members, all shop splices in each component part shall be made before such component part is welded to other parts of the members. Wherever weld reinforcement interferes with proper fit-up between components to be assembled for welding, these welds shall be ground flush prior to assembly.

6.2.4 Flame cutting in stainless steel is not permissible.

6.2.5 Approval of the welding procedure by the ENGINEER shall not relieve the CONTRACTOR of his responsibility for correct and sound welding without undue distortion in the finished structure.

6.2.6 No welding shall be done when the surface of the members is wet nor during periods of high wind.

BASE MATERIAL

WELDING PROCESS

FILLER MATERIAL NOTES

ROOT FILLER ROOT FILLER

Stainless Steel GTAW GTAW ER 70S2 OR

ER 70S3

ER 70S2 OR

ER 70S3

1 & 2

Carbon Steel SMAW SMAW E 6010 E 6013



SUBSECT D5

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SHEET 6 OF 8

TCE FORM NO. 329 R3

ISSUE

R5

6.2.7 Each layer of a multiple layer weld except root and surfaces runs may be moderately peened with light blows from a blunt tool. Care shall be exercised to prevent scaling or flaking of weld and base metal from overpeening.

6.2.8 No welding shall be done on base metal at a temperature below -50c. Base metal shall be preheated to the temperature as per relevant IS codes.

6.2.9 Inspection of Welds

6.2.10 All welds shall be inspected for flaws by any of the methods described under clause "Inspection". The choice of the method adopted shall be determined by the PURCHASER/ENGINEER.

6.2.11 The correction of defective welds shall be carried out as directed by the ENGINEER without damaging the parent metal. When a crack in the weld is removed, magnetic particle inspection or any other equally positive means as prescribed by the ENGINEER shall be used to ensure that the whole of the crack and material upto 25 mm beyond each end of the crack has been removed. Cost of all such tests and operations incidental to correction shall be to the CONTRACTOR's account.

6.3 Tolerances

6.3.1 The dimensional and weight tolerances for rolled shapes shall be in accordance with IS:1852 for indigenous steel and equivalent applicable codes for imported steel. The tolerances for fabrication of structural steel shall be as per IS:7215.

7. INSPECTION

7.1.1 The CONTRACTOR shall give due notice to the PURCHASER/ENGINEER in advance of the works getting ready for inspection. All rejected material shall be promptly removed from the shop and replaced with new material for the PURCHASER's/ENGINEER's approval/ inspection. The fact that certain material has been accepted at the CONTRACTOR's shop shall not invalidate final rejection at site by the PURCHASER/ENGINEER if it fails to conform to the requirements of these specifications, to be in proper condition or has fabrication inaccuracies which prevents proper assembly nor shall it invalidate any claim which the PURCHASER may make because of defective or unsatisfactory materials and/or workmanship.

7.1.2 No materials shall be painted or despatched to site without inspection and approval by the PURCHASER/ ENGINEER unless such inspection is waived in writing by the ENGINEER.



SUBSECT D5

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SHEET 7 OF 8

TCE FORM NO. 329 R3

ISSUE

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7.1.3 The CONTRACTOR shall provide all the testing and inspection services and facilities for shop work except where otherwise specified.

7.1.4 For fabrication work carried out in the field the same standard of supervision and quality control shall be maintained as in shop fabricated work. Inspection and testing shall be conducted in a manner satisfactory to the ENGINEER.

7.2 Inspection and tests on structural steel members shall be as set forth below :

7.2.1 Material Testing

If mill test reports are not available for any steel materials the same shall be got tested by the CONTRACTOR to the ENGINEER's satisfaction to demonstrate conformity with the relevant specification.

8. TESTS ON WELDS

8.1 Liquid Penetrant Inspection

In the case of welds examined by Liquid Penetrant Inspection, such tests shall be carried out in accordance with relevant IS Code. All defects shown shall be repaired and rechecked.

8.2 Dimensions, Workmanship & Cleanliness

Members shall be inspected at all stages of fabrication and assembly to verify that dimensions, tolerances, alignment, surface finish and painting are in accordance with the requirements shown in the CONTRACTOR's approved fabrication drawings and the ENGINEER's drawings.

9. MARKING OF MEMBERS

9.1 After checking and inspection, all members shall be marked for identification during erection. This mark shall correspond to distinguishing marks on approved erection drawings and shall be legibly painted on it. However permanent marks are not acceptable..

9.2 Erection marks on like pieces shall be in identical locations. Members having lengths of 7.0 m or more shall have the erection mark at both ends.

10. METHOD OF MEASUREMENT



SUBSECT D5

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SHEET 8 OF 8

TCE FORM NO. 329 R3

ISSUE

R5

10.1 For the purpose of payment, the weight of the actual completed structures shall be calculated from the approved drawings for different items of work. The CONTRACTOR shall submit to the PURCHASER relevant material list containing weight of each item.

10.2 The weight of a member made out of standard rolled section such as beams, channels, angles, etc. shall be based on the standard IS:808 without deductions for holes, notches, bevel cuts, etc. Where a component consists of a cut joist or channels, the full weight of the rolled section shall be considered only if more than half the depth of the original section is used. Otherwise, only half the section unit weight shall be considered for calculation of the weight of the components.

10.3 For gussets/plates used in trusses, bracings, columns, beams, etc, the area shall be that of the minimum circumscribing rectangle except as stated in 14.3 above.

10.4 The weight of any built-up members shall be based on the weight of each component.

END



SUBSECTION: D6

TCE.6758A-E-590-002 STRUCTURAL STEEL ERECTION SHEET 1 OF 3

TCE FORM 329 R3

CONTENTS

1. SCOPE ...................................................................................................................................... 2

2. APPLICABLE CODES & SPECIFICATIONS ........................................................................ 2

3. ERECTION ............................................................................................................................... 2

4. INSPECTION ............................................................................................................................ 3

5. TOLERANCES ......................................................................................................................... 3

6. METHOD OF MEASUREMENT ............................................................................................ 3

7. CLEAN UP OF WORK SITE ................................................................................................... 3



SUBSECTION: D6


TCE FORM 329 R3

1. SCOPE

1.1 This specification covers the general requirements for erection of structural steel. It covers

the supply and delivery of all necessary materials, labour, scaffolding, tools, tackles,

equipment and everything that is necessary for the satisfactory completion of the job on

schedule.

2. APPLICABLE CODES & SPECIFICATIONS

2.1 The following specifications, standards and codes are made a part of this specification. All

standards, specifications and codes of practice referred to herein shall be the latest editions,

including all applicable official amendments and revisions.

2.2 In case of discrepancy between this specification and other documents referred to herein,

this specification shall govern. In case of discrepancy between tender drawings and this

specification, the tender drawings shall govern.

a) Structural

IS:800 Code of Practice for General Construction in Steel

IS:7205 Safety Code for Erection of Structural Steel Work

IS:7215 Tolerances for Fabrication of Steel Structures

3. ERECTION

3.1 All structural steel shall be erected as shown on the drawings. Proper size steel cable

slings, etc., shall be used for hoisting. Guys shall not be anchored to existing structures,

etc. unless so permitted by ENGINEER in writing. Care shall be taken to see that ropes in

use are always in good condition.

3.2 Structural steel frames shall be erected plumb and true. Frames shall be lifted at such

points that they are not liable to buckle and deform. Trusses shall be lifted only at node

points. In the case of trusses, roof girders, all of the purlins and wind bracing shall be

placed simultaneously and the columns shall be erected truly plumb on screed bars over the

pedestals. All steel columns and beams shall be checked for plumb and level individually

before and after connections are made. Temporary bracings shall be introduced wherever

necessary to take care of all loads to which the structure may be subjected, including

erection equipment and the operation thereof. Such bracings shall be left in place as long as

may be required for safety and stability.



SUBSECTION: D6


TCE FORM 329 R3

3.3 Test certificates shall be furnished by CONTRACTOR.

3.4 Fixing of staging members to concrete cell walls through plate EPs/Anchor fasteners or

placing in the cutout available in cell walls/grouting.

4. INSPECTION

4.1 ENGINEER / OWNER or their authorised representatives shall have free access to all parts

of the job during erection and all erection shall be subjected to their approval. In case of

faulty erection, all dismantling and re-erection required will be at CONTRACTOR’s cost.

5. TOLERANCES

The tolerances on erected steel structures shall be as per recommendations of process

technologists/suppliers which will be indicated in the drawings.

6. METHOD OF MEASUREMENT

6.1 For the purpose of payment, the weight of the actual completed structures shall be

calculated from the approved drawings for different items of work. The

VENDOR/CONTRACTOR shall submit to the PURCHASER relevant material list

containing weight of each item.

6.2 The weight of a member made out of standard rolled section such as beams,

channels, angles, etc. shall be based on the standard IS:808 without deductions for

holes, notches, bevel cuts, etc. Where a component consists of a cut joist or

channels, the full weight of the rolled section shall be considered only if more than

half the depth of the original section is used. Otherwise, only half the section unit

weight shall be considered for calculation of the weight of the components.

6.3 For gussets/plates used in trusses, bracings, columns, beams, etc, the area shall be

that of the minimum circumscribing rectangle except as stated in 14.3 above.

6.4 The weight of any built-up members shall be based on the weight of each

component.

7. CLEAN UP OF WORK SITE

7.1 During erection, the CONTRACTOR shall without any additional payment, at all times

keep the working and storage areas used by him, free from accumulation of waste materials

or rubbish. Before completion of erection, he shall remove or dispose of in a satisfactory

manner all temporary structures, waste and debris and leave the premises in a condition

satisfactory to OWNER/ENGINEER.




SHOP INSPECTION AND TESTS SHEET 1 OF 7

ISSUE R9


1.0 SCOPE This specification covers the requirements for Shop Inspection and Tests to be

carried out by the PURCHASER/CONSULTANT/INSPECTION AGENCY. 2.0 GENERAL 2.1 The plant and equipment covered by the PURCHASE ORDER/CONTRACT

shall be subjected to inspection and testing. The VENDOR/CONTRACTOR shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-VENDOR’s/SUB-CONTRACTOR’s works to ensure the mechanical accuracy of components, compliance with approved drawings, identification and acceptability of all materials, parts and equipment.

2.2 For supply of systems, the VENDOR/CONTRACTOR shall, at the start of the

PURCHASE ORDER/CONTRACT, furnish a total list of items in his scope of work. This list, giving a brief description of the item, quantity, names of probable SUB-VENDORS/SUB-CONTRACTORS, and a blank column for agency for final approval of drawings and documents, shall be submitted for approval by PURCHASER/CONSULTANT. The blank column shall be filled by PURCHASER/CONSULTANT. The list shall be submitted within two weeks from the date of Letter of Intent.

2.3 For systems and major items such as pressure and load bearing items,

machineries etc., the VENDOR/CONTRACTOR shall furnish quality plan giving details of checks and tests to be conducted by them on material, process, sub-assembly and assembly. These shall include requirements as prescribed in the applicable specifications, codes and statutory requirements. The quality plan shall be reviewed by the PURCHASER/CONSULTANT and the stages to be witnessed and verified shall be indicated by the PURCHASER/CONSULTANT in the approved quality plan.

2.4 The VENDOR/CONTRACTOR shall give the PURCHASER/CONSULTANT

written notice of any material being ready for testing as per format enclosed. The clear notice period shall be seven (7) days for local inspection and fifteen (15) days for outstation inspection. Such tests shall be to the VENDOR’s/CONTRACTOR's account except for the expenses of the PURCHASER/CONSULTANT. The PURCHASER/CONSULTANT, unless the inspection of the tests is virtually waived, shall fix a date for inspection with the VENDOR/CONTRACTOR and attend such tests within fifteen (15) days of the date on which the equipment is notified as being ready for test and inspection failing which, the VENDOR/CONTRACTOR may proceed with the tests and shall forthwith forward to the PURCHASER/CONSULTANT duly certified copies of tests in triplicate. If the VENDOR/CONTRACTOR fails to offer the equipment for inspection as per the agreed date, he is liable to pay for the time and expenses for the infructuous visit of the PURCHASER/CONSULTANT.

2.5 In all cases where inspection and tests are required whether at the premises or

works of the VENDOR/CONTRACTOR or of any SUB-VENDOR/SUB-CONTRACTOR or at laboratory, the VENDOR/CONTRACTOR, except where otherwise specified, shall provide free of charge all facilities such as labour,





ISSUE R9


materials, electricity, fuel, water, stores, test bed, apparatus and instruments, laboratory tests etc. as may be required by the PURCHASER/CONSULTANT to carry out effectively such tests of the equipment in accordance with the PURCHASE ORDER/CONTRACT and shall give facilities to the PURCHASER/ CONSULTANT to accomplish testing.

2.6 The PURCHASER/CONSULTANT shall at all working hours have access to all

parts of the VENDOR’s/CONTRACTOR's and his SUB-VENDOR’s/SUB-CONTRACTOR's factory where the items of the plant are being prepared, for carrying out inspection activities as deemed necessary. A set of the relevant latest approved drawings with approval marking of the PURCHASER/ CONSULTANT and drawings for proprietary items shall be made available by the VENDOR/CONTRACTOR to the PURCHASER/CONSULTANT, for reference during inspection.

2.7 In the case of stage inspection hold points, the VENDOR/CONTRACTOR shall

proceed from one stage to another only after the component is inspected by the PURCHASER/CONSULTANT and written permission given to proceed further. The same procedure shall be adopted for any rectifications and repairs suggested by the PURCHASER/CONSULTANT.

2.8 The PURCHASER/CONSULTANT shall have the right to inspect any

machinery, material, structures, equipment or workmanship furnished or used by the VENDOR/CONTRACTOR and may reject any which is defective or unsuitable for the use and purpose intended, or which is not in accordance with the intent of the PURCHASE ORDER/CONTRACT. The VENDOR/ CONTRACTOR, upon demand by the PURCHASER/CONSULTANT, shall remedy or replace at the VENDOR’s/CONTRACTOR's expense such defective or unsuitable items of the plant, or the PURCHASER/CONSULTANT may, at the expense of the VENDOR/CONTRACTOR, remedy or replace such defective or unsuitable items of the Plant.

2.9 All principal mill test reports, the VENDOR/CONTRACTOR inspection and tests

reports, test certificates and test curves shall be supplied for all inspection and tests carried out including other records such as stress relieving charts, radiographic charts and other non-destructive testing records in accordance with the provisions of the PURCHASE ORDER/CONTRACT, duly certified by the main VENDOR/CONTRACTOR. The PURCHASER/CONSULTANT shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

2.10 The PURCHASER/CONSULTANT shall within fifteen (15) days from the date of

inspection as defined herein give notice in writing to the VENDOR/ CONTRACTOR of any non-conformance pertaining to all or any equipment and workmanship which in his opinion is not in accordance with the PURCHASE ORDER/CONTRACT. The VENDOR/CONTRACTOR shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the PURCHASER/CONSULTANT giving reasons therein that no modifications are necessary to comply with the PURCHASE ORDER/CONTRACT.





ISSUE R9


2.11 When the factory tests and documentation have been satisfactorily completed at the VENDOR’s/CONTRACTOR's or SUB-VENDOR's/CONTRACTOR's works, the PURCHASER/CONSULTANT shall issue acceptance note or shipping release note or a certificate to this effect within fifteen (15) days after completion, but if the tests are not witnessed by the PURCHASER/ CONSULTANT, the certificate or comments thereof shall be issued within fifteen (15) days of the receipt of the VENDOR’s/CONTRACTOR's test certificate by the PURCHASER/CONSULTANT. Failure of the PURCHASER/ CONSULTANT to take such an action shall not prevent the VENDOR/ CONTRACTOR from proceeding with the work. The completion of these tests or the issue of the certificates shall not bind the PURCHASER/ CONSULTANT to accept the equipment, should it, on further tests after erection, be found not to comply with the PURCHASE ORDER/CONTRACT.

2.12 None of the plant and the equipment to be furnished or used in connection with

the PURCHASE ORDER/CONTRACT shall be despatched until shop inspection, satisfactory to the PURCHASER/CONSULTANT has been made. However, such shop inspection and/or certification shall not relieve the VENDOR/CONTRACTOR of his responsibility for furnishing the plant and the equipment conforming to the requirements of the PURCHASE ORDER/ CONTRACT nor prejudice any claim, right or privilege which the PURCHASER/ CONSULTANT may have because of the use of defective or unsatisfactory items. Should the PURCHASER/CONSULTANT waive the right to inspect any item, such waiver shall not relieve the VENDOR/CONTRACTOR in any way from his obligation under the PURCHASE ORDER/CONTRACT. In the event of the PURCHASER’s/CONSULTANT's inspection revealing poor quality of goods, the PURCHASER/CONSULTANT shall be at liberty to specify additional inspection procedures, if required, to ascertain the VENDOR/CONTRACTOR's compliance with the equipment specifications.

3.0 SUB-ORDERS AND SUB-CONTRACTS 3.1 In order to facilitate the inspection of bought-out materials and plant, the

VENDOR/CONTRACTOR shall submit for approval, three (3) copies of all sub-orders and sub-contracts placed by him as soon as these are issued. Copies of any drawings referred to in the sub-order or sub-contracts shall also be submitted, unless agreed otherwise by the PURCHASER/CONSULTANT.

3.2 The sub-orders, sub-contracts and drawings referred to above shall include all

components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly despatched to site from the SUB-VENDOR’s/SUB-CONTRACTOR's works.

3.3 All sub-orders and sub-contracts of the main VENDOR/CONTRACTOR shall

clearly be marked with the main VENDOR’s/CONTRACTOR's name and the PURCHASER’s/CONSULTANT’s name and the PURCHASE ORDER/ CONTRACT reference. These shall include the following statement:

The plant or the equipment which is the subject of this PURCHASE ORDER/

CONTRACT shall comply in every respect with the requirements of the





ISSUE R9


PURCHASER’s/CONSULTANT's technical specifications and shall be subject to inspection and tests to the satisfaction of the PURCHASER/CONSULTANT.

3.4 For the purpose of this para, it is obligatory on the VENDOR/CONTRACTOR

that he advises his SUB-VENDOR/SUB-CONTRACTOR of the pertinent clauses in this specification when ordering bought-out plant, equipment or materials. In particular, the VENDOR/CONTRACTOR shall advise every SUB-VENDOR/SUB-CONTRACTOR that he is required to supply design calculations, drawings, inspection reports and test certificates strictly in accordance with this specification and technical information for inclusion in the Instruction Manual as specified in Section E of the Enquiry Document. The SUB-VENDORS/SUB-CONTRACTORS should also be reminded that they shall include with their offer all tools and appliances necessary for proper maintenance and all spare parts in accordance with Section E of the Enquiry Document. Itemised prices of the recommended spare parts shall be submitted together with the appropriate part numbers and drawings.

3.5 Sub-ordering and sub-contracting for major items such as pressure and load

bearing items, machinery etc. can be done only with the approval of the PURCHASER/CONSULTANT.

4.0 MATERIAL TESTS 4.1 In the event of the PURCHASER/CONSULTANT being supplied with the

certified particulars of tests which have been carried out for the VENDOR/ CONTRACTOR by the supplier of material, the PURCHASER/CONSULTANT may, at his own discretion, accept the same as proper evidence of compliance with the requirements of appropriate specifications for the materials.

4.2 The VENDOR/CONTRACTOR is to provide test pieces as required by the

PURCHASER/CONSULTANT to enable him to determine the quality of material supplied under the PURCHASE ORDER/CONTRACT. If any test piece fails to comply with the requirements, the PURCHASER/CONSULTANT may reject the entire lot of material represented by the test piece.

4.3 Critical materials used in manufacture of the equipment and construction of the

plant covered by the PURCHASE ORDER/CONTRACT may also be subjected to one or more of the Non-Destructive Tests (NDT) as called for in the enquiry document or as mutually agreed. Salvaging of material due to unacceptable defect is to be attempted by the VENDOR/CONTRACTOR only after getting specific concurrence from the PURCHASER/CONSULTANT and according to the approved procedures.

5.0 WELDING 5.1 All welding involved in construction and fabrication of the plant and items

covered under the PURCHASE ORDER/CONTRACT shall be carried out in accordance with specifications and applicable codes.

5.2 Welding procedures and welders' qualifications shall be approved by the

PURCHASER/CONSULTANT. Where applicable, welders shall be tested as





ISSUE R9


detailed in codes specified for pipe welding, vessel welding and structural welding and appropriate to the corresponding weld position using test pieces of appropriate parent metal to be used on the job. The PURCHASER/ CONSULTANT shall have the right to have any welder re-tested at any time during the PURCHASE ORDER/CONTRACT.

5.3 Recommendations of applicable codes shall be followed for non-destructive

tests, wherever applicable. 5.4 Copies of all welding procedures, procedure qualification records, welders'

performance qualification certificates, post-heating and stress relieving records, NDT records and other test results shall be made available upon request of the PURCHASER/CONSULTANT.

6.0 FABRICATION AND INSPECTION Fabrication and inspection procedures for vessels, heat exchangers, pipes,

tubes and valves etc. shall be in accordance with procurement specifications, quality plan, applicable codes or any other approved equal.

7.0 TESTS AT MANUFACTURER'S WORKS 7.1 GENERAL The tests at works shall include electrical, mechanical and hydraulic tests in

accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards and approved drawings and specifications and in addition any test called for by the PURCHASER/CONSULTANT to ensure that the plant being supplied fulfils the requirements of the specifications. The VENDOR/ CONTRACTOR shall carry out all the shop tests and inspections specified under individual items of the equipment in Section-D of the enquiry document, in addition to those normally required as per codes and standards. For items not covered by any code or specifically mentioned in the specifications, the tests are to be agreed with by the PURCHASER/CONSULTANT. If considered necessary by the PURCHASER/CONSULTANT, multi-part assemblies shall be fully erected and tested in the works prior to packing and despatch to the site.

7.2 TEST CERTIFICATES Test certificates including test records, performance curves and balancing

certificates shall be supplied according to the Distribution Schedule. All the tests shall be carried out in accordance with the provisions of the PURCHASE ORDER/CONTRACT.

All test certificates must be endorsed with sufficient information to identify the

material or the equipment to which the certificates refer, and must carry at the top right hand corner the identification of the PURCHASER/CONSULTANT and the PURCHASE ORDER/CONTRACT.





ISSUE R9


7.3 CALIBRATION All instruments used for critical measurement such as pressure gauges for leak

tests, instruments for measuring performance parameters; instruments for precision dimension measurements shall have valid calibration certificates traceable to national standards. This means that the calibrating agency engaged by the VENDOR/CONTRACTOR shall use instruments which are in turn calibrated by Government approved agencies and such information shall be recorded in the calibration certificate issued by the calibrating agency by giving the certificate number, date and date of validity of the certificate given by the Government approved agency.

FORMAT FOR INSPECTION REQUEST FROM THE

VENDOR/CONTRACTOR To, TATA CONSULTING ENGINEERS LIMITED,

Attn: Mr/Ms

PROJECT MANAGER Dear Sir/Madam, Items detailed below are ready for inspection. Please arrange inspection and

confirm the date. 1. PURCHASER 2. PROJECT 3. PURCHASE ORDER/CONTRACT

REFERENCE NUMBER

4. CONSULTANT (TCE) REFERENCE

NUMBER

5. SUB-VENDOR/SUB-CONTRACTOR 6. SUB-VENDOR’s/SUB-CONTRACTOR’s

ADDRESS

7. PLACE OF INSPECTION AND ADDRESS 8. CONTACT PERSON, PHONE, FAX AND

E-MAIL ID

9. DESCRIPTION OF ITEM AND QUANTITY 10. NATURE OF INSPECTION REQUIRED





ISSUE R9


11. PROPOSED DATES 12. WEEKLY HOLIDAY We confirm that the items have been fully inspected and tested by us. All stages

of inspection as per approved quality plan have been carried out by us and all material test certificates, quality control records and test reports and valid calibration reports of measuring and testing instruments with traceability to national level are ready with us.

Thanking you and awaiting your confirmation, Yours faithfully, Note 1 Following clear notice periods (Date of Receipt at TCE to Date of

Inspection) are required: (a) Local Inspection - 7 days (b) Outstation Inspection - 15 days Note 2 Weekly Holidays for TCE - Saturday and Sunday cc: Purchaser cc: Sub-Vendor/Sub-Contractor


FILE NAM

E: M418604R

2.DO

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L NO

.

DESCRIPTION

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UA

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ATION

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TER

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RO

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SEA

T, BAC

K SEAT

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TEST-H

YD

RO

STATIC

SEA

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TEST - AIR

SE

T PO

INT

DIS

C S

TRE

NG

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PE

RFO

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AN

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OP

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TYPE

TESTS

RO

UTIN

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TS

AD

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, HA

RD

NES

S, S

PAR

K, TH

ICK

NES

S

EN

DU

RA

NC

E (TY

PE) TE

ST

TCE

.M4-186-04

SP

EC

IFICA

TION

NO

1 PRESSURE PARTS - MATERIALS D C D D B B B C D D

SHO

P INSPEC

TION

REQ

UIR

EMEN

TS VA

LVES-META

LLIC

TATA

CO

NSU

LTING

ENG

INEER

S LIMITED

2 TRIMS (SEATS, STEM, PLUG, DISC ETC.) C D B B

3 SPRINGS C CX C

4 DIAPHRAGM C D

5 NON - METALLIC ITEMS, IF ANY C D

6 ACTUATORS, POSITIONERS, IF ANY A A Az A C C

7 FINISHED ITEMS A A A A B A

8 SAFETY RELIEF VALVES - ADDITIONAL TESTS D A A

9 BUTTER FLY VALVES - ADDITIONAL TESTS B

10 CONTROL VALVES - ADDITIONAL TESTS AY

11 LININGS, IF ANY A A

TCE

FOR

M N

O. 329 R

3

LEGEND A - WITNESSED BY TCE. B - WITNESSED BY TCE IF REQUIREMENT IS SPECIFIED. C - RECORDS VERIFIED BY TCE WHEREVER APPLICABLE. D - A OR C, AT TCE'S DISCRETION WHEREVER APPLICABLE. X - SCRAG TEST AND LOAD / DEFLECTION TEST. Y - INCLUDING Cv. Z - FOR ACTUATOR CHAMBER.

NOTES 1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.

2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.

3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS MENTIONED IN TCE. M4 - 904 AND RELEVANT TECHNICAL SPECIFICATIONS.

4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

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FILE NAM

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2.DO

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SE

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L NO

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DESCRIPTION

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L EXA

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ATION

DIM

EN

SIO

NS

MA

TER

IAL TE

ST CE

RT.

IDE

NTIFIC

ATIO

N A

ND

C

OR

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LATIO

N

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AS

ON

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ST

WE

LDIN

G Q

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LIFICATIO

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FIT UP

BA

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CH

IP-PT

PT / M

T

RA

DIO

GR

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Y

OV

ALITY, TH

INN

ING

HE

AT TR

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EN

T

SU

RFA

CE FIN

ISH

HY

DR

OS

TATIC

LEAK TES

T

HA

RD

NE

SS TE

ST

SPA

RK

, AD

HE

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TEST

THIC

KN

ESS C

HE

CK

MA

TER

IAL C

HE

CK

TEST

TCE

.M4-186-05

SP

EC

IFICA

TION

NO

.

A ORDERED ON MANUFACTURER

SHO

P INSPEC

TION

REQ

UIR

EMEN

TS PIPES A

ND

PIPE FITTING

S-META

LLIC

TATA

CO

NSU

LTING

ENG

INEER

S LIMITED

1 PLATES / PIPES FOR FABRICATED ITEMS D D C D D

2 ROLLING, FORMING FOR FAB. ITEMS D D D

3 BUTT, GROOVE WELDS FOR FABRICATED ITEMS D D B C/A D D B B

4 FINISHED ITEMS A A C A B C B B D

5 LININGS, IF ANY A A A A

6 COATINGS, IF ANY A A

B ORDERED ON DEALERS / STOCKISTS ETC. A A C A A C AX AX AX D

TCE

FOR

M N

O. 329 R

3

LEGEND

A - WITNESSED BY TCE.

B - WITNESSED BY TCE IF REQUIREMENT IS SPECIFIED.

C - RECORDS VERIFIED BY TCE WHEREVER APPLICABLE.

D - A OR C, AT TCE'S DISCRETION WHEREVER APPLICABLE.

X - FOR LINED ITEMS.

NOTES

1 - ALL STAGES SHALL BE CHECKED 100% BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.




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FILE NAM

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MBE

RS

DESCRIPTION

VIS

UA

L EXA

MIN

ATION

DIM

EN

SIO

NS

MA

TER

IAL TE

ST CE

RT.

BO

DY LEA

K TEST

SEA

T LEAK

TEST

FLOW

TES

T

OP

ER

ATIO

N TE

ST

PE

RFO

RM

AN

CE TE

ST

PE

RC

OLATIO

N TES

T

CH

AN

GE

IN D

IA. A

ND

LE

NG

TH

KIN

K TES

T

AC

CE

LER

ATE

D A

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ING

WE

IGH

T PER

UN

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NG

TH

BA

LAN

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G

FITME

NT

MAK

ES A

ND

RA

TING

S OF

PA

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WIR

ING

, FUN

CTIO

N

CH

EC

K

INTE

RLO

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H.V

., I,R., C

ON

TINU

ITY TE

ST

FLAM

E/S

MO

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DE

TEC

TION

FIRE TES

T

TYPE

TEST

RO

UTIN

E TES

T

TCE

.M4-186-30

SP

EC

IFICA

TION

NO

.

1 LANDING / HYDRANT VALVE A A C A A D A

SHO

P INSPEC

TION

REQ

UIR

EMEN

TS FIR

E PRO

TECTIO

N EQ

UIPM

ENT

TATA

CO

NSU

LTING

ENG

INEER

S LIMITED

2 BRANCH PIPES, NOZZLES, HOSE COUPLINGS A A C A

3 FIRE HOSES A A C A B A B B A

4 WATER MONITOR A A C A A A

5 PORTABLE FIRE EXTINGUISHER A A C D

6 M.V., H.V. SPRAY NOZZLES WITH QUARTZOID BULB A A C A

7 DELUGE VALVE A A C A A A

8 FOAM TENDER A A C A A A

9 MAIN AND JOCKEY PUMP A A C D A A D

10 DIESEL ENGINE A A C C A A C

TCE

FOR

M N

O. 329 R

3

LEGEND

A - WITNESSED BY TCE.




NOTES

1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.




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FILE NAM

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MBE

RS

DESCRIPTION

VIS

UA

L EXA

MIN

ATION

DIM

EN

SIO

NS

MA

TER

IAL TE

ST CE

RT.

BO

DY LEA

K TEST

SEA

T LEAK

TEST

FLOW

TES

T

OP

ER

ATIO

N TE

ST

PE

RFO

RM

AN

CE TE

ST

PE

RC

OLATIO

N TES

T

CH

AN

GE

IN D

IA. A

ND

LE

NG

TH

KIN

K TES

T

AC

CE

LER

ATE

D A

GE

ING

WE

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T PER

UN

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NG

TH

BA

LAN

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G

FITME

NT

MAK

ES A

ND

RA

TING

S OF

PA

RTS

WIR

ING

, FUN

CTIO

N

CH

EC

K

INTE

RLO

CK TE

ST

H.V

., I.R., IN

TER

LOC

K

TEST

FLAM

E/S

MO

KE

DE

TEC

TION

FIRE TES

T

TYPE

TEST

RO

UTIN

E TES

T

TCE

.M4-186-30

SP

EC

IFICA

TION

NO

.

11 PIPES, FITTINGS, VALVES A A C D D

SHO

P INSPEC

TION

REQ

UIR

EMEN

TS FIR

E PRO

TECTIO

N EQ

UIPM

ENT

TATA

CO

NSU

LTING

ENG

INEER

S LIMITED

12 FIRE HOSE BOXES A A C A

13 SMOKE DETECTOR A A C A

14 FIRE DOOR A A C A

15 FIRE DAMPER A A C A

16 CONTROL / ZONAL PANEL A A C A A A A A

17 MOTORS > 30 KW / <30 KW D D C A/C

TCE

FOR

M N

O. 329 R

3

LEGEND

A - WITNESSED BY TCE




TAC APPROVAL CERTIFICATES SHALL BE FURNISHED, WHEREVER CALLED FOR.

NOTES

1. ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.

2. WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.

3. THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS MENTIONED IN TCE. M4 - 904 AND RELEVANT TECHNICAL SPECIFICATIONS.

4. THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

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FILE NAM

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DESCRIPTION

VIS

UA

L EXA

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ATION

DIM

EN

SIO

NS

MA

TER

IAL TE

ST C

ER

TIFICA

TE

IDE

NTIFIC

ATIO

N A

ND

C

OR

RE

LATIO

N

ULTR

AS

ON

IC TE

ST

WE

LDIN

G

QU

ALIFIC

ATIO

NS

FIT UP

BA

CK C

HIP

- PT

PT / M

T

RA

DIO

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APH

Y

WE

LD P

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FILE,

UN

DE

RC

UT, O

VE

RLAP

STR

AIGH

TNES

S, D

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ING

SU

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CE FIN

ISH

CO

ATIN

G TH

ICK

NES

DIP

, STRIP, A

DH

ESIO

N

TESTS

TCE

.M4-186-35

SP

EC

IFICA

TION

NO

.

1 STRUCTURAL MATERIALS, PLATES D D C A B

SHO

P INSPEC

TION

REQ

UIR

EMEN

TS STR

UC

TUR

AL FA

BR

ICA

TION

TATA

CO

NSU

LTING

ENG

INEER

S LIMITED

2 FASTENERS A A C A

3 FLAME CUT / SHEARED EDGES B

4 BUTT AND GROOVE WELDS A A C/A D D B B A

5 FILLET WELDS A A C/A D B A

6 PROTOTYPE ASSEMBLED STRUCTURE A A A AX

7 FINAL ASSEMBLED STRUCTURES A A A AX A

8 GALVANIZING (IF SPECIFIED) A A A A

9 PAINTING (IF SPECIFIED) A A A

LEGEND

A - WITNESSED BY TCE. B - WITNESSED BY TCE IF REQUIREMENT IS SPECIFIED. C - RECORDS VERIFIED BY TCE WHEREVER APPLICABLE. D - A OR C, AT TCE'S DISCRETION WHEREVER APPLICABLE.

X - SHALL BE CHECKED ON LEVELLED, RIGID FLOORING FOR STRAIGHTNESS / VERTICALITY / DEFLECTION / FLATNESS, CAMBER, SWEEP (FOR CURVED PORTIONS), LATERAL VARIATION BETWEEN WEB AND FLANGE, SQUARENESS OF STIFFENERS.

NOTES 1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.




TCE

FOR

M N

O. 329 R

3

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CONSULTING ENGINEERS LIMITEDMUMBAI


³

³




³


OISD - GDN - 192 July, 2000 FOR RESTRICTED CIRCULATION No.

SAFETY PRACTICES DURING CONSTRUCTION

OISD-GDN-192

Oil Industry Safety Directorate Government of India

Ministry of Petroleum & Natural Gas 7th Floor , New Delhi House

27, Barakhamba Road New Delhi - 110001

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OISD - GDN - 192 July, 2000 FOR RESTRICTED CIRCULATION No.


Prepared by

COMMITTEE ON SAFETY PRACTICES DURING CONSTRUCTION





NOTE OISD (Oil Industry Safety Directorate) publications are

prepared for use in the Oil and Gas Industry under Ministry of Petroleum & natural Gas. These are the property of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the

accuracy and reliability of the data contained in these documents. OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use.

These documents are intended to supplement rather

than replace the prevailing statutory requirements.


FOREWORD

The Oil Industry in India is nearly 100 years old. Due to various

collaboration agreements a variety of international codes, standards and practices are in vogue. Standardisation in design philosophies, operating and maintenance practices at a national level was hardly in existence. This lack of uniformity coupled with feedback from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state of art in designing, operating and maintaining oil and gas installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986

constituted a Safety Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry in formulating and implementing a series of self-regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. Accordingly OISD constituted a number of functional committees comprising of experts nominated from the industry to draw up standards and guidelines on various subjects.

The present document on “Safety Practices during Construction”

was prepared by the Functional Committee on “Safety Practices during Construction”. This document is based on the accumulated knowledge and experience of industry members and the various national and international codes and practices.

It is hoped that provisions of this document if implemented

objectively, may go a long way to improve the safety to reduce accidents in Oil and Gas Industry. Users are cautioned that no document can be substitute for the judgment of responsible and experienced engineer.

Suggestions are invited from the users after it is put into practice to

improve the document further. Suggestions for amendments, if any, to this standard should be addressed to:

The Co-ordinator Committee on “Safety Practices during Construction”




This document in no way supersedes the statutory regulations of

Chief Controller of Explosives (CCE), Factory Inspectorate or any other statutory body, which must be followed as applicable.


FUNCTIONAL COMMITTEE ON SAFETY PRACTICES DURING CONSTRUCTION

NAME ORGANISATION LEADER Shri A.K. Tandon EIL, New Delhi.

MEMBERS 1. Shri U.M. Rao GAIL, Noida.

2. Shri K.N. Ravindran CRL, Cochin

3. Shri P.K. Anand ONGC, Mumbai.

4. Shri H.N. Das ONGCL, Nazaria.

5. Shri Jagnandan Tyagi IOC(PL) Nodia.

6. Shri M.C Lohar IBP Co. Ltd., Calcutta.

7. Shri J.C. Agrawal IOC, Mktg, New Delhi.

8. Shri S.M. Ghotavadekar HPCL, Mumbai.

9. Shri Sanjoy Ghose BPCL, Mumbai.

10. Shri H. C Jha “Hari” IOC-Panipat Refinery.

11. Shri Suhas Kate HPCL, Visakh.

Member-Coordinator

Shri A.K. Ranjan OISD, New Delhi


CONTENTS SECTION Page No. 1.0 Introduction 1 2.0 Scope 1 3.0 Definitions 1 4.0 General Duties 2 4.1 General Duties Of Execution Agencies 2 4.2 General Duties Of Owners 3 5.0 Safety Practices At Work Places 3 5.1 General Provisions 3 5.2 Means Of Access And Egress 4 5.3 Housekeeping 4 5.4 Precautions Against The Fall Of Materials And Persons, 4

And Collapse Of Structures 5.5 Prevention Of Unauthorised Entry 4 5.6 Fire Prevention And Fire Fighting 4 5.7 Lighting 5 5.8 Plant, Machinery, Equipment and Hand Tools 5 6.0 Construction Activities 6 6.1 Excavation 6 6.2 Scaffolding, Platforms & Ladders 8 6.3 Structural Work, Laying Of Reinforcement & Concreting 10 6.4 Road Work 13 6.5 Cutting/Welding 13 6.6 Working In Confined Spaces 14 6.7 Proof/Pressure Testing 15 6.8 Working At Heights 16 6.9 Handling And Lifting Equipment 17 6.10 Vehicle Movement 21 6.11 Electrical 22 6.12 Offshore 24 6.13 Demolition 27 6.14 Radiography 28

6.15 Sand/Shot Blasting / Spray Painting 28

6.16 Work above Water 29

7.0 Additional Safety Precaution for Units with Hydrocarbons 29 8.0 First Aid 30 9.0 Documentation 31 10.0 Safety Awareness & Training 31 11.0 References 32

Annexure I 33



1.0 INTRODUCTION

Safety in Construction Management deserves utmost attention especially in the hydrocarbon industry, such as Exploration, Refineries, Pipelines and Marketing installations, Gas Processing units etc. Construction is widely recognised as one of the accident prone activities. Most of the accidents are caused by inadequate planning, failure during the construction process and/or because of design deficiencies. Besides property loss, accidents also result in injuries and fatalities to the personnel; same needs to be prevented.

The reasons for accidents during construction activities are related to unique nature of the industry, human behaviour, difficult work-site conditions, extended odd duty hours, lack of training & awareness and inadequate safety management. Unsafe working methods, equipment failure and improper housekeeping also tend to increase the accident rate in construction.

Ensuring good quality of materials, equipment and competent supervision along with compliance of standard engineering practices shall go a long way to in built safety into the system.

The objective of this standard is to provide practical guidance on technical and educa-tional framework for safety and health in construction with a view to:

(a) prevent accidents and harmful effects on the health of workers arising from employment in construction;

(b) ensure appropriate safety during implementation of construction;

(c) provide safety practice guidelines for appropriate measures of planning, control and enforcement.

2.0 SCOPE

This document specifies broad guidelines on safe practices to be adhered to during construction activities in oil industry. However, before commencing any job, specific hazards and its effects should be assessed and necessary corrective/preventive actions should be taken by all concerned. The document is intended only to supplement and not to

replace or supersede the prevailing statutory requirements, which shall also be followed as applicable. For Personal Protective Equipment, OISD-STD-155 (Part I&II) shall be referred to. The scope of this document does not include the design aspects and quality checks during construction.

3.0 DEFINITIONS

Definitions of various terminology are given below:

• Adequate, appropriate or suitable are used to describe qualitatively or quantitatively the means or method used to protect the worker.

• Brace: A structural member that holds one point in a fixed position with respect to another point; bracing is a system of structural members designed to prevent distortion of a structure.

• By hand: The work is done without the help of a mechanised tool.

• Competent Authority: A stautory agency having the power to issue regulations, orders or other instructions having the force of law.

• Competent person: A person possessing adequate qualifications, such as suitable training and sufficient knowledge, experience and skill for the safe performance of the specific work. The competent authorities may define appropriate criteria for the designation of such persons and may determine the duties to be assigned to them.

• Execution agency:

Any physical or legal person, having contractual obligation with the owner, and who employs one or more workers on a construction site

• Owner:

Any physical or legal person for whom construction job is carried out.

It shall also include owner's designated representative/consultant/nominee/agent, authorised from time to time to act for and on its behalf, for supervising/


coordinating the activities of the execution agency.

• Hazard: Danger or potential danger.

• Guard-rail: An adequately secured rail erected along an exposed edge to prevent persons from falling.

• Hoist: A machine, which lifts materials or persons by means of a platform, which runs on guides.

• Lifting gear: Any gear or tackle by means of which a load can be attached to a lifting appliance but which does not form an integral part of the appliance or load.

• Lifting appliance: Any stationary or mobile appliance used for raising or lowering persons or loads.

• Means of access or egress: Passageways, corridors, stairs, plat-forms, ladders and any other means for entering or leaving the workplace or for escaping in case of danger.

• Scaffold: Any fixed, suspended or mobile temporary structure supporting workers and material or to gain access to any such structure and which is not a lifting appliance as defined above.

• Toe-board: A barrier placed along the edge of a scaffold platform, runway, etc., and secured there to guard against the slipping of persons or the falling of material.

• Worker: Any person engaged in construction activity.

• Workplace: All places where workers need to be or to go by reason of their work.

4.0 GENERAL DUTIES 4.1 GENERAL DUTIES OF

EXECUTION AGENCIES

4.1.1 Execution agency should:

i) provide means and organisation to comply with the safety and health measures required at the workplace.

ii) provide and maintain workplaces, plant, equipment, tools and machinery and organise

construction work so that, there is no risk of accident or injury to health of workers. In particular, construction work should be planned, prepared and undertaken so that:

(a) dangers, liable to arise at the workplace, are prevented;

(b) excessively or unnecessarily strenuous work positions and movements are avoided;

(c) organisation of work takes into account the safety and health of workers;

(d) materials and products used are suitable from a safety and health point of view;

(e) working methods are adopted to safeguard workers against the harmful effects of chemical, physical and biological agents.

iii) establish committees with repre-sentatives of workers and management or make other arrangement for the participation of workers in ensuring safe working conditions.

iv) arrange for periodic safety inspec-tions by competent persons of all buildings, plant, equipment, tools, machinery, workplaces and review of systems of work, regulations, standards or codes of practice. The competent person should examine and ascertain the safety of construction machinery and equipment.

v) provide such supervision to ensure that workers perform their work with due regard to safety and health of theirs as well as that of others.

vi) Employ only those workers who are qualified, trained and suited by their age, physique, state of health and skill.

vii) satisfy themselves that all workers are informed and instructed in the hazards connected with their work and environment and trained in the precautions necessary to avoid accidents and injury to health.

viii) Ensure that buildings, plant, equipment, tools, machinery or workplaces in which a dangerous defect has been found should not be used until the defect has been rectified.


ix) Organise for and remain always prepared to take immediate steps to stop the operation and evacuate workers as appropriate, where there is an imminent danger to the safety of workers.

x) establish a checking system by which it can be ascertained that all the members of a shift, including operators of mobile equipment, have returned to the camp or base at the close of work on dispersed sites and where small groups of workers operate in isolation.

xi) provide appropriate first aid, training and welfare facilities to workers as per various statutes like the Factories Act, 1948 etc. and, whenever collective measures are not feasible or are insufficient, provide and maintain personal protective equipment and clothing in line with the requirement as per OISD-STD-155 (Vol. I& II) on Personnel Protective Equipment. They should also provide access to workers to occupational health services.

xii) Educate workers about their right and the duty at any workplace to participate in ensuring safe working conditions to the extent of their control over the equipment and methods of work and to express views on working procedures adopted as may affect safety and health.

xiii) Ensure that except in an emergency, workers, unless duly authorised, should not interfere with, remove, alter or displace any safety device or other appliance furnished for their protection or the protection of others, or interfere with any method or process adopted with a view to avoiding accidents and injury to health.

xiv) Ensure that workers do not operate or interfere with plant and equipment that they have not been duly authorised to operate, maintain or use.

xv) Ensure that workers do not sleep, rest or cook etc in dangerous places such as scaffolds, railway tracks, garages, confined spaces or in the vicinity of fires, dangerous or toxic

substances, running machines or vehicles and heavy equipment etc.

xvii) Obtain the necessary clearance/permits as required and specified by owner

xviii) As per the Govt. circular as

amended from time to time all contractors who employ more than 50 workers or where the contract value exceeds Rs. 50 crores, the following facilities are to be provided by contractor at site :

• Arrangement for drinking water • Toilet facilities • A creche where 10 or more women

workers are having children below the age of 6 years

• Transport arrangement for attending to emergencies

xix) should deploy a safety officer at site

4.2 GENERAL DUTIES OF OWNERS

4.2.1 Owners should:

i) co-ordinate or nominate a competent person to co-ordinate all activities relating to safety and health on their construction projects;

ii) inform all contractors on the project of special risks to health and safety;

iii) Ensure that executing agency is aware of the owner's requirements and the executing agency's responsibilities with respect to safetry practices before starting the job.

5.0 SAFETY PRACTICES AT WORK PLACES

5.1. GENERAL PROVISIONS

5.1.1 All openings and other areas likely to pose danger to workers should be clearly indicated.

5.1.2 Workers & Supervisors should use the safety helmet and other requisite Personal Protective Equipment according to job & site requirement. They should be trained to use personal protective equipment.

5.1.3 Never use solvents, alkalis and other oils to clean the skin.

5.1.4 Lift the load with back straight and knees bent as far as possible. Seek the help in case of heavy load.


5.1.5 Ensure the usage of correct and tested tools and tackles. Don't allow the make shift tools and tackles.

5.1.6 No loose clothing should be allowed while working near rotating equipment or working at heights.

5.2 MEANS OF ACCESS AND EGRESS

Adequate and safe means of access (atleast two, differently located) to and egress from all workplaces should be provided. Same should be displayed and maintained.

5.3 HOUSEKEEPING

5.3.1 Ensure:

i) proper storage of materials and equipment;

ii) removal of scrap, inflammable material, waste and debris at appropriate intervals.

5.3.2 Removal of loose materials, which are not required for use, to be ensured. Accumulation of these at the site can obstruct means of access to and egress from workplaces and passageways.

5.3.3 Workplaces and passageways, that are slippery owing to oil, grease or other causes, should be cleaned up or strewn with sand, sawdust, ash etc.

5.4 PRECAUTIONS AGAINST THE FALL OF MATERIALS & PERSONS AND COLLAPSE OF STRUCTURES

5.4.1 Precautions should be taken such as the provision of fencing, look-out men or barriers to protect any person against injury by the fall of materials, or tools or equipment being raised or lowered.

5.4.2 Where necessary to prevent danger, guys, stays or supports should be used or other effective precautions should be taken to prevent the collapse of structures or parts of structures that are being erected, maintained, repaired, dismantled or demolished.

5.4.3 All openings through which workers are liable to fall should be kept

effectively covered or fenced and displayed prominently.

5.4.4 As far as practicable, guardrails and toe-boards should be provided to protect workers from falling from elevated workplaces.

5.5 PREVENTION OF UNAUTHORISED ENTRY

5.5.1 Construction sites located in built-up areas and alongside vehicular and pedestrian traffic routes should be fenced to prevent the entry of unauthorised persons.

5.5.2 Visitors should not be allowed access to construction sites unless accompanied by or authorised by a competent person and provided with the appropriate protective equipment.

5.6 FIRE PREVENTION AND FIRE FIGHTING

5.6.1 All necessary measures should be taken by the executing agency and owner to:

i) avoid the risk of fire; ii) control quickly and efficiently

any outbreak of fire; iii) bring out a quick and safe

evacuation of persons. iv) Inform unit/fire station control

room, where construction work is carried out within existing operating area.

5.6.2 Combustible materials such us packing materials, sawdust, greasy/oily waste and scrap wood or plastics should not be allowed to accumulate in workplaces but should be kept in closed metal containers in a safe place.

5.6.3 Places where workers are employed should, if necessary to prevent the danger of fire, be provided with:

i) suitable and sufficient fire-extinguishing equipment, which should be easily visible and accessible;

ii) an adequate water supply at sufficient pressure meeting the requirements of various OISD standards.

5.6.4 To guard against danger at places having combustible material,


workers should be trained in the action to be taken in the event of fire, including the use of means of escape.

5.6.5 At sites having combustible material, suitable visual signs should be provided to indicate clearly the direction of escape in case of fire.

5.6.6 Means of escape should be kept clear at all times. Escape routes should be frequently inspected particularly in high structures and where access is restricted.

5.7 LIGHTING

5.7.1 Where natural lighting is not adequate, working light fittings or portable hand-lamps should be provided at workplace on the construction site where a worker will do a job.

5.7.2 Emergency lighting should be provided for personnel safety during night time to facilitate standby lighting source, if normal system fails.

5.7.2 Artificial lighting should not produce glare or disturbing shadows.

5.7.3 Lamps should be protected by guards against accidental breakage.

5.7.4 The cables of portable electrical lighting equipment should be of adequate size & characteristics for the power requirements and of adequate mechanical strength to withstand severe conditions in construction operations.

5.8 PLANT, MACHINERY, EQUIPMENT AND HAND TOOLS

5.8.1 General Provisions

i) Plant, machinery and equipment including hand tools, both manual and power driven, should:

a) be of proper design and construction, taking into account health, Safety and ergonomic principles.

b) be maintained in good working order;

c) be used only for work for which they have been designed.

d) be operated only by workers who have been authorised and given appropriate training.

e) be provided with protective guards, shields or other devices as required.

ii) Adequate instructions for safe use should be provided.

iii) Safe operating procedures should be established and used for all plant, machinery and equipment.

iv) Operators of plant, machinery and equipment should not be distracted while work is in progress.

v) Plant, machinery and equipment should be switched off when not in use and isolated before any adjustment, clearing or maintenance is done.

vi) Where trailing cables or hose pipes are used they should be kept as short as practicable and not allowed to create a hazard.

vii) All moving parts of machinery and equipment should be enclosed or adequately guarded.

viii) Every power-driven machine and equipment should be provided with adequate means, immediately accessible and readily identifiable to the operator, of stopping it quickly and preventing it from being started again inadvertently.

ix) Operators of plant, machinery, equipment and tools should be provided with PPEs, including where necessary, suitable ear protection.

5.8.2 Hand tools

i) Hand tools should be repaired by competent persons.

ii) Heads of hammers and other shock tools should be dressed or ground to a suitable radius on the edge as soon as they begin to mushroom or crack.

iii) When not in use and while being carried or transported sharp tools should be kept in sheaths, shields, chests or other suitable containers.

iv) Only insulated or nonconducting tools should be used on or near live electrical installations.


v) Only non-sparking tools should be used near or in the presence of flammable or explosive dusts or vapours.

5.8.3 Pneumatic Tools i) Operating triggers on portable

pneumatic tools should be: a) so placed as to minimise the risk of

accidental starting of the machine. b) so arranged as to close the air inlet

valve automatically when the pressure of the operator's hand is removed.

ii) Hose and hose connections for compressed air supply to portable pneumatic tools should be:

a) designed and tested for the pressure and service for which they are intended;

b) fastened securely on the pipe outlet and equipped with the safety chain, as appropriate.

iii) Pneumatic shock tools should be equipped with safety clips or retainers to prevent dies and tools from being accidentally expelled from the barrel.

iv) Pneumatic tools should be disconnected from power and the pressure in hose lines released before any adjustment or repair is made.

5.8.4 Electrical Tools

i) Low voltage portable electrical tools should generally be used.

ii) All electrical tools should be earthed, unless they are "all insulated" or "double insulated" tools which do not require earthing.

iii) All electrical tools should get inspected and maintained on a regular basis by a competent electrician and complete records kept.

5.8.5 Engines

i) Engines should:

a) be installed so that they can be started safely and the maximum safe speed cannot be exceeded.

b) have controls for limiting speed.

c) have devices to stop them from a safe place in an emergency.

ii) IC engines should not be run in

confined spaces unless adequate exhaust ventilation is provided.

iii) When IC engines are being fuelled:

a) the engine should be shut off. b) care should be taken to avoid

spilling fuel; c) no person should smoke or have an

naked light in the vicinity. d) a fire extinguisher should be kept

readily available.

iv) Secondary fuel reservoir should be placed outside the engine room.

6.0 CONSTRUCTION ACTIVITIES

The various common activities in construction are as under:

• Excavation • Scaffolding, Platforms & Ladders • Structural Work, Laying of

Reinforcement & Concreting • Road Work (Laying of roads) • Cutting /Welding • Working in Confined Space • Proof/Pressure Testing • Working at Heights • Handling & Lifting Equipments • Vehicle Movement • Electrical • Offshore • Demolition • Radiography • Sand/shot blasting/ spray

painting • Work above water

The safe practices to be followed during the implementation of above construction activities are given below:

6.1 EXCAVATION

6.1.1 All excavation work should be planned and the method of excavation and the type of support


work required should be decided considering the following:

i) the stability of the ground; ii) the excavation will not affect

adjoining buildings, structures or roadways;

iii) to prevent hazard, the gas, water, electrical and other public utilities should be shut off or disconnected, if necessary;

iv) presence of underground pipes, cable conductors, etc.,

v) the position of culvert/bridges, temporary roads and spoil heaps should be determined;

6.1.2 Before digging begins on site, all excavation work should be planned and the method of excavation and the type of support work required decided.

6.1.3 All excavation work should be supervised.

6.1.4 Sites of excavations should be thoroughly inspected:

i) daily, prior to each shift and after interruption in work of more than one day;

ii) after every blasting operation; iii) after an unexpected fall of

ground; iv) after substantial damage to

supports; v) after a heavy rain, frost or snow; vi) when boulder formations are

encountered.

6.1.5 Safe angle of repose while excavating trenches exceeding 1.5m depth upto 3.0m should be maintained. Based on site conditions, provide proper slope, usually 450,and suitable bench of 0.5m width at every 1.5m depth of excavation in all soils except hard rock or provide proper shoring and strutting to prevent cave-in or slides.

6.1.6 As far as possible, excavated earth should not be placed within one meter of the edge of the trench or depth of trench whichever is greater.

6.1.7 Don't allow vehicles to operate too close to excavated area. Maintain atleast 2m distance from edge of excavation. No load, plant or equipment should be placed or moved near the edge of any excavation where it is likely to cause

its collapse and thereby endanger any person unless precautions such as the provision of shoring or piling are taken to prevent the sides from collapsing.

6.1.8 Adequately anchored stop blocks and barriers should be provided to prevent vehicles being driven into the excavation. Heavy vehicles should not be allowed near the excavation unless the support work has been specially designed to permit it.

6.1.9 If an excavation is likely to affect the security of a structure on which persons are working, precautions should be taken to protect the structure from collapse.

6.1.10 Barricade at 1m height (with red & white band/self glowing caution board) should be provided for excavations beyond 1.5m depth. Provide two entries/exits for such excavation.

6.1.11 Necessary precautions should be taken for underground utility lines like cables, sewers etc. and necessary approvals/clearances from the concerned authorities shall be obtained before commencement of the excavation job.

6.1.12 Water shall be pumped/bailed out, if any accumulates in the trench. Necessary precautions should be taken to prevent entry of surface water in trenches.

6.1.13 During rains, the soil becomes loose. Take additional precaution against collapse of side wall.

6.1.14 In hazardous areas, air should be tested to ascertain its quality. No one should be allowed entry till it is suitable for breathing.

6.1.15 In case of mechanised excavation, precaution shall be taken to not to allow anybody to come within one meter of extreme reach of the mechanical shovel. The mechanised excavator shall be operated by a well-trained experienced operator. When not in operation, the machine shall be kept on firm leveled ground with mechanical shovel resting on ground. Wheel or belt shall be suitably jammed to prevent any accidental movement of the


machine. Suitable precautions as per manufacturer guidelines should be taken for dozers, graders and other heavy machines.

6.1.16 In case of blasting, follow strictly IS:4081-1986 & Indian Explosive Act and rules for storage, handling and carrying of explosive materials and execution of blasting operation.

6.2 SCAFFOLDING, PLATFORMS & LADDERS

6.2.1 Metal as material of construction

i) A scaffold should be provided and maintained or other equally safe and suitable provision should be made where work cannot safely be done on or from the ground or from part of a building or other permanent structure.

ii) Scaffolds should be provided with safe means of access, such as stairs, ladders or ramps. Ladders should be secured against inadvertent movement.

iii) Every scaffold should be constructed, erected and maintained so as to prevent collapse or accidental displacement when in use.

iv) Every scaffold and part thereof should be constructed :

(a) in such a way so as not to cause hazards for workers during erec-tion and dismantling;

(b) in such a way so as guard rails and other protective devices, platforms, ladders, stairs or ramps can be easily put together;

(c) with sound material and of requisite size and strength for the purpose for which it is to be used and maintained in a proper condition.

v) Boards and planks used for scaf-folds should be protected against splitting.

vi) Materials used in the construction of scaffolds should be stored under good conditions and apart from any material unsuitable for scaffolds.

vii) Couplers should not cause deformation in tubes. Couplers should be made of drop forged steel or equivalent material.

viii) Tubes should be free from cracks, splits and excessive corrosion and be straight to the eye, and tube ends cut cleanly square with the tube axis.

ix) Scaffolds should be designed for their maximum load as per relevant code.

x) Scaffolds should be adequately braced.

xi) Scaffolds which are not designed to be independent should be rigidly connected to the building at designated vertical and horizontal places.

xii) A scaffold should never extend above the highest anchorage to an extent which might endanger its stability and strength.

xiii) Loose bricks, drainpipes, chimney-pots or other unsuitable material should not be used for the construction or support of any part of a scaffold.

xiv) Scaffolds should be inspected and certified:

(a) before being taken into use; (b) at periodic intervals thereafter as

prescribed for different types of scaffolds;

(c) after any alteration, interruption in use, exposure to weather or seismic conditions or any other occurrence likely to have affected their strength or stability.

xv) Inspection should more particularly ascertain that:

(a) the scaffold is of suitable type and adequate for the job;

(b) materials used in its construction are sound and of sufficient strength;

(c) it is of sound construction and stable;

(d) that the required safeguards are in position.

xvi) A scaffold should not be erected, substantially altered or dismantled except by or under the supervision.

xvii) Every scaffold should be maintained in good and proper condition, and every part should be kept fixed or secured so that no part can be


displaced in consequence of normal use.

xviii) If out-rigger scaffolding is to be used, it should be specifically designed and inspected before putting in use.

6.2.2 Lifting appliances on scaffolds

i) When a lifting appliance is to be used on a scaffold:

(a) the parts of the scaffold should be carefully inspected to determine the additional strengthening and other safety measures required;

(b) any movement of the scaffold members should be prevented;

(c) if practicable, the uprights should be rigidly connected to a solid part of the building at the place where the lifting appliance is erected.

6.2.3 Prefabricated scaffolds

i) In the case of prefabricated scaffold systems, the instructions provided by the manufacturers or suppliers should be strictly adhered to. Prefabricated scaffolds should have adequate arrangements for fixing bracing.

ii) Frames of different types should not be intermingled in a single scaffold.

iii) Scaffolding shall be erected on firm and level ground.

iv) All members of metal scaffolding shall be checked periodically to screen out defective / rusted members. All joints should be properly lubricated for easy tightening.

v) Entry to scaffolding should be restricted.

vi) Erection, alteration and removal shall be done under supervision of experienced personnel.

vii) Use of barrels, boxes, loose bricks etc., for supporting platform shall not be permitted.

viii) Each supporting member of platform shall be securely fastened and braced

ix) Where planks are butt-joined, two parallel putlogs shall be used, not

more than 100mm apart, to give support to each plank.

x) Platform plank shall not project beyond its end support to a distance exceeding 4 times the thickness of plank, unless it is effectively secured to prevent tipping. Cantilever planks should be avoided.

xi) The platform edges shall be provided with 150mm high toe board to eliminate hazards of tools or other objects falling from platform.

xii) Erect ladders in the “four up-one out position”

xiii) Lash ladder securely with the structure.

xiv) Using non-slip devices, such as, rubber shoes or pointed steel ferules at the ladder foot, rubber wheels at ladder top, fixing wooden battens, cleats etc.

xv) When ladder is used for climbing over a platform, the ladder must be of sufficient length, to extend at least one meter above the platform, when erected against the platform in “four up-one out position.”

xvi) Portable ladders shall be used for heights not more than 4mt. Above 4mt flights, fixed ladders shall be provided with at least 600 mm landings at every 6mt or less.

xvii) The width of ladder shall not be less than 300mm and rungs shall be spaced not more than 300mm.

xviii) Every platform and means of access shall be kept free from obstruction.

xix) If grease, mud, gravel, mortar etc., fall on platform or scaffolds, these shall be removed immediately to avoid slippage.

xx) Workers shall not be allowed to work on scaffolds during storms or high wind. After heavy rain or storms, scaffolds shall be inspected before reuse.

xxi) Don't overload the scaffolding. Remove excess material and scrap immediately.

xxii) Dismantling of scaffolds shall be done in a pre-planned sequential manner.


6.2.4 Suspended scaffolds/boatwain's chair

i) In addition to the requirements for scaffolds in general as regards soundness, stability and protection against the risk of falls, suspended scaffolds should meet the following specific requirements.

(a) platforms should be designed and built with dimensions that are compatible with the stability of the structure as a whole, especially the length;

(b) the number or anchorage should be compatible with the dimensions of the platform;

(c) the safety of workers should be safeguarded by an extra rope having a point of attachment independent of the anchorage arrangements of the scaffold;

(d) the anchorage and other elements of support of the scaffold should be designed and built in such a way as to ensure sufficient strength;

(e) the ropes, winches, pulleys or pulley blocks should be designed, assembled, used and maintained according to the requirements established for lifting gear adapted to the lifting of persons according to national laws and regulations;

(f) Before use, the whole structure should be checked by a competent person.

6.2.5 Bamboo Scaffolding

i) In general, it should be avoided as far as possible. It should not be used in the unit/off-site areas and where hot work is to be done.

ii) For construction and maintenance of residential and office buildings, situated outside explosive licensed area, bamboo scaffold, if used, should conform to provisions given in lS-3696 (Part 1)-1987.

6.3 STRUCTURAL WORK, LAYING OF REINFORCEMENT & CONCRETING

6.3.1 General provisions

i) The erection or dismantling of buildings, structures, civil

engineering works, formwork, falsework and shoring should be carried out by trained workers only under the supervision of a competent person.

ii) Precautions should be taken to guard against danger to workers arising from any temporary state of weakness or instability of a structure.

iii) Formwork, falsework and shoring should be so designed, constructed and maintained that it will safely support all loads that may be imposed on it.

iv) Formwork should be so designed and erected that working platforms, means of access, bracing and means of handling and stabilising are easily fixed to the formwork structure.

6.3.2. Erection and dismantling of steel and prefabricated structures

i) The safety of workers employed on the erection and dismantling of steel and prefabricated structures should be ensured by appropriate means, such as provision and use of:

(a) ladders, gangways or fixed platforms;

(b) platforms, buckets, boatswain's chairs or other appropriate means suspended from lifting appliances;

(c) safety harnesses and lifelines, catch nets or catch platforms;

(d) Power-operated mobile working platforms.

ii) Steel and prefabricated structures should be so designed and made that they can be safely transported and erected.

iii) In addition to the need for the stability of the part when erected, the design should explicitly take following into account:

(a) the conditions and methods of attachment in the operations of transport, storing and temporary support during erection or dismantling as applicable;

(b) Methods for the provision of safeguards such as railings and working platforms, and, when necessary, for mounting them


easily on the structural steel or prefabricated parts.

iv) The hooks and other devices built in or provided on the structural steel or prefabricated parts that are required for lifting and transporting them should be so shaped, dimensioned and positioned as:

(a) to withstand with a sufficient margin the stresses to which they are subjected;

(b) Not to set up stresses in the part that could cause failures, or stresses in the structure itself not provided for in the plans, and be designed to permit easy release from the lifting appliance. Lifting points for floor and staircase units should be located (recessed if necessary) so that they do not protrude above the surface;

(c) To avoid imbalance or distortion of the lifted load.

v) Storeplaces should be so constructed that:

(a) there is no risk of structural steel or prefabricated parts falling or overturning;

(b) storage conditions generally ensure stability and avoid damage having regard to the method of storage and atmo-spheric conditions;

(c) racks are set on firm ground and designed so that units cannot move accidentally.

vi) While they are being stored, transported, raised or set down, structural steel or prefabricated parts should not be subjected to stresses prejudicial to their stability.

vii) Every lifting appliance should:

(a) be suitable for the operations and not be capable of accidental disconnection;

(b) be approved or tested as per statutory requirement.

viii) Lifting hooks should be of the self-closing type or of a safety type and should have the maximum permissible load marked on them.

ix) Tongs, clamps and other appliances for lifting structural steel and prefabricated parts should:

(a) be of such shape and dimensions as to ensure a secure grip without damaging the part;

(b) be marked with the maximum permissible load in the most unfavourable lifting conditions.

x) Structural steel or prefabricated parts should be lifted by methods or appliances that prevent them from spinning accidentally.

xi) When necessary to prevent danger, before they are raised from the ground, structural steel or prefabricated parts should be provided with safety devices such as railings and working platforms to prevent falls of persons.

xii) While structural steel or prefabricated parts are being erected, the workers should be provided with appliances for guiding them as they are being lifted and set down, so as to avoid crushing of hands and to facilitate the operations. Use of such appliances should be ensured.

xiii) A raised structural steel or prefabricated part should be so secured and wall units so propped that their stability cannot be imperiled, even by external agencies such as wind and passing loads before its release from the lifting appliance.

xiv) At work places, instruction should be given to the workers on the methods, arrangements and means required for the storage, transport, lifting and erection of structural steel or prefabricated parts, and, before erection starts, a meeting of all those responsible should be held to discuss and confirm the requirements for safe erection.

xv) During transportation within the construction area, attachments such as slings and stirrups mounted on structural steel or prefabricated parts should be securely fastened to the parts.

xvi) Structural steel or prefabricated parts should be so transported that the conditions do not affect the stability of the parts or the means of transport result in jolting, vibration or stresses due to blows, or loads of material or persons.


xvii) When the method of erection does not permit the provision of other means of protection against fall of persons, the workplaces should be protected by guardrails, and if appropriate by toe-boards.

xviii) When adverse weather conditions such as snow, ice and wind or reduced visibility entail risks of accidents, the work should be carried on with particular care, or, if necessary, interrupted.

xix) Structures should not be worked on during violent storms or high winds, or when they are covered with ice or snow, or are slippery from other causes.

xx) If necessary, to prevent danger, structural steel parts should be equipped with attachments for suspended scaffolds, lifelines or safety harnesses and other means of protection.

xxi) The risks of falling, to which workers moving on high or sloping girders are exposed, should be limited by all means of adequate collective protection or, where this is imposs-ible, by the use of a safety harness that is well secured to a strong support.

xxii) Structural steel parts that are to be erected at a great height should as far as practicable be assembled on the ground.

xxiii) When structural steel or prefabricated parts are being erected, a sufficiently extended area underneath the workplace should be barricaded or guarded

xxiv) Steel trusses that are being erected should be adequately shored, braced or guyed until they are permanently secured in position.

xxv) Load-bearing structural member should not be dangerously weakened by cutting, holing or other means.

xxvi) Structural members should not be forced into place by the hoisting machine while any worker is in such a position that he could be injured by the operation.

xxvii) Open-web steel joists that are hoisted singly should be directly

placed in position and secured against dislodgment.

6.3.3 Reinforcement

i) Ensure that workers use Personnel Protective equipment like safety helmet, safety shoes, gloves etc.

ii) Don't place the hand below the rods for checking clear distance. Use measuring devices.

iii) Don't wear loose clothes while checking the rods.

iv) Don't stand unnecessarily on cantilever rods.

v) To carry out welding/cutting of rods, safety procedures/precautions as mentioned in Item No. 6.5 to be followed.

vi) For supplying of rods at heights, proper staging and/or bundling to be provided.

vii) Ensure barricading and staging for supplying and fixing of rods at height.

viii) For short distance carrying of materials on shoulders, suitable pads to be provided.

ix) While transporting material by trucks/trailers, the rods shall not protrude in front of or by the sides of driver's cabin. In case such protrusion cannot be avoided behind the deck, then it should not extend 1/3rd of deck length or 1.5M which ever is less and tied with red flags/lights.

6.3.4 Concreting

i) Ensure stability of shuttering work before allowing concreting.

ii) Barricade the concreting area while pouring at height/depths.

iii) Keep vibrator hoses, pumping concrete accessories in healthy conditions and mechanically locked.

iv) Pipelines in concrete pumping system shall not be attached to temporary structures such as scaffolds and formwork support as the forces and movements may effect their integrity.


v) Check safety cages & guards around moving motors/parts etc. provided in concreting mixers.

vi) Use Personal Protective Equipment like gloves, safety shoes etc. while dealing with concrete and wear respirators for dealing with cement.

vii) Earthing of electrical mixers, vibrators, etc. should be done and verified.

viii) Cleaning of rotating drums of concrete mixers shall be done from outside. Lockout devices shall be provided where workers need to enter.

ix) Where concrete mixers are driven by internal combustion engine, exhaust points shall be located away from the worker's workstation so as to eliminate their exposure to obnoxious fumes.

x) Don't allow unauthorised person to stand under the concreting area.

xi) Ensure adequate lighting arrangements for carrying out concrete work during night.

xii) Don't allow the same workers to pour concrete round the clock. Insist on shift pattern.

xiii) During pouring, shuttering and its supports should be continuously watched for defects.

6.4 ROAD WORK

6.4.1 Site shall be barricaded and provided with warning signs, including night warning lamps at appropriate locations for traffic diversion.

6.4.2 Filled and empty bitumen drums shall be stacked separately at designated places.

6.4.3 Mixing aggregate with bitumen shall preferably be done with the help of bitumen batch mixing plant, unless operationally non-feasible.

6.4.4 Road rollers, Bitumen sprayers, Pavement finishers shall be driven by experienced drivers with valid driving license.

6.4.5 Workers handling hot bitumen sprayers or spreading bitumen aggregate mix or mixing bitumen

with aggregate, shall be provided with PVC hand gloves and rubber shoes with legging up to knee joints.

6.4.6 At the end of day's work, surplus hot bitumen in tar boiler shall be properly covered by a metal sheet, to prevent anything falling in it,

6.4.7 If bitumen accidentally falls on ground, it shall be immediately covered by sprinkling sand, to prevent anybody stepping on it. Then it shall be removed with the help of spade.

6.4.8 For cement concrete roads, besides site barricading and installation of warning signs for traffic diversion, safe practices mentioned in the chapter on "Concreting", shall also be applicable.

6.5 CUTTING/WELDING

6.5.1 Common hazards involved in welding/cutting are sparks, molten metal, flying particles, harmful light rays, electric shocks etc. Following precautions should be taken: -

i) A dry chemical type fire extinguisher shall be made available in the work area.

ii) Adequate ventilation shall be ensured by opening manholes and fixing a shield or forced circulation of air etc, while doing a job in confined space.

iii) Ensure that only approved and well-maintained apparatus, such as torches, manifolds, regulators or pressure reducing valves, and acetylene generators, be used.

iv) All covers and panels shall be kept in place, when operating an electric Arc welding machine.

v) The work piece should be connected directly to Power supply, and not indirectly through pipelines/structures/equipments etc.

vi) The welding receptacles shall be rated for 63 A suitable for 415V, 3-Phase system with a scraping earth. Receptacles shall have necessary mechanical interlocks and earthing facilities.

vii) All cables, including welding and ground cables, shall be checked for


any worn out or cracked insulation before starting the job. Ground cable should be separate without any loose joints.

viii) Cable coiling shall be maintained at minimum level, if not avoidable.

ix) An energised electrode shall not be left unattended.

x) The power source shall be turned off at the end of job.

xi) All gas cylinders shall be properly secured in upright position.

xii) Acetylene cylinder shall be turned and kept in such a way that the valve outlet points away from oxygen cylinder.

xiii) Acetylene cylinder key for opening valve shall be kept on valve stem, while cylinder is in use, so that the acetylene cylinder could be quickly turned off in case of emergency. Use flash back arrestors to prevent back-fire in acetylene/oxygen cylinder.

xiv) When not in use, valves of all cylinders shall be kept closed.

xv) All types of cylinders, whether full or empty, shall be stored at cool, dry place under shed.

xvi) Forced opening of any cylinder valve should not be attempted.

xvii) Lighted gas torch shall never be left unattended.

xviii) Store acetylene and oxygen cylinders separately.

xix) Store full and empty cylinders separately.

xx) Avoid cylinders coming into contact with heat.

xxi) Cylinders that are heavy or difficult to carry by hand may be rolled on their bottom edge but never dragged.

xxii) If cylinders have to be moved, be sure that the cylinder valves are shut off.

xxiii) Before changing torches, shut off the gas at the pressure reducing regulators and not by crimping the hose.

xxiv) Do not use matches to light torches, use a friction lighter.

xxv) Move out any leaking cylinder immediately.

xxvi) Use trolleys for oxygen & acetylene cylinder and chain them.

xxvii) Always use Red hose for acetylene and other fuel gases and Black for oxygen, and ensure that both are in equal length.

xxviii) Ensure that hoses are free from burns, cuts and cracks and properly clamped.

xxix) Avoid dragging hoses over sharp edges and objects

xxx) Do not wrap hoses around cylinders when in use or stored.

xxxi) Protect hoses from flying sparks, hot slag, and other hot objects.

xxxii) Lubricants shall not be used on Ox-fuel gas equipment.

xxxiii) During cutting/welding, use proper type goggles/face shields.

6.6 WORKING IN CONFINED SPACES

6.6.1 Following safety practices for working in confined space like towers, columns, tanks and other vessels should be followed in addition to the safety guidelines for specific jobs like scaffolding, cutting/welding etc.

i) Shut down, isolate, depressurise and purge the vessel as per laid down procedures.

ii) Entry inside the vessel and to carry out any job should be done after issuance of valid permit only in line with the requirement of OISD-STD-105.

iii) Ensure proper and accessible means of exit before entry inside a confined space.

iv) The number of persons allowed inside the vessel should be limited to avoid overcrowding.

v) When the work is going on in the confined space, there should always be one man standby at the nearby manway.


vi) Before entering inside the vessels underground or located at lower elevation, probability of dense vapours accumulating nearby should also be considered in addition to inside the vessel.

vii) Ensure requisite O2 level before entry in the confined space and monitor level periodically or other wise use respiratory devices.

viii) Check for no Hydrocarbon or toxic substances before entry and monitor level periodically or use requisite Personal Protective Equipment.

ix) Ensure adequate ventilation or use respiratory devices.

x) Depending upon need, necessary respirator system, gas masks and suit shall be worn by everyone entering confined space. In case of sewer, OWS or in the confined area where there is a possibility of toxic or inert gas, gas masks shall be used by everyone while entering.

xi) Barricade the confined spaces during hoisting, radiography, blasting, pressure testing etc.

xii) Use 24V flameproof lamp fittings only for illumination.

xiii) Use tools with air motors or electric tools with maximum voltage of 24V.

xiv) House keeping shall be well maintained.

xv) Safety helmet, safety shoes and safety belt shall be worn by everyone entering the confined space.

xvi) Don't wear loose clothing while working in a confined space.

xvii) In case of the vessels which are likely to contain pyropheric substances (like Iron Sulphide), special care need to be taken before opening the vessel. Attempt should be made to remove the pyropheric substances. Otherwise, these should be always kept wet by suitable means.

xviii) The cutting torches should also be kept outside the vessel immediately after the cutting.

xix) The gas cylinders used for cutting/welding shall be kept outside.

xx) All cables, hoses, welding equipment etc., shall be removed from confined space at end of each work day, even if the work is to be resumed in the same space the next day.

xxi) To the extent possible sludge shall be cleared and removed from outside before entering.

xxii) No naked light or flame or hot work such as welding, cutting and soldering should be permitted inside a confined space or area unless it has been made completely free of the flammable atmosphere, tested and found safe by a competent person. Only non-sparking tools and flameproof hand lamps protected with guard and safety torches should be used inside such confined space or area for initial inspection, cleaning or other work required to be done for making the area safe.

xxiii) Communication should be always maintained between the worker and the attendant.

6.7 PROOF/PRESSURE TESTING

6.7.1 Review test procedure before allowing testing with water or air or any other fluid.

6.7.2 Provide relief valves of adequate size while testing with air or other gases.

6.7.3 Ensure compliance of necessary precautions, step wise loading, tightening of fasteners, grouting etc. before and during testing.

6.7.4 Inform all concerned in advance of the testing.

6.7.5 Keep the vents open before opening any valve for filling/draining of liquid used for hydrotesting. The filling/draining should not exceed the designed rate for pressure testing.

6.7.6 Provide separate gauges of suitable range for pressurising pump and the equipment to be tested.

6.7.7 Provide gauges at designated locations for monitoring of pressures.


6.7.8 Check the calibration of all pressurising equipment and accessories and maintain records.

6.7.9 Take readings at pre-defined intervals.

6.8 WORKING AT HEIGHTS

6.8.1 General Provision

i) While working at a height of more than 3 meters, ISI approved safety belt shall be used.

ii) While working at a height of more than 3 meters, permit should be issued by competent person before commencement of the job.

iii) Worker should be well trained on usage of safety belt including its proper usage at the time of ascending/descending.

iv) All tools should be carried in tool kits to avoid their falling.

v) If the job is on fragile/sloping roof, roof walk ladders shall be used.

vi) Provide lifeline wherever required.

vii) Additional safety measures like providing Fall Arrestor type Safety belt, safety net should be provided depending upon site conditions, job requirements.

viii) Keep working area neat and clean. Remove scrap material immediately.

ix) Don't throw or drop material/equipment from height.

x) Avoid jumping from one member to another. Use proper passageway.

xi) Keep both hands free while climbing. Don't try to bypass the steps of the ladder.

xii) Try to maintain calm at height. Avoid over exertion.

xiii) Avoid movements on beam.

xiv) Elevated workplaces including roofs should be provided with safe means of access and egress such as stairs, ramps or ladders.

6.8.2 Roof Work

i) All roof-work operations should be pre-planned and properly supervised.

ii) Roof work should only be undertaken by workers who are physically and psychologically fit and have the necessary knowledge and experience for such work.

iii) Work on roofs shouldn't be carried on in weather conditions that threaten the safety of workers.

iv) Crawling boards, walkways and roof ladders should be securely fastened to a firm structure.

v) Roofing brackets should fit the slope of the roof and be securely supported.

vi) Where it is necessary for a person to kneel or crouch near the edge of the roof, necessary precautions should be taken.

vii) On a large roof where work have to be carried out at or near the edge, a simple barrier consisting of crossed scaffold tubes supporting a tubing guardrail may be provided.

viii) All covers for openings in roofs should be of substantial construction and be secured in position.

ix) Roofs with a pitch of more than 10 should be treated as sloping.

x) When work is being carried out on sloping roofs, sufficient and suitable crawling boards or roof ladders should be provided and firmly secured in position.

xi) During extensive work on the roof, strong barriers or guardrails and toe-boards should be provided to stop a person from falling off the roof.

xii) Where workers are required to work on or near roofs or other places covered with fragile material, through which they are liable to fall, they should be provided with suitable roof ladders or crawling boards strong enough and when spanning across the supports for the roof covering to support those workers.

xiii) A minimum of two boards should be provided so that it is not necessary for a person to stand on a fragile roof to move a board or a ladder, or for any other reason.


6.8.3 Work on tall chimneys

i) For the erection and repair of tall chimneys, scaffolding should be provided. A safety net should be maintained at a suitable distance below the scaffold.

ii) The scaffold floor should always be at least 65 cm below the top of the chimney.

iii) Under the working floor of the scaffolding the next lower floor should be left in position as a catch platform.

iv) The distance between the inside edge of the scaffold and the wall of the chimney should not exceed 20 cm at any point.

v) Catch platforms should be erected over:

(a) the entrance to the chimney; (b) Passageways and working

places where workers could be endangered by falling objects.

vi) For climbing tall chimneys, access should be provided by:

(a) stairs or ladders; (b) a column of iron rungs securely

embedded in the chimney wall; (c) Other appropriate means.

vii) When workers use the outside rungs to climb the chimney, a securely fastened steel core rope looped at the free end and hanging down at least 3 m should be provided at the top to help the workers to climb on to the chimney.

viii) While work is being done on independent chimneys the area surrounding the chimney should be enclosed by fencing at a safe distance.

ix) Workers employed on the construction, alteration, maintenance or repair of tall chimneys should not:

a) work on the outside without a safety harness attached by a lifeline to a rung, ring or other secure anchorage;

b) put tools between the safety harness and the body or in pockets not intended for the purpose;

c) haul heavy materials or equipment up and down by hand to or from the workplace on the chimney;

d) fasten pulleys or scaffolding to reinforcing rings without first verifying their stability;

e) work alone; f) climb a chimney that is not

provided with securely anchored ladders or rungs;

g) Work on chimneys in use unless the necessary precautions to avoid danger from smoke and gases have been taken.

x) Work on independent chimneys should not be carried on in high winds, icy conditions, fog or during electrical storms.

6.9 HANDLING AND LIFTING EQUIPMENT:


Following are the general guidelines to be followed with regard to all types of handling and lifting equipment in addition to the guidelines for specific type of equipments dealt later on.

i) There should be a well-planned safety programme to ensure that all the lifting appliances and lifting gear are selected, installed, examined, tested, maintained, operated and dismantled with a view to preventing the occurrence of any accident;

ii) All lifting appliances shall be examined by competent persons at frequencies as specified in "The Factories act".

iii) Check thoroughly quality, size and condition of all lifting tools like chain pulley blocks, slings, U-clamps, D-shackles etc. before putting them in use.

iv) Safe lifting capacity of all lifting & handling equipment, tools and shackles should be got verified and certificates obtained from competent authorities before its use. The safe working load shall be marked on them.

v) Check periodically the oil, brakes, gears, horns and tyre pressure of all moving equipments like cranes,


forklifts, trailers etc as per manufacturer's recommendations.

vi) Check the weights to be lifted and accordingly decide about the crane capacity, boom length and angle of erection.

vii) Allow lifting slings as short as possible and check packing at the friction points.

viii) While lifting/placing of the load, no unauthorised person shall remain within the radius of the boom and underneath the load.

ix) While loading, unloading and stacking of pipes, proper wedges shall be placed to prevent rolling down of the pipes.

x) Control longer jobs being lifted up from both ends.

xi) Only trained operators and riggers should carry out the job. While the crane is moving or lifting the load, the trained rigger should be there for keeping a vigil against hitting any other object.

xii) During high wind conditions and nights, lifting of heavy equipments should be avoided. If unavoidable to do erection in night, operator and rigger should be fully trained for night signaling. Also proper illumination should be there.

xiii) Allow crane to move on hard, firm and leveled ground.

xiv) When crane is in idle condition for long periods or unattended, crane boom should either be lowered or locked as per manufacturer's guidelines.

xv) Hook and load being lifted shall remain in full visibility of crane operators, while lifting, to the extent possible.

xvi) Don't allow booms or other parts of crane to come within 3 meters reach of overhead electrical cables.

xvii) No structural alterations or repairs should be made to any part of a lifting appliance, which may affect the safety of the appliance without the permission and supervision of the competent person.

6.9.2 Hoists

i) Hoist shafts should be enclosed with rigid panels or other adequate fencing at:

(a) ground level on all sides; (b) all other levels at all points at

which access is provided; (c) all points at which persons are

liable to be struck by any moving part.

ii) The enclosure of hoist shafts, except at approaches should extend where practicable at least 2mt above the floor, platform or other place to which access is provided except where a lesser height is sufficient to prevent any person falling down the hoistway and there is no risk of any person coming into contact with any moving part of the hoist, but in no case should the enclosure be less than 1mt in height.

iii) The guides of hoist platforms should offer sufficient resistance to bending and, in the case of jamming by a safety catch, to buckling.

iv) Where necessary to prevent danger, adequate covering should be provided above the top of hoist shafts to prevent material falling down them.

v) Outdoor hoist towers should be erected on firm foundations, and securely braced, guyed and anchored.

vi) A ladderway should extend from the bottom to the top of outdoor hoist towers, if no other ladderway exists within easy reach.

vii) Hoisting engines should be of ample capacity to control the heaviest load that they will have to move.

viii) Hoists should be provided with devices that stop the hoisting engine as soon as the platform reaches its highest stopping place.

ix) Winches should be so constructed that the brake is applied when the control handle is not held in the operating position.

x) It should not be possible to set in motion from the platform a hoist, which is not designed for the conveyance of persons.


xi) Winches should not be fitted with pawl and ratchet gears on which the pawl must be disengaged before the platform is lowered.

xii) Hoist platforms should be capable of supporting the maximum load that they will have to carry with a safety factor.

xiii) Hoist platforms should be equipped with safety gear that will hold the platform with the maximum load if the hoisting rope breaks.

xiv) If workers have to enter the cage or go on the platform at landings there should be a locking arrangement preventing the cage or platform from moving while any worker is in or on it.

xv) On sides not used for loading and unloading, hoist platforms should be provided with toe-boards and enclosures of wire mesh or other suitable material to prevent the fall of parts of loads.

xvi) Where necessary to prevent danger from falling objects, hoist platforms should be provided with adequate covering.

xvii) Counterweights consisting of an assemblage of several parts should be made of specially constructed parts rigidly connected together.

xviii) Counterweights should run in guides.

xix) Platforms should be provided at all landings used by workers.

xx) Following notices should be posted up conspicuously and in very legible characters:

(a) on all hoists:

• on the platform: the carrying capacity in kilograms or other appropriate standard unit of weight;

• on the hoisting engine: the lifting capacity in kilograms or other appropriate standard unit of weight;

(b) on hoists authorised or certified for the conveyance of persons:

• on the platform or cage: the maximum number of persons to be carried at one time;

(c) on hoists for goods only:

• on every approach to the hoist and on the platform: prohi-bition of use by persons.

xxi) Hoists intended for the carriage of persons should be provided with a cage so constructed as to prevent any person from falling out or being trapped between the cage and any fixed part of the structure when the cage gate is shut, or from being struck by the counterbalance weight or by articles or materials tailing down the hoistway.

xxii) On each side in which access is provided, the cage should have a gate fitted with devices which ensure that the gate cannot be opened except when the cage is at a landing and that the gate must be closed before the cage can move away from the landing.

xxiii) Every gate in the enclosure of the hoist shaft which gives access from a landing place to the cage should be fitted with devices to ensure that the gate cannot be opened except when the cage is at that landing place, and that the cage cannot be moved away from that landing place until the gate is closed.

6.9.3 Derricks

Stiff-leg derricks

i) Derricks should be erected on a firm base capable of taking the combined weight of the crane structure and maximum rated load.

ii) Devices should be used to prevent masts from lifting out of their seating.

iii) Electrically operated derricks should be effectively earthed from the sole plate or framework.

iv) Counterweights should be so arranged that they do not subject the backstays, sleepers or pivots to excessive strain.

v) When derricks are mounted on wheels:


a) a rigid member should be used to maintain the correct distance between the wheels;

b) they should be equipped with struts to prevent them from dropping if a wheel breaks or the derrick is derailed.

vi) The length of a derrick jib should not be altered without consulting the manufacturer.

vii) The jib of a scotch derrick crane should not be erected within the backstays of the crane.

Guy derricks

i) The restraint of the guy ropes should be ensured by fitting stirrups or anchor plates in concrete foundations.

ii) The mast of guy derricks should be supported by six top guys spaced approximately equally.

iii) The spread of the guys of a guy derrick crane from the mast should not be more than 450 from the horizontal.

iv) Guy ropes of derricks should be equipped with a stretching screw or turnbuckle or other device to regulate the tension.

v) Gudgeon pins, sheave pins and fool bearings should be lubricated frequently.

vi) When a derrick is not in use, the boom should be anchored to prevent it from swinging.

6.9.4 Gin poles

i) Gin poles should:

(a) be straight; (b) consist of steel or other suitable

metal; (c) be adequately guyed and

anchored; (d) be vertical or raked slightly

towards the load; (e) be of adequate strength for the

loads that they will be required to lift/move.

ii) Gin poles should not be spliced and if a gin pole is composed of different elements, they should be assembled in conformity with their intrinsic material strength.

iii) Gin poles should be fastened at their feet to prevent displacement in operation.

iv) Gin poles, which are moved from place to place and re-erected, should not be taken into use again before the pole, lifting ropes, guys, blocks and other parts have been inspected, and the whole appliance has been tested under load.

v) When platforms or skips are hoisted by gin poles, precautions should be taken to prevent them from spinning and to provide for proper landing.

6.9.5 Tower cranes

i) Where tower cranes have cabs at high level, persons, capable and trained to work at heights, should only be employed as crane operators.

ii) The characteristics of the various machines available should be considered against the operating requirements and the surroundings in which the crane will operate before a particular type of crane is selected.

iii) Care should be taken in the assessment of wind loads both during operations and out of service. Account should also be taken of the effects of high structures on wind forces in the vicinity of the crane.

iv) The ground on which the tower crane stands should have the requisite bearing capacity. Account should be taken of seasonal variations in ground conditions.

v) Bases for tower cranes and tracks for rail-mounted tower cranes should be firm and level. Tower cranes should only operate on gradients within limits specified by the manufacturer. Tower cranes should only be erected at a safe distance from excavations and ditches.

vi) Tower cranes should be sited where there is clear space available for erection, operation and dismantling. As far as possible, cranes should be sited so that loads do not have to be handled over occupied premises, over public thoroughfares, other construction works and railways or near power cables.


vii) Where two or more tower cranes are sited in positions where their jibs could touch any part of the other crane, there should be direct means of communication between them and a distinct warning system operated from the cab so that one driver may alert the other of impending danger.

viii) The manufacturers' instructions on the methods and sequence of erection and dismantling should be followed. The crane should be tested before being taken into use.

ix) The climbing operation of climbing tower cranes should be carried out in accordance with manufacturers' instructions. The free-standing height of the tower crane should not extend beyond what is safe and permissible in the manufacturers' instructions.

x) When the tower crane is left unattended, loads should be removed from the hook, the hook raised, the power switched off and the boom brought to the horizontal. For longer periods or at times when adverse weather conditions are expected, out of service procedures should be followed. The main jib should be slewed to the side of the tower away from the wind, put into free slew and the crane immobilised.

xi) A windspeed measuring device should be provided at an elevated position on the tower crane with the indicator fitted in the drivers' cab.

xii) Devices should be provided to prevent loads being moved to a point where the corresponding safe working load of the crane would be exceeded. Name boards or other items liable to catch the wind should not be mounted on a tower crane other than in accordance with the manufacturers' instructions.

xiii) Tower cranes should not be used for magnet, or demolition ball service, piling operations or other duties, which could impose excessive loading on the crane structure.

6.9.6 Lifting ropes

i) Only ropes with a known safe working capacity should be used as lifting ropes.

ii) Lifting ropes should be installed, maintained and inspected in accordance with manufacturers' instructions.

iii) Repaired steel ropes should not be used on hoists.

iv) Where multiple independent ropes are used, for the purpose of stability, to lift a work platform, each rope should be capable of carrying the load independently.

6.10 VEHICLE MOVEMENT

6.10.1 Park vehicles only at designated places. Don't block roads to create hindrance for other vehicles.

6.10.2 Don't overload the vehicle.

6.10.3 Obey speed limits and traffic rules.

6.10.4 Always expect the unexpected and be a defensive driver.

6.10.5 Drive carefully during adverse weather and road conditions.

6.10.6 Read the road ahead and ride to the left.

6.10.7 Be extra cautious at nights. Keep wind screens clean and lights in working condition.

6.10.8 All vehicles used for carrying workers and construction materials must undergo predictive/preventive maintenance and daily checks

6.10.9 Driver with proper valid driving license shall only be allowed to drive the vehicle

6.10.10 Routes shall be leveled, marked and planned in such a way so as to avoid potential hazards such as overhead power lines and sloping ground etc.

6.10.11 While reversing the vehicles, help of another worker should be ensured at all times

6.10.12 An unattended vehicle should have the engine switched off

6.10.13 Wherever possible one-way system shall be followed

6.10.14 Barriers/fixed stops should be provided for excavation/openings to prevent fall of vehicle


6.10.15 Load should be properly secured

6.10.16 The body of the tipper lorry should always be lowered before driving the vehicle off.

6.10.17 Signs/signals/caution boards etc. should be provided on routes .

6.11 ELECTRICAL


i) Only persons having valid licenses should be allowed to work on electrical facilities.

ii) No person should be allowed to work on live circuit. The same, if unavoidable, special care and authorisation need to be taken.

iii) Treat all circuits as "LIVE" unless ensured otherwise.

iv) Electrical "Tag Out" procedure "MUST" be followed for carrying out maintenance jobs.

v) Display voltage ratings prominently with "Danger" signs.

vi) Put caution/notice signs before starting the repair works.

vii) All electrical equipment operating above 250V shall have separate and distinct connections to earth grid.

viii) Proper grounding to be ensured for all switch boards and equipment including Portable ones prior to taking into service.

ix) Make sure that electrical switch boards, portable tools, equipments (like grinding machine etc.) don't get wet during their usage. If it happens, stop the main supply, make the tools dry and then only use them. Check proper earthing.

All temporary switch boards/ KIOSKS put up at work site should be suitably protected from rain and the level of same should be high enough to avoid contact with water due to water logging.

x) Don't work wet on electrical system.

xi) Don't overload the electrical system.

xii) Use only proper rated HRC fuses.

xiii) Industrial type extension boards and Plug sockets are only to be used.

xiv) ELCB for all temporary connections must be provided. Use insulated 3-pin plug tops.

xv) All power supply cables should be laid properly and neatly so that they don't cause hindrance to persons working and no physical damage also takes place to the cables during various construction activities.

xvi) All Power cables to be properly terminated using glands and lugs of proper size and adequately crimped.

xvii) Use spark-proof/flame proof type electrical fittings in Fire Hazard zones as per area classification under OISD-STD-113.

xviii) Check installations of steel plates/pipes to protect underground cables at crossings.

xix) Don't lay unarmored cable directly on ground, wall, roof or trees. All temporary cables should be laid at least 750 mm below ground and cable markers should be provided. Proper sleeves should be provided at road crossings. In case temporary cables are to be laid on wooden poles/steel poles, the minimum cable heights should be 4.5 M.

xx) Maintain safe overhead distance of HT cables as per Indian Electricity Rules and relevant acts.

xxi) Don't connect any earthing wire to the pipelines/structures.

xxii) Don't make any unsafe temporary connections, naked joints/wiring etc.

xxiii) Ensure that temporary cables are free from cuts, damaged insulation, kinks or improper insulated joints.

xxiv) Check at periodic intervals that pins of sockets and joints are not loose.

xxv) Protect electrical wires/equipments from water and naked flames.

xxvi) Illuminate suitably all the work areas.

xxvii) All switchboards should be of MS structure only and incoming source should be marked.

xxviii) Hand lamps should not be of more than 24V rating.

xxix) Fire extinguishers (DCP/CO2/Sand buckets) should be kept near


temporary switch boards being used for construction purposes. Don't use water for fighting electrical fires.

xxx) Insulating mats shall be provided in the front and back end of switch boards.

xxxi) All parts of electrical installations should be so constructed, installed and maintained as to prevent danger of electric shock, fire and external explosion.

Periodic checking/certification of electrical safety appliances such as gloves, insulating mats, hoods etc. to be done/witnessed along with maintaining a register at site signed by competent authority.

xxxii) A notice displaying following, should be kept exhibited at suitable places:

a) prohibiting unauthorised persons from entering electrical equipment rooms or from handling or interfering with elec-trical apparatus;

b) containing directions as to procedures in case of fire, rescue of persons in contact with live conductors and the restoration of persons suffering from electric shock;

c) specifying the person to be notified in case of electrical accident or dangerous occurrence, and indicating how to communicate with him.

xxxiii) No other cables/pipes to be laid in trench used for electrical cables.

xxxiv) Utmost care should be taken while excavating Earth from cable trench to avoid damage or any accident.

xxxv) Sub-station floor cut-outs meant for switch board installations to be covered wherever installation is incomplete.

NOTE: A Residual Current Operated Circuit Breaker (RCCB) or Earth Leakage Circuit Breaker (ELCB), when installed, protects a human being to the widest extent. RCCB or ELCB should be provided as per Indian Electricity Rules.

6.11.2 Inspection and maintenance

i) All electrical equipment should be inspected before taking into use to

ensure suitability for its proposed use.

ii) At the beginning of every shift, the person using the electrical equipment should make a careful external examination of the equipment and conductors, especially the flexible cables.

iii) Apart from some exceptional cases, work on or near live parts of electrical equipment should be forbidden.

iv) Before any work is begun on conductors or equipment that do not have to remain live:

a) the current should be switched off by a responsible authorised person;

b) precautions should be taken to prevent the current from being switched on again;

c) the conductors or the equipment should be tested to ascertain that they are dead;

d) the conductors and equipment should be earthed and short-circuited;

e) neighbouring live parts should be adequately protected against accidental contact.

v) After work has been done on conductors and equipment, the current should only be switched on again on the orders of a competent person after the earthing and short-circuiting have been removed and the workplace reported safe.

vi) Electricians should be provided with approved and tested tools, and personal protective equipment such as rubber gloves, mats etc.

vii) All conductors and equipment should be considered to be live unless there is a proof of the contrary.

viii) When work has to be done in dangerous proximity to live parts the current should be cut off. If for operational reasons this is not possible, the live parts should be fenced off or enclosed by qualified staff from the sub-station concerned.


6.11.3. Testing

i) Electrical installations should be inspected and tested and the results recorded.

ii) Periodic testing of the efficiency of the earth leakage protective devices should be carried out.

iii) Particular attention should be paid to the earthing of apparatus, the continuity of protective conductors, polarity and insulation resistance, protection against mechanical damage and condition of connections at points of entry.

6.12 OFFSHORE

6.12.1 General

The isolated nature of offshore installations are hazardous. They call for greater need for safety and survival at offshore. Safety at offshore is safety of installations and safety of personnel. Safety problems and accidents at offshore have high risks due to limited space, helicopter operation, sea transport etc. Following are the general safety guidelines to be followed in addition to the safety guidelines stipulated for specific jobs dealt later on:

i) Workers should be well trained to do their job independently with high degree of self-control and self-discipline.

ii) On arrival at offshore, everyone should be briefed about the safety rules to be followed at offshore, evacuation system etc. All personnel should wear overall (dangri), helmet and shoes for personnel protection.

iii) In case of emergency, workers should follow instruction of Field Production Superintendent (F.P.S.) In certain cases instructions may be given to abandon the offshore installation and evacuate the persons to safe location.

iv) To overcome above problems, offshore personnel must receive training for using life saving appliances and other personal survival techniques.

v) Any person working at offshore should have one person as standby for any eventuality.

6.12.2 Drilling Rigs

i) Location of jack up rigs should not be less than 5 Kms from shipping route. Orientation of the rig, wind direction etc are required for safe landing of helicopter. Information w.r.t. sea currents, wind speed, Hi-lo tide etc are required for mooring of supply vessels.

ii) Sea bed condition at every location should be ensured for safety of rig.

iii) Radio and other communication facilities should be such to maintain contact with base all times.

iv) During toeing of rig, the rig deck should be clear of load, toeing lines should be in good condition and tensions in various toeing lines should be constantly monitored.

v) Few steps during toeing are:

a) crane booms should be secured to their vesta,

b) all hatches and water tight doors should be closed,

c) number of personnel on board should be restricted,

d) evacuate in case of emergency and operation should be completed preferably in day light.

6.12.3 Drilling

i) In view of CO2 and H2S gas cut from well, effective ventilation should be provided where drilling is in progress.

ii) Safety alarm shall be checked in advance in view of failure of ventilation system.

iii) Suitable sensors for H2S and Methane should be function tested time to time and suitable colour code should be given.

iv) Working areas of the crane should be illuminated during night to avoid accident.

v) Clear space should be available for despatch and receipt of load and, in particular, basket transfer of passengers. Persons engaged in loading/unloading of materials should be protected from falling into the sea.


vi) Signal light should be fitted at the top of the jib.

vii) Crane hook should be fitted with safety latches.

viii) Experienced person should be engaged in operation of specific equipment like winches, cranes etc.

ix) At least three cable turns shall always be there on the winch drum.

x) Adequate communication like walkie talkie, round robin phone should be available between the crane operator, supervisor and helper.

xi) Crane operation should be completely stopped during helicopter landing/taking off.

xii) Except for helicopter landing deck, all decks, platforms, bridges, ladders should have rigid and fixed guard rails atleast one meter high and should have one intermediate rail midway between the handrail and 100 mm toe board.

xiii) Wooden ladders shall not be used at offshore.

xiv) Flow sensor in the flow line should be ensured for safe working and to avoid blow out.

xv) Hydrogen sulphuide gas In offshore is of great risk and at 10 ppm (0.001%) concentration in air, a person should not be exposed for more than 8 hours, If concentration is more, then breathing apparatus should be used. Corrosion of equipment is also caused by H2S.

xvi) Portable H2S gas detector should be continously used.

6.12.4 Production Platforms

i) In case hydrocarbon Is released due to overpressure, leak, overflow, gas blow etc., shut down process to stop flow of hydrocarbon. Prevent ignition of released hydrocarbon and in case of fire shut in the process complex and follow emergency contigency plan.

ii) Sub surface safetv valve (SSSV)) below the well head should be actuated during uncontrolled well -flow and they should be regularly checked.

iii) Surface safety valve or SDV should be checked for no gas leakage from bleed port / flange etc., in the well head area. It should not be in "mechanical override" or bypassed from panel.

iv) High pressure gas lift lines - blowdown system should be O.K.

v) Auto actuation of SDVs in the inlet of pressure vessels should be O.K. and in "normal position" from shutdown panels. A record of status of switches normal/bypassed in auto-con* panels (PSH, PSL, LSL, ILSL) should be maintained.

∗ Shut Down Panels

vi) Welders rectifier set and electrical connections to it should be checked and approved by electrical-in- charge for proper electrical safely.

vii) “SCADA" telementry system if available should be operational for remote opening and closing of wells at unmanned platforms (through RPMC).

viii) Local ESD/FSD (near the work site) should be provided for jobs of very critical nature, so that the persons working can access it immediately in emergency for safety. Safety officer should judge the requirement & inform FPS for the same.

ix) Railings and Gratings etc. in and around work area should be O.K. and inspected to avoid slippage of man into sea.

x) Emergency shut down (ESD) system is initiated when an abnormal condition is detected. ESD should be checked once in six months.

xi) Platform should be manned round the clock.

xii) Welding and cutting work should be regulated by hot work permit.

xiii) All detectors should be calibrated as per recommendation of the manufacturer.

xiv) No system should be by-passed which affects the system of platform.


xv) In H2S field platforms, due care shall be taken as per recommendations.

xvi) Follow the instructions of F.P.S. during stay at platform

6.12.5 Fire Prevention And Control

i) Provision be made for safe handling and storage of dirty rags, trash, and waste oil. Flammable liquids and chemicals applied on platform should be immediately cleaned.

ii) Paint containers and hydrocarbon samples, gas cylinders for welding and cutting should be stored properly. Cylinders should be transported in hand-cart.

iii) Smoking should be restricted and no smoking area should be identified.

iv) Special attention should be given to crude oil pump seals, diesel and gas engines which are potential source of ignition in the event of failure.

v) Fire and smoke detectors i.e. ultraviolet heat, thermal and smoke detector should be function tested once in three months.

vi) Fire is controlled in offshore by water spraying, Halon, CO2 flooding, DCP and sprinkler system.

vii) Foaming agent is applied for controlling fire in liquid hydrocarbon. The system is not effective in gas fire.

viii) Light weight breathing system should be used.

ix) The fire control plan at offshore should reveal control station, fire alarms and fire detectors, deluge valves and sprinkler, fire extinguishing appliances, fireman outfit and ventilation system.

x) Fire fighting equipment should be maintained in ready to use condition.

6.12.6 Life Saving Appliances

i) Life boats with a speed of 6 knots and carrying capacity upto 50 persons are used in offshore.

ii) No. of life boats on one installation should have a capacity to

accommodate twice the number of persons onboard installation.

iii) Launching appliances and life boat equipment should be checked every week.

iv) Boat landing areas should be adequately illuminated.

v) Life raft has no power and they rely on drift.

vi) Life jacket lifts the wearer after entering water.

vii) Life buoys are used to rescue persons if any person accidentally falls in the sea.

viii) All life saving appliances should be inspected by the MMD surveyor /sr. officials once a year.

ix) Every life boat shall be inspected once a week.

x) Every life boat and life raft should be serviced once a year by a competent authority,

6.12.7 Safety Precautions during Helicopter Transportation

i) Passenger briefing regarding safety rules while travelling in helicopter should be carried out before boarding the helicopter.

ii) Emergency procedure should be briefed to all the passenger In case helicopter is to ditch into the sea.

iii) Heli-pad should have a non-skid surface. Nylon rope net should be stretched on the deck.

iv) Proper drainage should be available on helideck.

v) There should be no obstruction on the helideck itself and within 3 meters of its parameter. Closest super structure above the helideck should have red obstruction light.

vi) While landing fire crew of two persons should be standby adjacent to helideck.

vii) Heli-deck should be properly illuminated for night landing.

viii) During switching off helicopter, persons should not be allowed to go out/ towards helicopter


6.13 DEMOLITION

6.13.1. General provisions

i) When the demolition of any building or structure might present danger to workers or to the public:

(a) necessary precautions, methods and procedures should be adopted, including those for the disposal of waste or residues;

(b) the work should be planned and undertaken only under the supervision of a competent person.

ii) Before demolition operations begin:

(a) structural details and builders' drawings should be obtained wherever possible;

(b) details of the previous use should be obtained to identify any possible contamination and hazards from chemicals, flammables, etc.;

(c) an initial survey should be carried out to identify any structural problems and risks associated with flammable substances and substances hazardous to health. The survey should note the type of ground on which the structure is erected, the condition of the roof trusses, the type of framing used in framed structures and the load-bearing walls;

(d) a method of demolition should be formulated after the survey and recorded in a method statement having taken all the various considerations into account and identifying the problems and their solutions;

iii) All electric, gas, water and steam service lines should be shut off and, as necessary, capped or otherwise controlled at or outside the construction site before work commences.

iv) If it is necessary to maintain any electric power, water or other services during demolition operations, they should be adequately protected against damage.

v) As far as practicable, the danger zone round the building should be adequately fenced off and sign

posted. To protect the public a fence 2m high should be erected enclosing the demolition operations and the access gates should be secured outside working hours.

vi) The fabric of buildings contaminated with substances hazardous to health should be decontaminated. Protective clothing and respiratory devices should be provided and worn.

vii) Where plant has contained flammable materials, special precautions should be taken to avoid fire and explosion.

viii) The plant to be demolished should be isolated from all other plant that may contain flammable materials. Any residual flammable material in the plant should be rendered safe by cleaning, purging or the application of an inert atmosphere as appropriate.

ix) Care should be taken not to demolish any parts, which would destroy the stability of other parts.

x) Demolition activities should not be continued under adverse climatic conditions such as high winds, which could cause the collapse of already weakened structures.

xi) To prevent hazards parts of struc-tures should be adequately shored, braced or otherwise supported.

xii) Structures should not be left in a condition in which they could be brought down by wind pressure or vibration.

xiii) Where a deliberate controlled collapse technique is to be used, expert engineering advice should be obtained, and:

(a) it should only be used where the whole structure is to come down because it relies on the removal of key structural members to effect a total collapse;

(b) it should only be used on sites that are fairly level and where there is enough surrounding space for all operatives and equipment to be withdrawn to a safe distance.

xiv) When equipment such as power shovels and bulldozers are used for


demolition, due consideration should be given to the nature of the building or structure, its dimensions, as well as to the power of the equipment being used.

xv) If a swinging weight is used for demolition, a safety zone having a width of at least one-and-a-half times the height of the building or structure should be maintained around the points of impact.

6.13.2. Demolition of structural steelwork

i) All precautions should be taken to prevent danger from any sudden twist, spring or collapse of steelwork, ironwork or reinforced concrete when it is cut or released.

ii) Steel construction should be demolished tier by tier.

iii) Structural steel parts should be lowered and not dropped from a height.

6.14 RADIOGRAPHY

6.14.1 All radiography jobs shall be carried out as per BARC Safety Regulations

6.14.2 During field radiography, nearby area around the radiation source should be cordoned off.

6.14.3 If the field radiography is to be done at the same location repeatedly, it is advisable to provide either a wire fencing around or a temporary brick enclosure.

6.14.4 Special permission/permit should be taken for radiography from area-in-charge.

6.14.5 As far as possible, field radiography should be done only during night time when there is little or no occupancy there.

6.14.6 Radiation warning signals should be pasted all along the cordoned off area.

6.14.7 Entry into the restricted area by unauthorised persons should be strictly prohibited during exposure.

6.14.8 The radiation level alongwith the cordon should be monitored by a suitable and well-calibrated radiation survey meter.

6.14.9 All personnel working with radiography sources should wear appropriate protective equipment and film badges issued by BARC.

6.14.10 Protection facilities such as manipulator rod, remote handling tongs, lead pots, radiation hazard placards and means of cordon off shall be available at each site.

6.14.11 The radiography source shall never be touched or handled directly with hands.

6.14.12 The package containing radiography cameras and sources should never be carried by public transport like bus, train etc.

6.14.13 Radiography sources and cameras, when not in use, should be stored inside a source pit with lock and key arrangement as approved by BARC. The storage room should preferably be located in an isolated area of minimum occupancy and radiation level outside the storage room should not exceed 0.25 mR/hr as per BARC Regulations.

6.14.14 In case of an accident (due to loss or of damage to radiography source), action should be taken in line with BARC Safety Rules/Guidelines.

6.15 SAND/SHOT BLASTING/ SPRAY

PAINTING

6.15.1 Sand blasting should be used only after approval from competent person.

6.15.2 Air Compressor used for sand/shot blasting/painting should have guard and positioned away from the work place.

6.15.3 Exhaust of the prime mover, if IC engine is used, should be directed away from the work place.

6.15.4 In case of motor driven compressor, the body of the motor as well as the compressor to be properly earthed.

6.15.5 The hoses used for compressed air should be of proper quality, and health of the same to be ensured through regular check/ test.


6.15.6 The operator of sand/shot blasting/painting should wear suitable PPE's including mask.

6.15.7 Adequate measures to be taken to suppress dust/spray particle.

6.15.8 Sand used for sand blasting should be suitably covered & protected from to rain/moisture.

6.15.9 When these activities are done in confined places, adequate measure to be taken for proper ventilation.

6.16 WORK ABOVE WATER

6.16.1 General Provisions i) Where work is done over or in close

proximity to water & where possibility of drowning exists, provision should be made for:

a) Preventing workers from falling into water;

b) The rescue of workers in danger of drowning;

c) Safe and sufficient transport.

ii) Provisions for the safe performance of work over or in close proximity to water should include, where appropriate, the provision and use of suitable and adequate:

a) fencing, safety nets and safety harnesses;

b) lifebuoys, life jackets and manned boats;

c) protection against such hazards as reptiles and other animals.

iii) Gangways, pontoons, bridges, footbridges and other walkways or work places over water should:

a) possess adequate strength and stability;

b) be sufficiently wide to allow safe movement of workers;

c) have level surfaces free from tripping hazards;

d) be adequately lit when natural light is insufficient;

e) where practicable and necessary, to prevent danger, be provided with toe-boards, guard rails, hand ropes etc.

f) be secured to prevent dislodgment by rising water or high winds;

g) if necessary, be equipped with ladders which should be sound, of sufficient strength and length and be securely lashed to prevent slipping.

iv) All deck openings including those for buckets should be fenced.

6.16.2 Rescue & Emergency procedures

i) Persons who work over water

should be provided with some form of buoyancy aid. Life jackets should provided sufficient freedom of movement, have sufficient buoyancy to bring persons to the surface and keep them afloat face upwards, be easily secured to the body, be readily visible by way of self luminous paint/strip.

ii) Nobody should work alone on or above water.

iii) Each worker should be trained in the procedure to be followed in the event of an emergency.

7.0 ADDITIONAL SAFETY PRECAUTION FOR UNITS WITH HYDROCARBONS In addition to general safety precautions as outlined above for the activities in Clause 6.0, following additional safety precautions need to be taken for the sites within the operating area or nearby, where presence of Hydrocarbons cannot be ruled out.

i) No job shall be carried out without a valid permit. Permit should be in line with OISD-STD-105 "Work Permit System".

ii) Smoking should be prohibited in all places containing readily combustible or flammable materials and "No Smoking" notices be prominently displayed.

iii) In confined spaces and other places where flammable gases, vapours or dusts can cause danger, following measures should be taken:

(a) only approved type electrical installations and equipment, including portable lamps, should be used;

(b) there should be no naked flames or source of ignition;

(c) oily rags, waste and clothes or other substances liable to spontaneous ignition should be removed without delay to a safe place;

(d) ventilation should be provided.


iv) Regular inspections should be made of places where there are fire risks. These include the vicinity of heating appliances, electrical installations and conductors, stores of flammable and combustible materials, welding and cutting operations.

v) Welding, flame cutting and other hot work should only be done after issuance of work permit in line with the requirement of OISD-STD-105 after appropriate precautions, as required, are taken to reduce the risk of fire. For carrying out other jobs also, OISD-STD-105 should be followed strictly.

vi) Fire-extinguishing equipment should be well maintained and inspected at suitable intervals by a competent person. Access to fire-extinguishing equipment such as hydrants, portable extinguishers and connections for hoses should be kept clear at all times.

vii) All supervisors and a sufficient number of workers should be trained in the use of fire-extinguishing equipment, so that adequate trained personnel are readily available during all working periods.

viii) Audio means to give warning in case of fire should be provided where this is necessary to prevent danger. Such warning should be clearly audible in all parts of the site where persons are liable to work. There should be an effective evacuation plan so that all persons are evacuated speedily without panic and accounted for and all plant and processes shut down.

ix) Notices should be posted at conspicuous places indicating:

(a) the nearest fire alarm; (b) the telephone number and

address of the nearest emergency services.

x) The work site shall be cleared of all combustible materials, as Sparks and molten metal coming from the welding job can easily ignite combustible materials near or below the welding site. If the combustible materials cannot be removed from the area, the same shall be properly shielded.

xi) A dry chemical type fire extinguisher shall be made available in the work area. Also fire protection facilities like running hoses etc. as per permit should be complied with.

xii) Wherever required, welding screens shall be put up to protect other equipment in adjoining areas against flying sparks. Material used should be metal/asbestos/water curtain.

xiii) Welding or cutting of vessels/ equipments used in Hydrocarbon/ hazardous chemicals shall be done after proper gas freeing and verifying the same with the explosive-meter.

xiv) The confined space/equipment shall be gas freed and cleaned.

xv) Absence of any toxic gas and any flammable gas above explosion limit shall be ensured with the help of gas detection instrument and explosive meter respectively.

xvi) Used and hot electrode stubs shall be discarded in a metal bucket.

xvii) Use approved and certified flame arrestors for vehicles.

xviii) Work permit to be obtained, if construction work is carried out within existing operating area.

8.0 FIRST AID

First aid facilities should be provided in line with various statutory regulations like factory act etc. However following care should be taken:

i) First aid, including the provision of trained personnel should be ensured at work sites. Arrangement should be made for ensuring the medical attention of the injured workers. First aid box should be as per the Factory rules.

ii) Suitable rescue equipment, like stretchers should be kept readily available at the construction site.

iii) First-aid kits or boxes, as appropriate and as per statutory requirements, should be provided at workplaces and be protected against contamination by dust, moisture etc.


iv) First-aid kit or boxes should not keep anything besides material for first aid in emergencies.

v) First-aid kits and boxes should contain simple and clear instructions to be followed, be kept under the charge of a responsible person qualified to render the first aid and be regularly inspected and stocked.

vi) Where the work involves risk of drowning, asphyxiation or electric shock, first-aid personnel should be proficient in the use of resuscitation and other life saving techniques and in rescue procedures.

vii) Emergency telephone numbers of nearby Hospitals, Police, Fire Station and Administration should be prominently displayed.

9.0 DOCUMENTATION

The intention of keeping documentation of all types of accident(s) is to prevent recurrence of similar accident(s). All accidents should be reported as per OISD Guidelines (OISD-GDN-107) and Factories act, 1948.

All accidents (major, minor or near miss) should be investigated, analysed and recommendations should be documented along with implementation status.

All related data should be well-documented and further analysis highlighting the major cause(s) of accidents be done. This will help in identifying thrust areas and training needs for prevention of accidents.

10.0 SAFETY AWARENESS &

TRAINING

Safety awareness to all section of personnel ranging from site-in-charge to workmen helps not only preventing the risk but also build up the confidence. Time and expenditures also get saved as a result.

Safety awareness basically seeks to persuade/inform people on safety besides supplementing skill also. Awareness programme may include followings:

i) Poster: Posters with safety slogan in humorous, gruesome demonstrating manner may be used to discourage bad habits attributable to accidents by appealing to the workers' pride, self-love, affection curiosity or human aspects. These should be displayed in prominent location(s).

ii) Safety Sign Boards: Different type of message of cautioning, attention, notice etc. should be displayed at the appropriate places for learning/ awareness of the workmen while working at site.

iii) Films & Slides: Film(s) narrating the accident including the causes and possible remedial ways of preventing the recurrence of a similar accident should be displayed at regular intervals. Slides consisting main points of the film show may also be shown to workers.

iv) Talks, lectures & conferences: The success of these events would depend much on audience’s understandings of the speaker (s). The speakers are to be knowledgeable and good presenter. Speakers should know to hold the attention and to influence the audiences.

v) Competitions: Organise competition(s) between the different deptts/categories of workers. The sense of reward/recognition also will improve safety awareness and result in enhancing safety levels.

vi) Exhibitions: Exhibitions also make the workers acquainted with hazards and means of preventive measures.

vii) Safety Publication: Safety publications including pocket books dealing with ways of investigation and prevention in the field of safety and so on, may be distributed to workers to promote the safety awareness.

viii) Safety Drives: From time to time, an intensive safety drive by organising a safety day or a safety week etc. should be launched.

ix) Training: Training for covering the hazards for different trade should be imparted. Training should also include the specific hazards related


to a job in addition to the general safety training as has been dealt in various chapters and should include all workers. Reference may be drawn from OISD-STD-154.

11.0 REFERRENCES

i) Factory Act, 1948

ii) Indian Electricity Rules

iii) Safety & Health in Construction by ILO

iv) The Building & Other Construction Workers (Regulation, Employment and Conditions of Service) Act 1996


ANNEXURE I

LIST OF SAFETY CODES FOR CIVIL WORKS PUBLISHED BY BUREAU OF

INDIAN STANDARDS Sr.no Code No. Title

01. IS : 818 Code of Practice for Safety and Health Requirements in Electric and Gas Welding and Cutting Operations – First Revision.

02. IS : 875 Code of practice for Structural safety of buildings: Masonry walls

03. IS : 933 Specification for Portable Chemical Fire Extinguisher, Foam Type – Second Revision.

04. IS : 1179 Specification for Equipment for Eye and Face Protection during Welding – First Revision.

05. IS : 1904 Code of practice for Structural safety of buildings: Shallow foundations

06. IS : 1905 Code of practice for Structural safety of buildings: Masonry walls

07. IS : 2171 Specification for Portable Fire Extinguishers, Dry Powder Type –Second Revision.

08. IS : 2361 Specification for Building Grips – First Revision.

09. IS : 2750 Specification for Steel Scaffoldings.

10. IS : 2925 Specification for Industrial Safety Helmets – First Revision.

11. IS : 3016 Code of Practice for Fires Precautions in Welding and Cutting Operations – First Revision.

12. IS : 3521 Industrial safety belts and harnesses

13. IS : 3696 – Part I Safety Code for Scaffolds and Ladders : Part I – Scaffolds.

14. IS : 3696 – Part II Safety Code for Scaffolds and Ladders : Part II – Ladders.

15. IS : 3764 Safety Code for Excavation Work.

16. IS : 4014 -Part I & II Code of practice for Steel tubular scaffolding

17. IS : 4081 Safety Code for Blasting and Related Drilling Operations.

18. IS : 4082 Recommendations on staking and storage of construction materials at site

19. IS : 4130 Safety Code for Demolition of Buildings – First Revision.

20. IS : 4138 Safety Code Working in Compressed Air-First Revision

21. IS : 4756 Safety code for Tunneling works

22. IS : 4912 Safety requirements for Floor and Wall Openings, Railings and toe Boards –First Revision.

23. IS : 5121 Safety Code for Piling and other Deep Foundations.

24. IS : 5916 Safety Code for Construction involving use of Hot Bituminous Materials.

25. IS : 5983 Specification for Eye Protectors – First Revision.

26. IS : 6922 Structures subject to underground blasts, criteria for safety and design of

27. IS : 7155 Code of recommended practices for conveyor safety

28. IS : 7205 Safety Code for Erection on Structural Steel Works.


Sr.no Code No. Title

29. IS : 7069 Safety Code for Handling and Storage of Building Materials.

30. IS : 7293 Safety Code for Working with Construction Machinery.

31. IS : 7323 Guidelines for operation of Reservoirs

32. IS : 7969 Safety code for handling and storage of building material

33. IS : 8758 Recommendation for Fire Precautionary Measures in construction of Temporary Structures and Pandals.

34. IS : 8989 Safety Code for Erection of Concrete Framed Structures.

35. IS : 9706 Code of Practices for construction of Arial ropeways for transportation of material

36. IS : 9759 Guidelines for de-watering during construction

37. IS : 9944 Recommendations on safe working load for natural and man-made fibre roap slings

38. IS : 10291 Safety code for dress divers in civil engineering works

39. IS :10386 – Part I Safety Code for Construction, Operation and Maintenance for River Valley Projects.

40. IS :10386 – Part II Safety Code for Construction, Operation and Maintenance of River Valley Projects.

41. IS : 11057 Code of practice for Industrial safety nets

42. IS : 13415 Code of Practice on safety for Protective barriers in and around building

43. IS : 13416 Recommendations for preventive measures against hazards at working places

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Ref.: NIT NO. 6758A TCE/BPCL RFQ-001 Tender No. TCE ......OISD-GDN-192 SAFETY PRACTICES DURING...

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Transcript of Ref.: NIT NO. 6758A TCE/BPCL RFQ-001 Tender No. TCE ......OISD-GDN-192 SAFETY PRACTICES DURING...