instructions to bidder - bharat petroleum tender...instructions to bidder 1. competitive offers are...

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INSTRUCTIONS TO BIDDER

INSTRUCTIONS TO BIDDER

1. Competitive offers are invited in two-part bid- Bid Qualification Cum Techno Commercial Bid and Price Bid - from eligible bidders.

2. Successful bidders will be issued LOI by CPO (Mktg). The P.O. and agreement shall be issued by regional set up of E&P.

LOI will be issued immediately on approval of the tender. The quoted rates shall remain firm till the completion of work.

3. Offers should strictly be in accordance with the tender terms & conditions and our specifications. Bidders are requested to carefully study all the documents/ annexures and understand the conditions, specifications, drawings etc. before submitting the tender and quoting the rates. In case of doubt, written clarifications should be obtained, but this shall not be a justification for request for extension of due date for submission of bids.

4. REFERENCE FOR DOCUMENTATION:

a. The number and date of Collective Request for Quotation (CRFQ) must appear on all correspondence before finalization of Rate Contract / Purchase Order.

b. After finalization of Contract / Purchase Order, the number and date of Contract/Purchase Order must appear on all correspondence, drawings, invoices, dispatch advices, (including shipping documents if applicable) packing list and on any documents or papers connected with this order.

5. RIGHT OF CORPORATION TO ACCEPT OR REJECT TENDER:

The right to accept the tender will rest with the corporation.

6. LANGUAGE OF BID:

The Bid and all supporting documentation and all correspondence exchanged by bidder and Corporation, shall be written in English language only.

7. Bidders shall also have to essentially sign an Integrity Pact (IP) for participating in this tender, as per the proforma contained herein. The salient points to be noted in regard to IP are:

a. Proforma of Integrity Pact has been uploaded in the bidding forms of the tender documents. Bidder shall be required to download and print it such that it is legible. All pages of the printed copy of IP should be duly signed by the authorized signatory as specified below and witnessed. Thereafter, that copy should be scanned and uploaded by bidder along with other bid documents. Bidder’s failure to upload the IP duly signed along with the bid document shall result in the bid not being considered for further evaluation.

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b. If the bidder has been disqualified from the tender process prior to the award of the contract in accordance with the provisions of the Integrity Pact, BPCL shall be entitled to demand and recover from Bidder, Price reduction amount by forfeiting the EMD/Performance Guarantee as per provisions of the Integrity Pact.

c. If the contract has been terminated according to the provisions of the Integrity Pact, or if BPCL is entitled to terminate the contract according to the provisions of the Integrity pact, BPCL shall be entitled to demand and recover from contractor, Price reduction amount by forfeiting the Performance Guarantee amount as per provisions of the Integrity Pact.

All documents attached with the Bid Qualification Cum Techno Commercial Bid and

the price bid shall form the part of the tender. Bid Qualification criteria documents, techno-commercial bid and the price bid will be submitted online. Bidders are also requested to submit the hard copies of the Documents against the Bid Qualification Criteria and the EMD by the due date at the following address:

Mr. Sanson T Koleth/ Varun Sharma Central Procurement Organisation (Mktg) ‘A’ Installation, Sewree Fort Road, Sewree, Mumbai 400015 Email ID: [email protected] / [email protected]

Contact: (022) 24176420/6133 Mob. 7045918748

8. All the supporting documents should be legible and duly signed, stamped and attested by the authorized signatory as specified below, before uploading them online.

9. The bid shall be required to be digitally signed with a class IIB or above digital signature by the authorized signatory.

Online submission of the tender under the digital signature of the authorized signatory shall be considered as token of having read, understood and totally accepted all the terms and conditions. Bidder’s digital signature on the documents shall be considered as total acceptance of the terms & conditions.

10. Earnest Money Deposit (EMD):

a) The bidders shall submit an interest-free Earnest Money Deposit of Rs. 1 Lakh

(Rupees O n e lakh only) by crossed account payee Demand Draft drawn on any nationalized/scheduled bank in favour of “BHARAT PETROLEUM

CORPORATION LTD” payable at Mumbai.

b) EMD should be submitted in physical form in a sealed cover addressed to

Procurement Leader (Services), boldly super-scribed on the outer cover –

CRFQ number

Item

Closing date/Time

Name of the bidder

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It should be dropped in the tender box or sent by Registered Post/Courier to the following address so as to reach on or before the due date & time of the tender:

Central Procurement Organization (CPO), ‘A’ Installation, Sewree Fort Road, Sewree, Mumbai-400015

BPCL will not be responsible for non-receipt of instrument(s) due to postal delay/loss in transit etc.

c) Cheques, cash, Money Orders, Fixed deposit Receipts etc. towards EMD are

not acceptable. Similarly, request for adjustment against any previously deposited EMD/Pending Dues/Bills/Security Deposits of other contracts etc. will not be accepted towards EMD.

d) Bid received without the EMD is liable to be rejected.

e) Bidders registered with BPCL also should submit the EMD as mentioned above.

f) Units registered with National Small Industries Corporation (NSIC) and/or

Micro or Small Enterprises (MSE) are however, exempted from payment of EMD, subject to:

The unit being registered for the item tendered. Registration certificate being valid as on date of quotation.

Bidder registered with NSIC/ MSE shall furnish a self attested Xerox copy of the valid certificate for the same.

As the case may be, such vendors must upload a photocopy of valid NSIC Registration Certificate/ Renewed copy of certificate duly attested by a gazetted officer/notorised, (photocopy of application for registration as NSIC or for renewal will not be acceptable), Udyog Aadhaar Memorandum (UAM) and/or a valid MSE registration with any notified body specified by Ministry of Micro, Small and Medium Enterprises, failing which such bid will be treated as bid received without EMD and liable to be rejected

g) Registration with DGS&D will not entitle the bidder to claim exemption from

payment of EMD.

h) EMD is liable to be forfeited and bidders shall be barred for a period of one year from taking part in any tender floated by BPCL in future, in the event of:

i. Withdrawal of offers during the validity period of the offer.

ii. Non-acceptance of LOI/order, if and when placed.

iii. Any unilateral revision in the offer made by the bidder during the validity of the offer.

iv. Non payment of Security Deposit for Performance.

i) EMD will be refunded to the successful bidder(s) after they submit the Security Deposit against the Purchase Order issued by E&P.

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11. SECURITY DEPOSIT

As per General Conditions of Contract (GCC), vendor claiming exemption of EMD should submit the amount equal to EMD as security deposit before placement of Purchase Order.

12. VALIDITY OF QUOTE:

The quote shall be valid for 180 days from the opening date of the tender. This condition supersedes GCC condition.

13. COMPLETION PERIOD OF THE PROJECT:

6 months from the date of issuance of Letter of Intent (LOI).

The time includes necessary time required for mobilizations apart from the execution of work and also includes intervening monsoon period, if any.

14. The complete process for submitting the bid is as follows:

A. TECHNICAL BID:

a. Accept the contents of the following annexures by selection from the drop down menu provided. Deviations (if any) shall be required to be mentioned in the Deviation Form only.

i Instruction to Bidders Annexure I

ii General Instructions to bidders for e-tendering

Instructions to Bidder

Annexure II

iii Bid Qualification Criteria and Evaluation Methodology Me=MethodolGeneral Instructions to bidders for

Annexure III

iv Document Upload for Bid Qualification Criteria (BQC)

Annexure IV

v General Conditions of Contract & Safety Requirements

Annexure V

vi Payment Terms (as given in Detailed Technical specification and scope of job)

Annexure VI

vii Integrity Pact Annexure VII

viii Technical Specification for the Tender Annexure VIII ix Deviation Statement Annexure IX x Declaration of Liquidation / Holiday Listing Annexure X

b. Performa of Integrity Pact (IP) has been uploaded in the tender documents in bidding forms. Bidder shall be required to download and print it such that it is legible. All pages of the printed copy of IP should be duly signed by the

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authorized signatory and witnessed. Thereafter, that copy should be scanned and uploaded by bidder along with other bid documents.

c. Upload a scanned copy of all the Bid Qualification Documents.

d. Bidders to note that any deviation if any to the technical/commercial terms and

conditions of this tender should be mentioned only in the “DEVIATION” bid form attached. If any bidder fails to do so, it shall be construed that they have no deviations whatsoever to the tender terms and conditions. It is also reiterated that BPCL will not take cognizance of any clarifications/comments mentioned by the bidder in any other document. Similarly if any document is uploaded by the bidder, which inter alia would imply variation or deviation to tender specifications or any terms and conditions of the tender, it shall be taken into consideration for techno commercial evaluation if and only if the reference to the same is mentioned in the deviation bid from.

e. Corrigendum (if issued) after publishing of tenders shall be required to be

acknowledged by the bidder as token of acceptance and submitted together with the bid by the due date.

B. PRICE BID: Price Bids have to be submitted online. Bidders should NOT mention any

price anywhere else in the bidding forms. Bidders who have mentioned any Prices anywhere else in the tender are liable to get rejected for further evaluation.

15. Incomplete bids are liable to be rejected. No further correspondence/enquiries raised on this issue by the bidder shall be entertained. Any terms and conditions stated by the Bidder in his bid will not be binding on the Corporation.

16. Unsolicited / conditional discounts if offered by any party will not be considered and offers of parties offering such unsolicited discounts are liable to be rejected.

17. ACCEPTANCE/EVALUATION OF BIDS BY THE CORPORATION:

a) BID QUALIFICATION & TECHNO-COMMERCIAL BID

Based on the information and documents submitted, only parties meeting the Bid Qualification Criteria will qualify for the techno commercial evaluation. Price bid of only those bidders shall be opened who qualify in the Techno-commercial bid.

b) PRICE BID

i. Through this tender, BPCL seeks to surface the lowest price supplier for the subject job. Hence the order shall be awarded to the bidder with lowest Total Cost for the complete job, considering all the price schedules attached with the tender.

ii. The price bid evaluation will be done on the overall lowest Quote offer basis by adding all parts of price bid by taking into account the following:

Quoted basic price

Other cash outflows that shall include VAT/CST and Service Tax

(Service tax will be loaded by BPCL in the price Bid).

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iii. Input tax credit (if applicable for the tender) will be considered by BPCL in the

evaluation and in such case, the award of work will be on net cash outflow basis

considering ITC.

Note: VAT as quoted by the bidder shall be deemed as final and binding for the purpose of bid evaluation. In case a bidder enters “zero” VAT or an erroneous VAT, the bid evaluation for finalizing the L1 bidder will be done considering the quoted VAT rate. No request for change in VAT will be entertained after submission of bids.

In cases where the bidder quotes a wrong VAT rate, for releasing the final order, the following methodology will be followed:

In case the actual VAT rate applicable for the state is lower than the quoted VAT rate, the actual VAT rate will be added to the quoted basic rates. The final cash outflow will reduce to the extent of the revised VAT.

In case the actual VAT rate applicable for the state is more than the quoted VAT rate, the basic rates quoted will be reduced proportionately, keeping the final cash outflow the same as the overall quoted amount.

Based on the Total Cash Outflow calculated as above, BPCL shall place orders.

vi. The C orp orat ion reserves the right to reje ct any and /or e very t ender without

assigning any reason whatsoever and/or place order on one or more bidders and/ or carry out negotiations with any bidder in the manner considered appropriate by the Corporation.

vii. The Corporation reserves its right to allow Public Sector Enterprises (Central/ State), purchase preference as admissible/applicable from time to time under the existing Govt. policy. Purchase preference to a PSE shall be decided based on the price quoted by PSE as compared to L1 Vendor at the time of evaluation of the price bid.

viii. The Corporation also reserves its right to allow Micro and Small Enterprises (MSEs) and MSEs owned by Scheduled Caste (SC) or the Scheduled tribe (ST) entrepreneurs, purchase preference as admissible / applicable from time to time under the existing Govt. policy. Purchase preference to a MSE and a MSE owned by SC/ST entrepreneurs shall be decided based on the price quoted by the said MSEs as compared to L1 Vendor at the time of evaluation of the price bid.

Bidders claiming purchase preference as MSE need to submit Notarized copy of all the pages of the EM-II certificate, issued by the authorities mentioned in the Public procurement policy of MSEs- 2012 / Udyog Aadhaar Memorandum (UAM).

18. PAYMENT TERMS FOR CONTRACT:

As mentioned in the Detailed Technical specification and scope of job. (if mentioned in the tender).

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19. LIQUIDATED DAMAGES FOR DELAY: As mentioned in the General Conditions of Contract clause no. 22. Service Tax is applicable on LD amount, and that service tax shall be collected in addition to LD amount.

20. NEW STATUTORY LEVIES: The taxes, duties, rates, and Cess quoted shall be final. New tax, if any, introduced later shall be on BPCL account from the date of bid submission (or extended date, if any) up to contract period. During contractual period, any variation in existing taxes, duties, rates and cess shall be borne by BPCL. Any upward statutory variation in taxes, duties rates and cess (including any new tax) beyond contractual completion date shall be borne by the bidder. However, in case of downward variation, the same shall be passed on to BPCL.

21. Bidders may have to attend the concerned office of the Corporation for clarifications and/or pre-bid meeting and/or negotiations/clarifications if required at their own cost, in respect of their bids without any commitment from the Corporation.

22. POLICY ON HOLIDAY LISTING Th e guidel ines and proced ures for Holiday Listing are available separately in BPCL website and shall be applicable in the context of all tenders floated and consequently all orders/ contracts / purchase orders. It can be accessed using the following link: https://bharatpetroleum.in/pdf/holidaylistingpolicyfinal.pdf

23. It shall be understood that every endeavour has been made to avoid errors which can materially affect the basis of the tender and the successful bidder shall take upon himself and provide for risk of any error which may subsequently be discovered and shall make no subsequent claim on account thereof.

24. Courts in the city of Mumbai alone shall have jurisdiction to entertain any application or other proceedings in respect of anything arising under this tender either before or after or during finalization of the tender.

25. CONCLUSION OF CONTRACT

In a situation where the L1 bidder is not lowest for some specific line items and the L1/L2 parity is likely to be affected during the execution of the contract, due to variation in quantities of individual line items in contract based on site conditions, then the final payment could be restricted to ensure that the overall total payment of the executed work does not exceed the overall amount that would have been payable to the then L1 as per the latter’s quoted rates.

26. ARBITRATION : SETTLEMENT OF DISPUTE BETWEEN GOVT. DEPT./PUBLIC

SECTOR UNDERTAKINGS IN A PURCHASE OR SERVICE CONTRACT

In the event of any dispute or differences between the VENDOR / CONTRACTOR / SUPPLIER and the OWNER, if the VENDOR / CONTRACTOR / SUPPLIER is a Government Department, a Government Company or a undertaking in the public sector, then in suppression of the provisions of clause 91 of the GCC, stands modified to the following extent:- All disputes and differences of whatsoever nature arising out of or in relation to this Contract / Agreement or in relation to any subsequent contract / agreement between

https://bharatpetroleum.in/pdf/holidaylistingpolicyfinal.pdf

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the parties shall be attempted to be resolved amicably by mutual discussions between the parties. If they are not settled at the implementation level of officers, then these unresolved disputes/ differences will be referred for resolution by discussions with the concerned Director of BPCL and the concerned Director of Vendor/Contractor/Supplier. In case same does not resolve the difference within 30 days, arbitration clause as hereunder would apply.

In the event of any dispute or difference relating to the interpretation and application of the provisions of the contracts, such dispute or difference shall be referred by either party for Arbitration to the sole Arbitrator in the Department of Public Enterprises to be nominated by the Secretary to the Government of India in-charge of the Department of Public Enterprises. The Arbitration and Conciliation Act, 1996 shall not be applicable to arbitration under this clause. The award of the Arbitrator shall be binding upon the parties to the dispute, provided, however, any party aggrieved by such award may make a further reference for setting aside or revision of the award to the Law Secretary, Department of Legal Affairs, Ministry of Law & Justice, Government of India. Upon such reference the dispute shall be decided by the Law Secretary or the Special Secretary/Additional Secretary, when so authorized by the Law Secretary, whose decision shall bind the Parties finally and conclusively. The Parties to the dispute will share equally the cost of arbitration as intimated by the Arbitrator.

27. List of abbreviations used :

The terms “BPC”, “BPCL”, The Corporation, the Company and Owner in the appropriate context means Bharat Petroleum Corporation Limited, the Company registered under Companies Act 1956 and includes its successors and assignees.

The term “LOI” in the appropriate context means Letter of Intent

The term “PO” in the appropriate context means Purchase Order

Site Address: - Sewree Khaucreek Installation, Bharat Petroleum Co. Ltd. Sewree Fort Road, Sewree-East. Mumbai-400015.

Site Contact Persons: - Nagesh M Kamble Site Engineer Mob: 09890641414

Vivek Vohra Project Leader Mob: 022-27764541

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General Instructions to vendors for e-tendering

1. Interested parties may download the tender from BPCL website

(http://www.bharatpetroleum.in) or the CPP portal (http://eprocure.gov.in) or from the

e-tendering website (https://bpcleproc.in) and participate in the tender as per the instructions given therein, on or before the due date of the tender. The tender available on the BPCL website and the CPP portal can be downloaded for reading purpose only. For participation in the tender, please fill up the tender online on the e-tender system available on https://bpcleproc.in.

2. For registration on the e-tender site https://bpcleproc.in, one can be guided by the “Instructions to Vendors” available under the download section of the homepage of the website. As the first step, bidder shall have to click the “Register” link and fill in the requisite information in the “Bidder Registration Form”. Kindly remember your e-mail id (which will also act as the login ID) and the password entered therein. Once you complete this process correctly, you shall get a system generated mail. Thereafter, login in to the portal using your credentials. When you log in for the first time, system will ask you to add your Digital Signature. Once you have added the Digital Signature, please inform the vendor administrator @ [email protected] for approval. Once approved, bidders can login in to the system as and when required.

3. As a pre-requisite for participation in the tender, vendors are required to obtain a valid Digital Certificate of Class IIB and above (having both signing and encryption certificates) as per Indian IT Act from the licensed Certifying Authorities operating under the Root Certifying Authority of India (RCIA), Controller of Certifying Authorities (CCA). The cost of obtaining the digital certificate shall be borne by the vendor.

In case any vendor so desires, he may contact our e-procurement service provider M/s. E-Procurement Technologies Ltd., Ahmedabad (Contact no. Tel: +91 79 4001 6816 | 6848 | 6844 | 6868) for obtaining the digital signature certificate.

4. Corrigendum/amendment, if any, shall be notified on the site https://bpcleproc.in. In case any corrigendum/amendment is issued after the submission of the bid, then such vendors who have submitted their bids, shall be intimated about the corrigendum/amendment by a system-generated email. It shall be assumed that the information contained therein has been taken into account by the vendor. They have the choice of making changes in their bid before the due date and time.

5. Vendors are required to complete the entire process online on or before the due date/time of closing of the tender:

6. Directions for submitting online offers, electronically, against e-procurement tenders directly through internet:

(i) Vendors are advised to log on to the website (https://bpcleproc.in) and arrange to register themselves at the earliest.

(ii) The system time (IST) that will be displayed on e-Procurement web page shall be the time considered for determining the expiry of due date and time of the tender and no other time shall be taken into cognizance.

(iii) Vendors are advised in their own interest to ensure that their bids are submitted in e-Procurement system well before the closing date and time of bid.

(iv) If the vendor intends to change/revise the bid already submitted, they shall have to withdraw their bid already submitted, change / revise the bid and submit once

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again. However, if the vendor is not able to complete the submission of the changed/revised bid within due date & time, the system would consider it as no bid has been received from the vendor against the tender and consequently the vendor will be out of contention. The process of change / revise may do so any number of times till the due date and time of submission deadline. However, no bid can be modified after the deadline for submission of bids.

(v) Once the entire process of submission of online bid is complete, they will get an auto mail from the system stating you have successfully submitted your bid in the following tender with tender details.

(vi) Bids / Offers shall not be permitted in e-procurement system after the due date / time of tender. Hence, no bid can be submitted after the due date and time of submission has elapsed.

(vii) No manual bids/offers along with electronic bids/offers shall be permitted.

7. For tenders whose estimated procurement value is more than Rs. 10 lakhs, vendors can see the rates quoted by all the participating bidders once the price bids are opened. For this purpose, vendors shall have to log in to the portal under their user ID and password, click on the “dash board” link against that tender and choose the “Results” tab.

8. No responsibility will be taken by BPCL and/or the e-procurement service provider for any delay due to connectivity and availability of website. They shall not have any liability to vendors for any interruption or delay in access to the site irrespective of the cause. It is advisable that vendors who are not well conversant with e-tendering procedures, start filling up the tenders much before the due date /time so that there is sufficient time available with him/her to acquaint with all the steps and seek help if they so require. Even for those who are conversant with this type of e-tendering, it is suggested to complete all the activities ahead of time. It should be noted that the individual bid becomes viewable only after the opening of the bid on/after the due date and time. Please be reassured that your bid will be viewable only to you and nobody else till the due date/ time of the tender opening. The non availability of viewing before due date and time is true for e-tendering service provider as well as BPCL officials.

9. BPCL and/or the e-procurement service provider shall not be responsible for any direct or indirect loss or damages and or consequential damages, arising out of the bidding process including but not limited to systems problems, inability to use the system, loss of electronic information etc.

In case of any clarification pertaining to e-procurement process, the vendor may contact the following agencies / personnel:

1. For system related issues :

a. M/s. E-Procurement Technologies Ltd at contact no. Tel: +91 79 4001 6816 | 6848 | 6844 | 6868 followed with a e-mail to id [email protected]

mailto:[email protected]

BID QUALIFICATION CRITERIA AND EVALUATION METHODOLOGY ANNEXURE III.

1. BRIEF SCOPE OF WORK

Engineering and Projects Department of M/s Bharat Petroleum Corporation Ltd. plans to undertake Oil water Separator / Effluent Treatment plant at Sewree Installation. The estimated completion time for the job is 6 months from the date of LOI. The LOI will be issued to the successful bidder immediately after tender approval by CPO(M), while the Purchase order shall be issued by E&P(WR) for the execution of the job.

2. BID-QUALIFICATION CRITERIA

BPCL would like to qualify vendors for undertaking the above work as indicated in the brief scope. The detailed bid qualification criteria for short listing vendors shall be as follows:

I. Technical Criteria:

1.1 The Bidder shall have experience of having successfully completed at least one Mechanical type OWS or ETP for petroleum products of minimum capacity 120m3/hr in India during last 7 years ending on last day of the month previous to the one in which tender is invited.

Necessary documents should be submitted in support of the same. Bidder shall submit the Signed Agreement/PO copy/ Work order along with the completion certificate or any other document from the client indicating P.O/W.O/ or any other reference to the work which proves successful installation and commissioning of the item, clearly showing the capacity of the OWS/ETP. II. Financial Criteria: a. The average annual turnover of the Bidder for the last three accounting years should be

equal to or more than Rs. 33 Lakhs.

“Turnover shall mean Consolidated Turnover in case of a Bidder having wholly owned subsidiaries”. b. The bidders should have positive net worth as per the latest audited financial statement. Bidder shall furnish Annual Report/ audited balance sheets including Profit and Loss Accounts along with the Bid to establish Bidder's conformance to Qualification Criteria. c. Bidder shall not be under liquidation, court receivership or similar proceeding.

Undertaking to this effect to be submitted by the bidder.

III. Bids may be submitted by: The bids may be submitted by the Indian vendor (which has completed 3 financial years after date of commencement of business) only. JV/Consortium bids will not be accepted. IV. General : a. Bidder shall furnish all necessary documentary evidence along with the bid. In absence of such documents, BPCL reserve the right to reject the Bid without making any reference to the Bidder or assigning any reason what-so-ever. Offers received without sufficient documentary proof are liable for rejection. b. All the bidding document related to technical qualification criteria should be duly verified by any one of the following independent third party inspection agency viz. LRIS/SGS/GLISPL/IRS/DNV/ElL/TATAProjects/PDIL/UL/RITESLtd./MECON/ICS/BVIS/ CEIL. All the bidding documents related to financial Qualification Criteria should be duly verified by any of the above mentioned TPIA or a practicing Chartered accountant. All charges of the Third party or Chartered Accountant, for attestations and verification shall be borne by the Bidders for document verification. In case of BPCL work order/P.O., certification by TPIA is not mandatory. Completed value in such case will be cross checked from our SAP system and completion certificate/other documents to satisfy completed value is not mandatory. c. The bidders who are already registered with BPCL should also submit all documents as per the BQC. d. BPCL reserves the right to accept / reject any or all bid- qualification documents at their sole discretion without assigning any reason whatsoever. e. BPCL, at its discretion reserves the right to verify information/documents submitted and inspect the facilities at party’s work to confirm their capabilities. BPCL also reserves the right to independently assess the capability and capacity of the bidder for execution of the project. f. BPCL decision on any matter regarding short listing of bidders shall be final. g. Failure to submit documents to meet the above Qualification Criteria will render the Bid liable to be rejected. Therefore, the bidder shall in his own interest furnish complete documentary evidence in the first instance itself, in support of their fulfilling the Qualification Criteria as given above. BPCL reserves the right to complete the evaluation based on the details furnished without seeking any additional information. h. All documents submitted should be in English only.

4. EVALUATION METHODOLOGY Tender for “OIL WATER SEPARATOR/ETP SYSTEM AT SEWREE INSTALLATION” will be invited through Press advertisement as two part bid. The bid qualification evaluation of the received bids will be done as per the above bid qualification criteria and the technical bids of the qualified bidders will be evaluated subsequently. Only the price bids of techno-commercially qualified bidders will be opened and evaluated. The complete job will be awarded to the overall lowest bidder.

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BHARAT PETROLEUM CORPORATIONLTD.

(A Government of India Enterprise)

TENDER DOCUMENT FOR DESIGN, SUPPLY AND INSTALLATION OF OWS / ETP SYSTEM AT BPCL SEWREE

INSTALLATION

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CHAPTER – 1 The Scope of supply includes installation of Oil Water Separator System meeting inlet and outlet oily-water parameter as specified in bid document (i.e. as per MR, Data Sheets & Job Specifications), Design, Engineering, getting approvals from Purchaser/ TPIA, procurement of raw material, manufacturing, testing & inspection, packing & forwarding & transportation, Unloading, Storage at site, Site Security of materials, Site handling, Installation, Pre-commissioning and Commissioning of the OWS System meeting stipulated oily water conditions specified in the

tender document including supply of spares during commissioning till guarantee period. Civil work is excluded from the supplier’s scope, however supply of anchor bolts for all items and design, preparation of civil drawings and stage verification of dimensions of civil works are included in the present Bidder’s scope. The technical requirements details of Oil Water Separator System to be supplied are given in Table below:-

OIL WATER SEPARATOR SYSTEM FOR SEWREE INSTALLATION Design, Engineering, getting approvals from Purchaser/ TPIA, procurement of raw material, manufacturing, testing & inspection, Supply including packing & forwarding and transportation (on FOT site basis) of the OWS System meeting stipulated oily water conditions specified in the tender document including supply of Mandatory Spares as per list enclosed and also supply of spares required during commissioning till guarantee period. Mandatory Spares may be used by the Vendor during commissioning till guarantee Period. However, these spares shall be replaced free of cost to BPCL at SEWREE INSTALLATION. Supply of anchor bolts is included in the present Bidder’s scope. The Oil Water Separator System of capacity 120 m3/hr consisting of the following complete as specified but not limited to the same:- i)Tentative analysis of the effluent at the inlet to OWS System Oil content : 3000 ppm, Specific gravity : 0.65 to 0.9 ii) Analysis of treated effluent required pH : 6 to 8.5 Oil & Grease : 5 ppm max. Suspended solids:- 100 mg/l However vendor to ensure & design ETP/OWS system to meet the treated effluent specifications as mentioned above irrespective of effluent at the inlet to OWS.

1 MECHANICAL

Primary separating system consisting of plate separator fitted inside 1.1 the underground effluent holding tank, bar screen at inlet, Belt type Set 1

oil skimmer/compressor etc. complete as per specification.

1.2 Secondary separating system consisting of

a) Multimedia filter with frontal piping, valves, etc. Set 1

b) Coalescer filter/ ACF with frontal piping, valves, etc. Set 1

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1.3 Pump set of capacity of 120 m 3 /hr. with suitable head including

electrical motor, common base plate, accessories, etc. Set 2(1W+1S)

1.4

Oil recovery pump of capacity 2 m 3 /hr @ 35 mWC with motor and

Set 2(1W+1S) all accessories.

Suitable Cap. Submersible Pump (Portable) and flexible delivery pipe 1.5 of 10 m. long for sludge removal from the effluent underground Set 1

holding tank with suitable power connections, cable, etc.

1.6 Interconnecting piping/compressor system as per annexure details & Lot 1 valves for complete OWS System

1.7 Travelling Beam with suitable capacity chain pulley block Set 1

1.8 Floating Oil transfer pump of capacity 2 m 3 /hr @ 35 mWC along Set 1 with motor and all accessories.

2 ELECTRICAL

2.1 Motor Control Centre (MCC) for all Electrical drives Sets 1

2.2 Earthing & Lightning protection Lot 1

2.3 Power cables, Control cables, Cable trays, Supports, Local Lot 1 Control Station (LCS) & accessories

3 INSTRUMENTATION

Oil water interface detectors. Nos 4

Float type level switch Nos 2

Interconnecting cabling, GI conduits, cable trenches Lot 1

Control panel including annunciation & pushbuttons Nos 1

Differential Pressure Gauge Nos 1

Pressure Gauge Nos 8

Online analyser Nos 1

Total (I) LS 1

Unloading, Storage at site, Site Security of materials, Site handling, Installation/ Erection, testing, painting, Pre-commissioning and Commissioning of Mechanical, electrical and Instrumentation

II equipment of Oil Water Separator System. Civil work is excluded LS 1 from the supplier’s scope, However, design, preparation of civil drawings and stage verification of dimensions of civil structures are

Included in the present Bidder’s scope.

III AMC

1 For 1 st year LS 1

2 For 2 nd year LS 1

3 For 3 rd year LS 1

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Notes

1. The list of items and its quantities given in BOQ are the minimum required and any additional items/ quantities required to meet the performance of the system shall be supplied by the contractor within the agreed contract price. The contract price shall remain firm and will not change on any account. Any item (Mechanical/Electrical/Instrumentation ie. Apart from civil work) is to be supplied /installed/commissioned/tested/stabilized by the vendor within the agreed contract price. No additional payment will be made for any part which is required for successful commissioning of the ETP/OWS system & not mentioned in the tender terms. Vendor to visit the site/Prepare the BOQ/ work out on scope of job & quote accordingly. Also, vendor needs to provide detailed break-up of cost separately in the bid submitted. TPIA charges are also in the scope of vendor. TPIA will be one agency from IRS/BV/EIL /PDIL/DNV. 2. Item No. III (AMC) will be considered for evaluation. Validity of quoted AMC charges shall be upto 3 months after expiry of guarantee/ warrantee/Defect Liability period of OWS system. BPCL, on his own discretion, may place separate order for AMC after completion of guarantee/ warrantee/ Defect Liability period.

Delivery Schedule:- Delivery Schedule shall be as follows:- Supply, erection, testing and commissioning shall be completed within the period of 24 (twenty four) weeks

from the date of issue of LOI (Letter of intent). For supply: 16 (sixteen) weeks from the date of issue of LOI (Letter of intent). For erection & commissioning: 24 (twenty four) weeks from the date of issue of LOI(Letter of intent).

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APPENDICES

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APPENDICES TO SCC

C O N T E N T S

Appendix -1 : Scope of Work & Supply

Appendix -2 : Time Schedule

Appendix -3 : Terms of Payment

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SCOPE OF WORK & SUPPLY

(APPENDIX - 1 to SCC)

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APPENDIX-1 TO SCC

1.0 SCOPE OF WORK & SUPPLY

1.1 Owner’s Scope of Work

Scope of work shall be as detailed in Particular Job Specification, Technical Specifications, Schedule of Rates & various other parts of this Bidding Document. All civil work related to execution of work.

1.2 Owner’s Scope of Supply

Owner’s scope of supply shall be as specified in Particular Job Specification, Technical

Specifications, Schedule of Rates & various other parts of the Bidding Document.

1.3 Contractor’s Scope of Supply

All materials required for successful completion of works in all respects shall be supplied by the Contractor and the cost of such supply shall be deemed to have been included in the quoted price without any additional liability on the part of Owner.

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TIME SCHEDULE

(APPENDIX - 2 to SCC)

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APPENDIX-2 TO SCC

Delivery Schedule:- Delivery Schedule shall be as follows:- Supply, erection, testing and commissioning shall be completed within the period of 24 (twenty four) weeks from the

date of issue of LOI (Letter of intent). For supply: 16 (sixteen) weeks from the date of issue of LOI (Letter of intent). For erection & commissioning: 24 (twenty four) weeks from the date of issue of LOI(Letter of intent).

________________________________

(STAMP & SIGNATURE OF BIDDER)

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APPENDIX-3 TO SCC

TERMS OF PAYMENT

TERMS OF PAYMENT

Pending completion of the whole works, provisional progressive payments for the part of work executed by the contractor shall be made by Owner on the basis of said work completed and certified by the Owner’s representative as per the agreed milestone payment schedule and the percentage break-ups given below.

Contractor shall submit his invoices to the Owner’s representative fortnightly in the manner as instructed by Owner. Each invoice will be supported by documentation acceptable to Owner and certified by the Owner’s representative. Payments made by owner to the contractor for any part of the work shall not deem that the Owner has accepted the work. All payments against running bills are advance against the work and shall not be taken as final acceptance of work / measurement carried out till the final bill. Owner will release payment through e-payments only as detailed in the bidding document.

PAYMENT TERMS

SR. NO. DESCRIPTION % PAYMENT

(% OF QUOTED

AMOUNT)

1 APPROVAL OF DESIGN, DRAWINGS, DOCUMENTS, DATA SHEETS ETC. & RELEASED FOR CONSTRUCTION.

5%

2 COMPLETION OF ASSEMBALY OF EQUIPMENT AT VENDIR’S FACTORY & SUBMISSION OF IRN BY TPIA FOR DISPATCH

40%

3 DELIVERY OF ETP/OWS SYSTEM AT SITE 20%

4 ERECTION & COMMISSIONING OF SYSTEM 5%

5 COMPLETION OF TESTING/COMMISSIONING / SAT 20%

6 SUCESSESFULL COMPLETION OF 1st WARRENTY YEAR 2 %

7 SUCESSESFULL COMPLETION OF 2st WARRENTY YEAR 2 %

8 COMPLETION OF 1ST YEAR AMC (TO BE PAID MONTHLY ON PRO-RATA BASIS)

2 %

9 COMPLETION OF 2ND YEAR AMC (TO BE PAID MONTHLY ON PRO-RATA BASIS)

2 %

10 COMPLETION OF 3RD YEAR AMC (TO BE PAID MONTHLY ON PRO-RATA BASIS)

2 %

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4.0 PAYMENT METHODOLOGY

4.1 The contractor shall raise invoices as per payment terms basis. Bidder shall enclose all documents as per check list issued by TPIA/ BPCL.

4.2 The payments to the Contractor will be released within a period of 15 days from the date of receipt of the complete invoice as per the terms and conditions of the

Contract.

4.3 BPCL has separate entity for Bill processing i.e. BPEC & will be issued a receipt at the time of the submission of the bills. The contractor can see the status of their bill on BPCL’s website / vendor portal.

4.4 Employer will release payment through e-payments only as detailed in the Bidding Document.

4.5 No Interest charges for delay in payments, if any, shall be payable by the Owner.

4.6 All payments against running bills are advance against the work and shall not be taken

as final acceptance of work/ measurement carried out till the final bill.

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SCOPE OF WORKS

FOR

OIL WATER SEPARATOR SYSTEM

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Instructions to Bidders:-

a) The intent of this specification is to entrust the complete work of the OIL WATER

SEPERATOR SYSTEM (OWS)/ETP for execution on a turnkey basis. b) This specification forms a part of the tender documents and shall be read in conjunction with the same. c) The scope of work covers mechanical, structural, and electrical and instrumentation works. d) The work shall be executed as per the specification. The Bidder shall, however, include all such items of work whether specifically mentioned or not, which are essential to make the system complete in all respects and for satisfactory working of the proposed scheme. e) The Bidder shall give the lump sum price as per Price bid of this specification. f) The Bidder shall arrange to transport, unload and store at SEWREE INSTALLATION, all equipment to be supplied by him. g) The Bidder shall remain responsible for the safe custody of all equipment/ material till these are erected, tested, commissioned and handed over to the Purchaser. h) All equipment/ materials shall be designed, manufactured, erected and tested in accordance with the latest Indian Standards or to generally accepted Codes of Practices. They shall also comply with the statutory requirement of the Govt. of India and respective State Govt. i) All supplies shall be new and best of their kinds. j) The Bidder shall satisfy himself by a visit to the site to ascertain the actual site conditions before quoting. Failure to do so shall not absolve him of his responsibilities about proper execution of the job. No claims for extra payments due to any special site conditions will be entertained after the award of contract. k) The site shall be cleared after erection is completed. l) Wherever necessary, the Purchaser reserves the right of selecting the manufacturer of equipment/ equipment components in the interest of standardisation. m) The Bidder shall satisfy the Purchaser that he possesses the necessary technical experience and expertise and has adequate facilities and staff to ensure that the contract shall be of the best quality and workmanship. Necessary particulars in this regard shall be furnished with the tender. n) Delivery and erection schedule shall be submitted along-with the tender in the form of a bar chart. However, the Bidder shall note that the supply, erection, testing and commissioning shall be completed within the period of 24 (twenty four) weeks from the date of issue of LOI (Letter of intent). Delivery Schedule shall be as follows: - For supply : 16 (sixteen) weeks from the date of issue of LOI For erection & commissioning: 24 (twenty four) weeks from the date of issue of LOI. o) On completion of work, five sets of all drawings (editable) with one CD, incorporating all changes that might have been effected during the course of the execution of the contract and five sets of the test certificates for each item of equipment shall be supplied.

p) All moving parts of equipment which can conceivably cause injury to the operator or other

personnel in the vicinity of working area shall be suitably guarded according to the safety regulations. q) Each equipment shall be equipped with suitable lifting attachments such as lifting lugs, eye bolts etc. to facilitate erection and maintenance. r) All the rotating parts shall be statically and dynamically balanced. s) Any permission from the statutory bodies, if necessary, for execution of the work shall be arranged by the Bidder.

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t) All electrical equipment to be supplied by the Bidder shall comply with the latest revision of the Indian Electricity Rules and also with the statutory requirements of the Govt. of India and the respective State Govt. u) Safety, earthing and other provisions specified therein for installation and operation of the electrical equipment. v) The Bidder shall study the specification and satisfy himself regarding the workability of the equipment and shall take full responsibility for the guaranteed operation of the equipment with respect to output, performance and smooth working. w) If the Bidder desires to deviate from any requirement of the specification, the same shall be

clearly mentioned and the price implication of such deviations shall be clearly indicated.

SCOPE OF WORK

a) Design and engineering of complete system of OIL WATER SEPERATOR SYSTEM comprising below ground receiving cum primary settling tank with Oil skimmer (Belt type) and Plate Separator, oil collection pit, Multimedia Pressure Filter, Coalescer filter/ Activated Carbon filter, Filter feed pumps, Oil recovery pumps, Floating oil transfer pump, inter connecting piping, valves, fittings, electrics and instrumentation with both manual and automatic mode of operation, etc. on total turn-key basis. b) The successful Bidder for the OWS package will provide the necessary documents and adequate reports for submission to the Pollution Control Board authorities after completion of job. c) The contractor shall also facilitate inspection of plant by Pollution Control Board after installation of plant, if required. d) Construction of civil structures is not in scope of Bidder. However, preparation of civil drawings and supervision of erection of civil structures shall be in scope of Bidder. e) Supply/ fabrication, assembly, shop testing, painting, packing, loading at works, insurance, transportation to site, unloading, storage at site, preservation, handling at site, erection, testing, painting and commissioning of pump sets, pressure filter, coalescer filter/ activated carbon filter, oil skimmer, inclined plate separators, valves, pipes & fittings, electrics, instruments, etc. f) MCC Panel, LCS & Control Panel for OWS System shall be skid-mounted FLP type with canopy & all accessories including associated FRLS power & control cables. g) Scope shall include providing Online oil content meter and alarm system : Purimeter microprocessor-based equipment used for continuously measuring oil content in water shall be provided with the system. A representative sample from the oily water separator shall be continuously passed through the PURIMETER cell. The cell continuously scans the sample and the meter displays its oil content directly in PPM. The PURIMETER gives an audio-visual alarm in case the oil content in the effluent exceeds a pre set limit. The PURIMETER shall generally be used directly on line. h) Testing and commissioning of the entire system.

i) Submission of editable soft copies and hard copies of drawings, technical design

calculations etc. for approval of Accepting Officer/ TPIA. j) Providing security watch & ward staff and fire fighting arrangement at site during erection

and commissioning.

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k) Successful Bidder shall bring in any special instruments required for performance testing at his own cost, and they may be taken back after completion of such P.G. test. The contractor shall indicate the acceptable accuracy of instruments he proposes to bring for P.G. test alongwith Calibration certificates. m) Supply of oils, lubricants, chemicals, resins, etc., during testing, trial run, commissioning

and also during maintenance period is in the scope of work of Bidder. n) Supply of special tools, tackles and other accessories required for erection,

commissioning and operation of the plant. o) Requirement of spares for normal operation as indicated in the BOQ. p) The following drawings shall be submitted along with offer/ after placement of order:

a) P & I diagram for OWS (Including Pipeline sizes ) b) Hydraulic level diagram for OWS. c) GA drawing showing all the units/ equipments of OWS incorporating all the principal

dimensions. d) GA drawing showing piping layout of OWS including pipe supporting arrangements etc. e) Outline and general arrangement drawings incorporating all principal dimensions.

f) Sectional drawing of each equipment incorporating data on materials of construction. g) Predicted performance curves for the pumps. h) Sizing and thickness calculations for pressure filter, coalescer filter/ ACF shall be

submitted. i) Power requirement and SLD

q) The approval/ comments, if any, of/ on the drawings shall be communicated by Owner/ TPIA within a week of receipt of the same. Within 15 days of approval of drawings/ documents, the Bidder shall supply 6 copies of approved drawings and documents and relevant catalogues, manuals etc., to Owner/ TPIA alongwith one CD-ROM containing editable drawings/ documents. r) The supplier shall supply 6 sets of the following documents for approval before dispatch of

equipment:

i. Material test certificates. ii. Static and dynamic balancing test certificates on rotary parts. iii. Shop performance data, calibration curves and certified characteristic of pumps, and other

equipment.

s) The supplier shall supply operation and maintenance manual alongwith the equipment. The manuals shall meet the following requirements :- The instruction manuals shall present the categories of information in practical, complete and comprehensive manner prepared for use by operating and/ or maintenance personnel.

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i. Instructions for initial installation. ii. Instructions for operation, maintenance and repair. iii. Recommended inspection points and periods of inspection. iv. Ordering information for all replaceable parts. v. Lubrication chart. vi. Drawings and other illustrations shall be included or copies of drawings shall be bound in the manual. Test, adjustment and calibration information as appropriate shall be included and shall be identified to the specific equipment, Safety and warning notices and installation, maintenance and operating cautions shall be emphasized. vii. A part list shall be included showing part nomenclature, manufacturers’ part number and/ or other information necessary for accurate identification and ordering of replacement parts.

viii. If a standard manual is furnished covering more than the specific requirement purchased, the applicable model no., parts no. and other information for the specific equipment purchased shall be clearly identified.

ix. The instruction manual shall include a list of all special tools and tackles furnished with complete drawings and instructions for use of such tools and tackles.

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ANNUAL MAINTENANCE CONTRACT (AMC) FOR A PERIOD OF 3 YEARS

AFTER EXPIRY OF AGREED WARRANTY PERIOD i AMC is in the scope of contractor for complete systems (OWS) supplied, erected and

commissioned at SEWREE INSTALLATION for a period of 3 years after expiry of agreed

warranty period.

ii During the contract period, supplier shall ensure visit of their service personnel to the site

minimum TWO times a year on half yearly basis (apart from the break down calls) for carrying out regular maintenance work. The half yearly visits will be planned in consultation with BPCL.

iii During warranty period, any replacement of parts/ rectification shall form an integral part of the contract and agreed contract price. Since the equipment is under warranty obligations, no extra payment towards replacement of components, parts etc. shall be allowed. Bidder can use the Mandatory spares, if required. However, same has to be replaced by the Bidder before the end of the warranty period.

iv The effective date of Annual Maintenance Contract shall be from the date of successful completion of warranty period as per contract and on request from the purchaser. During preventive/ break down visits, any replacement/ consumable required will be provided by BPCL. M/s. BPCL will provide the same, if available, from their stock. In case the same is not available, the AMC Contractor shall provide the details of specification of parts/ consumables, quantity required and the sources to procure from and furnish the same. Alternately, M/s BPCL may also ask the Contractor to provide the same at extra cost with prior approval. The Contractor shall ensure that breakdown calls are attended within 24 hours of information.

v The rate quoted shall be firm for the entire period of maintenance contract.

vi At the end of Maintenance duration, the system shall be handed over to the Purchaser/

Owner complete in all respects in good working condition along with records.

vii If the Purchaser desires to associate his operating personnel alongwith the AMC the

same. However, this shall not relieve the AMC Contractor of his obligations under this

contract. viii AMC Contractor who is engaged in carrying out AMC shall bring his own tools and tackles,

site testing equipment required for maintenance of equipment and system etc. AMC Contractor shall provide at his expense all equipment/ services necessary for rectifying/ repairing of equipment. Ix The AMC Contractor shall be responsible to make necessary arrangements to rectify/

repair any defective equipment expeditiously with the approval of purchaser. In case any

external agency is required, with the approval of purchaser, the Contractor shall make necessary arrangements for the same. x AMC Contractor shall furnish to the Purchaser preventive maintenance schedule (as per relevant O & M Manuals) one month in advance and same shall be carried out without affecting the normal working of the plant. xi AMC Contractor shall adhere to all statutory regulations and accepted safety norms of the installation in maintenance of the equipment/ system. xii AMC Contractor shall be responsible for the safety of equipment/ system at no extra cost to the Purchaser. xiii AMC Contractor shall keep all the working premises clean. xiv The Contractor shall abide by and work to the instructions, suggestions and to the requirements of the operational persons, representing the Purchaser, during Warranty and AMC Periods.

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xv In case the Bidder does not undertake the AMC Contract later when awarded or does not abide by the terms of the contract for supply of spares as well as the AMC Contract, then BPCL reserves the right to encash the performance bank guarantee available with them besides blacklisting and putting the Bidder on holiday list of BPCL for a period of five years. xvi The scope of service that will be rendered during AMC visits for checking mechanical & hydraulic performance of the equipment supplied and rectification of defects, shall include the following but not limited to the same. However, the Bidder shall furnish the detailed scope of work included in the AMC contract alongwith the offer. a. Leakage. b. Bearing conditions temperature & sound etc. c. Vibration/ Noise d. Taking trial run & check for performance e. Alignment f. Sealing connections g. Lubrications h. Other general checks & other complaints if any.

Note :- The present job would be awarded up to SAT. Separate order on basis of rates as quoted now would be placed by the user function of BPCL, on his own discretion, for payment for completion of warrantee period & 3 years AMC after completion of guarantee/ warrantee/ Defect Liability period, as per payment terms.

TAKE OVER/TERMINATION POINTS

i. The battery limits for the Inlet of effluent water for this package starts from Bar screen

chamber with 2 nos. inlet pipe of one metre length of DN 300 RCC NP3 class. ii. The invert level of DN 300 RCC NP3 class pipe will be at 2000 mm. below from finished

ground level. iii. The battery limit for back wash line shall be 10 m from the inlet to the Multimedia Filter.

The necessary restricted orifice, isolation valves and nipples required to be connected to

water line are also included in the bidders scope. iv. The battery limit for Bypass line and Oil free water line shall be 10 m from outlet of multimedia

& coalescer/ activated carbon filter.

v. The battery limit for Recovered oil pipeline shall be 10 m from outlet of oil recovery pump-

P4. The necessary non return valve and isolation valves on pipelines is included in vendors’s

scope.

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List of mandatory spares to be maintained throughout 3 years of period after commissioning. 1 MECHANICAL

1.1 Filter Feed Pump

a) O Ring set Set 2 b) Gland packing/ mechanical seal Set 2 c) Bearings for pump & motor Set 2

1.2 Oil recovery pump

a) O Ring set Set 2

b) Gland packing/ mechanical seal Set 2 c) Bearings for pump & motor Set 2

1.3 Submersible handling pump


1.4 Oil Skimmer

Bearings for Gear box & motor Set 1 Belt Nos 1

1.5 Floating Oil transfer pump


2 Electrical

2.1 Contactor For

a) Feed water pump motor feeder Nos 1 b) Oil skimmer motor feeder Nos 1 c) Oil recovery pump motor feeder Nos 1

2.2 One number MPCB of each rating Set 1 2.3 LED indicating lamp

a) Red Colour Nos 2 b) Green Colour Nos 2 c)Amber Colour Nos 2

3 INSTRUMENTATION

3.1 Oil water interface detectors. Nos 1 3.2 Float type level switch Nos 1 3.3 Fuse for control panel 1

3.4 Indicating lamp/ annunciation window Set

2

3.5 Pressure Gauge Nos 1

Prices to be included in Item No. I.

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Technical Specifications

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a) Design parameters Capacity of treatment plan required: 120 m 3 /hr (for Sewree Khaucreek Installation) A) Tentative analysis of the effluent at the inlet to ETP

a) Oil content : 30000 Ppm b) Specific

gravity : 0.65 to 0.9

B) Analysis of treated effluent required

a) pH : 5.5 to 9 b) Oil &

Grease : 5 ppm

max. c) Capacity : 120

m3/hr Treated effluent parameters shall be as per MOEF /CPCB Gazette Notification dt 18th March 2008 (or latest revision). The analysis of treated effluent parameters shall be done by BPCL approved MOEF. certified water testing Labs in presence of approved TPI and BPCL.. b) Treatment Scheme (Refer Drg.)

The proposed treatment scheme for OIL WATER SEPERATOR SYSTEM consists of the

following: -

Receiving tank with screen for arresting suspended solids.

Primary settling tank with oil skimmer and Plate Separator. Filter Feed pumps.

Multi Media Pressure filter.

Coalescer filter/ Activated Carbon filter for Polishing. Floating oil transfer pump.

Oil collection tank with recovered oil transfer pump.

Sludge transfer pumps. MS pipes, fittings, valves, etc.

Instrumentation & Electrics etc.

All necessary electrical & instrumentation system.

Power supply will be made from BPCL’s MCC room to OWS MCC room. Instrumentation cables will be laid upto the local station by vendor.

Process Description:-

i) Primary Separation Primary separation of the oil from the effluent shall be achieved in a

below ground RCC tank. The tank shall be divided into three sections: -

a) receiving section b) parallel plate section and c) Outlet section.

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The sections shall be divided by RCC walls. The receiving section shall receive oily water

from the terminal tankage through underground pipe/drains. The effluents will be passed

through inlet chamber size minimum of 1.5m x 1.5m for easy approach, the inlet chamber

provided with bar screen for removal of large floating objects. Screen and screen frame shall

be of SS 304.Riser pipes shall be provided on the wall between the receiving section and

parallel plate section which shall ensure that water from the lower half only of the receiving

section gets transferred to the parallel plate section. Size of underground sump (including all

the three sections) shall have an effective storage volume of minimum of 200 m3 below the

invert level of inlet pipe. A drain pit with suitable slope is provided to collect the sludge and

easy removal of sludge by using sludge handling portable submersible pump. A Suitable Cap.

Submersible Pump (Portable) and flexible delivery pipe of 10 m. long for sludge removal from

the effluent underground holding tank with suitable power connections, cable etc. shall be

provided in such a way that single pump can be used for removal of sludge in each

compartment (all three section) of the underground holding tank. A diverter wall shall be

provided in the parallel plate section, which shall divert the floating

Oil towards the centre of the tank. A floating oil skimmer shall be mounted in the neck created

by the diverter wall. The skimmer shall skim off the floating oil and discharge it to an

underground oil-collecting tank. The parallel plate section shall house a stack of plates. The

plate stack shall be made of corrugated plates having flutes at 45°. The stack shall be

mounted inside a SS frame which shall be guided into the RCC tank using guide angles

provided at four corners of the tank. A wall shall be provided to separate this section from the

outlet section. Riser pipes similar to those mounted in the receiving section shall be provided

on the wall, which shall open into the outlet section. Beam with chain pulley arrangement shall be provided above the parallel section to lift the plate stack for cleaning and maintenance purpose. The outlet section shall have sufficient storage volume. Water from the outlet section is pumped to filtration units for removing smaller oil particles. Negative Suction pumps are placed on the ground level with an RCC foundation. Floating oil transfer pump: A suitable gear pump shall be provided to transfer floating oil from holding tank directly to the oil collection tank, with floating suction arrangement.

NOTE: All the three section are separated by RCC wall. All underground sump provided with

handrail all around. Over flow pipe inserts leads over-flow water to nearest storm water drain.

Each section of underground tank shall be provided with individual ladder/ rungs.

ii) Filtration Unit: - The filter shall be Multimedia pressure sand filterusing graded sand as

the filter media. The sand shall be graded from course to fine to coarser in the direction

of flow. This can be achieved by providing low-density materials like anthracite as

coarse materials on the top of the filter sand. The filter shall be down flow pressure

sand filter type with inlet at the top and outlet at the bottom. The filter body shall be a

pressure vessel constructed out of MS plates designed as per IS: 2825. Filter shall

have a provision for collecting the oil and oil water interface detection system shall be

mounted on the top part for monitoring the oil water interface. The filter shall be

provided with backwashing facilities. Back washing of filter is from water line available

from the terminal and the same is let into receiving section of primary separation

system. Water will be available at approx. 7 kg/cm2.g. Back wash line shall be provided

with necessary valves, pressure reducing valve/ restricted orifice, differential pressure

indicator and nipples, required to be connected to water line of the terminal. The shell

and dished end thickness shall be minimum 8 mm.

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iii. Polishing unit.

The filtered water emerging from the multimedia pressure filter shall be sent to a polishing unit consisting of a coalescer filter or activated carbon filter. As the filter media shall be made of materials that have the capacity to attract the dispersed oil phase in water media. The smaller oil particles rising velocity is increased by Agglomerating of small globules thus creating larger, faster rising globules and collected on the top of filter. The filter body shall be a pressure vessel constructed out of MS plates designed as per IS: 2825. An oil water interface detection system shall be mounted on the top part for monitoring the oil water interface and sends a signal to control panel to open the valves manually to drain the oil to oil pit. The shell and dished end thickness shall be minimum 8 mm. iv) Pumps with drive motors:-

Capacity and head required for all the pump sets are indicated in the tender drawing. The

operation of the pump shall be automatic based on a level control system mounted in the respective sumps/ tank. Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal. The coupling between the prime mover and the pump shall allow each unit to be removed without disturbing the other. The pump shall be manufactured and marked in accordance with IS: 5120 or DIN 24255. The pump rated capacity, total dynamic head and other performance requirements shall be as per the requirement of the OWS. The pump shall be designed to have the best efficiency at the specified duty point. The pump set shall be suitable for continuous operation at any point within the range of operation selected. The pump shall have a continuous rising head capacity characteristic from the duty point towards the shut-off point, the maximum being shut-off. The horse power characteristic shall preferably be non-over loading type beyond the rated capacity point. The material of construction of components other than those specified shall be as per

standard of the pump manufacturer and shall be indicated separately. The pumps shall be suitable for parallel operation. Pump along with its drive shall run smooth without undue noise and vibration. Replaceable/ renewable wearing rings shall be provided for both the casing and the impeller or for the casing only. The power rating of the drive shall be selected such that a minimum margin of 15% is available over the pump input power required at the duty point. The complete assembled unit shall be designed so that all covered parts including shafts and bearings shall be easily accessible for inspection, maintenance and replacement with minimum down time. The RPM of the pump shall normally not exceed 1500. Filter feed

pump shall have 1500 RPM.

MOC of body and impeller shall be Cast Iron & shaft and shaft sleeve will be of SS-304. End suction pumps shall be provided with spacer coupling. The rotor assembly with impeller and shaft sleeve shall be dynamically balanced at 150% of operating speed. Pump casing shall be made of cast iron and tested at 150% of shut-off head or 200% of rated total head whichever is higher. Coupling guard shall be provided for all types of pumps. Suction and discharge flanges shall be drilled in accordance with IS: 1538.

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The gland packing should be easily accessible for changing without having to disassemble the pump. The prime mover of the pump shall be flame proof AC electric motor as indicated under 'Electrics'. If pump is of DIN 24255 STD, it should meet all specs of DIN. v) Triple offset butterfly valves (Wafer type)

Triple offset Butterfly valves shall be designed and manufactured to have a rigid

structural stability, flow efficiency, effective seating (Zero Leakage) and compact design for ease of operation and to give reliable performance. Valve body shall be of CI and disc material shall be of SG iron. The valves shall be provided with integrally mounted body liner. Liner shall be of Nitrile. Valves shall be of PN 1.6 rating and shall conform to BS: 5155/ IS: 13095/ API 609/ AWWA C 504. Valves of sizes 200mm and above only shall be Triple offset butterfly valves.

vi) Ball valves:- Ball valves shall be of full bore type 2 pieces/ 3 piece and screwed ends

/socket weld ends. The valve upto 1.5 shall conform to BS: 5351 in all aspects of

design and manufacture, and valves of size 2” & above shall meet to BS: 6755 in

matters of testing Valves shall be designed to provide smooth and easy operation,

repeatedly and consistently. The valve shall be designed for ease of maintenance,

dismantling, replacement of parts and re-assembly at site if required. Valves of

sizes 50 mm to 200 mm shall be provided with self locking lever with valve

positions marked on the indicator plate, and shall be ball valve only. vii) Pipes and Fittings:-

A) Pipe :- GI pipes:- IS: 1239 (Part-I) -2004, Heavy up to DN 150 mm. IS: 1978,

YST 240 DN200 and above.

B) Fittings:- As per IS : 1239 (Part-II)

viii) Oil Skimmer. The belt type oil skimmer shall be installed in the receiving section of

the Plate Separator. The oil skimmer shall have the following major components. a. Oil skimmer roller:- The oil skimmer roller shall be fabricated out of mild steel plates. The roller shall be sealed from both sides. The roller shall be coated with special oleophyllic material, which has the capacity to absorb oil. The roller assembly shall be mounted in such a way that a part of the roller always remains submerged. b. Scraper with oil receiving tank:- A scraper shall be provided for scraping off the oil sticking to the roller. A small tank shall be provided for receiving the scraped oil. The scraper blade shall be Teflon coated. Oil from the oil-receiving tank shall be led to a bigger underground tank by means of a flexible hose. C:- Prime mover:- The oil skimmer roller shall be driven by an electric motor through a gearbox

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ix) Oil drains system:- The coalescer/ activated carbon filter and the multimedia filtration unit

shall be fitted with automatic oil drain systems provided with a sensor. When the level

of oil collected in the oil-collecting dome increases to a preset level, the interface

detector shall send a signal to the control panel, which shall give the alarm to open the

valve automatically and drain out the oil. Valve shall be triple offset butterfly valve with

electro-pneumatically operated. When the level of water in the dome goes up to a

preset level, Interface detector sends the alarm to control panel to close the valve

automatically. Air will be available from instrument air supply of terminal. These valves

shall fully work in automation.

x) Online oil content meter and alarm system:- Providing Online oil content meter and alarm system: Purimeter, a microprocessor-based equipment used for

continuously measuring oil content in water shall be provided with the system. A

representative sample from the oily water separator shall be continuously passed

through the PURIMETER cell. The cell continuously scans the sample and the meter

displays its oil content directly in PPM. The PURIMETER gives an audio-visual alarm in

case the oil content in the effluent exceeds a pre-set limit. The

PURIMETER shall generally be used directly on line.

xi) Supply/installation & commissioning of Compressor system with following specification.

Sr.No. Tech detail Specs

1 No. of air compressors 1 2 Capacity - LPH 200

3 Type of air compressor - Reciprocating

4 Application - For Oil Disharge Electro Pnuematic valves

5 Duty - continouos

6 Air tank - As per Manufacturer std. 100ltrs.

7 Delivery pressure at the Air tank - 10Kg/cm2 8 Compressor Loading / Unloading - manually

9 No. of stages - Single

10 Cooling type - Air cooled

11 Lubricated / non-lubricated - Splash Lubricated

12 Drive - Electric Motor

13 Pressure Switch Set Cut In ---4-6 KG/CM2 Auto Cut Off ------ 10KG/CM2

14 Drive Power 1.5HP/1.1KW 3phase

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Any other job to complete the commissioning of air compressor system is in vendor’s scope.

Vendor to fill following details/specification of Oil in Water Analyser

Sr.No. Description Yes/No Remarks

1 General

1.1 MANUFACTURER Vendor to Specify

1.2 MODEL NO. Vendor to Specify

1.3 CHANNEL /STREAMS Single Channel

1.4 METHOD UV Fluorescence Type Reagent Free Analysis

1.5 RANGE 0-100 ppm Oil in Water

2 SAMPLE CONDITIONS

2.1 TEMPERATURE +5 to +80 °C

2.2 PRESSURE 0.3 - 2 bar

2.3 FLOW RATE >10-30 LPH or less

2.4 SUS. SOLIDS LEVEL Less than 100 micron

3 ANALYSER

3.1 TYPE : Advanced Microprocessor Based System

3.2 PROGRAMMING: User Defined, Freely Programmable

3.3 OPERATION: Reagent & Chemical Free Analysis

3.4 OPERATION CYCLE: Continuous

3.5 CLEANING : Automatic built-in cleaning function, User Programmable Periodic Type

3.6 ACCURACY Within IMCO limits

3.7 DISPLAY TYPE : Alpha Numeric Display 240 x 128 Pixels LCD with Backlit

3.8 GRAPHICAL ANALYSIS: Graphical Trend Analysis, time based

3.9 KEYPAD : Touch Screen Type/ Weather proof press key type

3.10 RESPONSE TIME : Less than 10 seconds

3.11 MEASURING CYCLE TIME : Freely Programmable/ Normally 3-5 min.

3.12 ANALOG OUTPUT

Two Analog Outputs; 0/ 4- 20 mA, DC, Isolated, Programmable at site, 1 No. 4-20 mA factory set for 0-100 ppm

3.13 CALIBRATION Manual Calibration facility, Calibration Certificate to be provided along with the unit.

3.14 AUTO ZERO Automatic Zero during cleaning cycle.

3.15 INTERFERENCE CORRECTION

Interference Correction by Reference photo Detector

3.16 ENCLOSURE FLP

3.17 ENCLOSURE Epoxy coated Steel Enclosure

3.18 ALARM SIGNAL

4 relay signals for high or low process value set points, monitor failure, microprocessor failure etc. To be Programmed at site.

3.19 POWER SUPPLY 110-230V AC, 50Hz.

3.2 DIGITAL INTERFACE RS 485 (MODBUS). Modbus details must be mentioned in As Built Documents.

3.21 DIMENSION Vendor to Specify

3.22 TEMP. LIMITS 0-50 °C

3.23 WEIGHT Vendor to Specify

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3.24 ELECTRICAL CONNECTIONS On Back Panel

4 ACCESSORIES

4.1 ANALYSER Cleaning canister

4.2 SAMPLING PART Sample Handling System with Filter

4.3 MOUNTING Standalone type CRCA Rack/ Flash Mounting type

4.4 ACCESSORIES/SPARES All new spares & accessories to be used with YOM not more than 1 Yr of placement of P.O.

Questionnaire :-The filled questionnaire shall be submitted by the Bidder along with their offers

Technical parameter Filter feed pump

Oil recovery pump

Submersible handling pump

floating oil transfer pump

1 Make

2 Model No

3 Capacity M3/Hr

4 Total Head mWC

5 Efficiency @ Rated parameters %

6 Pump Speed RPM 900

7 Type of liquid pump can handle Oil water/Oil Sludge

8 Minimum Submergence in case of submersible pump M

9 Material Of Construction

a Casing

b Impeller

c Impeller shaft

d Gland & Packing

e Wearing Rings

f Shaft Sleeve

10 Drive Details

a Power Reqd. (kW)

b Drive Motor kW

c Motor Speed

d Insul. Class

e Frame Size

f Enclosure Type

11 Documents Enclosed

a Drawings (GA & C.S) Yes/No

b Performance Curve Yes/No

c Part List Yes/No

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For butterfly valve

1 Make

2 MOC

3 Type

4 Standard to which it confirms

5 End connection details

For ball valve

1 Make

2 MOC

3 Type



For gate valve

1 Make

2 MOC

3 Type



For coalescer/ Activated filter

1 Make

2 MOC

3 Design code

4 Operating pressure

5 Design pressure

6 Test pressure

7 Filter media

8 Thickness of Shell / Dished end

9 Size

For multimedia filter

1 Make

2 MOC

3 Design code

4 Operating pressure

5 Design pressure

6 Test pressure

7 Filter media

8 Size

9 Thickness of Shell / Dished end

For belt skimmer

1 Make

2 MOC of skimmer frame

3 MOC of belt

4 Dimension of belt

5 MOC of Scrapper

6 Gear box make

7 Motor make

8 Motor rating

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For Plate separator

1 Make

2 MOC

3 Design code

4 Size

Electrical All electrical equipments shall be designed for an ambient temperature of 50 deg C. For other site

conditions like altitude, humidity etc. technological part of the TS may be referred. Incomer power supply

to the OWS shall be at 415 V +/- 10%, 50HZ+/- 5%, combined variation + 10%. Any other voltage level

necessary for the plant shall be generated by the bidder within his scope. Scope of work for electrics shall

include design, procurement, supply, transportation, unloading, storage at site, installation, testing and

commissioning of all electrical equipment broadly covering the following: a)Motors (Flame proof) b)Motor Control Centre (MCC) with Incoming feeder with MCCB and outgoing feeders with

MCCB/ MPCB, Contactor etc. The incomer and outgoing feeders shall have over current, short circuit

and earth fault protection. Control supply shall be derived using 415/110V control transformer.

Purchaser MCC panel shall be located in the MCC room. All auxiliary contactors, relays etc. required

for automatic operation of the plant shall be provided in the MCC of OWS. MCC of OWS shall have

feeder for the power supply to the control panel also. 20% spare feeders subject to a minimum of one

feeder of each rating shall be provided.

The incoming cable to the MCC will be supplied and laid upto the MCC of OWS by the

purchaser/BPCL as per the load data furnished by the bidder. Termination at the supply end will be

done by the purchaser. Termination at the MCC of OWS end shall be included in the scope of this

package. All necessary gland, lugs and accessories shall be supplied by the bidder.

c) Control panel: (please refer the instrumentation part of the T.S). All necessary cables,

interfacing relays, contacts etc. for interfacing between MCC and control panel shall be included in the

scope.

d) Power & control cables: All power cables and control cables for all the drives are included in the scope. All cables shall be armoured type and shall be XLPE insulated, FRLS, anti rodent and termite protected. Power

cables shall have copper conductor (Upto 6 sq mm) or Aluminium conductor (Above 6.0 sq mm). They shall be

of required cross section as per detailed engineering by the bidder. Control cables shall be with 2.5 sq.mm

stranded copper conductor and shall be FRLS type. All cables required for feeding various loads of this package

shall be included. FLP/ Non-FLP double compression glands and heavy duty tinned copper lugs shall be

considered. Derating factor of 06 shall be consider for Aluminium cables and 0.75 foe copper cable while sizing

the conductor. At places were cables entering to the buildings/crossing the roads/traveling through paved areas etc.,

should be provided with GI Pipes.

e) Flame proof local start/ stop push button stations.

f) Earthing: Sufficient number of earth pits shall be provided. They shall be interconnected with 50 x

6 mm GI earthing strips. All equipments and structures shall be earthed as per Indian Electricity Rules

and relevant standards like IS 3043. Minimum size of GI strip for connecting the equipment to the

underground earthing system shall be 25 x 6 mm. Main grid shall be of 50 X 6 mm G.I. earth strip

Motors shall be connected by 25X3 mm earth strip or G.I. wire. Connection to plant earthing shall be

in the scope of bidder provided plant earthing connection shall be made available to OWS battery limit.

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g) Cable trays: Necessary cable trays including its covers, supporting structure etc. shall be

considered. All outdoor and indoor cable trays shall be of G.I. type. All supporting structure shall be

painted in line with other structures as specified in the technological part of this specification.

h) Any equipment which is not specifically included above but necessary for the turnkey execution of the

OWS is deemed to be included in the scope. Bidder is requested to go through the technological portion of

the T.S and include all electrics for completion of the project on turnkey basis.

e) Statutory clearance : Statutory clearance from statutory authorities like CEA or other electrical

inspectorate having jurisdiction in the area shall be included in the scope a) Test reports : Type test reports for the MCC Panel of OWS System is to be submitted purchasers

ref & record. All the equipment’s to be tested as per approved QAP and test reports shall be submitted

to the purchaser for review/ record.

Note:- 1) Type test certificates from authorised independent lab shall be submitted (short circuit, weather proof and fame proof from CCOE/PESO and DGMFR) 2)At manufacturer's works, the MCC shall be subjected to routine tests such as, IR test, HV test, functional tests etc. as per relevant standards and test certificate shall be furnished. Wherever flame proof equipment is necessary as per relevant guidelines, same shall be provided

irrespective of whether explicitly mentioned or not. SPECIFICATION OF ELECTRIC MOTORS As per standard technical specification of LT motor

Illumination: Complete illumination of OWS System area is excluded from the scope of bidder. MOTOR CONTROL CENTRE (MCC) (FLAME PROOF TYPE)

MCC shall incorporate DOL starters for the motors and other MCCB/ required for the OWS (fuses shall not

be used).

The MCC shall consist of suitably rated incoming MCCB rated for 415V, 3ph 50 Hz supply. Working/ stand-by, Local/ Remote, Auto/ manual selector switches as per technological

requirement.

Outgoing feeders for each motor with MCCB/ MPCB, Power and auxiliary contactors.

Outgoing power feeder for control panel with MCCB etc.

Emergency stop Push Buttons for the motor feeders.

Voltmeter/ ammeter with meter selector switches. Bi-metallic Over-load relays with built-in-single phase prevention feature and with manual re-set

(accessible from the front of the panel) if it is not covered In the MPCB.

The control voltage shall be 110 V AC derived through suitable 415 V/110V control transformer. Feeder modules shall have indicating lamps for ON/ OFF/ TRIP (RED/ GREEN/ AMBER) LED

lamps and reset buttons. Weather proof and flame proof OWS MCC panel Incoming and outgoing feeders shall be compartmentalized.

Panel interior and exterior shall be painted with approved colour. Panel wiring shall be carried out using 2.5 sq.mm PVC insulated copper wires.

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Control circuit shall be designed to take care of logic of pump interlocks like level switches etc. Un-

drilled 3 mm thick Gland Plates shall be provided at top and Bottom of the Panel as required. External

control wiring shall be carried out using 2.5 sq.mm PVC insulated armoured copper conductor cable. Components in the outgoing feeders shall be as per type -2 co-ordination chart. Ammeter, Ammeter selector switch, CT for Ammeter shall be provided as per the requirement.

TECHNICAL PARTICULARS OF MCCOF OWS SYSTEM DESIGN CRITERIA-MCC FLP

A SWITCH BOARD

1 Rated voltage and frequency 415V, 3phase, 4wire, 50Hz

2 Maximum voltage 500 V

3 Continuous current rating at design & Amb As per approved SLD at

temperature 50ºC with IP 54 enclosure

4 Type of enclosure as per IS 12063 Flame proof and weather

proof

5 Applicable standard IS 12063, 8623

6 Design ambient temp 50º C

One second Short time rating of switch board 25 kA

7 with minimum busbars, feeder busbars,

kA(RMS)

8 Dynamic through fault current with complete

busbars, kA (Peak)

9 Tier formation (Max.)

10 Maximum No. Of cable terminations in each As per approved SLD type of cubicle

11 Incoming termination of LT switch board Cables

12 Incoming termination top/bottom Bottom for cable

13 Outgoing feeder cable entry top /bottom Bottom

14 Minimum Clearances at front and back of board Outdoor type with cannopy

15 Dimensions L x B x H

16 Maximum Dimensions of shipping sections L x 2.5 x 1.5 x 2.4 M B x H

17 Min. Clearances in air in mm

Between phase 25.4 mm

Between live parts and ground 19.0 mm

18 One minute PF withstand voltage 2.5 kV

19 Paint shade 631 of IS-5

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B BUSBARS

1 Busbar material & cross section

a E91E Aluminium Max.

Main busbars current density 0.6 A / mm²

b Bus connections to circuit breakers

2 Continuousrating at design ambient temp.

3 Main busbars

4 As per rated currents of

Bus connections to circuit breakers breakers

Temperature. rise at rated continuous current

5 of the busbars in the busbar chamber 35 deg.C over 50 deg.C

6 Type of busbar insulators Resin cast/fiber glass

C Breakers

1 Type of breakers

2 Standards applicable IS 13947-2 / IEC947- part-II

3 Rated service voltage 415V, 3 ph. 50 Hz

4 Highest system voltage 500V, 3 ph. 50 Hz

5 Rated current at design ambient for breakers

6 Rating with breaker in IP 52: enclosure in two tier formation in the LT switch board

7 Symmetrical breaking capacity in kA (RMS)

a at 415V, 0.25 PF 25 kA RMS

b at 440V, 0.25 PF 25 kA RMS

8 Making capacity kA (Peak) 52.5 kA Peak

9 1 sec. Short time rating, kA (RMS) 25 kA RMS

10 With releases in any settin 25 kA RMS

Thermal release setting ranges: (temperature 11 compensated) 12 Short circuit release range

13 Short circuit release timer setting range 0.1 to 0.6 sec settable

(All the releases O/L, S/C and E/F shall be

14 Static/microprocessor based).

Cables:- Scope of work will cover supply, erection, terminations, testing and commissioning of power and

control cables between all equipment and MCC.

L T POWER CABLES -1100 V GRADE

A) General Power Cable for use on medium voltage shall be heavy duty type, 1100 V grade with 3 ½ , 4 core stranded & compacted electrical purity aluminium conductor, High conductivity annealed plain copper , XLPE insulation, extruded FRLS PVC (Type ST-2) inner sheath, single round wire / flat strip galvanized steel armour, extruded FRLS PVC (Type ST-2) outer sheathed, conforming to IS-5831, IS-8130, IS-3975, IS 7098 - 1985(Part-I), IEC-502 and suitable for operation. It shall be possible to continuously operate the cable at a maximum conductor temperature of 85 deg cent. The insulation of phase conductors shall be coloured red, yellow and blue and the neutral black.

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B) Materials:- Conductor

Stranded and compacted plain aluminium of grade H2 and class 2 flexibility or high

conductivity annealed plain copper , conforming to IS. The conductors shall be stranded. Conductors of nominal area less than 25 Sqmm shall be

circular only. Conductors of nominal area 25 Sqmm and above may be circular or shaped. Insulation:- Extruded cross-linked polyethylene (XLPE) insulation material conforming to

Table 1 of IS 7098 (Part-1). Dry/Inert gas/Radiant curing shall be adopted for

curing/cross linking of polyethylene. Wet/steam curing is not acceptable.

iii) Inner Sheath Extruded FRLS PVC compound conforming to type ST1 of IS: 5831. Filler material

shall also be Type ST-2 PVC.

Armouring for multi-core cables shall be single round galvanized steel wires where the

calculated diameter below armouring does not exceed 13 mm and by galvanized steel strips

where this dimension is greater than 13 mm. Requirement and methods of test for armour

material and uniformity of galvanization shall be as per IS : 3975 and IS : 10810

(Part-41). All Cables shall have round wire GI armour only. The dimensions of armour shall be as per method (b) of IS: 1554 Part-I. Armouring for

single core cable shall be with H4 grade hard drawn aluminium round wire of 2.5 mm

diameter. Overall outer Sheath Extruded FRLS PVC compound conforming to type ST2 of IS:

5831.(rendered resistant to water, UV radiation, fungus, termite and rodent attack by

suitable chemical additives) C)Properties of FRLS compound Critical Oxygen index More than 29% Temperature

index More than 250 degrees .C at Oxygen content of 21%. Smoke density rating More than

40% Acid gas, Gas generation Less than 20%

CONTROL CABLES 1100 V GRADE General Control Cable for use on medium voltage shall be heavy duty type, 1100 V grade with multi-core stranded & compacted electrical purity aluminum conductor / electrolytic grade High conductivity annealed plain copper conductor , PVC insulation, extruded FRLS PVC (Type ST-2) inner sheath, single round wire / flat strip galvanized steel armour, extruded FRLS PVC (Type ST-2) outer sheathed, conforming to IS-5831, IS-8130, IS-3975 IS 7098 - 1985(Part I), IEC-502 and suitable for operation. It shall be possible to continuously operate the cable at a maximum conductor temperature of 85 deg cent.

Material:- Conductor Stranded and non-compacted & circular electrolytic grade High conductivity annealed plain copper conductor , conforming to IS: Insulation Extruded cross-linked polyethylene (XLPE) insulation material conforming to Table 1 of IS 7098 (Part-1). Inner Sheath Extruded FRLS PVC compound conforming to type ST2 of IS: 5831. Filler material shall

also be Type ST-2 PVC. Armour Armouring for multi-core cables shall be single round galvanized steel wires where the calculated

diameter below armouring does not exceed 13 mm and by galvanized steel strips where this dimension is greater than 13 mm. Requirement and methods of test for armour material and uniformity of galvanization

shall be as per IS : 3975 and IS : 10810 (Part-41). All Cables shall have round wire GI armour only. The

dimensions of armour shall be as per method (b) of IS: 1554 Part-I. Armouring for single core cable shall be with H4 grade hard drawn aluminium round wire of 2.5 mm diameter.

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Overall outer Sheath Extruded FRLS PVC compound conforming to type ST2 of IS: 5831.(rendered

resistant to water, UV radiation, fungus, termite and rodent attack by suitable chemical additives) Properties of FRLS compound:- Critical Oxygen index More than 29% Temperature index More than 250 degrees .C at Oxygen content of

21%. Smoke density rating More than 40% Acid gas, Gas generation Less than 20%

All cables shall be properly dressed and clamped to the cable trays. Cable tags shall be provided at both

ends and at intervals for easy identification of cables. Local push button stations:- Shall be flame proof / explosion proof designed for gas groups IIA & IIB as per IS: 2148 1981 (re-affirmed

2004). Shall consist start/stop push button stations. Flameproof double compression cable glands to be

provided for suitable cable size. Enclosure for LCS shall be with IP: 65 and canopy for rain water

protection.

CABLE TRAYS/ RACKS STRUCTURES FOR CABLE LAYING :

a)Cable Trays/ racks (GI) (including its covers) shall be installed, complete with all necessary coupler

plates, drop out trays, horizontal elbows vertical elbows, tees, reducers, hangers, supports at every 1.5 meter

length. b)GI cable trays shall be provided for indoor and outdoor cabling system.

c) Constructional details and supporting arrangement for the cable trays, shall be furnished by the

contractor. Cable racks for cable trays shall be fixed at a maximum interval of 1.5 m. d)Cables leaving the ground / floor shall be protected up to 2m height by conduits/ metallic guards.

e)GI cable trays specification

i)Cable trays of prefabricated ladder and perforated types and the associated accessories such as coupler

plates, tees, elbows, etc., shall be fabricated from 14 gauge (2.0 mm thick) galvanized mild steel sheets. ii)GI Ladder type cable trays shall be selected from sizes 150mm, 300 mm, 450 mm & 600 mm. widths.

They shall be fabricated from 50 x 50 x 6 mm MS angles for longitudinal members and 30 x 6 mm flats for cross members. iii)Cable trays, accessories shall be hot dip galvanized to a minimum thickness of 75 microns.

iv) The spacing of rungs for ladder type of trays shall be not more than 250 mm. v) Vertical raceways shall be formed by either structural members or slotted angles or by running the

prefabricated trays vertically. Cable tray supports structures of different sizes. The sizes selected shall be fabricated from SS adequate for

the weight of cables/trays encountered. The tray shall be suitable of withstanding a load of 70 kg at the

centre and UDL of 70 kg with a support span of max. 3000 mm without exceeding the deflection limit. If

galvanizing is spoiled at any place, the same shall be painted with cold galvanized paint. Supporting vertical

racks and horizontal hooks shall be of 50 x 50 x 6 mm MS angles. Cable racks and hooks shall be welded

construction. f)All necessary frame works and fixings for the support of cables and accessories shall be supplied. g)Cables shall be suitably protected against heat and mechanical damages. h)To avoid damage during cable laying, cable structures shall have no scales, abrasive or rough surfaces

for cutting edges.

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DOCUMENTATION REQUIREMENT A ALONG WITH BID a) SLD of MCC. b)Signed list of clause-by-clause deviations c)List of recommended spares for 3 years normal operation

B AFTER AWARD OF ORDER

a)G. A. drawings of motor, main terminal box, space heater TB, thermistor / RTD T.B.

b)SLD of MCC, GA drawing of MCC and Schematic drawing for MCC.

c)Duly filled up Motor data sheet, Panel, Cables available under Questionnaire part of these TS.

d) Test certificate

e)G. A. drawing of motor, main terminal box, space heater TB, thermistor / RTD T.B

f)Weight of MCC, Dimension of MCC panel.

g)Internal Quality Assurance Plan

h)Type test certificates for MCC, motors, push buttons, cables etc.

i)Type test certificates for MCC, motors, push buttons, cables etc

j)Motor characteristics curves:

1.Speed-torque

2.Current-time

3.Thermal withstand

4.P.F. vs load

5.Efficiency vs load

6.Current-speed

7.Speed-time

All applicable standards (Latest IS standards are applicable)

Erection guidelines:-

General

All electrical equipment shall be erected, tested & commissioned as per relevant Indian standards, codes of

practices and good engineering practice. Scope shall include minor civil works like chipping, grouting, etc

for erection of the panels and cable trench work for cable laying.

The scope includes receiving and storage of equipment at site, transportation, handling, installation, testing

and commissioning of all units/items under the scope of supply of the contractor. His scope also includes

installation and termination of cables to / between owner's electrical equipment and sealing of cable

conduits, floor/ slab openings, minor civil works required for erection etc.,

Unpacking shall be properly done at site. Breakage, defects, missing (if any) items shall be made good

immediately. All packing materials shall be removed and components shall be thoroughly cleaned.

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Transportation to respective foundation, after checking and unpacking, shall be done by the contractor.

Transportation shall be done systematically using wall/ floor openings, provided exclusively for the

purpose, using proper lifting tackles. No part of GI piping, structures, ducts shall be used for lifting

equipment without prior consent of owner/engineer.

Contractor shall be fully responsible for claiming any damages from insurance company wherever required. Base frames of equipment shall be fixed to foundations by anchor bolts.

Equipment/ cabling and other electrical system installation shall be carried out in accordance with the latest

editions of relevant Indian Standards and codes of practice and the installation shall fully comply, with the

requirement of the Indian Electricity Rules and statutory regulations that are in force, at the place of

installation.

Earthing as per IS an earth resistance of not more than 3 ohms for the OIL WATER SEPERATOR

SYSTEM and dual earth connection to all equipment shall be carried out as per standards. 3043/1987 IE rules including earth pits as required to achieve

Cabling installation:-

The cables shall be laid in cable trenches / GI pipes / cable trays / directly buried in the ground. In paved

area cable shall be laid in GI pipes only.

Civil works of RCC cable trenches or earth trench, excavation of trenches of required width and depth in all

types of soil, clearing natural obstructions including rock cutting if any required along the cable routing,

laying of cable on 8 cm of riddled sand and covered with 8 cm of riddled sand providing 75 mm thick RCC cover slabs/bricks, back filling with earth (after cable laying), and finally compacting to original ground

level of cable trenches, all other equipment, materials and components required for cable laying are

included in the scope of work. The maximum trench depth shall normally be 1m If the trench is to cross railway tracks/ roads or any load

bearing area the cables shall be taken through suitable GI conduits/ pipes/ ducts. Installation of cables

directly buried in ground shall generally conform to the requirements given in IS: 255.

Cables laid directly in underground trenches (where permitted by owner/TPIA) shall be in one layer only,

more than one layer is not permissible. For crossing the road/ rail track, cables shall be laid in concrete cable ducts/ hume pipes/ GI pipes.

The scope includes but not limited to,

i)Cable testing and handling.

ii)Laying, meggering, termination, dressing and clamping of cables.

iii)Tagging and marking of cables.

iv)LT tests on cable.

v)Identification of phases.

vi)Connection of equipment.

vii)Making of cabling ready for charging after completing all associated works. PANELS:- The contractor shall follow the following sequence of erection of panels.

1. Erection of base channel and alignment

2.Assembly

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3.Alignment 4.Welding and anchoring 5.Installation and wiring of relays, meters etc., 6.Laying, meggering, termination, dressing and clamping of power and control cables. 7.Tagging and marking of cables 8.Earthing station, earthing strips, earthing equipment and measurement of earth resistance as per IER 1956/IS 3043 with the latest revision.

9.Connection of power and control cables.

10.Checking and testing of all relays, meters, other protective accessories and control and power circuit wiring, phase sequence connection, checking of all circuit breakers for proper alignment of handles with doors. 11.Using a vacuum cleaner, remove dust, small particles etc., 12.Clean all insulating surfaces with dry

cloth or as indicated by the manufacturers. 13. Functional tests 14.Submission of completion report to owner's representative. TESTING AND COMMISSIONING GENERAL:- The successful Bidder, based on the broad outline procedure indicated in this specification, shall finalize

with owner/ engineer, the detailed procedure for testing and commissioning along with time schedules for

both. The contractor shall adhere to the general guidelines given for testing & commissioning of the equipment/

items implicitly covered under heading special instructions to contractor general condition of contract and

technical specification.

On successful completion of erection of each item /equipment, a final inspection will be carried out at site

by owner/ engineer, for correctness and completeness of erection. The successful Bidder shall provide adequate supervisory/ skilled personnel and all tools and tackles,

testing equipment and instruments required for complete checking of installations and testing and

commissioning of all equipment and accessories.

The Bidder shall furnish with the offer a complete list of equipment, tools and tackles, instruments etc.

which he intends to bring to site for erection, start up, testing and commissioning of equipment.

The testing and commissioning of all equipment under the scope of the Bidder shall be carried out in

accordance with the latest edition of relevant Indian Standards and IE Rules.

The testing of all sub systems as well as the equipment as a whole shall be carried out to ensure that the

equipment and its components are in satisfactory condition and will successfully perform their functional

operation.

Test reports shall be submitted in required number of copies duly signed by the CONTRACTOR, TPIA and

M/s BPCL. The results of all tests shall conform to the requirements of the specification as well as any specific

performance data guaranteed during finalization of the contract. All equipment after testing shall be energized only after certification by the qualified testing engineer that

the equipment is ready for energisation and with the concurrence of M/s BPCL/TPIA In the absence of rain, Bidder shall arrange for 50m 3 of oil water mix and shall conduct the test of OWS for

commissioning will be as per the design parameters mentioned in the clause no. 03.01 and the treated

effluent shall be tested in the laboratory to meet the Pollution Control Board norms.

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ii.Mechanical Inspection and check up of the equipment

After installation, but before any power supply is connected, the contractor shall make a complete

mechanical check and clean all erected electrical equipment and systems. This shall include, but not

limited, to the following:

(a) Visually inspect all equipment/item for defects if any and check equipment numbers against drawings to

ensure that equipment has been correctly located and proper installation is done. (b) Check nameplates of individual feeders and others, distribution boards, etc., for conformity with data

given on the supplier's drawings/ standards/ specification sheets.

(c) Check that motors turn freely by hand. (d) Remove, clean and replace if necessary, drain plugs of all motors. (e) Check connections to all equipment for tightness. (f) Check correctness of cabling and its terminations. (g) Check phasing, polarity. (h) Check all electrical & mechanical interlocks & other equipment for safety and to ascertain that those are

functioning as per intention and accomplish their purposes. (i) Check all plug in contacts for alignment and grip. (j) Check all contactors for free manual operation.

(k) Remove all blocking devices installed for shipment.

(l) Check all the coils for their continuity and proper voltage.

(m) Check that the MCCB/MPCB/MCB are correctly rated & installed, are clean, undamaged and fit for

operation. (n) Check, that all disconnect switches are clean, undamaged & operate properly. Ensure that all contacts are

tight/ joints, linkages & contacts properly lubricated (where applicable). Check interlocks and auxiliary devices

and also the operation of the circuit breakers with the protection relay circuit connected. (o) Vacuum clean equipment before energizing.

Panels Shall be tested for –

Insulation resistance test - Functional and operational checks of circuits - Testing for correct operation of

protective relays and calibration if any.

AC MOTORS:-

i) .IR test of stator and rotor windings.

ii) Ensure that checking / testing of associated switchboard, cables, relays / meter interlocking as

mentioned in relevant chapters are completed. iii) Check tightness of cable connection iv) Checking continuity of winding v) Check tightness of earth connections vi) Check direction of rotation in de-coupled condition during kick-start vii) Check for temperature rise of body in no load and on load conditions. viii) Measure no load current for all phases

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ix) Check for tripping of motor from local / remote switches and from electrical / technological

protection including differential protection x) Checking of vibration. xi) Checking of noise level during load running. xii) Measurement of stator and bearing temperatures (if applicable) for every Half an hour interval till

saturation comes xiii) Checking tightness of foundation bolts. xiv) Check operation of speed switch (if there). xv) Check continuity of temperature detectors.

xvi) Check alignment, paralleling of shafts, level of lubricating oil etc. as per manufacturer's manual.

INSTRUMENTATION:- The scope shall include design, supply, erection, testing and commissioning of all the items required to make the systems complete in all respects and shall include all activities required to meet the technical requirements as spelt out in this specification. Any items which are not explicitly spelt out here, but are required for the completeness of the work shall also be included under the respective items/systems. Bidder shall list out the same and submit it with the offer. Following potential free relay contact shall be given for customer’s plant PLC station indication (Digital inputs): -

1. OWS on (Pump +Belt skimmer on) 2. OWS fault (Trip or other faults in OWS)

Bidder shall keep provision in the Terminal Blocks of panel to connect the above mentioned signals

to clients PLC. Supply, laying & termination of necessary cables, alongwith accessories, to Control

Room (approx. 1000 m. away from OWS) shall be in the scope of Bidder.

OWS shall be fully automatic in operation. Bidder to submit operation and control philosophy

based on the P&ID and other relevant documents attached with this tender for approval during

detailed engineering. All drives shall have auto/ manual selection in the control so that manual

operation is restricted to doing maintenance and checking. Oil provided. This will actuate the belt skimmer even when the OWS is not running. However, the

feed pumps shall be interlocked with the skimmer such that whenever

The Instruments used in OIL WATER SEPERATOR SYSTEM (OWS) should meet the requirement of

monitoring and control of all significant variables in accordance with the process & operating

requirements along with process/ safety interlocks & alarms for abnormal conditions. The system shall

be designed to ensure that the accuracy of instruments and the overall system accuracy shall meet the

process requirements.

All field devices shall be rated for minimum IP 65 protection class and enclosure shall be explosion-

proof conforming to IS 2148 and shall be suitable to hazardous area-classification Class 1, Div II, Group

II A & B. The instruments shall be approved from CMRI and CCOE/PESO.

DESIGN BASIS/ TECHNICAL RULES FOR FIELD INSTRUMENTS:

Pressure Gauge/Differential Pressure Gauge:

1. In addition to pressure gauges, at the inlet and outlet of the Multimedia Filter, one number

differential pressure gauge also shall be provided. 2. Bourdon type/Diaphragm type-sensing element as per IS 3624 with an accuracy of be +/- 1% of

span or better shall be used in pressure gauges, differential pressure gauges depending on the process service. The accuracy shall include the combined effect of linearity, hysteresis and repeatability.

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3. The sensing element and other wetted part materials of pressure gauges shall be of SS 316. Movement material of gauges shall be of SS 316. Outer casing and bezel material shall be either made of die cast aluminium with epoxy coating.

4. All pressure gauges shall be provided with external zero adjustment facility, over range protection, blow out disc etc. Pressure gauges used in pulsating pressure applications (e.g. delivery side of pumps, etc.) shall be provided with externally adjustable pulsation dampener or snubber.

5. The sensing element of pressure gauges shall withstand the specified over-pressure i.e., atleast 125%

of span) for at least 30 minutes, without affecting their elastic characteristics.

6.Pressure gauges shall have dial size of 150 mm diameter. Gauges of smaller dial size may be used for

machine- mounting applications.

7.Pressure gauges shall be supplied with two-way gauge cock of SS material. Window shall be Toughened glass/Shatter proof glass.

8.Pressure gauges shall be liquid filled.

Level/ Oil Switch:

1.Switches shall be of rugged, simple design capable of withstanding occasional stresses. In hazardous

areas, hermetically sealed micro switches with minimum rating of 240 VAC, 5A shall be used. Switching

action shall be Snap acting Micro switch 2.Output contact per set point shall be 2NO+2NC (DPDT), potential free. Housing material shall be Die

cast aluminum. All wetted parts shall be of SS 316. 3.Set point repeatability shall be +/- 2% of scale.

4.For level gauges/switches, Float material for Oil sensor shall be PVC and Water sensor shall be SS. Control Panel:- 1.Control Panel shall be located near OWS system for monitoring and control of overall system of OWS. Panels shall be totally enclosed; flush-front, freestanding upright floor mounted type/ wall mounted type. Floor

mount panels shall be mounted on box-type base-frame. Panels shall be made of cold rolled cold

annealed (CRCA) sheet steel. The panel shall be made of sheet steel of thickness 1.6/ 2mm. the panel shall

have IP 65, explosion-proof suitable for hazardous area. 2.The panel shall have suitable annunciation for alarm conditions such as level high, level low, OWS ON, pump

trip, Pump ON, OWS fault etc. Pushbuttons for local operation of pump and Complete shutdown of

OWS shall be provided.

3.Sizes of panels and cabinets, as approved by purchaser/ TPIA, shall only be supplied.

4.Panel doors shall have flush-type and lockable door-handles. Panel doors shall have mesh-covered

louvers at top & bottom, for air circulation. Additionally, wherever necessary, push-pull type circulating

fans shall be provided for cooling of equipment inside. 5. All equipment inside the panel shall be located in such a manner that their terminals and adjustments are

readily accessible. 6.Panels shall be dust and vermin proof. Suitable gaskets shall be provided, for this purpose.

7.Panels shall be supplied in finish-painted, completely wired and tested condition. Colour shade of panels

shall conform to RAL 7032/7035. Outside shade of panels shall generally be RAL 7032/7035, unless

otherwise specified. The inside of panels shall be of brilliant-white. Panel base channel shall be painted

black.

8.Panels shall have lifting hooks or eyebolts on the top at the four corners, for ease of transportation.

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9.The inside of panels / local panels shall be illuminated, preferably using incandescent type lamp. The

illumination lamp shall be switched on/off using either a door switch or a toggle switch.

10.An inscription plate (with white letters on a black background) containing the tag no. etc. shall be

provided for each instrument / device mounted on the panel. 11.Separate nameplates shall be provided for rear-panel mounted instruments.

12.Anti-vibration mounting or shock absorber shall be provided for panel-mounted instruments in

vibration-prone areas.

13.In case a bus bar is used for power supply distribution, the bus-bar shall be shrouded with a transparent

Bakelite plate. 14.Panels or cabinets shall be provided with the following items:

Power socket (of 240V AC, 15W rating) for soldering, etc. Pair of earthing bolts on either side of the panel (at the bottom) for power earthing.

Copper bus-bar (of size 25x3mm.) mounted on an insulated base inside the panel with holes.

Separate busbars shall be considered for instrument earth and panel earth.

Power Supply for the control panel & Instruments shall be generated by the Bidder from main power

supply feeder (provided by Client). The Bidder shall supply a power DB with MCB’s for distributing power

to individual instrument in the field. OWS ON Status and Alarm Annunciation of the system shall be made available in the TAS PLC (clients

scope) located in Automation Control Room (Administration building). In addition 2 contacts shall be

considered in the panel which can be configurable for other parameters. Supply, Laying, termination of

cables from field instruments to control panel is in the scope of OWS Bidder. PREFERRED MAKE

Pumps: KIRLOSKAR/ KSB/ MATHER & PLATT/ BEACON WEIR/ JYOTI/ FLOWMORE/ PROCESS PUMPS

Dual plate check valves: ADVANCE/ SMI/ R&D MULTIPLES Butterfly valves: FOURESS/ AUDCO/ BDK/ INTER VALVE/ JASH/ VIRGO/ ADVANCE

Triple offset Butterfly valves: Virgo, LET, Advance.

Ball valves:-

1)M/s Hopkinsons Limited (UK) 2)M/s O.M.S. Saleri (Italy) 3)M/s

Pibi Viesse SPA (Italy) 4)M/s

Nuovo Pignone (Italy) 5)M/s Perar

SPA (Italy) 6)M/s Larsen & Toubro Ltd. (Audco India Limited, Chennai)

7)M/s Microfinish Valves Ltd. (Hubli) 8)M/s Pietro Fiorentini (Italy)

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9)M/s Raimondi Valve S.P.A. (Italy)

10)M/s Virgo Engineers (Pune)

11)M/s Flow Chem Pressure Gauges/ Differential Pressure Gauges: General Instruments, Waree, AN Instruments.

PREFFERED MAKES OF EQUIPMENT – ELECTRICAL

1 FLAME PROOF MOTORS KIRLOSKAR / BHARAT BIJILE / CROMPTON GREAVES

L & T / SIEMENS / CONTROL & SWITCH GEAR / LT SWITH BOARDS / GE POWER CONTROLS / LOTUS SWITCH GEAR /

2 PMCC / MCC / MLDB / POWER CONTROL EQUIPMENT. OTHER

VFDDB / CPDB. REPUTED MAKES SUBJECT TO APPROVAL OF OWNER / TPIA.

3 LT POWER CABLES POLYCAB / RPG / KEI / TORRENT / CCI / LAPP

4 LT CONTROL CABLES FINECAB / VARSHA / DELTON / TERRACOM / RPG / KEI / CCI

5 MCB MDS LEGRAND / GE POWER / INDO ASIAN /

HAVELS

6 PROTECTIVE RELAYS, SIEMENS / AREVA /ABB / GE-MULTILIN / EASUN AUXILIARY RELAYS &

REY ROLLE / SEG

SEMAPHORES

INSTRUMENT AUTOMATIC ELECTRIC / KAPPA / JYOTHI / 7 TRANSFORMERS Current

Transformers PRAGATHI / INSTRANS / KALPA / PRECISE

INDICATING / RECORDING

AUTOMATIC ELECTRIC / MECO / IMP / RISHAB / 8 UNIVERSAL / SIMCO / BHEL / ENERCON

Meters (SCHNEIDER)

9 CONTROL SELECTOR KAYCEE / AREVA / SALZER / SIEMENS / TEKNIC /

SWITCHES PUSH BUTTONS L & T / BCH/ VAISHNOV

10 AUXILIARY CONTACTORS SIEMENS / L&T / TC / ABB / GE POWER Timers CONTROL / BCH / TELEMECHANIQUE

11 CONTROL CONTACTORS AREVA / BCH / L&T / SIEMENS / ABB

12 CABLE TRAY PATNY & CO / TECHNOFAB / INDIANA / SADHANA

13 CABLE GLANDS SMI / COMET / MAYUR / JANSON CABLE LUGS / SOCKETS /

14 FERRULES / CAGE CLAMP DOWELLS / CONNECT WEL / ISMAL / WAGO TERMINALS

15 MCCB, ACB ABB / L&T / CGL / GE POWER / SCHNEIDER / SIEMENS

16 G. I. PIPE TATA / JINDAL / APOLLO / ZENITH

17 MS / GI CONDUITS J.K.TUBE / BEC / APOLLO

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18 FLAMEPROOF EQUIPMENT Baliga / CEAG/ FCG / Sudhir / Flame pack

19 DIGITAL METERS L & T / SEM / ENERCON

20 INDICATING LAMPS L& T / BCH / VAISHNO / SIEMENS / ESSEN

21 SOLID STATE L&T / PROCON / INSTALLARM / MINILEC ANNUNCIATOR

INSPECTION:- The equipment shall be inspected by the Purchaser/ TPIA works prior to dispatch. The equipment will be inspected as per the tests pre-identified in the approved quality assurance plan (QAP), relevant approved drawings, specifications, data sheet etc. The Contractor shall finalise the QAP (enclosed) within two weeks after placement of P.O. with authorized

TPIA.

The Purchaser and their authorised agency shall have free access to the manufacturer’s workshop to ensure

the quality of the equipment being manufactured. Contractor to give inspection call with a clear notice of 10 days for inspection. The inspection call shall be

accompanied by internal inspection/ test reports by the manufacturer ensuring that the equipment has been

manufactured and tested as per the requirement/ approved QAP. In case of any subcontracting, only the

main contractor shall give inspection call enclosing internal inspection report of subcontractor verified by

the main contractor. The manufacturer shall furnish all relevant documents and test certificates as required by the inspection

agency during inspection. Materials shall be tested only in recognised test houses. The Contractor/ manufacturer shall provide all necessary assistance to the inspection agency during

inspection. The Contractor shall provide all required measuring instruments to carry out the inspection. These

instruments shall be calibrated by an agency of National/ International recognition. The inspection agency shall have the right to demand re-testing of any material/ re-calibration of

instruments. The charges for such tests shall be to the account of the Contractor only. No equipment shall be dispatched without inspection and receipt of inspection certificate and dispatch

clearance from the inspection agency.

In case of waiver category items, the same shall be pre-identified in QAP itself. For such items, the Contractor shall furnish necessary certificates as agreed upon. For these items also, the Contractor shall obtain inspection waiver certificate and dispatch clearance from the inspection agency before dispatch of equipment. Issue of inspection certificate/ waiver certificate for any equipment does not absolve the Contractor from his

contractual obligations towards satisfactory performance of the equipment. Should any equipment be found

defective in whole or part thereof after receipt at site or during erection/ commissioning, the same shall be

made good by the contractor free of cost.

Erection:-

General

The erection of all plant and equipment shall be carried out according to the latest engineering practices and

according to the working drawings, specifications, instructions etc. duly approved by the Owner. The

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Contractor shall carry out the works in the presence and/ or as per the instructions of site engineers/

supervisory personnel deputed by the Owner. The erection shall be carried out by highly skilled workmen. The Contractor shall take care of the equipment as well as supporting structures within the required

accuracy and tolerance limits. It shall be deemed as a contractual obligation that the pipes are not thrown

out of alignment or lifted off during commissioning and subsequent operation.

There may be more than one contractor working in the area at the same time. As such the work has to be

carried out in proper co-ordination and consultation with the M/s BPCL/ TPIA and all other parties

concerned with the work. The Contractor shall take due notice of the working conditions, practices and

agreements prevalent in the area of the plant site and satisfy himself before quoting.

The Contractor shall be responsible for paying strict attention to statutory regulations for prevention of

accidents and to other safety rules. The regulations for prevention of accidents shall be displayed at

appropriate places and should be distinctly visible to all personnel working in the area.

The Contractor shall supply all required consumables, construction and erection materials, petrol, diesel oil,

kerosene, lube oil, solvents, sealing compounds, tapes, brazing and soldering materials, welding sets, pipe

bending machines, cables, clamping tools, gauges, erection bolts, nuts and packing sheets/compounds,

temporary supports, wooden blocks, spacers, templates, jute and cotton wastes, sand and emery paper etc.

as required for satisfactory completion of work.

The Contractor shall make his own arrangement for handling the equipment and pipes at the stores and

transporting it to the site of installation. In addition to the above, the Contractor shall follow all the relevant erection clauses/ conditions stated

under various chapters of this specification. Pump sets The pump base frame shall be erected on prepared foundation and levelled with shims and wedges with the

help of precision levels and other instruments. After levelling, grouting of foundation bolts shall be

completed. When tightening the foundation bolts the base plate levels should not get affected. Final level

achieved should be of the order of 0.05 mm per meter. The pump and driver shall be placed on their respective machined pads ensuring that the feet make full

contact. Normally a 0.002 inch feeler strip should not pass between the feet and the pad when the pump and

motor are freely placed. The coupling if not supplied fitted with the pump and drive unit, should be carefully fitted with a pusher or by

means of heating in an oil bath of approximately 180 deg F. The coupling shall never be hammered onto the

shaft as this may cause serious damage to bearings and mechanical seals. Run-out on a coupling after fitment

should be between 0.05 mm and 0.1 mm TIR. Before proceeding with any alignment thepump and driver

bearings should be thoroughly cleaned and flushed with recommended grade of lubricant and the individual

units should be checked for freeness of rotation. The coupling shall be aligned radially and angularly using

two dial gauges. Connection of suction and delivery pipes shall be made in such a manner that the connection to the pump flanges

does not develop any undue stress and the weight of the pipes is not transmitted to the pump. After completion of the pipe work, the pump set shall be grouted up to the flanges of the base frame.

Grouting should be filled from inside the base frame and all cavities filled up. After the grout has set, the

alignment should be re-checked and compared with the values recorded prior to grouting.

During manual rotation, it shall be ensured that the shaft assembly moves freely and no noise develops from

bearings.

Before coupling the driver to the pump it shall be ensured that the direction of rotation of the motor

corresponds to that of the pump indicated by the manufacturer/supplier.

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Valves:-

Before erection of valves, it shall be ensured that :-

i. All grit and foreign matter are removed from the inside of the valves before connecting the pipes. ii. All the faces are thoroughly cleaned and coated with a thin layer of mineral grease. iii. It shall be ensured that adequate support is provided for the pipeline and valve. The valve should

never carry the weight of the pipeline. Hangers or supports placed near the valve will provide better supports.

iv. The connecting pipeline should be cleaned and flushed of sediments, sand and other foreign matter before installing the valves.

v. Unless it is operationally critical butterfly valves shall be mounted with the shaft horizontal and as per the direction of flow indicated on the valve.

vi. The valves should be tightly closed when being installed, to prevent any foreign matter from

getting in between the working parts of valves.

vii. The gasket shall be lubricated with graphite or other recommended lubricant. viii. It shall be ensured that the joining material sits squarely between the flanges of valves and

pipelines without obstructing the waterway. ix. Valves and other appurtenances shall be so located that they are easily accessible for operations

repairs and maintenance.

Piping:-

Laying and joining of pipe lines.

The Bidder shall supply/fabricate and install pipes and fittings in strict compliance with the detailed

engineering drawings. Deviations if considered necessary to suit site conditions could however, be

permitted in consultation with and with prior approval of the M/s BPCL/ TPIA. ii.All openings in the piping shall be kept effectively closed until assembled in the system to avoid foreign

matter entering into the system. iii.All piping shall follow the general arrangement shown, shall be cut accurately to measurements

established for the work by the Bidder and shall be installed without springing. iv.All piping shall be installed with adequate clearance for lighting, bracing, doors, windows and other

openings. v.Piping shall be arranged in the straightest possible runs with minimum amount of fittings. Flanges of the

pipelines, fittings, etc., must be so mounted that top boltholes are symmetrical about the vertical axis of the

flange

Openings provided in the walls for pipelines must be closed with bricks or mortar with 10 to 20 mm

clearance between the brickwork and pipe. The clear space must be stuffed with felt or asbestos. vii.The Contractor shall supply/ fabricate and install pipe supports and all that is necessary to completely

support all the piping and piping components including but not limited to beam clamps, pipe clamps,

fabricated structural supports, guides and anchors, brackets, saddles, U-bolts, etc. Only approved type of anchor fasteners shall be used for RCC ceiling and walls. Also supporting members required in addition to

building structure shall be furnished and installed. Concrete pedestals for supporting the pipes as well as

valves are also included in the Bidder's scope of work. Viii Screwed joints:- Pipe sealant shall be used to makeup screwed joints and shall be applied to male

threads only. Threaded parts shall be wiped clean of oil or grease using appropriate solvent if necessary and

allowing proper time for drying before applying the sealant. Pipe shall be free from fins and burs. Pipe ends

shall be reamed or filled out to size of bore and all chips shall be removed.

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Ix Flanged joints:- Flanged joint shall be used for connections to vessels, equipment, flanged valves, road

crossings and also on suitable straight lengths of pipelines of strategic points to facilitate erection and

subsequent maintenance work. x.All above ground piping shall be laid on RCC sleepers excepting below roads where pipe lines would be

underground and laid through RCC hume pipes. Guides have to be provided on every third sleepers.

The Contractor shall provide anchor supports/ expansion loops wherever necessary. Underground piping:-

Excavation for pipelines shall be in open trenches to lines and grades shown on the detailed engineering

drawings. Excavation of trenches shall be carried out as per the procedure explained under Clause 03.18

(Civil works). Pipelines shall be buried to a minimum depth of 700mm (from top of the pipe). Wherever

required, the contractor shall support all trenches of adjoining structures with adequate timber supports.

At road crossing the pipes shall be laid in the encasing pipes. RCC NP3 class pipe shall be used as the

encasing pipe. The encasing pipe shall project beyond the berm on both sides of the road.

On completion of testing and painting of pipelines, trenches shall be refilled as per the procedure explained

under Clause 03.18 (Civil works). SITE TESTING AND PAINTING General:- After erection at site the plant and equipment shall be subjected to tests to prove satisfactory

performance as individual equipment and also as a system on the whole. The Bidder shall include and conduct field tests for all pumps, and piping systems. These tests shall be

made after installation is completed and before the systems are placed in service. Field tests covered by ISI and Governmental and local codes shall govern in so far as they exceed

corresponding requirements of this specification or cover omissions therein. All tests shall be performed as

specified in the presence of M/s TPIA and must be accepted by him. The successful Bidder shall conduct a

preliminary test and repair or correct all faulty work before calling M/s TPIA to observe the test for

acceptance of the systems.

In all cases of tests, the successful Bidder shall provide free of charge, labour, materials, tools,

consumables, fuel, stores, apparatus and instruments as may be necessary to carry out such tests efficiently.

Pipelines

Erected pipelines together with fittings shall be tested by hydraulic pressure. The value of test pressure shall

be equal to 1.5 times the working pressure. Pipelines to be painted shall be subjected to hydraulic test before painting. Equipment shall be disconnected

before the test. Combined tests of equipment with the pipeline is not allowed. Air vents shallbe provided at all

high points of the piping where the test shall be conducted in order to purge air pockets while the piping

system is being filled up.

Hydraulic test pressure shall be maintained for a duration which shall be mutually decided upon. At this

pressure the pipelines shall be inspected and all welded joints shall be tapped by a 1.5 kg hand hammer. Hydraulic test will be considered satisfactory if during the tests, manometric pressure does not decrease and

no leakage or mist is found in the joints, fittings etc. Defective spots found in the joints must be rectified. The joint shall be dismantled and fresh jointing is to be

done. After eliminating all defects, hydraulic tests shall be repeated.

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Portions in which the same defects are found during repeated tests, must be rejected and replaced by new

ones and tested again. The successful Bidder shall arrange at his own expenses all equipment, material, instruments and

consumables to conduct the various site tests to demonstrate specified performance of all plant and

equipment offered by the Bidder.

Representatives of M/s BPCL/ TPIA and the successful Bidder shall make a statement regarding the

acceptance of the erected pipelines mentioning defects found during the tests, characteristics of the defects

and the method of their elimination.

Painting:- Painting shall be as per specification:

COMMISSIONING AND PERFORMANCE GUARANTEE Commissioning Testing and commissioning of the plant as well as all the accessories including obtaining approval from the

respective state pollution control boards shall be completed within one month from the date of intimation of

readiness of the plant by M/s BPCL for successful commissioning.

Before preparation for commissioning, all the equipment and pipelines shall be certified by the Purchaser

for commissioning. The site shall be thoroughly cleaned. All sorts of foreign materials such as welding rod ends, welding

beads, metal chips etc., shall be removed by the Contractor from the site before commencement of

commissioning. Before commissioning, all the pipelines shall be blown with compressed air until the air discharged is free

from dust particles etc. The Contractor shall supply all lubricants, oil and other consumables required for commissioning of the

system. Commissioning of the various equipment and system shall be carried out by the Contractor as per the

accepted procedure and as per the instructions of the supplier of these equipment. On completion of the installation but before energisation of the electrical system, all installations shall be

physically checked and properly tested. The Contractor under the supervision of the Purchaser shall conduct

these checks and tests. Any defect observed during such checks and tests shall be made good by the

contractor before commencement of commissioning. Performance Guarantee The performance and guarantee test shall be conducted in accordance with the conditions specified and as per

relevant codes/ standards. The parameters guaranteed by the Bidder shall have no tolerance values, except as

permitted by Standards/ codes. Other testing requirements of individual equipment/ item as specified elsewhere

in this tender document shall also be complied with. Guarantee certificate is to be submitted from the

manufacturer with a Guarantee cover for 12 months from date of commissioning.

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DOCUMENTS TO BE FURNISHED Drawings, Data & Information to be furnished along with the Offer The following drawings/ data/ information shall be submitted by the Bidder along with his technical offer. In the

absence of the minimum drawings/ data / information as given below the bid is liable to be rejected. i)P & I/ flow diagram, HLD showing the complete system indicating all field and panel mounted

instruments. ii)Preliminary layout drawings for the complete scope of work

a)Dimensional General Arrangement Drawing of each equipment

b)Quality Assurance Plan and Inspection & Test Matrix

c)Data sheets for all instruments and equipment

d)Write-up on operation & control philosophy for various systems.

e)Leaflets and catalogues etc. covering equipment/ instrument features.

f)Information, instruction drawings and all other related data regarding erection and commissioning of the

supplied plant. g)Project schedule with detailed bar chart. Drawings, Data & Information to be furnished after award of the Contract

a)The following document/information shall be furnished by the contractor

b)P & ID/ Flow diagram, showing the complete system with associated controls.

c)Detailed equipment layout drawings.

d)Detail design and data for equipment

e)Detailed specification for all procurement items

f)Specification and data sheets for instrumentation items.

g)Loop diagrams.

h)Quality Assurance Plan.

i)Performance test curves and test certificates for all equipment as per the requirement of technical

specifications. j)Any other data / curve deemed necessary by Purchaser/ TPIA.

k)Write-up on specific features of equipment, if any.

l)Instruction manuals for maintenance, overhaul and replacement of parts of various equipment.

m)Replacement parts list with ordering information. n)Final Quality Assurance Plan and Inspection & Test Matrix.

o)Leaflets and catalogues etc. covering equipment features. p)

Detailed project schedule. q)Painting specification for all equipment / piping r)SOP

for operation of ETP- not more than one page

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Electrics:- The Contractor shall submit General Arrangement Drawings indicating Bill of Material (rating, makes and quantities of components) Outline dimensions etc., Single Line diagram, control schematic and Power and Control Cable Schedules for the system for approval by Owner/TPIA. Instrumentation:- Process and instrumentation (P & I) diagrams indicating all field and panel mounted instruments using ISA symbols and using suitable tag numbers against each instrumentation equipment. Alarm and interlock functions shall also be indicated in the P & I diagram. Specification of each instrumentation equipment indicating model no., application, scale range, quantity,

tag no, (as per P & I diagram), accuracy, power consumption etc shall be submitted. Data sheets for each

instrument as per standard format shall also be submitted with all the required details filled in along with

detailed technical literature. Test Certificate & Documents:- For each of the items being manufactured, following test certificates and documents duly endorsed by the

manufacturer / contractor shall be submitted to Inspection Agency. i) Raw materials identification & physical and chemical test certificates for all materials used in manufacture of the

equipment (except IS 2062-1992 Gr.A & IS 210-1993,FG-150). ii) WPS, PQR & WPQ Documents as per applicable code. iii) Details of stage-wise inspection & rectification records for fabricated items, castings, forging and machined

articles. iv) Control dimension chart with records of alignment, squareness etc. v) Manufacturer's material test certificates and performance / relevant test certificates for all bought - out items. vi) Details of heat-treatment and stress relieving charts as per specification. vii) Non-Destructive Test reports as per respective code. Viii) Static/dynamic balancing certificate for rotating components/machines. ix) Hardness test certificate. x) Pressure Test Certificates xi) Performance Test Certificates for all characteristics. xii) Geometric accuracy and repeatability test reports of machine tools. xiii) Routine / type / calibration / acceptance / special test certificates for electrical items. xiv) Diagnostic features of NC/CNC system and test certificates for electrical items. xv) Surface preparation and painting certificates. xvi) Certificates from competent authority for the items coming under statutory regulations. xvii) Any other NDT/DT test inspection/TPIA/Test certificate/QAP/MTC/OEM certificate required, to be submitted

by vendor.

_________________________------------------------XXXXXX--------------------------

SPECIFICATION FOR FABRICATION OF STRUCTURAL

STEELWORKS 1.0.0 SCOPE: This specification covers supply, fabrication, testing, painting and

delivery to site of structural steelworks including supply of all consumable stores and rivets, bolts, nuts, washers, electrodes and other material required for fabrication and field connections of all structural steelworks covered under the scope of the Contract.

2.0.0 SCOPE OF WORK 2.1.0 WORK TO BE PROVIDED FOR BY THE CONTRACTOR: The work to be provided for by the Contractor, unless otherwise

specified elsewhere in the Contract, shall include but not be limited to the following.

(a) Preparation of complete detailed fabrication drawing required

for all the structures covered under the scope of the Contract based on design drawings to be furnished by the Owner.

(b) To submit design calculations and detailed fabrication drawings

in case any designed sections are to be made. (c) To submit design calculation for hoists and connections

developed by the Contractor along with detailed fabrication drawings.

(d) Furnish all materials, labour, tools and plant power and all

consumables required for fabrication and supply, all necessary rivets, bolts, nuts, washers, welding electrodes for field connections

(e) Furnish shop painting of all fabricated steelworks as per

requirements of this specification. (f) Suitably mark, bundle and pack for transport of all fabricated

materials. (g) Insure, load and transport all fabricated steel work and field

connection materials to site.

(h) Maintain a fully equipped workshop at site for fabrication, modification and repairs of steel work at site as may be required to complete the works in accordance with the Contract.

Work by others No work under this specification will be provided for by any agency

other than the Contractor, unless specifically mentioned otherwise elsewhere in the Contract.

2.2.0 CODES AND STANDARDS All work under this specification shall, unless otherwise specified in the

Contract, conform to the requirements of the latest revision and / or replacements of the following or any other relevant Indian Standard Specifications and Codes of practice.

--IS 800 /IS 9595 and other relevant Indian standards. --Drawings and supplementary sketches and standards 2.3.0 CONFORMITY WITH DESIGNS The Contractor shall design all connections, supply and fabricate all

steelworks and furnish all connection materials in accordance with the approved drawings and/or as instructed by the Engineer. The material shall be in accordance with the provisions of the Contract and/ or as approved by the Engineer. Provision of all relevant Indian Standard Specifications and codes of practice shall be followed unless otherwise specified in the contract.

2.4.0. MATERIALS TO BE USED 2.4.1 STEEL All steel materials to be used in construction within the purview of this

specification shall comply with any of the following Indian standard specifications as may be applicable.

IS : 226 Structural steel (Standard quality) IS : 2062 Structural steel (weldable quality) 2.4.2 ELECTRODES All electrodes to be used under the Contract shall comply with any of

the following Indian Standard Specifications as may be applicable.

IS : 814 -- Covered electrodes for metal are welding of structural

steel IS : 815 -- Classification and coding of covered electrodes for

metal arc welding of mild steel and low alloy high tensile steel.

2.4.3 BOLTS AND NUTS Blots and nuts (including lock nuts) shall conform to IS : 1363, IS :

1364, IS : 1367, IS : 3640, IS : 3757, IS : 6623, & IS : 6639 as appropriate..

2.4.4 WASHERS Washers shall conform to IS : 5369, IS : 5370,l IS : 5372 , IS : 5374,

IS : 6610, and IS : 6649 as appropriate. 2.4.5. OTHER MATERIALS Other materials used in association with structural steel - works shall

conform to appropriate Indian Standards. 2.5 RECEIPT & STORING OF MATERIALS 2.5.1 GENERAL All materials shall be so stored as to prevent deterioration and to ensure

the preservation of their quality and fitness for the work. Any material, which has deteriorated or has been damaged, shall be removed from the Contractor's yard immediately, failing which the Engineer shall be at liberty to get the material removed and the cost incurred thereof shall be realised from the Contractor.

In case the fabrication is carried out in Contractor's fabrication shop

outside the plant site where other fabrication works are also carried out, all materials meant for use in this contract shall be stacked separately with easily identifiable marks.

2.5.2 STEEL The steel to be used in fabrication shall be stored in separate stacks off

the ground section wise and lengthwise so that they can be easily inspected, at any time. If required by the Engineer, the materials may have to be stored under cover and suitably painted for protection against weather.

2.5.3 ELECTRODES The electrodes for electric arc welding shall be stored in properly

designed racks, The electrodes shall be kept in dry and warm condition if necessary.

2.5.4 BOLTS, NUTS, AND WASHERS Bolts, Nuts and washers and other fastening materials shall be stored on

racks off the ground with a coating of suitable protective oil. These shall be stored in separate gunny bags or compartments according to diameter, length and quality.

2.5.5 PAINTS Paints shall be stored under cover in airtight containers. Paints supplied

in sealed containers shall be used up as soon as possible once the container is opened.

2.6.0 QUALITY CONTROL The Contractor shall establish and maintain quality control procedures

for different items of work and materials to the extent he deems necessary to assure that all work is performed in accordance with this specification. In addition to the Contractor's Representative as far as possible, all inspection by the Engineer or Engineer's Representative shall be made at the Contractor's fabricating shop whether located at site or elsewhere, The Contractor shall co-operate with the Engineer or Engineer's Representative in permitting for inspection to all places where work is being done and in providing free of cost all necessary help in respect of tools and plant, labour and materials required to carry out the inspection. Materials or workmanship not in reasonable conformance with the provisions of this specification may be rejected at any time during the progress of the work

The quality control procedures shall cover but not be limited to the

following items of work: (I) Steel : Manufacturer's test certificates/test

reports of representative samples of materials.

(II) Bolts, Nuts & : Manufacturer's certificate, dimension checks, material testing washers

(III) Electrodes : Manufacturer' certificate, thickness and quality of flux seating.

(IV) Welders : Qualifying tests (V) Welding Sets : Performance tests. (VI) Welds : Inspection, x-ray (VII) Paint : Manufacturer's certificate, physical

inspection 2.7.0 STANDARD DIMENSIONS, FORMS AND WEIGHTS The dimensions and tolerances of all rolled shapes, rivets, bolts, nuts,

studs, washer etc. and other members used in the fabrication of any structure shall, wherever applicable, conform to the requirements of the latest relevant Indian standards.

2.8.0. SHOP DRAWINGS The Contractor shall, within thirty (30) days after the award of the

Contract, prepare and submit for approval complete shop drawings for all fabrication work based on the Design/ Drawings furnished to him and, before proceeding with the fabrication work, shall get the said shop drawings approved and this shall include but not be limited to the following :

(a) Assembly drawings giving exact sizes of the sections to be used

and identification marks of the various sections. (b) Dimensional drawings of base plates, J.D. bolt locations etc. (c) Comparison sheets to show that the proposed alternative

sections if any, are as strong as the original sections shown on the design Drawings.

(d) Any other drawings or calculations that may be required for the

works or substituted parts thereof.

The shop drawings shall give all the necessary information for the fabrication, erection and painting of the steelworks in accordance with the provisions of this specification. Shop drawings shall be made in accordance with the best modern practice and with due regard to sequence, speed and economy in fabrication and erection. The drawings shall be drawn to a scale large enough to cover all the necessary information adequately. Welding symbols used shall be in accordance with the requirements of the Indian standard specification IS : 803 -- Scheme of symbols for welding.

The Contractor shall be responsible for and shall pay for any alteration of the work due to any discrepancies, errors or omissions on the drawings provided that such discrepancies, errors or omissions are not due to inaccurate information or particulars on the Design Drawings furnished to the contractor. In the latter case, the Contractor will be paid for any alteration that has to be made after the materials have been fabricated by the Contractor.

3.0.0 WORKMANSHIP 3.1.0 FABRICATION 3.1.1 GENERAL All workmanship shall be equal to the best practice in modern structural

shops, and shall confirm to the provisions of the Indian standard IS:300- Code of practice in modern structural steel in general building construction and other relevant Indian standards or equivalent.

3.1.2 STRAIGHTENING MATERIAL Rolled materials before being laid off or worked, must be clean, free

from sharp bends or twists and straight within the tolerances allowed by the Indian Standard Specification IS:1852 -Specification for rolling and cutting tolerance for hot-rolled steel products. If straightening is necessary, it may be done by mechanical means or by the application of a limited amount of localised heat. The temperature of heated areas, as measured by approved methods, shall not exceed 600o C.

3.1.3 CUTTING Cutting shall be effected by shearing, cropping or sawing. Use of a

mechanically controlled gas cutting torch may be permitted for mild steel only. Gas cutting without a mechanically controlled torch may be permitted if special care is taken and under expert hand, subject to the approval of the Engineer. To determine the effective size of members cut by gas, 3 mm shall be deducted from each cut edge.

3.1.4 PLAINING OF EDGES Plaining of sheared or cropped edges of plates or shapes or of edges

gas-cut with a mechanically controlled torch shall not be required, unless specifically required by design and called for on the Drawings, included in a stipulation for edge preparation for welding or as may be required after the inspection of the cut surface. Surfaces cut with hand-

flame shall generally be ground, unless specifically instructed otherwise by the Engineer.

3.1.5 CLEARANCES The erection clearance for cleated ends of members connecting steel to

steel shall be preferable but not greater than 2 mm at each end. The erection clearance at the ends of beams without web cleats shall be not more than 3 mm at each end, but where , for practical reasons , greater clearance is necessary, suitably designed seating shall be provided.

3.2.0 WELDED CONSTRUCTION 3.2.1 GENERAL Welding shall be in accordance with relevant Indian Standards and as

supplemented in the Specification. Welding shall be done by experienced and good welders who have been qualified by tests in accordance with IS : 817.

3.2.2 PREPARATION OF MATERIAL Surfaces to be welded shall be free from loose scale , slag, rust, grease,

paint and any other foreign material . Joint surfaces shall be free from fins and tears.

3.2.3 ASSEMBLING Parts to be fillet welded shall be brought in as close contact as

practicable and in no event shall be separated by more than 4 mm. If the separation is 1.5 mm or greater , the size of the fillet welds shall be increased by the amount of the separation. Abutting parts to be butt-welded shall be carefully aligned.

3.2.4 WELDING SEQUENCE In assembling and joining parts of a structure the procedure and a

sequence of welding shall be such as to avoid needless distortion and minimise shrinkage stresses. Where it is impossible to avoid high residual stresses in the closing welds of rigid assembly, such closing welds shall be made in compression elements.

When required by the Engineer, welded assemblies shall be stress

relieved by heat treating in accordance with the provisions of the relevant Indian standard or any other Standard approved by the Engineer.

3.2.5 WELDING TECHNIQUE The technique of welding employed, the appearance and quality of

welds made, and the methods of correcting defective work shall all conform to the relevant Indian Standards.

3.2.6 TEMPERATURE No welding shall normally be done on parent material at a temperature

below (-) 5oC. However, if welding is to be undertaken at a low temperature, adequate precautions as recommended in relevant Indian Standard shall be taken. When the parent material is less than 40 mm thick and the temperature is between (-) 5oC and 0oC, the surface around the joint to a distance of 100mm or 4 times the thickness of the material, whichever is greater, shall be pre-heated. All requirements regarding pre-heating of the parent material shall be in accordance with the relevant I.S. standard.

3.2.7 PEENING Where required, intermediate layers of multiple-layer welds may be

peened with the light blows from a power hammer, using a round-nose tool. Peening shall be done after the weld has cooled to a temperature warm to the hand. Care shall be exercised to prevent scaling or flaking of weld and base metal from over peening.

3.2.8 EQUIPMENT These shall be capable of producing proper current so that the operator

may produce satisfactory welds. The welding machine shall be of a type and capacity as recommended by the manufacturers of electrodes or as may be approved by the Engineer.

3.3.0 INSPECTION & TESTING OF WELDS The method of inspection shall be according to IS : 822 and extent of

inspection and testing shall be in accordance with the relevant application standard or, in the absence of such a standard, as specified by the Site-in-Charge. Welds shall not be painted or otherwise obscured until they have been inspected, approved and accepted.

The Site-in-Charge or his representative shall have access to the

Contractor's work at all times and the Contractor shall provide him with all facilities necessary for inspection during all stages of fabrication and erection with, but not limited to, the following objectives.

I) To check the conformity with the relevant standards and

suitability to various welding equipment's and their performance.

II) To witness / approve the welding procedure qualification. III) To witness / approve the welders performance qualification. IV) To check whether shop / field welding being executed is in

conformity with the relevant specifications and codes of practice.

A) Visual Inspection All finished welds (i.e. 100 percent) shall be visually inspected

and the following types of weld defects & faults shall be looked into.

a) Weld defects accruing at the surface such as blow holes,

exposed porosity, unfused welds etc. b) Surface cracks in the weld metal or in the parent metal

adjacent to it. c) Damages to the parent metal such as undercuts, burning,

overheating etc. d) Profile defects such as excessive convexity or concavity,

overlapping, unequal leg lengths, excessive reinforcement, incompletely filled grooves, excessive penetration, beads, root grooves etc.

e) Distortion due to welding i.e., local shrinkage, camber,

bowing, twisting, rotation, wariness etc. f) Linear eccentric, angular and rotational misalignment of

parts. g) Dimensional errors. B) Mechanical Tests The mechanical testing ( such as tensile load tests, bent tests,

impact tests etc. ) shall be done in accordance with the relevant standards and as per the instructions of the Site-in-Charge.

C) Magnetic Particle / Dye Penetration / Ultrasonic Examination: The examination shall be done at random as directed by the

Site-in-Charge. Whenever such tests are directed, the tests shall be carried out on joints chosen by him. The tests shall be carried out by employing approved testing procedure in accordance with IS : 822.

D) Radiographic Examination Radiographic examination shall be carried out only in special

cases for random joints as directed by the Site-in-Charge. The Contractor shall be paid extra for such examination except for penalty radiographic tests for which the cost shall be borne by him. The Contractor shall make necessary arrangement at his own expense for providing the radiographic equipment, films and all other necessary materials required for carrying out the examination. The tests shall be carried in the presence of the Site-in-Charge by employing approved testing procedure in accordance with IS : 822. The Contractor shall fulfil all the statutory safety requirements while handling x-ray and Gamma- ray equipment and provide the Site-in-Charge all the necessary facilities at site such as dark room, film viewer etc., to enable him to examine the radiographs.

3.3.1 REPAIR OF FAULTY WELDS Welds not complying with the acceptance requirements (as specified by

IS codes & the Site-in-Charge) shall be corrected-whole or portions -either by removing & replacing or as follows:

a) Excessive convexity - Reduced to size by removal of excess

weld metal. b) Shrinkage cracks - Defective portions removed down to sound

metal and cracks in parent plates and craters. c) Under cutting - Additional weld metal deposited. d) Improperly fitted/misaligned - welding cut & edges suitably

prepared parts rewelded. e) Members distorted - Member straightened by mechanical means. In removing defects of a weld, gouging, chipping, oxygen cutting or

grinding shall not extend into the parent metal to any substantial amount beyond the depth of weld penetration, unless cracks or other defects exist in the parent plates. The weld or parent plates shall not be undercut in chipping, grinding, gouging or oxygen cutting.

No repair of defective welds shall be carried out without proper

permission of the Site-in-Charge and his approval for the corrective procedure.

3.3.2 SPLICING

3.3.2.1 Splicing of built up / compound / latticed sections shall be done in such a fashion that each component of the section is joined in a staggered manner.

3.3.2.2 Where no butt weld is used for splicing, the meeting ends of two pieces

of joist / channel / built up section shall be ground flush for bearing on each other and suitable flange and web splice plates shall be designed and provided for the full strength of the flange / web of the section and welds designed accordingly.

3.3.2.3 Where full strength butt weld is used for splicing (after proper edge

preparation of the web and flange plates) of members fabrication out of joist / channel / built up section, additional flange and web plates shall be provided, over and above the full strength butt welds, to have 40 % strength of flange and web.

3.3.2.4 Where a cover plate is used over a joist / channel section the splicing of

the cover plate and channel / joist sections shall be staggered by minimum 50 mm . Extra splice plate shall be used for the cover plate and joist / channel section as per clause 3.3.2.2 or 3.3.2.3 .

4.0 MARKING FOR IDENTIFICATION 4.1 Each component shall be distinctly marked (with paint) before delivery

in accordance with the marking diagrams and shall bear such other marks as will facilitate erection.

4.2 For small members which are delivered in bundles or crates, the

required marking shall be done on small metal tags securely tied to the bundle.

5.0 SHOP ERECTION The steelwork shall be temporarily shop erected complete or as directed

by the Site-in-Charge, so that the accuracy of it may be checked before despatch.

6.0 INSPECTION & TESTING OF STRUCTURES 6.1 The Site-in-Charge (or his authorised representative) shall have free

access at all times to those parts of the Contractor's works which are concerned with the fabrication of the steel work and shall be provided with all reasonable facilities for satisfying himself that the fabrication is being undertaken in accordance with the provisions of these specification & other relevant IS Codes.

6.2 Should any structure or part of a structure be found not to comply with

any of the provisions of these specifications & other relevant of the

structure, once rejected shall be resubmitted for inspection, except in cases where the Site-in-Charge or his authorised representative considers the defect as rectifiable.

6.3 Defects which may appear during fabrication / erection shall be made

good only with the consent of the Site-in-Charge and procedure laid down by him.

6.4 All necessary gauges and templates shall be supplied free to the Site-in-

Charge by the Contractor whenever asked for during inspection. The Site-in-Charge, may at his discretion, check the test results obtained at the Contractors works by independent tests at a test houses, the cost of such tests shall be borne by the Contractor.

7.0 SHOP PAINTING 7.1 All components and members of steel work shall be given one shop

coat of red oxide zinc chromate primer immediately after the surfaces have been properly prepared (i.e. degreased, derusted, descaled & cleaned) in accordance with IS :1477. The primer coat shall be applied over completely dry surfaces (using brushes of good quality) in a manner so as to ensure a continuous and uniform film without "holidaying". Special care shall be taken to cover all the crevices, corners, edges etc. The primer coat shall be air-dried and shall have a minimum film thickness of 25 microns (tolerance +/- 10%) after drying.

7.2 Surfaces, which are inaccessible after shop assembly, shall receive the

full-specified protective treatment before assembly (this shall not apply to the interior of sealed hollow sections).

7.3 Steel surfaces shall not be painted within a suitable distance of any

edges to be welded if the paint specified would be harmful to welders or impair the quality of the welds.

7.4 Welds and adjacent parent metal shall not be painted prior to

deslagging, inspection and approval by the Site-in-Charge. 7.5 Parts to be encased in concrete shall not be painted. 8.0 PACKING 8.1 All items shall be suitably packed in case these are to be despatched

from the fabrication shop to the actual site of erection so as to protect them from any damage / distortion or falling during temporarily braced to avoid warping during transportation.

8.2 Small parts such as gussets, cleats etc., shall be securely wired on to their respective main members.

8.3 Bolts, nuts, washers etc. shall be packed in crates. 9.0 TRANSPORTATION Loading and transportation shall be done in compliance with

transportation rules. In case, certain parts can not be transported in the lengths stipulated in the drawings the position and type of additional splice joints shall be got approved by the Site-in-Charge.

10.0 SITE (FIELD) ERECTION 10.1 PLANT & EQUIPMENT The suitability and capacity of all plant and equipment used shall be to

the complete satisfaction of the Site-in-Charge. 10.2 STORING & HANDLING All steel work shall be so stored and handled at site so that the members

are not subjected to excessive stresses and any damage. 10.3 SETTING OUT Prior to setting out of the steel work, the Contractor shall get himself

satisfied about the correctness of levels, alignment, location of existing concrete pedestals / columns / brackets and holding down bolts / pockets provided therein. Any minor modification in the same including chipping, cutting and making good, adjusting the anchor bolts etc., if necessary, shall be carried out by the Contractor at his own expense. The positioning and levelling of all steelwork including plumbing of columns and placing of every part of the structure with accuracy shall be in accordance with the drawings and to the complete satisfaction of the Site-in-Charge.

11.0 SAFETY & SECURITY DURING ERECTION 11.1 The contractor shall comply with IS : 7205 for necessary safety and

adhere to safe erection practices and guard against hazardous as well as unsafe working conditions during all stages of erection.

11.2 During erection, the steelworks shall be securely bolted or otherwise

fastened and when necessary, temporarily braced / guyed till the completion, including those due to the wind, erection equipment & its

operation etc. For the purpose of guying, the Contractor shall not use other structure in the vicinity.

11.3 No permanent bolting or welding shall be done until proper alignment

has been achieved. 11.4 Proper access, platform and safety arrangement shall be provided for

working and inspection, (at no extra cost) whenever required. 12.0 FIELD CONNECTIONS 12.1 FIELD BOLTING Field bolting shall be carried out with the same care as required for

shop bolting. 12.2 FIELD WELDING All field assembly and welding shall be executed in accordance with the

requirements for shop assembly and welding. Holes for all erection bolts - where removed after final erection shall be plugged by welding. Alternatively erection bolts may be left and secured.

13.0 GROUTING 13.1 Prior to positioning of structural columns / girders / trusses over the

concrete pedestals / columns / brackets, all laitance & loose material cleaned (using compressed air) and made thoroughly wet. Thereafter, the structural members shall be erected, aligned & plumbed maintaining the base plates / shop plates at the levels shown in the drawings, with necessary shims / pack plates / wedges.

13.2 After installing the structure, the forms shall be constructed around and

joints made tight to prevent leakage. Grouting (under the base plates / shop plates including grouting of sleeves & pockets) shall be done with ordinary / non -shrink grout as shown in drawings and having the required strength. Non - shrink grout shall be of premix type and of approved quality and standard make and mixed with water in proportion as specified by the manufacturer.

13.3 The grout mixture shall be poured continuously (without any

interruption till completion) from one side of the base plate and spread uniformly with flexible steel strips and rammed with rods, till the space is filled solidly and the grout mixture carried to the other side of the base plate.

13.4 The grout mixture shall be allowed to harden for a period as decided by

the Engineer-in Charge. At the end of this period, the shims / wedges /

pack plates may be removed and anchor bolts tightened uniformly. The alignment of the structure shall now be rechecked and if found correct, the voids left by the removal of shims / wedges / pack plates (if removed) must be filled up with a similar mixture of grout. In case after checking, serious misalignment is indicated, the grout shall be removed completely and fresh grouting done after making appropriate correction of alignment.

14.0 SCHEME AND SEQUENCE OF ERECTION The Contractor shall furnish the detailed scheme and sequence of

erection to match with the project schedule and get the same approved by the Site-in-Charge.

15.0 PAYMENT 15.1 Payment for structural steel works shall be made on the basis of

admissible weight in metric tons of the structure accepted by the Site-in-Charge. The rate shall include supplying, fabricating, erecting in position, testing / examining (excluding radiography only) of bolted and / or welded structural steel works of all types (including all built up / compound sections made out of rolled sections and /plates) including all handling, transporting, storing, straightening if required, cutting, edge preparation, preheating, bolting and welding of joints (including sealing the joints of box section with continuous welding), finishing edges by grinding, fixing in line & level with temporary staging & bracing and removal of the same after erection, grouting with ordinary / non - shrink grout as specified, including preparation of fabrication & erection, drawings, erection schedule and getting them reviewed, preparing the surfaces for painting, surface cleaning, wire brushing, removal of mill scale, dust, rust, oil or grease and applying one coat of red oxide zinc chromate primer after fabrication etc. all complete as specified.

15.2 The weight for payment shall be determined from the fabrication

drawings and respective bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineer - in- Charge before making the payment. The weight shall be calculated on the basis of IS handbook wherever applicable. In case sections used are different from IS sections, then Manufacturers Hand Book shall be adopted. No allowance in weight shall be made for rolling tolerances.

16.0 PAINTING AFTER ERECTION 16.1 GENERAL 16.1.1 The Contractor shall carry out the painting work in all respects with the

best quality of approved materials (conforming to relevant IS Codes) and workmanship in accordance with the best engineering practice. The

Contractor shall furnish characteristics of paints (to be used) indicating the suitability for the required service condition. The paint manufacturers instruction shall be followed as far as practicable at all times. Particular attention shall be paid to the following.

-- Proper storage to avoid exposure & extremes of temperature -- Surface preparation prior to painting -- Mixing & thinning -- Application of paint and the recommended limit on time

intervals between consecutive coats. 16.1.2 Painting shall not be done in frost or foggy weather, or when humidity

is such as to cause condensation on the surfaces to be painted. 16.1.3 Surface, which shall be inaccessible after site assembly shall receive the

full, specified protective treatment before assembly. 16.1.4 Primers & finish coat paints shall be from the same manufacture in

order to ensure compatibility 16.2 RUB DOWN & PRIMER APPLICATION The shop coated surfaces shall be rubbed down thoroughly with emery /

abrasive paper to remove dusts, rust, other foreign matters and degreased., If required, in accordance with IS : 1477, cleaned with warm fresh water and air dried. The portions, from where the shop coat has peeled off, shall be touched up and allowed to dry. Primer coat of red oxide zinc chromate primer (conforming to IS : 2074) shall be applied by brushing / spraying in a manner so as to ensure a continuous and uniform film throughout. Special care shall be taken to cover all the crevices, corners, edges etc. The primer coat shall be air-dried and shall have a minimum film thickness of 25 microns (tolerance +/- 10%) after drying.

16.3 FINAL PAINT APPLICATION After the primer is hard dry, the surfaces shall be dusted off and one

coat of synthetic enamel paint of approved colour & shade (conforming to IS : 2932) shall be applied by brushing / spraying so that a film free from "holidaying" is obtained. The colour & shade of first coat of paint shall be slightly lighter than the second coat in order to identify the application of each coat. The second coat of paint shall be applied after the first coat is hard dry. The minimum thickness of each film shall be 20 microns (+/- 10 % tolerance) after drying.

16.4 INSPECTION & TESTING OF PAINTING WORKS 16.4.1 All painting materials including primers & thinners brought to site by

the Contractor for application shall be procured directly from reputed manufacturers as per specification and shall be accompanied by manufacturer's test certificates. Paint formulation without certificates shall not be accepted.

16.4.2 The Site-in-Charge at his discretion may call for additional tests for

paint formulation. The Contractor shall arrange to have such tests including batch wise test of wet paints for physical & chemical analysis. All costs shall be borne by the Contractor.

16.4.3 The painting work shall be subject to inspection by the Site-in-Charge

at all times. In particular, the stage inspection will be performed and approval at every stage is required before proceeding with the next stage. The record of inspection shall be maintained. Stages of inspection are as follows:

a) Surface preparation b) Primer application c) Each coat of paint 16.4.4 Any defect noticed during the various stages of inspection shall be

rectified by the Contractor to the entire satisfaction of the Site-in-Charge before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work the Contractor shall be responsible for making good any defects found during final inspection / guarantee period / defect liability period, as defined in General Conditions of Contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat. The thickness shall be measured at as many locations as decided by the Site-in-Charge. The Contractor shall provide standard thickness measuring instrument such as elkometer (with appropriate range for measuring dry film thickness of each coat) free of cost to the Site-in-Charge whenever asked for.

16.4.5 GUARANTEE The Contractor shall guarantee that the chemical and physical

properties of paint materials used are in accordance with the requisite specifications.

16.5 PAYMENT Payment for painting of structural steelworks shall be made on the basis

of weight in metric tons of the painted structures accepted by the Site-in-Charge.

The rate shall include supplying & applying two coats of synthetic

enamel paint or aluminium as specified of approved quality and shade over a coat of red oxide zinc chromate primer besides one coat of shop primer already applied to structural steel works of all types / shapes at all locations and positions including storage, surface degreasing, cleaning, drying, touching up of shop primer coat, providing temporary staging, testing etc., all complete as specified.

PLT MANIFOLD SHED

17 m X 7 m

STANDARD SPECIFCATIONS FOR

FABRICATION ERECTION OF PRODUCT AND

FIRE FIGHTING PIPELINES

1.0 GENERAL

This specification is intended to cover the technical requirements for the execution of piping

prefabrication, assembly and erection of the entire pipe work.

2.0 SCOPE

Fabrication and erection of all piping systems from piping materials supplied by owner in

accordance with this specification and applicable drawings and standards.

Testing & Flushing

Fabrication and erection of supporting elements i.e. guides, stop anchors clips etc. including

applying one coat of zinc phosphate primer as specified.

Coating and wrapping of under ground piping

All piping systems shall be fabricated, installed, flushed, tested in accordance with this

specification and applicable codes / drawings standards. Any deviation from the specification

and drawing shall be permitted only after obtaining the written approval of the Site in charge.

3.0 APPLICABLE CODES & STANDARDS

ASME Code of pressure piping for liquid ASME B 31.4

Transportation System for Hydro carbons

Code of petroleum refinery piping ANSI B 31.3

Code of procedure for manual metal arc welding of IS : 9595

Carbon steel

Welder qualification ASME Sec. IX

All codes referred shall be the latest editions.

4.0 PRE-QUALIFICATION

The contractor shall fabricate all pipe work in conformity with the requirements of general

arrangement drawings and specifications. Where specific detail of fabrication are not indicated

on the drawings or not specified herein, fabrication / erection shall be done in accordance with

ASME B 31.4 latest edition.

The contractor shall be responsible for working the exact dimensions as shown on the drawings

irrespective of individual tolerances permissible. Where errors and / or omissions occur on the

drawings, it shall be the contractor’s responsibility to notify the site incharge prior to fabrication

or erection.

5.0 ALIGNMENT

The pipes to be joined by welding shall be aligned correctly with the proper tolerances on

diameters, wall thickness and out of roundness. The same alignment shall be preserve during

welding. For the internal misalignment due to difference in wall thickness of the mating

component exceeding 1/16”, the component with the higher wall thickness shall be internally

machined / grounded, so that the adjoining surfaces are approx. flushed.

6.0 LAYOUT, CUTTING & FITTING UP

For laying out headers, tees, laterals and other irregular details, cutting templates shall be used

to ensure accurate cutting and proper fit up.

All cutting shall follow the outline of the templates.

Machine cut bevels to form the welding groove are preferred in carbon steel pipe. However,

smooth, clean, slag free flame cut bevels are acceptable.

Tack welds with full penetration shall be used and shall become the part of the finished weld.

Defective welds or tack welds with lack of penetration are not acceptable and shall be chipped /

ground out.

No temporary weld attachment shall be with extended clamps / attachments.

7.0 OTHER ALINGMENT CONSIDERATIONS

All flanges facing shall be true and perpendicular to the axis of the pipe to which they are

attached. Flange bolt holes shall straddle the normal centre line unless different orientation is

shown in the drawings to match the equipment connections etc.

8.0 METER BENDS AND FABRICATED REDUCERS

The specific application of welded mitre bends and fabricated reducers shall be as per the

pipeline route and alignment. The piping rates shall be inclusive of fabrications / erection of

mitre bends and reducers. However, the contractor shall be paid separately for fabrication of

bends and reducers.

9.0 CLEANING OF PIPING

On completion of fabrication, all pipes and fittings shall be cleaned. Inside and outside by

suitable means (mechanical cleaning tool, wire brush etc.) before erection to ensure that

assembly is free from all loose foreign material such as scale, sand, weld spatter, particles,

cutting chips etc.

All field fabricated piping shall also be cleaned at the completion of the fabrication. All burrs,

welding circles and weld spatter shall be removed by any suitable means (mechanical tools. wire

brush etc.).

Both shop and filed fabricated piping shall be blown out with compressed air at the termination

of cleaning and capped.

10.0 WELDING

All welding shall be performed in accordance with the welding specifications attached.

11.0 ERECTION

The intent of pre-fabrication is to accelerate progress of pipe work and to minimize work in the

field; such pre-fabrication should be based on approved piping layout furnished to be

contractor. Field weld means position weld of pre-fabricated piece at the site or near the plant.

However, the contractor shall bear in mind that there can be variations in dimensions between

those appearing in the layouts and those actually occurring as the site due to minor variations in

the location of equipment etc. The contractor shall, therefore, provide adequate field joints, if

required other than shown in the drawings and fit in section, permitting the pre assembly to be

installed without any modification. In any case no extra claim will be entertained on this

account.

All piping shall be routed and located as shown in the piping drawings keeping in view the piping

specifications. No deviations from the arrangement shown shall be permitted without the

express consent of the site incharge.

While fittings up mating flanges, care shall be exercised to properly align the pipes and to check

the flanges of trueness, so that faces of the flanges can be pulled up together without inducing

any stresses at the pipes and equipment nozzles. The bolt holes of flanges in the vertical plane

shall straddle the vertical centre line of the pipe in the erected position and for flanges in the

horizontal plane unless otherwise indicated on the drawings.

Flanged connections at the pump, other equipment shall be made in such a way as not induce

any stresses due to misalignment, excessive gaps etc. The final tightening shall be redone when

the machines are aligned completely. Temporary protective covers shall be provided at the all

flanged connections of pumps equipment until the piping is finally connected.

Slopes specified for various lines in the drawings shall be maintained by the contractor.

After piping is erected in final position, it shall be cleaned, tested for tightens and kept dry

wherever instructed as described in this specification.

12.0 VALVES

The valves spindle positions are shown in the arrangement drawings and the contractor shall be

required to follow them. He shall however, bring it to the notice of the site incharge in case he

encounters some difficulty in installing them.

Wherever practicable and except when otherwise shown on the drawings, valve stems shall be

installed in a vertical direction and shall not be installed with stems below the horizontal axis.

13.0 SUPPORTS

Pipe supports, guides and anchors for piping shall be fabricated and provided as shown in the

drawings. No anchors on piping shall be used except at locations shown in the drawings. The

pipe shall be secured firmly at anchor supports.

Fabrication and direction of supporting elements and structural fixtures wherever required and

pointed out by the site incharge, whether indicated in drawing or not, to prevent vibration,

excess sag etc. shall be carried out by the contractor.

14.0 LAYING OF UNDERGROUND PIPING

The contractor shall dig the pipeline trenches where necessary according to the drawing, true to

the line and gradient as per specifications and as directed by the site incharge.

The contractor shall be responsible for correct layout and gradient of the line. Errors, if any,

shall be rectified by the contractor.

15.0 TRENCHING

The trench shall be cut true to the line leveled with the help of sight rails provided at every 30

M, at change of direction, gradient and at any suitable distance as directed by the site incharge.

If the trench is excavated below the required level indicated in the drawing the extra depth shall

be filled with concrete or approved equivalent material as directed by the site incharge.

The trench shall be excavated so as to provide an average cover of 1000 mm or equal to the

diameter of the largest pipe to be laid in the trench, or as shown in drawings, whichever is

greater. The average cover will be reckoned from top of the pipe of the largest diameter to be

laid in the trench, to the finished grade. The width of the trench shall be sufficient to give free

working space as per IS 783. Generally it shall not be less than 150 mm on either side of 1/3 of

dia of pipe, whichever is greater.

No excavated material shall be deposited within 1.5 meter from the excavated trench.

In case of road cutting, all material i.e. metal, bricks etc. shall be taken out carefully and kept

separately for reuse in road work and shall be redone up to the original level prior to cutting the

road with the excavated road materials after laying and testing of the pipeline within 10 days

from the date of starting the work at the cost of contractor. The contractor shall provide

suitable barricades to prevent accidents. He shall also provide reasonable by pass at his own

cost when a road is cut for laying pipeline.

During excavation, if some obstacle is met with, the same shall be reported to the site incharge

and dealt with as instructed by him.

The contractor shall dewater, shore or do whatever might be required to excavate the trench,

install the pipe in it and backfill the trench, in accordance with the specifications. Dewatering

shall be done in advance of the laying of the pipe to allow adequate inspection of padding of the

bottom if required and dewatering shall be continued throughout during laying of pipe and back

filling of the trench.

In muddy slushy ground the bed shall be provided with a layer of a sand or lean concrete as

directed by the site incharge.

The trench shall follow the gradient of pipeline as specified in the drawing. The contractor shall

keep the trench in good condition. Until the pipe is laid and tested, no extra claim shall be

entertained due to its caving or settling down either before or after the pipe is laid. All materials

to shore the trench in order to prevent caving are to be furnished and removed by the

contractor at no extra cost to the owner.

In case pipe is lowered in caved trench and back filled before being inspected by the site

incharge the contractor shall re-excavate the trench, for inspection and backfill it at his own

cost.

16.0 LAYING

The pipe shall be lowered either by mechanical method or by hand when the trench is ready and

bottom of the trench is graded as per required pipe laying conditions and specifications.

16.1 BY MACHINE

The shop coated pie, already transported to the pipe laying site / convenient length of pipe

assembly coated and wrapped near the trench after hydrostatic testing shall be placed on clean

square cut skids suitably spaced so as to keep the pie away from touching the ground. The pie

may be lowered down in the trench by the launcher cranes, with sufficient care to protect the

coating and wrapping of the pipeline.

At tie in welds and other places, the contractor shall clean, apply primer, coat and wrap

manually. Also short sections of pipelines, which are impracticable to shop treat may be hand

treated but only on the prior written approval of the site incharge.

16.3 METHOD & TIME OF LOWERING PIPE

Under favorable temperature conditions and using methods, which will not damage coating, the

pipe may be lowered in to the trench.

Pipe previously set on skids because of unfavorable temperature conditions shall be lowered

into the trench normally in the cool of the morning and only when the temperature of the pie is

below at the softening point of the coating materials.

All skid marks and other places of damage shall be thoroughly examined to ensure proper

patching where necessary, before the pipe is finally lowered in the trench.

16.4 HANDLING COATED PIPE

Coated pipe shall not be placed in trench until cave in plugs, hard clods, stones, skids, welding

rods etc have been removed from there. Where the trench has a hard or jagged bottom,

sufficient fine dirt or sand shall be placed therein, before the pipe is lowered.

Coated pipe shall not be handled or moved by means of cable or chains or by prying with skids

or bars, it shall be tied and lowered by using the belts of a standard width and design for the size

of pipe being handled.

Coated pipe shall not be dragged along the ground or otherwise handled in a manner that will

spoil the coating.

16.5 LINING UP & WELDING

The ends of the pipeline shall be kept securely closed to prevent entry of any foreign material,

moisture after lowering into the trench.

Before making joints, the pipe shall be carefully laid so as to be perfectly aligned in both plan

and profile, and the end closures provided shall be removed.

Tie in shall be made in the coolness or when the ambient temperature is not exceeding 29 Deg.

C or softening temperature of the coating material, whichever is less.

Free access shall be provided for the welding of the circumferential joints by increasing the

width and depth of the trench at these points. There should be no obstruction to the welder

from any side so that good welded point is obtained.

16.6 BACK FILLING

After testing and in section of the pipeline to the entire satisfaction of the site incharge, the

trench shall be back filled with the excavated material. No trench shall be back filled without

the approval of the site incharge.

Back filling with the excavated material shall be done in layers of 200 mm, well watered and

rammed to avoid any settling afterwards.

The contractor shall place soil over the trench to such a height as well as in opinion of the site

incharge, to provide adequately for future settlement of the trench backfill.

If due to exigencies of the work some portion of the pipeline is backfilled without approval of

the site incharge, the site incharge shall have the right to order uncovering of the pipe for

examination and the cost of such uncovering shall be borne by the contractor.

The backfill material shall be free from stone pieces.

Surplus excavated soil or rubbish material shall be removed by the contractor at his own cost to

a place designated by the site incharge.

When the trench has been dug through roads, all backfill shall be thoroughly compacted. In

certain cases, special compaction methods may be required by the site incharge. This shall be

done by the contractor at no extra cost to the owner.

When the trench has been dug through unlined ditched, the backfill shall be thoroughly

compacted in 150 mm layers for a distance of 1.50 m beyond the outside banks on either side.

The bank of the ditch shall also be compacted in 150 mm layers at no extra cost to the owner.

After the roads have been already graded, and if any are trenched or otherwise disturbed by the

contractor during laying of the pipelines, the contractor shall restore the road to its original level

and conditions. In the event, the contractor is required to place extra fill, gravel, or other special

materials it shall be done by him without any extra cost to the owner.

16.7 CLEAN UP OF SURROUNDINGS

As soon as the backfill is completed, the contractor shall immediately clean up the adjoining

area by removing all surplus and defective material and dispose of all refuse such as spurs, sheet

iron, broken skids etc to the complete satisfaction of the site incharge.

The earth on both sides of the pipeline trench which has been disturbed during the construction

of the pipeline shall be smoothened and left in a condition satisfactory to the site incharge.

17.0 INSPECTION

17.1 GENERAL

Owner’s inspector shall have free access to all work places or any other matters and places

concerned with the work.

Owner can send his officer / authorized person to shops where pre fabrication and evection of

pipelines are being done, with the following functions but not limited to :

a. To check welding performance and welding equipment used on the job are suitable and

area as per relevant standards.

b. To supervise welding procedure qualification

c. To supervise welder performance qualification tests / exams. Etc.

d. To check whether welding is conforming to relevant specification and the practice /

procedure followed is in accordance with t good pipeline construction practice.

e. To check any other performance to ensure quality of work

f. To check adequate safety precautions to be taken during progress of the work.

Contractor shall notify sufficiently advance the commencement of qualification tests, welding

work and acceptance tests to enable the owner’s inspector supervise the same. Qualification

certificate shall be issued after concurrence of the owner’s inspector.

Contractor shall provide the owner’s inspector with all facilities necessary for carrying out his

work at no extra cost to the owner, as and when required.

Approval from the owner’s inspector shall not relieve the contractor partially or fully of his

responsibilities and guarantees under this contract.

17.2 VISUAL INSPECTION

Inspection of all welds shall be carried out as per ANSI B 31.3. Finished welds shall be visually

inspected for parallel and axial misalignment of the work, cracks, inadequate penetration,

unrepaired burn through dimensions, and other surface defects, and it shall present a neat

workmanship. Under cutting adjacent to the final bead on the outside of the pipe shall not

exceed 0.8 mm in depth or 12.5% of the pipe wall thickness, whichever is smaller and the

cumulative length shall not be more than 50 mm in any continuous 300 mm length of weld.

17.3 REMOVAL OF DEFECTS / REPAIR JOBS

Defects which are not within the acceptable limits shall be removed from the joint completely

by chipping.

When whole joint is found unacceptable, the welds and the ends of the joints shall be restored.

Repairs shall be carried out with prior authorization of the site incharge.

8.0 TESTING

8.1 GENERAL

All the pipelines are to be tested at pressure 1.5 times the maximum operating pressure of the

system.

Testing could be done either by manual pump or motor drivers / pneumatic pump. The entire

pipe network shall be kept pressurized for at least 2 hours and pressure drop in the system shall

be observed. All the joints shall be thoroughly inspected by tapping lightly with a hammer and

by visual inspection.

All underground / aboveground pipes shall be tested for leakages to a minimum hydrostatic test

pressure of 10 kg/cm 2 gauge.

The testing shall be carried out in convenient section as approved by the site incharge.

If some defect is notice during the hydrostatic testing, the same shall be brought to the notice of

site incharge, joints if leaking, shall be rectified as per the welding specifications and instructions

of site incharge and tested to his satisfaction at no extra cost to the owner.

The site incharge shall be notified in advance by contractor of all testing. The hydrostatic

testing, flushing of all the piping shall be carried out by contractor at his own cost.

Contractor shall make his own arrangements for flushing at suitable points as per the

instructions of the site incharge. Any extra work / modifications on this account shall be done

by the contractor at his own cost.

18.2 TEST MEDIUM

Clean construction water shall generally be used as the testing medium for the hydrostatic

testing of piping system.

18.3 CLEANING

All systems shall be cleaned and flushed free of all dirt, debris or loose foreign material after

testing.

18.4 TEMPORARY BLINDS

Open ends of piping systems such as at pumps or wherever equipment has been removed or

disconnected prior to hydrostatic testing or at a termination point of piping branch, connections

shall be blinded off by temporary blind flange made out of 10 mm thick MS plate.

18.5 VENTING

All piping system and equipment shall be properly vented to remove air from system during

filling.

18.6 PRESSURISING

Pressure shall be applied by means of a suitable test pump, which shall not be connected to the

system until ready to test. A pressure gauge shall be provided at the pump discharge to check

the pressure. The pump shall be attended to constantly during the test by an authorized

operator. The pump shall be disconnected after the pressure test is complete.

The test pressure is to be maintained for sufficient time to permit complete inspection of the

system under test, test shall be considered complete only when approval is given by the site

incharge.

18.7 TEST GUAGE

Contractor’s own test gauge shall be installed a close as possible to the lowest point in the

system being tested. Prior to installation, the test gauge shall be checked against a standard

gauge or calibrated with the aid of a dead weight tester. Calibration of these gauges shall be the

responsibility of the contractor.

18.8 DRAINING

All liens and equipment shall be completely drained after the hydrostatic test of a system has

been complete. High point vents shall be opened to prevent excessive vacuum and permit

complete draining.

If it becomes necessary to leave a system filled with the testing medium for any abnormal length

of time, arrangement of venting shall be made to provide for possible liquid expansion with

change in ambient temperatures.

18.9 RECORDS

Records in triplicate shall be made for each system as follows:

In case of underground piping layouts giving actual elevations of pipelines is laid.

Test certificates containing date of test, identification of the piping system, test fluid used, test

pressure and approval of site incharge.

Certificates for flushing containing flushing medium used in identification of the piping system

date of flushing and approval by owner’s inspector.

20.0 PAYMENT

Payment for piping shall be based on linear measurements calculated on the basis of the

execution drawings. The length shall be measured along the centre lines of pipes, centre lines of

bend and elbows, tests, reducers, flange joints. All type of valves shall be excluded from this

measurement Branch connections hall be measured from the outer surface of the header.

STANDARD SPECIFICATION

FOR WELDING OF CARBON STEEL PIPING

1. GENERAL

Following specification can be adopted for field and shop welding for carbon steel piping system

a. Butt welds between pipes, flanges, bends, branch connection, valves etc.

b. Fillet welds for junction of slip on flanges, butt and socket weld fittings, reinforcing pads,

etc.

Acceptable standards / procedures are as under :

a. Standard of welding pipes and related facilities – ANSI B 31.3 / ASME B 31.4

b. Code of practice for metal arc welding of carbon steel IS 9595 latest edition (for structural

work only)

In case of any variation between the provisions of the codes and the specifications given below,

the later shall prevail.

2.0 WELDING PROCEDURE QUALIFICATION

Welding procedure qualification for all piping shall be as per the latest edition of standard for

welding pipelines and related facilities, ASME Section – IX.

3.0 WELDER’S QUALIFICATION

Welder’s qualification for all piping shall be in accordance with ASME section IX. Inspector shall

witness the test and certify the qualification of each welder. Welders approved by the inspector

only shall be employed for the job.

4.0 IDENTIFICATION CARD FOR QUALIFIED WELDERS

4.1 After the welder is declared qualified, an identification card should be issued to the welder,

separate payment will be made for erection. The reducers will be measured and paid along with

the piping of large diameter.

No separate payment will be made for making pipe to pipe branch connection crosses with or

without reinforcing pads and the unit rates for piping are deemed to include all such work.

Fabrication, installation and removal of temporary spool piece etc to aid contractor’s work such

as fabrication, erection, flushing testing etc will neither be measured nor paid separately. The

same is deemed to be included in the unit rates for piping.

4.2 No welder shall be permitted to work without the possession of this identification card. If a

welder is found to perform a type of welding or in a position or on a material for which he is not

qualified, he should be debarred from doing further work. All such welds should be cut and

redone.

5.0 ADVERSE WEATHER CONDITIONS

If the welding is to be performed during rain or strong wind, suitable protection shall be

provided for the parts to be welded and the welder.

6.0 BASE MATERIALS

6.1 In general this specification shall be used in welding the carbon steel materials having a

specified tensile strength of 60,000 psi or less.

6.2 Backing rings, if required, shall be similar in chemical composition to the base material.

7.0 FILLER MATERIALS

7.1 Electrodes :

Electrodes used for welding shall conform to IS 814 and IS 815 latest editions.

The electrodes to be used shall be approved by the site incharge after conducting tests as per IS

814 testing procedure.

Manufacturer’s certificates for each batch of electrodes supplied is required.

Electrodes shall be stored in unopened original containers. They shall be stored adequately to

prevent moisture loss or moisture absorption and shall be handled in such a manner so as to

avoid the damage of coating.

Electrodes when used shall before of rust, oil, grease, earth or any other matter which could be

harmful for the quality of welding. The electrodes used shall be suitable to the welding process

and the base metal, and the weld properties shall not be lower than those of base metal.

8.0 WELDING PROCESS

8.1 This specification is for the manual shielded metal arc process, automatic or semi automatic

welding should be done only after the procedure and materials have been approved by the site

incharge.

8.2 The welding shall conform to the standard codes of welding practice welding of carbon steel in

general shall be in accordance with IS 9595 (for structural work only).

9.0 PREPARATIONOF WORK PIECES

9.1 End Preparation of Pipe :

Machining is preferred over flame cutting for end preparation. However, if flame cutting is

done, then all grooves, irregularities should be nearly ground off and oxidation is to be removed

from the edges.

9.2 Cleaning :

9.2.1 The ends to be welded shall be properly cleaned. All paint, oil grease, rust and oxide in general

shall be removed, as well as all earth, sand or any other material which could be harmful to be

welding. Ends shall be totally dry when welded.

9.2.2 All dirt or debris will be removed / cleaned in the pipelines. Prior to alignment, the inside of

each joint shall be adequately swabbed, either by use of leather of canvas belt disc of proper

diameter or other improved method.

9.3 Alignment & Spacing :

9.3.1 Pieces to be welded shall be aligned and spaced in a suitable manner so as to hold the ends

during welding at a distance to ensure full penetration, Root opening shall not be more than as

specified. Internal miss–alignment shall not exceed 1.5 mm.

9.3.2 For pipe with thickness 4 mm or larger, the pieces to be built welded shall be coupled by means

of pipe couplers or any yokes to bridge ‘C’ clamps.

9.3.3 Inspection shall be done for joint fit up check and alignment before starting the welding job.

10.0 ROOT RUNS

10.1 Butt Joints :

10.1.1 Electrode size shall be limited to 3.25 mm or (10 swg), electrode holder shall be connected with

proper polarity connection for the electrode approved for the use for pipe in horizontal position.

Upward method shall be used with the recommended values of current.

10.1.2 Full penetration should be ensured for root passes of butt joints for all types of techniques used

for welding.

10.1.3 The weld shall be properly chipped from inside by grinding or chiseling and a filler run shall be

given.

10.1.4 If welding is interrupted / completed for each run, slag, crates, weld irregularities shall be

removed by grinding or chiseling.

10.1.5 While welding is in progress, vibrations, shocks, displacement of the job which shall crease

stresses shall be avoided in order to prevent cracks or breaks in the weld.

10.2 Fillet Welds :

10.2.1 The max. Electrode size shall be limited to 4 mm or (8 swg) .

10.2.2 On completion of the root pass, any visual defect or irregularities shall be ground off to avoid

irregularities is in the next pass.

11. COMPLETION OF THE JOINTS

11.1 Electrodes size of more than 8 swg (4 mm or 5/32) is not recommended for filling of the wled.

Upward technique shall generally be used for pipe in horizontal and vertical position.

11.2 At each interruption of welding and after each run of welding is completed, chipping and slag

removal shall be done.

11.3 When the welding is complete, butt joints shall have a cover pass, it shall be slightly convex and

fuse into the surface of the base metal in such a manner as to have a gradual notch free finish

and good fusion at the joint edges. It shall not be chipped after completion. Welds shall have a

regular appearance and shall be free from defects.,

11.4 Each weld should have welder number embossed nearly for identification purpose.

STANDARD PROCEDURE FOR COAL TAR COATING AND WRAPPING OF

UNDERGROUND PIPELINES

1.0 SCOPE

This procedure covers the minimum requirements for materials, cleaning, priming, coating and

wrapping, inspection & testing of coal tar coating to be provided on the underground steel lines.

The underground lines protected by coating & wrapping as described in this procedure shall not

carry a liquid having a temperature greater than 60 deg. C.

2.0 MATERIALS

All materials used shall conform to the quality and testing requirement indicated in AWWA C

203-73 or ASTM standard,

2.1 COAL TAR PRIMER

Coal tar primer shall conform to the characteristics given in Annexure – II.

2.2 COAL TAR ENAMEL

Coal tar enamel shall conform to the characteristics given in Annexure – II.

2.3 FIBRE GLASS WRAPPER FOR INNER WRAPPING

The wrapper shall conform to the characteristics given in Annexure III.

2.4 KRAFT PAPER FOR OUTER WRAP

The Kraft paper shall conform to the characteristics given in Annexure IV.

3.0 APPLICATION

The job shall be performed in the following sequence:

i. Surface preparation

ii. Priming by coal tar primer

iii. Coating by coal tar enamel

iv. Inner wrapping with glass fiber mat

v. Final coat of coal tar enamel

vi. Outer wrap of Kraft paper

3.1 SURFACE PREPARATION

The surface to be wrapped and coated shall be shot blasted to commercial blast. Surface shall

be free of all rust, grease, dirt weld scales, weld burns etc.

Surface preparation shall be immediately followed by priming.

3.2 PRIMING

The priming shall be applied on the pipeline with uniform coating leaving no drips, floods, sags

or runs. Any holidays or unprimed places shall be re-primed immediately. The surface shall be

dry at the time of applying primer coat. Primer shall not be applied during rain or fog.

Drying time shall be minimum 24 hours, subsequent enamel coating shall be done within a

maximum of two days after ensuring that there is no dust, dirt or any foreign matter on the

primed surface.

3.3 COATING BY COAL TAR ENAMEL

The coal tar enamel shall be cut in large chunks on a suitable place free from dirt, weeds and

other forms of contamination.

Broken enamel shall be placed in a melting kettle and heated at a uniform rate to 240 – 250

deg.C or as recommended by the manufacturer.

Coating material shall bestir properly in the kettles at regular intervals of maximum 15 minutes.

First coat of coal tar enamel shall be poured and spread over the primed surface to a minimum

thickness of 2.00 mm.

The application shall be so manipulated as to achieve a uniform thickness throughout the

surface. The variation in thickness should not exceed +0.5 mm.

3.4 INNER WRAPPING WITH GLASS FIBRE MAT

After the first coat of coal tar, the fibrous glass mat shall be applied on the surface while the

enamel coating is still tacky. The wrap shall be applied with a lap of 25 mm minimum.

3.5 FINAL COAT OF ENAMEL & KRAFT PAPER WRAPPING

Immediately after the application of the first inner coating of enamel and wrapping of the mat a

final coat of coal tar enamel shall be applied.

Along with the final coat of enamel, kraft paper shall be spirally wound round the pipe with a

minimum of 25 mm overlap on each spiral.

The thickness of final coat shall be so adjusted that the total thickness is maintained between

4.5 mm and 5.00 mm. The coating shall be free of pin holes, bubbles of holidays.

4.0 FIELD JOINTS

Primer shall be applied with brushes after cleaning the pipe thoroughly.

After the primer is dried one coat of enamel along with Kraft paper shall be applied to maintain

the total thickness between 4.5 – 5.0 mm. The overlaps for the Kraft paper and fibrous glass mat

shall be minimum 100 mm.

No wrinkling in the wrapper shall be allowed and all the overlaps shall be cemented down with

hot coating material to secure a firm wrapping.

5.0 INSPECTION

All the materials supplied by contractor shall conform to the specifications mentioned here.

Samples shall be submitted by the contractor for testing purpose. Contractor shall submit

manufacturers’ certificates for all the materials.

The job shall be offered for inspection at the following stages :

i. Wrapping / coating materials compliance (Certificates must be available)

ii. Surface preparation

iii. Primer application

iv. Completion of final coat

v. After completion of the final coat wrapping / coating shall be offered for inspection.

Inspection personnel shall cut the samples (size about 50 mm x 50 mm) at every 2m.

Intervals in staggered directions to determine the thickness and bond of the coating

them same shall be suitably repaired after inspection maintained the thickness.

vi. Spark testing

vii. Spark testing after repairs, if any

The contractor shall furnish and operate at his own cost on electric powered holiday detector of

10,000 volts output for certifying that lining is free from holidays.

Spark testing shall be done after a minimum of 24 hours after the final coat.

ANNEXURE - I

COAL TAR PRIMER

The primer shall consists of processed coal tar pitch and refined coal tar oils only, suitably blended to

produce a liquid coating which may be applied by brushing or spraying. Primer shall produce effective

bond between the metal and the subsequent coating of coal tar enamel. Primer shall not contain benzol

or other toxic and / or highly voltaic solvents, added pigments or inert fillers or other substances. It shall

show not tendency to settle out in containers. The other main characteristics of primer shall be as

follows :

i. During time to touch at normal humidity - less than an hour

At 30 deg. C (70%)

ii. Maximum boiling point - 215 deg. C of solvent

iii. Penetration of residue 100 gwt - Under 7 at 25 deg. C

5 sec. (ASTM D5-597)

iv. Softening point of reside - 104 deg. C (min.)

(ASTM D 36-26)

ANNEXURE - II

CHARACTERISTICS OF COAL TAR ENAMEL (TO AWWA C – 203)

Coal tar enamel shall be composed of a specially processed coal tar pitch combined with an inert

mineral filler. No asphalt of either petroleum or natural base shall be acceptable as part of the

ingredients. The enamel shall have the characteristics conforming to AWWA C – 203 or equivalent.

Other physical characteristics shall be as follows :

MIN. MAX.

I. Softening point (ASTM D 36) 105 C -

II. Filler (ash) ASTM A 271 25% -

III. Fineness filler, through 200 mesh 90% -

IV. Specific gravity at 25 deg. C 1.40 1.60

(ASTM D 71)

V. Penetration (ASTM D 5)

- At 77 deg. F. – 100g – wt – 5 sec. 10 20

- At 1115 deg. F – 50 g. wt – 5 sec 15 35

VI. High temperature test at 162 deg. F. - 1.6 mm

(Sag) AWWA C 203

VII. Low temperature test at 20 deg. - None

F (Cracking)

VIII. Peal test - No peeling

IX. Spark test 10,000 volts low amperage - None

ANNEXURE - III

FIBRE GLASS WRAPPER

Reinforced fiber glass wrapper – 150 mm width, consisting of a uniform bonded mat. The binder to be

inert to coal tar enamel.

The fiber glass mat shall be thin, flexible and strong. The glass fiber shall be longitudinally reinforced by

continuous filament glass embedded in the mat at 9.35 mm nominal centre.

1. No disbanding of individual glass fibre shall occur during or following the embedding process.

2. The fibrous glass mat shall not give rise to any air gap when applied.

3. The wrapper shall be sufficiently porous t so that it can be embedded in the hot coal tar enamel.

OTHER PHYSICAL CHARACTERISTICS SHALLBE AS FOLLOWS :

1. Weight 45 – 50 gms / sq.,m.

2. Normal thickness 0.5 + 0.1 mm

3. Longitudinal tensile strength 45.36 kg min.

(20 deg x 6 deg wide specimen)

4. Tear strength in the transverse direction 3.63 kg

5. Porosity (mm of water at air velocity of 1.542 (max.)

1/02 m / sec.)

6. Moisture absorption (by wt. at relative 5% (max)

Humidity of 95% at 50 deg. C for 24 hours)

ANNEXURE – IV

KRAFT PAPER

The kraft paper for outer wrapping shall be water proof impregnated with coal tar and shall conform to

the characteristics given below :-

When unrolled at temperature from 0 deg. C to 50 deg. C, the wrapper shall not crack or stick to such an

extent as to cause breaking or tearing.

1. Weight 175 gms / sq.m.

2. Thickness 0.25 mm

3. Tensile strength per linear inch 23 kg (min)

4. Moisture absorption, (percentage of weight at a 5% (max)

Relative humidity of 95% and 50 deg. C for 24 hours.

SAFETY REQUIREMENTS : HEALTH, SAFETY & ENVIRONMENT 1.0 HEALTH, SAFETY & ENVIRONMENT POLICY OF BPCL. The objective of this document is to provide and establish safe & environment friendly work practices at all construction sites as per our corporate health, safety and environment policy given below. Commitment Together, we have the highest concern and commitment for protecting the Health and Safety of all employees, contractors, customers and the communities in which we operate and for conservation of the Environment. We will comply with all Statutory Regulations and may even go beyond these for the benefit of our environment. We consider Health, Safety and Environmental aspects are an integral part of our business planning and operation processes. Policy Based on these guiding principles, we shall : Demonstrate our commitment by …… Providing and maintaining safe facilities and working conditions. Recognising that all employees have responsibility for their own safety and

actions which could affect the safety of others. Adoption of appropriate technologies to minimise the impact of our activities

on the Environment. Establish clear objectives and targets to …… Improve continuously for prevention of accidents & occupational illnesses and

minimising any impact of our activities on the environment. Promote learning through training and sharing of experiences and best

practices; including with contractors, customers and the public, wherever required.. Inculcate values and attitudes conducive to achieve excellence in Health,

Safety and Environmental performance. Provide means to achieve our mission by …… Assigning clear roles and responsibilities at all levels and periodically

reviewing and recognising contribution to HSE objectives. Allocating adequate resources. Fostering a spirit of participation by all employees in Health, Safety and

Environmental conservation efforts. Creating appropriate forums for deliberations on Health, Safety and

Environmental issues. Monitor performance by ….. Periodically auditing work processes, systems & practices and promptly

correcting deficiencies. Incorporating HSE performance as a parameter for assessing the overall

performance of Employees, Business Units, Contractors and Business Associates. 78 Commensurate with above corporate HSE policy, policy of E&P to ensure health, safety and environmental protection at every construction site is as under: i. Adopting sound and safe engineering practices for each project at design and construction stage. ii. Taking due care to not cause any intentional damage to the environment during process of construction or material handling or both.

iii. All major projects shall be audited by a multimember team. The time gap between two consecutive safety audits at long duration project sites shall be around six months. iv. Every audited construction site and material warehouse shall conform to audit recommendations through compliance report to HQ. v. Every near miss and accident at construction site shall be reported immediately on-line by official present at incident location. vi. Investigation of any accident at construction site shall be done by a multimember team to determine root cause of accident and to recommend necessary changes in ground condition to prevent repetition of similar incident. vii. Workshop for contractors on Factory act, Minimum wages act, ESI & EPF acts, Contract labour and Building workers acts. viii. Workshops for contractors on industrial first aid procedures. ix. Increasing awareness through holding competitions among all categories of staff and contract workers on safety slogan, safety suggestions and detection of unsafe conditions and near misses. x. Delivering safety talks and holding safety committee meetings periodically with active participation from workers. xi. Observing National Safety Week and Fire Service week and World Environment day appropriately. 1.1 IMPLEMENTATION OF SAFETY & ENVIRONMENTAL REGULATIONS The contractor shall at his own expense arrange and comply with all safety provisions as stipulated by BPCL / Bureau of Indian Standards / Electricity act / OISD / Andhra Pradesh State Pollution Control Board and other acts as applicable in respect of all personnel, directly or indirectly employed by contractor for the work. The contractor shall ensure that he, his sub-contractor and workers employed by him shall comply with all safety / environmental regulations issued from time to time by BPCL. The contractor shall also be liable for any pecuniary liability arising on account of any violation by him of the safety & environmental requirements. If any injury to workers or loss or damage due to accident and / or environmental pollution to any property or a portion thereof occur as a result of failure on part of the contractor to comply with such regulations, the contractor shall be held responsible for the consequences thereof and shall keep BPCL harmless and indemnified. 79 2.0 OISD & BIS CODES OF PRACTICES The contractor shall abide by the following OISD codes: i. OISD – STD -105 Work Permit System ii. OISD – GDN – 192 Safety Practices During Construction The contractor shall abide by the following BIS codes: 1) IS:3764-1992- Excavation work-code of safety. 2) IS:4014(Part 1&2)-1967-Safety regulations for steel tubular scaffolding. 3) IS:3696(Part 1) -1987-Safety code for scaffolds. 4) IS:3696(Part2)-1987 –Safety code for Ladders. 5) IS:7293-1974-Safety code for working with construction machinery. 6) IS:4081-1986-Safety code for blasting and related drilling operations. 7) IS:3016-1982-Code of practice for fire precautions in welding and cutting operations. 8) IS:4130-1991-Demolition of buildings-Code of safety.

9) IS:5216(Part 1&2)-1982-Reccommendation on safety procedures and practices in Electrical work. 10) IS:5121-1969-Safety code for piling and other deep foundations. 11) IS:10667-1983-Guide for selection of industrial safety equipments for protection of foot and leg. 12) IS:1989(Part 2)-1986-Leather safety boots and shoes for heavy metal industry. 13) IS:6994(Part 1)-1973-Specification for safety gloves: Part1-Leather and cotton gloves. 14) IS:2925-1984-Specifiation for industrial safety helmets. 15) IS:3521-1983-Industrial safety belts and harnesses. 3.0 LEGISLATION ON ENVIRONMENTAL POLLUTION CONTROL The contractor shall abide by the following legislation: 1) Water (Prevention & Control of Pollution) Act 1974 & Rules. 2) Air (Prevention & Control of Pollution) Act 1981 & Rules. 3) Environment (Protection Act) 1986 & Rules 4) Hazardous Wastes (Management & Handling) Rules 1989 5) Public Liability Insurance Act 1991 & Rules. 6) Noise Pollution (Regulation & Control) Rule, 2000 4.0 BPCL’S OBILIGATIONS ON SAFETY & ENVIRONMENT The layout planning of the site shall be done by BPCL. Suitable and adequate space shall be provided to the contractor for his site office and storage of materials / equipment. However, approach to work spot and road around it, if required for movement of men and machineries for construction purpose, shall be made by contractor at his own cost. Electric power source and drinking water facilities at one point of site shall be provided by BPCL. Disaster Management Plan for the site shall be prepared by BPCL wherein the contractor shall be assigned a role, which shall be obligatory. 80 5.0 CONTRACTOR’S OBILIGATIONS ON SAFETY & ENVIRONMENT Any safety & environmental impact mitigation action plan prepared by BPCL shall be binding on contractor and the contractor shall adhere to the same. The following practices shall be mandatory on part of contractor:: 6.0 SAFETY POLICY OF CONTRACTOR The contractor shall have a safety policy, which shall deal with the following issues:. Arrangements for training at all levels with particular attention to key workers

such as workers working at height, crane operators etc, whose mistakes can be especially dangerous to other workers. Safe methods or systems of working in hazardous condition. The duties and responsibilities of supervisors and key workers. System to circulate all information / instructions / policies. Arrangements for setting up of safety committees. The selection and monitoring of sub-contractors (if any). The upkeep and maintenance of tools/machineries/safety appliances in

perfect working condition. Feed back system and corrective measures wherever required.

7.0 ENVIRONMENT POLICY OF CONTRACTOR The Contractor shall have a environmental policy, which shall deal with following matters

Commitment to not to cause adverse impact on ecologically sensitive areas. Environmental Impact mitigation measures. Feed back system & corrective measures, wherever required.

8.0 ROLE OF SAFETY CUM ENVIRONMENT IN-CHARGE The contractor shall designate a person possessing required experience and skill in safety and environmental issues as “Safety cum Environment In-charge”. His main duties shall consists of : Observance of safety action plan for the work and conditions stipulated in the

tender/agreement. Providing and maintenance of safety facilities like access roadways,

pedestrian routes, barricades and overhead protection. Providing and installation of safety signs. Circulating safety practices for each trade. Testing of lifting machineries such as cranes and goods hoists and lifting

gears such as ropes and shackles and obtaining certification from competent authority. 81 Inspection and maintenance of access facilities such as scaffolds and

ladders. Inspection and cleaning of welfare facilities such as toilets, clothing,

accommodation and canteens. Explaining the relevant parts of the safety plan to each worker group. Playing role in Disaster management plan. Identifying unsafe practice / equipment and rectifying the same. Dissemination of information on safety and environment protection Attending safety committee meetings and implementing all decisions taken by

safety committee. Ensuring proper use of personal protective equipment. Delivering Safety talk to workers. Implementing all Environmental Impact Mitigation measures.

9.0 ROLE OF SUPERVISOR Good planning and organization at work site and assignment of clear responsibility to supervisors are fundamental to safety and environment protection. Each supervisor shall ensure within his field of competence and domain the following:- Working condition and equipment are safe. Workplace safety is ensured. Workers are trained for the job they are supposed to do. Workplace safety measures are implemented. The best alternative to ensure safety and environment protection is adopted

within available resource and skill. Necessary personal protective equipments are available and used by

workers. Safety caution boards are displayed at right place. Unsafe practices are eliminated. Arranging rescue of workers, in case of accident. Playing his role in disaster management plan. Arrange tool box safety meeting frequently. Informing safety cum environment in-charge in case of any violation of safety

practices. Informing safety cum environment in-charge in case of any violation of

Environmental Impact Mitigation measures. 10.0 ROLE OF WORKER Every worker shall follow safety practices and environmental impact mitigation measure conveyed to him by the contractor’s supervisor. He shall take care of his tools and use personnel protective equipment in accordance with safety practices. 82 11.0 SAFETY COMMITTEE AT SITE The safety committee shall include representative of BPCL, representative of contractor identified as safety cum environment in-charge and representatives of various trades from workers. Ratio between BPCL representatives and that of contractor and various trades taken together shall be 1:1. Model code of practice: Safety committee is a key part of safety in the workplace. They shall accomplish the following:: a) Central focus : Overall look at safety requirements and to foresee problems that might otherwise cause difficulties. b) Sounding board. The committee is a visible and approachable body for safety or environmental complaints, suggestions, and the like. c) Central coordination. The coordination of safety training activities shall be accomplished by the safety committee. An effective safety committee encourages safety awareness, gets a large number of employees actively involved in the safety program over time, helps motivate employees to follow sound safety practices. An effective employee safety structure provides a feedback mechanism to identify and correct new safety hazards at the earliest stage. Once the safety committee structure is in place and working well, it is a natural vehicle for employee involvement, preparation and introduction of new safety rules, new preventative practices, and safety procedures on new equipment. Primarily safety committee shall look in to following: a) Detection of Hazard and determination of risks to workers, equipment, property and environment. b) Deciding actions to mitigate risks c) Drawing Disaster Management Plan d) How the committee can help management to enforce safety rules and environmental Impact mitigation measures. e) How to implement safety suggestions f) How to ensure compliance from workers. Ideally safety committee members should play following roles: a) Set a good example. Committee members must set a good example. They must be above average in their safe work habits and their positive attitude about safety and environment.. b) Be visible. Names of safety committee members should be posted prominently in their departments. c) Conduct safety inspections. Safety committee members should perform safety inspections. Members know the safe—and the unsafe—way to perform the jobs. Hence, they are right men to correct unsafe situation. d) Investigate accidents. Safety committee should investigates all lost work day accidents and record the findings.

e) Hold regular meetings. Safety committees must meet at least once a month, 83 and for their meetings to be effective the following matters must be considered: Safety cum environment in-charge shall in general act as chairperson cum secretary Preparing agenda & issuing in advance of the meeting to: — keep discussions on track — allow members to prepare for the meeting Issuing Minutes within two days containing: — written summary of proceedings — names of attendees — number of absentees — responsibilities for implementation assigned — timing of implementation assigned — cost of implementation — any approvals required — completed recommendations — uncompleted recommendations — accident review (if any) — safety training activities Duties of Safety Committee members shall be as under: Work safely yourself—set the example in the site. Attend and actively participate in safety committee meetings. Speak to your fellow workers if you believe that they are engaged in an

unsafe work practice; report things which you feel you can't handle. Listen to employee suggestions about safety and bring those that appear to

have merit to the notice of safety committee. Before each safety committee meeting review minutes and open items

affecting your section of job and have answers or a progress report on each item for the meeting. Model code of practice for Safety Talks: Safety talks should be delivered by any one of Safety Committee members by rotation. Duration could be anything depending on interest of audience and capacity of speaker to deliver oration. The speaker may like to use this opportunity to convey various decisions taken in Safety Committee to workers. He may prepare talk on following suggested topics or any topic of his choice but of relevance. Political or human relation related topic must not feature in Safety talks. i. Housekeeping 84 ii. Use of Safety Shoes iii. Use of Safety Helmet iv. Wearing of Safety Harness v. Safety from Cement and stone dust. vi. Checking scaffold before climbing vii. Right use of ladders. viii. Use of materials and tools while on scaffold. ix. Fall protection, i.e. toe boards, anchoring of safety harness, positioning of safety net.

x. Handling of Asphalt xi. Precautions during excavation. xii. Electrical faults. xiii. Safety from hanging live wires and high tension lines. xiv. Entering confined space. xv. Safety from toxic materials and fumes. xvi. Right posture for lifting weights. xvii. Slipping, tripping, drowning and falling hazards. xviii. Eye protection from arc welding and dust. xix. Precautions during operation of lifting appliances. xx. Safety during erecting shuttering. xxi. Safety during stripping of shuttering. xxii. Safety during use of concrete mixers and pouring of concrete. xxiii. Precaution during demolition of any structure. xxiv. Right storage of safety belts and other PPEs. xxv. Working on steep roof. xxvi. Safety from vehicles. xxvii. Need of communication and looking for safety of one another. xxviii. Look around safety. xxix. Air and water pollution. xxx. Nearby medical facilities. xxxi. Sun stroke and remedies xxxii. First aid in case of injury. xxxiii. Protection from AIDs. xxxiv. What to do if accident happens. 12.0 WORKING CONDUCT No one shall enter any part of the worksite other than for the purpose of carrying out the work. Contractor’s personnel shall abide by all rules and regulations stipulated, including the following: Smoking inside the premises of a working location is strictly prohibited except

in the designated areas. No source of ignition shall be taken to job site unless covered by a Hot Work

Permit. Personnel must also strictly adhere to the approved protective clothing and

equipment requirements. 85 It is essential that good house keeping is practiced at all time to keep the

work area neat and clean. No material on any of the site of work shall be so stacked or placed as to cause danger and inconvenience to any person. Consumption of liquor, drugs or any other intoxicating substances shall be

totally banned. 13.0 SITE PLANNING AND LAYOUT Proper advance planning shall be done in all matters including the following: Details regarding location of workshop / fabrication yard/ quality control

laboratory / store yard / electrical installations / construction machineries, medical and welfare facilities, lighting etc. shall be decided and identified. The working sequence. Clear access to work location.

Identifying and providing emergency exit. Displaying warning notices at vulnerable locations and routes for vehicles..

14.0 HOUSE KEEPING Maintain tidiness during construction by cleaning up rubbish/scrap/spilled oil

and grease. Keeping gangways, working platforms and stairways clear of equipment and

material not in immediate use. Removing or hammering down any nails projecting from timber etc. Arrange all machinery such as welding machine, generators, cutting machine

etc. in such a way that equipment are segregated and protected. Check all machines at periodic intervals. Do not accumulate saw dust and other combustible waste to avoid fire.

15.0 LABOUR ACTS: The Contractor shall comply with all provisions of applicable Labour Acts, such as (a) The Minimum Wages Act 1948. (b) The Factories Act 1948 (c) The Contract Labour (Regulations & Abolition) Act 1970 (d) The Building & other Construction Workers Act 1996. (e) The Employees State Insurance Act 1948 (f) The Employees Provident Funds & Miscellaneous Provisions Act, 1952. (g) Any other applicable Act. 16.0 LABOUR WELFARE MEASURES: The contractor shall extend all welfare measures to his workmen in line with provisions given in labour acts mentioned in previous clause 15. Some of those are reproduced below:- 86 First Aid box Treating injuries by a qualified and experienced medical practitioner. Arrangement for hospitalization, if needed. Payment of wages / PF / ESI etc. as per relevant labour act and maintaining

proof of the same. Ensuring fitness of workers and maintaining hygiene. Arrangements for clean & cold drinking water. Separate toilet and washing and resting facilities for male and female

workers. Canteen facility, if obligatory under contract labour act.. Crèche, if obligatory under contract labour act.

17.0 ROLE OF SUB-CONTRACTORS It shall be responsibility of the contractor to ensure that all sub-contractors engaged by him in accordance with terms of agreement with BPCL, comply with all safety practices and environment protection measures mentioned here and conveyed to him subsequently. 18.0 PERSONAL PROTECTIVE EQUIPMENT Personal protective equipment shall be of approved make and are essential for avoiding injuries to workers on the job. A register showing stock and issue of PPE shall be maintained by the contractor. The most common personal protective equipment are described below. 18.1 SAFETY SHOES Suitable safety footwear conforming to relevant BIS code shall be worn by

personnel, considering the nature of works and hazards such as: Risk of crushing by heavy objects. Penetration by sharp objects. Penetration by chemicals or harmful liquids. Weld spatter.

Leather safety shoes with steel toe caps shall be used for all heavy manual work and general construction. Shoes shall be abrasion resistant and suitable for wet and muddy conditions. Soles shall be slip resistant type. Light low-cut leather safety shoes with slip resistant soles shall be used for climbing job. Gum boot shall be used while working with bitumen, chemicals, mud and muck etc. 87 18.2 HAND GLOVES Hand gloves are mainly used to protect the hand from hazards of material handling, heat, electrical shock. etc. Various types of hand gloves are available. Some of those are described below: Flame-resistant gauntlet gloves made of leather or other suitable material.

They may be insulated for heat. Rubber gloves suitable for working in low voltage, medium voltage and high

voltage. Hand gloves made of asbestos for handling hot bitumen and other hot work. Hand gloves made of special material for protection against chemicals.

Hand Gloves shall conform to relevant BIS code. 18.3 SAFETY HELMETS Safety helmets shall be of yellow colour with chin strap. All workers are expected to wear safety helmet while inside the construction site. Sufficient number of safety helmets shall be kept at site for visitors. Safety helmets used by helpers of excavators shall have suitable arrangement to carry load on head. Safety helmet shall conform to relevant BIS code. 18.4 SAFETY JACKET All workers shall wear yellow colour jackets made of good quality cotton with trade name printed on back and front in bold letters. Safety cum Environment incharge and supervisors shall jackets of green colour made of good quality cotton with designation printed on back and front in bold letters. 19.0 PROTECTIVE CLOTHING DURING WELDING AND HANDLING TOXIC/HAZARDOUS MATERIALS Welders shall wear aprons or overalls and gloves made of flame resistant material. Hand held welding face shield shall be used for any welding job. Full face shield with respiratory filters shall be used for specialized welding jobs. For handling toxic or hazardous materials proper impervious overalls, gum boots, gloves; facemask and respiratory equipment like canister masks shall be used. All equipment shall conform to relevant BIS code. 19.1 GOGGLES Goggles shall be used to avoid risk from: - Flying particles / dust ingress. - Chemical splash – Radiation glare. - Hot sparks or metal splatter. - Harmful vapours. - Sand / grit blasting. 88 Goggles shall be single piece constructed of clear impact resistant plastic and

fitted with adjustable elastic straps. Goggles shall conform to relevant BIS code. 20.0 HEARING PROTECTION Hearing protection shall be worn by personnel involved with works in areas where noise level exceed 85 dB (A noise level beyond which normal conversation becomes difficult) on a continuous or regular intermittent basis. Protection is available in two basic types; 1) an external cup type defender which fits over the outside ear and 2) internal disposable type of ear plugs usually made of compressible foam, which fits inside ear. Whenever practicable, equipment generating high noise levels shall be fitted with sound mufflers and located at maximum possible distance away from any work place . For overhead welding ear protection in the form of wool or rubber plugs shall be done. All equipment shall conform to relevant BIS code. 21.0 WARNING SIGNS AND BARRIERS The contractor shall arrange necessary material to secure the work site and to warn the general public or other workers of hazards. This shall include - Warning signs. - Warning lights and signs in traffic control zone. - Barricades around excavations including illuminating warning signs. 22.0 RESPIRATORY PROTECTION / MASK Whenever there is doubt about the presence of toxic substances or the gases injurious to health, a respirator must be worn. The type of respirator to be used shall depend upon the hazard and work conditions. The simplest masks are disposable paper types. These are only effective against nuisance dusts. There are three types of half-face masks with filters. For protection against airborne particles, e.g. stone dust, with a coarse filter

fitted in the catridge (these filters have a specific lifetime and should be changed as necessary). For protection against gases and fumes, e.g. when using paints containing

solvents, with a filter containing activated carbon. A combination filter containing both a dust and gas filter. Catridge must be

replaced regularly. 89 A full facemask could be fitted with the same types of filter, and it also protects the eyes and face. Self-contained breathing apparatus with a full-face mask fed with air at positive pressure is another alternative and it must be used in confined spaces and whenever supply of air or oxygen is insufficient. Users must be trained in the use of self-contained breathing apparatus and must know the manufacturer’s specifications. All equipments shall be thoroughly checked prior to use to ensure: Oxygen Cylinders are full and gauges function correctly. All connections are proper Facemasks are in order.

All equipment shall conform to relevant BIS code. 23.0 SAFETY BELTS / HARNESSES The majority of fatal accidents in construction sites are due to fall from height. There are many types of safety belt and safety harness available depending on nature of work. A full safety harness should always be used in preference to a safety belt. Safety belts / harnesses shall conform to relevant BIS code and worn by all

workers working at a height greater than 2 mts above ground level. Details of Safety Belts / Harnesses are given in 26.5 “Working at Height”. 24.0 LIFE JACKET AND LIFEBUOYS For working over or near large and deep-water body this life saving device should be used. Life Jacket shall be tested for leak and usefulness before start of work. It shall conform to relevant BIS code. 25.0 RAIN COAT Rain coat shall be provided to workers during rainy season. The colour of rain coat shall be yellow. It shall conform to relevant BIS code. 26.0 SAFE CONSTRUCTION PROCEDURES / PRACTICES 26.1 EARTH EXCAVATION i) The site of the excavation or trench should be sloped or battered back to a safe angle of repose usually 45 degree or be supported with shoring by timbering or other suitable means to prevent collapse. The type of support necessary will depend on the type of excavation, type of soil, the nature of 90 ground and the ground water condition. Adequate timbering or sheeting shall be provided where excavation is deeper than 1.5 M. 100 mm wide “Safety tape” of yellow colour with one meter long phosphorescence band after every three meter shall be used to encircle excavated pit of any depth. For any pit of depth one meter or more, one meter high fence with a mid rail made of bamboo or steel pipes shall be provided for preventing people / animals from slipping into the pit. If the pit is by the side of vehicular drive way, in addition a prominent board shall be put up saying “Excavation in Progress”. ii) Pumping out of accumulated water from pit is to be done at regular intervals. Run-away water shall be prevented from entering the excavated area, as such water can cause erosion of soil and sudden collapse of earth. iii) If the excavation is carried out without shoring, necessary angle of repose shall be maintained at all times. iv) Labourers shall not be allowed to sleep or take rest inside the pit. Protection against insects / poisonous snake shall be provided. v) Excavated earth shall be stacked at least one meter away from cutting edge to avoid collapse of trench and sliding of heaped earth into trench. vi) Contractor shall ensure that the excavation does not damage any existing underground cables, pipelines, foundation of adjoining buildings or structures etc. Wherever excavation is near any adjoining building or structure, proper precaution shall be taken. vii) Before working / entering inside an existing excavated pit it shall be ensured that it is free from any toxic gasses or explosive gases. The underground water present in the pit shall be checked for acid content, if there is possibility of seepage of industrial affluent. viii) Adequate access to and escape from the excavated trench in the form of ladders provided at every thirty meters or less shall be ensured. Crossovers over excavated trench shall be provided at suitable interval for movement of workers. ix) If the excavated trench is adjacent to any parking space for vehicles, adequate and well-anchored stop blocks shall be provided on the surface to prevent vehicles from falling in to trench while reversing. Relevant BIS codes shall be followed for safe practices. 26.2 PILING AND OTHER DEEP FOUNDATIONS The following precautionary measures shall be taken:

Piling machine operators shall be over 18 years of age and properly trained. Prior to piling, all underground services shall be located and made safe There shall be a firm level base for the crane. If necessary crane mats shall

be provided. The workers shall use necessary personal protective equipment. All cranes, lifting appliances and lifting gear must have appropriate

certificates of testing and shall be of capacity required for the job. Particular attention shall be provided to the risk of damage to lifting gear from

sharp edges. 91 Cranes used for lifting or lowering workers, must be fitted with a dead man’s

handle and lowering shall be done under power. Relevant BIS Safety Code for piling and deep foundations shall be followed. 26.3 WORKING IN BASEMENT / UNDERGROUND TANK . Fatal and serious accidents could occur if proper precautions are not taken before entering confined space like basement or underground tank.. The following precautions shall be taken: i) Entry into the confined space shall be allowed only against Hot work permit. ii) Air circulation shall be ensured. Hot work in such places shall be taken up only after ensuring that ample supply of fresh air is available using additional blowers etc. Proper ventilation shall be ensured by opening manholes (either ends if available) and fixing a wind sail or forced circulation of air. Old tanks shall be filled with water and washed with water before entering into it. Sludge shall be cleared / removed from outside of the confined space, to the extent possible, before entering. iii) Workers shall be allowed entry in the confined space, only after ensuring absence of toxic and explosive gases. Purging of gases may be done by filling the underground confined space with water. iv) Everyone inside the confined space shall wear rescue harness, with lifelines attached to a point outside the confined space. Whenever workmen are allowed to enter a vessel or underground tank or confined space, it is necessary to keep one person (alert and trained) at each manhole or entry point. The person should keep watch through manhole and offer rescue assistance so as to ensure prompt pulling out of the workers from confined space in case of emergency. Proper communication system between confined space and outside shall be maintained. v) A proper procedure for rescue in an emergency shall be laid down, with specific duties allocated to specific persons. vii) An experience supervisor shall supervise the entire operation. viii) Monitoring of air supply must continue while work in progress. ix) Only trained workers shall be allowed entry into confined space.. x) The following equipment shall be provided.: Toxic gas meter, Oxygen meter and Explosive meter Rescue harnesses with adequate length of rope taking into account the

location of work site. Hand torches or lamps safe for use in a flammable atmosphere. Appropriate self contained breathing apparatus. First aid equipment.

Fire fighting equipment. An audible alarm for summoning help. Resuscitation equipment. Means of communication between confined space and outside. Boards & barricades.

92 26.4 DEMOLITION Demolition is a dangerous process and workers shall use requisite personal

protective equipment. Demolition must be supervised by supervisor with thorough knowledge not

only on demolition procedure, but also on the principles of structural construction. A survey of the physical characteristics and design of the structure to be

demolished must be carried out in order to choose a safe method of demolishing. The demolition action plan shall be drawn by the contractor including drawings or sketches showing the sequence of operations, the machinery and equipment to be used, personal protective equipment required etc. Before demolition begins, all service connections to the structure shall be disconnected. Arrangements must be made to erect a fence of height two meter encircling the structure under demolition It is dangerous to leave isolated walls or parts of a wall standing alone, as

those are liable to collapse from the effect of high winds and hence necessary supports should be given in such cases. Debris should not be allowed to build up against walls or floors with the

consequent risk of the structure getting overloaded. Vapour present inside the structure must be checked for toxic nature before

starting demolition work. Protective measures should be taken against dust, fumes, chemical deposits,

asbestos, glass wool etc. while carrying out demolition work. Disposal process and pit / yard should be identified for safe disposal of

debris. Relevant BIS safety code for demolition of structures shall be followed.

26.5 WORKING AT HEIGHT Scaffolds accidents occur primarily to the following reasons: Faulty design Faulty erection Weak foundation Inadequate strength of structural members Inadequacy of platforms, guard-rails and toe-boards.

Scaffolds are designed for live loads of workers and building materials, besides their own dead weight. However, a scaffold is usually designed only in case of important structures, like bridge girder/slab, very long beam/very large slab in buildings etc. In case of day today scaffoldings for general civil constructions / colour washing / painting / plastering etc., scaffolds are usually not designed, but erected based on experience. Scaffolds may be constructed of either timber, sal ballies, bamboo, or metal. Those may be single scaffold or double scaffold for light duty or heavy duty, as 93 the case may be. Single scaffolds are recommended for carpenter, painter and similar trade. Double scaffolds are recommended for masons and similar trade.

All scaffolds should conform to IS:3696(Pt.1)-1987. As bamboo and metal scaffoldings are used, salient features of those scaffoldings are given below: Single Pole Bamboo Scaffolds : Single scaffold consists of one row of upright poles or standards, placed not more than 1.8mt centres, fixed at suitable distance from the wall and connected horizontally by ledgers (bamboo placed horizontally ) spaced vertically at 1.5 to 1.8mt centres. Cross members (putlogs), supported on ledger on one side and hole in the wall on other side, are provided at 1.2mt centres. Double Pole Bamboo Scaffolds: It consist of two rows of up-rights or standards. The inner row is placed next to wall and other row placed 1.2 to1.5mt away from the wall. As in earlier case,ledger is provided every 1.5 to 1.8mt vertically. However, in this case , putlogs shall rest entirely on ledgers at both ends. Every single or double pole scaffolds, shall be effectively tied with adjacent structure. Diagonal face bracing or zig zag face bracing shall be provided on single pole scaffold and outer row of double pole scaffold. The maximum distance between braced bays in any lift of scaffold shall not exceed 10mt. Quality of Bamboo Bamboo should be reasonably straight, sound, free from splits, knots dry rot, worm holes and any other defect, which tend to reduce strength of bamboo. The mean diameter shall not be less than 80mm in case of single pole scaffold and 100mm in case of double pole scaffold, subject to minimum diameter of 50mm at thinner end. The slenderness ratio, i.e.L/d ratio shall not exceed 50, where L is the legnth of up-right or standard between putlogs. The diameter of bamboo shall not be measured at knot points. Where it is necessary to extend a up-right, the overlapping distance between two up -rights shall not be less than 600mm. Maximum Height of Bamboo Scaffolds IS:3696(Pt 1) has recommended use of Bamboo Scaffolds for heights upto 18mt, subject to conforming to provisions given there-in. Platform Width for Working on Scaffolds _ Where platform is not more than 2mt above ground or floor: For Painters,Decorators etc 300mm (min) For other types ,i.e., mason etc. 500mm (min) _ Where platform is more than 2mt above ground floor: For Painters,Decorators etc 900mm (min) For other types ,i.e., mason etc. 1200mm (min) 94 Railings & Toe Boards Railings consisting of top rail at a level of around 1000mm above platform and an intermediate rail halfway between top rail and platform shall be provided for all working platforms higher than 2mt above ground or floor. The platform edges shall be provided with 150mm high toe board to eliminate hazards of toolbar or other objects falling from platform. Where scaffolds are erected over areas, where people work or pass, the space between top rail and toe board shall be enclosed by tarpaulin or PVC sheets. Means of Access A safe and convenient means of access shall be provided to all platform level of scaffolds. Conventional means of access are the following: Ladder Stairway

Ramp Ladder: To ensure safe use of ladder, the following steps should be followed: Erecting ladders in the "four up-one out position" (i.e 75 degree angle

between ladder and ground) Lashing ladder securely with the structure. Using non-slip devices, such as, rubber shoes or pointed steel ferrules at the

ladder foot, rubber wheels at ladder top, fixing woollen battens, cleats etc. When ladder is used for climbing over a platform, the ladder must be or

sufficient length, to extend at least one meter above the platform, when erected against the platform in "four up-one out position". Portable ladders shall be used for flights not more than 4mt. Above 4mt

flights, fixed ladders shall be provided with at least 600 mm landings at every 6mt or less. The width of ladder shall not be less than 300mm and rungs shall be spaced

not more than 300mm. Stairway For scaffolds exceeding 4mt height, stairway are safest means of access. I t shall conform to the following: Treads and risers shall be of uniform width and height in any one flight. Minimum width of 1000mm. No unbroken vertical rise of more than 4mt. Maximum angle of ascent 50 degrees. Stair railings on all open sides. Hand rails on all enclosed sides. Railings and toe boards on all landings.

Ramp Ramp shall conform to the following: Open sides of ramp shall be protected by railing and toe board, where ramp

is 1.5mt or more above ground or floor. Where slope is more than 1 in 4, footholds shall be provided by stepping laths

of minimum size 50 x 30mm at interclass not exceeding 450mm. Maximum permissible slope is 2 in 3.

95 Metal Scaffolds With the evolution of concept of designing multi -storied and long span structures, metal scaffolds came into practice, mainly due to following advantages. Ease of assessing strength of scaffolds structure. Reusable many more times than bamboo. Possibility of human error while erection, is much less that in case of bamboo

scaffolding. Aesthetically neat and good looking.

Metal scaffolds shall conform to IS:2750 - 1964, in addition to IS3696(Pt 1). Scaffold tubes are usually 40mm N.B., mild still continuous weld conforming to IS:1239 or IS1161, grade YST 210, of lengths varying between 4.5mt to 6mt. These are manufactured and marketed by various agencies. As such, it is essential to obtain guaruntee certificate from the manufacturer about safety and stability of metal scaffolds under likely worst combination of loads. Other General Safety Requirements for all types of Scaffolds

Erection, alteration and removal shall be done under supervision of experienced personnel. Use of barrels, boxes, loose bricks etc., for supporting platform shall not be

permitted. Every platform and means of access shall be kept free from obstruction. Each supporting member shall be securely fastened and braced Where planks are butt-joined, two parallel putlogs shall be used, not more

than 100mm apart, to give support to each plank. Platform plank shall not project beyond its end support to a distance

exceeding four times the thickness of plank, unless it is effectively secured to prevent tipping. Cantilever planks shall be avoided. If Grease, mud, gravel, mortar etc., fall on platform or scaffolds, these shall

be removed immediately to avoid slipping. Workers shall not be allowed to work on scaffolds during storms or high wind.

After heavy rain or storms scaffolds shall be inspected by site-in-charge before reuse. All scaffolds or platforms shall be fastened with adjacent structure, and if

independent, scaffolds shall be braced properly. Scaffolding shall be erected on firm and level ground. In case of loose soil,

the soil should be compacted by watering and ramming, besides using wooden base plate of minimum thickness 30mm for erecting standards. All members of metal scaffolding shall be checked periodically to screen out

defective /rusted members. All joints should be properly lubricated for easy tightening. Clear access to scaffolds shall be maintained at all times. For prohibiting

entry of unauthorised persons in scaffolds area, barricades should be put up and warning notices prominently displayed. If scaffolds are used, where public movement is anticipated, entry of public

should be prohibited for the duration of the job. Where lifts are provided to hoist premixed concrete, reinforcement etc., to

upper floors, barricades should be raised to prevent accidental entry of 96 workers under the lift. Such lifts shall not be used for hoisting people, unless those are designed specifically for that purpose. Dismantling of scaffoldings shall be done in a pre-planned, sequential

manner in order to maintain stability throughout the process. If necessary, additional tying, bracing may have to be done to prevent sudden collapse of scaffolds structure. Before initiating dismantling process, precautions should be taken to ensure

removal of all loose materials from the scaffolds. Use of scaffolds, under dismantling process, must be prohibited. Wearing safety helmets shall be made mandatory within 10mt from scaffolds.

Dismantling of Form -work Action for dismantling form-work, used for supporting concrete casting, must be done after expiry of requisite number of days after casting and proper curing. Untimely dismantling of form-work may cause total collapseof structure. Bottom shuttering of chajia or sun-shed should not be removed, till the attached lintel is properly secured by brickwork, to avoid failure of lintal due to toppling / torque. In case of casting of multi-storied framed structure, casting of upper floor should

be avoided till expiry of minimum curing period of lower floor. But, if essential, bottom shuttering of the lower floor shall be suitably strengthened by additional props. INDUSTRIAL SAFETY BELTS & HARNESSES Primary functions of safety belt & harness are to minimise injury after a fall. Despite providing proper scaffolds, railing etc, possibility of slipping and falling can not be over-ruled. This equipment is the last check to prevent worker from getting fatal injury. Four types of safety belts & hareness are available in the market, depending on nature of various jobs. Failure to choose right type of safety belt & harness may led to endangering life of worker at the time of need. All safety belts and harness shall conform to IS3521-1989. Type Consists of Permissible fall Used for I Waist belt with safety line Not more than 0.6mt Building / Structural maintenance. II Waist belt with two shoulder straps & safety line Not more than 1.8mt. Construction, structural erection. III Waist belt with two hoisting straps & safety line, with provision for leg straps. Not more than 0.6mt. Working in confined atmosphere and rescuing. IV Waist belt with pole strap. - Working on electric line pole. Proper choice of anchoring point for anchoring the safety-line is essential. At many instances, the workers have met with fatal accidents due to anchoring with 97 weak supports. Sometimes anchoring points are found to be chosen by mistake in such a way, that should a person fall, he would hit against a rigid structure due to swinging action of the safety line. Hence anchoring point for safety-line needs to be judiciously chosen. Where proper anchoring points are not likely to be available, action should be taken in advance to provide for hooks and fixtures. The shock absorbing capacity of the safety-line is critical for reducing impact of fall. A stiff safety-line, would arrest a fall suddenly, resulting in an abnormal

impact load on body of the worker, causing injury. According to IS3521, safetyline should be made of nylon or polyester or synthetic fibre. It shall not break under minimum tensile load of 2000kg. The minimum diameter of test specimen shall be 10mm. Performance test of the Safety belt & Harness shall be carried out as per annexure - B of IS3521, by dropping an articulated anthropometric dummy weighing 100+5 kg with an overall height of 1.6mt to 1.8mt, and waist not more than 1000mm circumference. INDUSTRIAL SAFETY NETS Industrial Safety Nets are designed to catch workers and / or debris falling whilst working on high buildings or structural fabrications. The safety net should be installed as close to the work level as possible. Sufficient clearance should be maintained between the safety net and the ground or structure below, in order to accommodate full deflection of the net under impact. IS 11057-1984 specifies requirements for two types of safety nets. Suitable for use at maximum duty height (*) upto 6mt Suitable for use at maximum duty height (*)upto 1mt (* The maximum vertical distance between working level and the level at which safety net is to be placed in use.) Salient features are as under: Minimum nominal size shall be 4mtX 3mt. Shall be made with square or diamond mesh and the length of mesh side

shall not be more than 100mm. In cae of multi layer nets, all layers shall be joined together and fitted to a

common border cord or cords. A continuous length of net, with no joints shall be used. When in use (without any load,except dead weight of the net), the sag at

centre of the net shall be between one-fifth and one-fourth of the length of the shorter side. Performance shall be tested by actual drop test of a sand bag weighing

140kg, in accordance with appendix A of IS-11057-1984.(Safety nets are available with an overlay net to catch small tools and debris. But, the performance test shall be carried out only after removing such overlay net.) The deflection at the centre of the net during above drop test, shall not

exceed 2mt or one-half of the length of the shortest side, whichever is more. Manufacturer shall declare the duty height at which net conforms to IS11057

by fixing labels marked with indelible ink at two different positions on the net. The labels should also contain following information. _ Manufacturer’s name or trade mark _ Nominal size of safety net. _ Date of manufacture. 98 _ Deflection at centre of the net during above drop test. ROOFTOP LADDERS Asbestos cement sheets are usually used as industrial roofing material. These are very brittle. In some cases GI sheets are used, which when rusted, become fragile. The collapse of fragile roofs, while walking on it, can cause fall from rooftops. These roofing materials are often laid on slopes, causing additional hazards of slips and falls from edges. For working on fragile and / or slopping roof, the following safety measures shall be taken:

Crawling boards or roof top ladders shall be used. While working, the worker should always stay on those and remember not to

step on the roof surface, which may give way. Before commencing any work on fragile roof, the site-in-charge shall verify

the availability of crawling board or roof top ladder and competence of workers to use those equipment. 26.6 STORAGE TANKS / SPHERES / BULLETS The safety of tanks depends more on the standards and quality of inspection applied at all stages of construction than any other single feature. The contractor shall ensure adherence to relevant code and all safe practices required during construction of tanks including handling of plates from storage yard to fabrication yard 26.6.1 FABRICATION Before commencing the fabrication work, work area is to be made free from

combustible materials, used asbestos cloth and place proper fire extinguisher near work site. While gas cutting of structural items, there is a possibility of back fire to the

portable gas cutting set and hence cutting torch, rubber hoses pressure gauges shall be checked thoroughly at regular intervals. All personal protective equipment shall be worn by welder. Loose nylon or polyester dresses shall not be used during work. All gas cylinders to be kept, in upright position and avoid mishandling.

26.6.2 ERECTION Proper supports to be provided on both sides of plate after erection by guy

ropes/wires/cranes to hold the plate in position and to avoid falling of plates on ground. Only proper structural supports shall be used for workmen standing purpose

and not boxes / drums etc. . Holes in plate work to assist in erection are not permitted. Lugs nuts, clamps

etc. to assist in erection may be attached to tank shell plate by welding for erection. 99 The tank shell shall be safeguarded from damage due to wind by provision of

steel wire guy ropes or cables after erection of 3rd shell or 3 M height whichever is less until completion of roof. Support for steel scaffolding shall be checked. Each scaffolding shall be tied

up with other to avoid fall of welder from a height due to shifting/sliding of scaffolding from its position. To avoid accident at height “jacking up method” shall be adopted from safety

point of view. Suitable capacity of crane and authorized driver shall be deployed for

operation. 26.6.3 WELDING AND GAS CUTTING Adherence to relevant codes and employment of qualified and tested welder are two basic requirements for welding and gas cutting process. Hazards such as electricity, heat/flame, flammable gas etc. are present in this process. Hence following precautions must be followed while carrying out these operations. Hot work permit shall be obtained wherever applicable before

commencement of the work. All fire precautions as stipulated in IS:3016 (code of practice for fire

precautions in welding and cutting operations) shall be followed while welding/gas cutting. Fire extinguishers, sand buckets, water and gunny bags shall be provided

when hot work is in progress. Gas cylinders used for gas cutting and welding shall - Be of approved make. - Be stored upright, and is kept away from hot work and care shall be taken to prevent heating of gas cylinders. - Gas cylinder valves shall always be checked and shall be closed when not in use. - Be stored in a well-ventilated area. - Be fitted with safety caps when not in use. - Not be lifted by nozzle and rolled. All gas and oxygen regulators shall be fitted with Flashback arrestors, being

non-return valves designed to prevent an explosive mix developing in cylinder. Checking for leaks shall be with help of soapy liquid applied to each joint and

under no circumstances shall a naked flame be applied to any part of the cylinder. When working at a height, do not place cylinders directly beneath the working

area, as molten metal may fall onto the hoses, causing leaks and possibly igniting the gasses. During electric arc welding process, very high ultra violet radiation is

generated. The welder and any person working in close proximity, in order to prevent permanent damage to the eyes must wear suitable eye protection. When not in use, power supply to the holder and electrode shall be turned off. 100 Hose shall be in good condition, and properly clamped. Welding cable shall

have proper insulation with minimum number of joints. All equipments shall be properly earthed, and cables properly insulated and

connected. ELCB / RCCB shall be provided in every welding circuit. Earthing shall be

dedicated for each circuit. Diesel generating set shall have separate earthing. Circuit shall always be made by cables of right quality and cross section only. Diesel generating set shall be connected with welding transformer through switch board fitted over a rigid support at height of 100 cm from ground with appropriate ELCB / RCCB. The welder or welding operator shall be insulated from both the work and

metal electrode and holder. The bare metal part of an electrode holder shall never be permitted to touch the operator’s bare skin or wet clothing. Consistent use of well insulated electrode holders and cables, dry clothing on hands and body and insulation from the ground shall be helpful in preventing contact with electricity. Electrode should never be changed with bare hand or wet gloves or when

standing on wet floor / ground. Frame of welding unit (portable/stationary) should be grounded using

correctly rated wire/strip and earth pit. Resistance to earthing must be checked daily before start of work. Receptacles of power cables for portable welding unit should be used so that

it is impossible to remove the plug without opening the power supply switch.

If cable is worn, exposing bare conductors, it must be immediately replaced / insulated. Welding cables shall be kept dry and free of grease and oil to prevent

premature breakdown of the insulation. Cables laid on the floor/ground shall be protected in such a way that they will

not interfere with safe passage or become damaged or entangled. Welding cables shall be kept away from power supply cable or high tension

wires. Welding cables shall not be coiled or looped around any structure. While coupling several lengths of cables for use as a welding circuit,

insulated connectors on both the ground and electrode holder line shall be used if occasional coupling and uncoupling is necessary. Supervisor shall ensure that the portion in the circuit of liquid or gas

circulation e.g. the storage tank, pipelines, valves, pumps etc. where welding/cutting work is to be carried out, is blanked or isolated and purged with inert gas or washed thoroughly, so as to make absolutely certain that no inflammable liquid/gas is present in an amount, which can catch fire under action of heat, spark, flame, welding spatter or red hot objects. The area shall be checked and ascertained that concentration of combustible gas in the air is within permissible limit. Goggles, if used, shall be for welding with right shade conforming to ANSI Z

87.1 or BIS. The shade number of the glass to be used for various purpose/ process shall be as under: 101 OPERATION SHADE NO. OF THE GLASS Soldering 2 Torch brazing 3 or 4 Gas cutting (1” to 6”) 4 or 5 Gas cutting (over 6”) 5 or 6 Gas welding 5 Shielded metal arc welding 10 Other personal protective equipment shall be as under:

_ Protective cloth/apron long enough to cover wrists and forearms against heat, sparks, molten metal and radiation. Leather or asbestos apron can be used for this purpose. _ Flame resistant gloves _ Safety shoes _ Helmet / shoulder cover for over head welding as necessary _ Safety harness while working at heights _ Ear protection (wool or rubber plugs) in case of noise pollution or overhead welding. _ In a confined place or where fumes/gas emissions cannot be below the toxic level, respiratory protective equipment duly certified for the exposure by reputed Government organization, like DGFASLI, shall be used. Space of more than 284 cum. per welder should be provided. Clothing should be free from oil & grease. Collars and cuffs should be

buttoned and turned up inside. Pockets should be eliminated from the front vests, shirts and apron

After welding or cutting is completed a warning sign should be provided to keep workers away from heated surfaces. Electrode rod stubs should be kept in a proper waste container Gas cylinders for each type of gas should be stored separately. They should

be kept away from any source of heat and shielded from direct sun light. If stored, the store must be well ventilated. The cylinders in use should be retained upright in a rack or trolley and not be left free standing. While unloading /loading gas cylinder nozzle valve guard cap must be

properly fitted and cylinder shall be unloaded over rubber/soft mat. Regulators, noses, torches and other Oxy-fuel gas equipment should be kept

free. from grease, oil and other combustibles. Lubricants should never be used on Oxy-fuel gas equipment Oxygen should never be substituted by compressed air Oxygen pressure reducing regulator, hose or other pieces of apparatus

should never be used with any other gases. Oxygen cylinder should never be used without first connecting a suitable

pressure-reducing regulator to the cylinder valve. 102 Acetylene cylinder should be turned & kept in such a way that the valve outlet

will point away from oxygen cylinder While opening acetylene cylinder valve, key or spindle should not be turned

more than one and one-half turns - Gas cylinder should not be lifted by nozzle and rolled All gas and .oxygen regulators shall be fitted with flash back arresters ,being

no return valve design to prevent an explosive mix developing in cylinder Checking for leaks shall be by means of soapy liquid applied to each joint and

under no circum stance shall a naked flame be applied to any part of the cylinder. When working at height do not place cylinder directly beneath the working

area as molten metal may fall on the hoses causing leaks & possibly igniting the gas Acetylene cylinder key for opening valve must be kept on valve stem while

cylinder is in use so that it may be quickly turned off in case of emergency Acetylene should never be used at pressures in excess of 15 PS.I. The use

of higher pressures is prohibited by all insurance authorities and by law in many localities The gas hoses should be in a good condition and easily distinguishable and

protected against heat, sharp objects, dirt, oil & grease. LPG Cylinders, if used, should be stored kept in a well-ventilated place and

there should be no excavations, drains or basements nearby. LPG cylinders should never be stored below ground level or closer than 3 M

to cylinders containing oxygen or materials which are toxic and corrosive. Cylinders full or empty should never be stored upright with the valve

uppermost. The valve of empty LPG cylinders should be kept closed, if they are left open,

air will diffuse into the cylinder and may form an explosive mixture. For storage of large numbers of gas cylinders regulations of

NFPNA/OISD/CCOE should be observed. If an outlet valve of acetylene cylinder becomes clogged with ice or frozen, it

should be thawed with warm water (not boiling), applied only to the valve. A flame should never be used. This is because the fusible safety plugs on acetylene cylinder melts at about boiling point of water. Cylinders are not designed for temperatures in excess of 54°C and hence

storage/handling should be done keeping this in mind. Never bring cylinders into tanks Portable fire fighting facilities and first aid facilities should be made available

in ready condition Adequate water should be made available at work spot for emergency

requirements BIS Code IS: 3016-1982 on "code of practice for fire precautions in welding

and cutting operations" shall be referred for further safety measures. 27.0 PRECAUTIONS IN ELECTRICAL WORK Electrical hazards are different from other types of hazard found in construction work because the human senses provide no advance warning. It is the voltage that determines the current through the body. Since reduced voltage reduces the 103 severity of electric shock, attempt shall be made to work with reduced voltage of 110 V wherever possible. Some of the basic safety steps to be ensured by contractor at construction sites are given below: 1) Only authorized persons with license issued by State Electricity Boards or any other Government regulatory body, shall carry out operation and maintenance of electrical systems. 2) Work permit and isolation of the electrical system before taking up the work must be ensured. 3) Proper protective equipments like rubber hand gloves, insulated apron etc. shall be used. FLP fittings /enclosure as per IS: 2148 and certified by CCOE, Nagpur should only be used in Zone-1&2 area. Capacitors should be relieved of charges before working on them 4) Check for defective cables, loose joints in conduits, damaged fuse boxes, loose pins, faulty sockets and defective earthwire. Cable joints must be properly insulated and protected. 5) Do not overload electrical equipment. All circuits shall be provided with dedicated ELCB / RCCB. There shall also be dedicated earthing for each circuit. 6) Use right type of tools for the jobs. 7) After maintenance of flameproof fittings, ensure that the fittings meet requirements of flameproof standards. 8) Power supply cable shall be laid at least 45 cm below ground level from source to the work place. 9) Tag with marking should be provided on each cable for identification and correct connections to terminals must be ensured 10) The route and depth of any underground cables should be determined and power should be switched off if possible before execution of work for the existing cable 11) Jointing of cable shall always be made using proper junction box and flameproof junction box when in hazardous areas even in case of temporary connections. Power cables should not be tied in knots; it should be looped instead. 12) All equipments LT or HT that are likely to cause hazard shall be turned off

and segregated. All base terminals etc. shall be insulated, Rubber mats shall be used for LT/HT switch room, where applicable. 13) All electrical equipments like wires, switch board etc., shall be protected against rains or leaking water lines etc. In wet condition switches shall not be operated until it is dried up properly. Switches starters shall be placed well above ground level. 14) Proper earthing shall be provided for all electrical items and effectiveness of earthing shall be checked every time before commencing work/switching on the electrical system. 15) Electrical items shall be handled after isolation and care shall be taken to identify and replace damaged electrical items. Guard wire shall be provided for aboveground HT wires. 16) Ensure all ELCBs and RCCBs are of good quality and conform to correct ratings. 104 17) Always plug of right specification should be used for taking connection from a socket. 18) Cables should be kept out of the way of other workers (or with proper guard/warning) and are not in contact with water 19) Moving parts of all equipment should be properly guarded. 20) All electrical transmission and operational equipment must observe safety clearances as stipulated in IE Rules. 21) Fail safe features should be available for interlocking mechanism. 22) Suitable overcurrent tripping device should be provided in the electrical Circuit. 23) Earth leakage relay with high sensitivity should be provided in the electrical system. 24) Earth pits should be tested periodically and certified by the licensed electrician 25) Before working on an electrical line fuse should be physically removed and the line is isolated and a suitable locking mechanism must be provided to prevent accidental switching/fixing fuses by other persons. A notice board displaying "Men at work" message should be placed. The section of circuit under repair should be connected to earth. 26) Temporary switchboards at site must conform to the following: structures are firm and strong fully protected from rain and dust properly grounded all connections are made with right size lugs suitably barricaded rubber mat of correct rating is provided on floor Danger band indicating system voltage should be displayed

27) No electrical equipment /cables/parts should be touched with wet hand/cloths 28) Lightning arrestors should be provided . 29) Electrical maintenance workman working around a wet area near a fuse box must use wooden platform with rubber mat, insulated tools and rubber boots. 30) All electrical installation including incomer line, temporary distribution board, electric motor and machine must be installed as per IE Rules with proper earthing and must be inspected and certified by a licensed electrician at

periodic intervals. 31) IS: 5216-1982 -" Recommendations on safety procedures and practices in Electric Works" shall be referred for further safety measures. 28.0 SAFETY IN RADIOGRAPHY WORKS Planning and procedure for radiography initially shall be formulated by contractors and submitted to proper authority. Procedure $hall be thoroughly discussed by all related persons for familiarization. All radiation equipment and radioactive materials shall be stored, handled, transported or disposed off, so that, no person receives unnecessary dose of radiation. Shield ability of the radioactive materials container shall be inspected every six months. Warning signs and posters shall be displayed. Radiography shall be performed under the 105 direction of radioactive supervisors/officer responsible for this work. Supervisor and source must possess valid BARC certificate indicating- 1. Type & strength of source 2. The serial number of radiography camera 3. Names of radiographer 4. Training/competency of person handling the source All workers shall be experienced and knowledgeable of the work such as radiation procedure, operation of radiation apparatus and effects of radiation on the body. The following spaces or areas shall be classified as restricted areas. a) Storage place of radioactive materials b) Any area where the radiation exists at levels such that large portion of the body could receive a dose in excess of 30 milligram per week. c) Emergency storage area for radiation apparatus or radioactive material capsules. Warning signs, labels and fence shall be provided for restricted area to prevent trespassing. The area covered within a radius of 5 Mts. from the radiation working spot or location and subject to a dose of radiation in anyone hour in excess of 50 milligrams shall be called the radiation area and trespassing in that area shall be strictly prohibited. All workers entering the restricted area shall wear film badges sensitive to radiation. All workers who could receive a dose of radiation in excess of 100 milligrams per day shall wear a pocket dosimeter and the dose of radiation received shall be recorded everyday. The dose of radiation shall be checked by the supervisor for each radiation exposure when the dose of radiation exceeds 100 milligrams. In such case, suitable alternative for shortening the radiation time, reinforcing the shield plate etc. shall be arranged. During radiation work, dose of radiation at the boundary shall be measured and recorded. The radiography supervisor shall measure and record the surface dose rate of restricted area every day as under: a) Date of measurement b) Measuring method c) Description and capacity of apparatus d) Measured condition e) Results of measurement f) Name of measurement g) Any action taken Radioactive materials shall be stored separately from other material or

equipment. The storage place shall be 10 cm or more above the ground and locked to prevent unauthorized entry. Radioactive materials shall be stored in a case made of lead of ample thickness with a lock on the exterior surface of the 106 case. The description of materials, quantity and danger sign shall be distinctly visible. 29.0 WORKING WITH MACHINERIES / MATERIAL HANDLING EQUIPMENT 29.1 General Many accidents place while handling materials at site. It is 'highly hazardous operation. Hence special attention by contractor is required in this respect. Following precautions are essential: Safe working space for all handling equipment shall be provided. Proper

material stockyard should be made and all material should be stacked /arranged/kept in orderly manner with proper moving space for handling machinery. Proper wooden sleepers should be provided below steel plates and such other materials. Mixers, winches, cranes, bending machines etc., shall be overhauled

regularly as per manufacture's advice/maintenance schedule. Proper warning boards/signs shall be provided when machineries like cranes,

hoists are being operated. Brakes, clutches of winches shall be checked on regular basis. Chains,

ropes, belts shall be inspected and repaired/changed as necessary. All moving parts of the material handling equipment must be provided with

suitable guards. Lifting ropes should be inspected for kinking, loose wires, high strands,

corrosion, nicking, lubrication, change in diameter /cross section Slings and other lifting materials, which are not suitable for use should be

promptly withdrawn and destroyed Lifting chains should be inspected for bent links, cracks in weld areas or any

other section of link, traverse nicks and gauges and corrosion pits. Elongation of the lifting chain link due to over loading should be inspected

before using it. Maximum allowable wear at any point of link of the lifting chain is given

below: - CHAIN SIZE (mm) MAXIMUM ALLOWABLE WEAR(mm) 6 1 10 2 12 3 16 3.5 20 4 22 4.4 25 4.8 28 5.5 31 6.4 35 7 40 8 45 8.7 107 For lifting hook, if the throat opening exceeds 15% of the normal opening, it

should be replaced. When inspecting the hook, measurement must be made between the shank and narrowest point of the hook opening

A chain used for lifting should not be spliced by inserting a bolt between two links Strain should not be put on a kinked chain Hammer should not be used to force a hook over a chain link A safety hook fitted with a latch to prevent displacement of loads should only

be used for material handling/lifting IS: 7293-1974 (Code of Practice for Working with Construction Machinery)

shall be referred for further safety measures. 29.2 CRANES All works involving the use of crane shall be properly planned in advance and the following shall be ensured The crane is capable of lifting the load. Safe load capacity should be clearly

marked on jibs, winches, pulleys, slings and ropes. All job cranes should have an automatic safe load indicator which alerts the operator The condition of the ground at the crane location is satisfactory to support the

crane and the load The rotation of the cab and, therefore the boom is not restricted. Suitable

matting or plates are available to protect underground services and paving. All slings shackles, hooks etc. are of correct rating and in good condition Cranes and lifting equipments must be inspected and carry a valid test

certificate issued by an accredited testing agency. Crane hooks are to be fitted with properly functioning safety clips to prevent

displacement of the sling from the hook during the lift. Driver of the crane must be watchful and must ensure before driving the

vehicle either forward or reverse that no one is near the wheel of the vehicle and no one is trying to climb the vehicle while moving. . Crane operators and signalers must be trained and sufficiently experienced.

There should always be a signalman or a signaling system such as a telephone, if the crane operator cannot see the load throughout the lift. Hand signal shall be clear and distinct and shall follow recognized code or system. Workers must use safety shoes and helmets. They are also required to wear gloves and other PPE s for handling materials. Raising, lowering and braking of jib should not be done abruptly in order to

prevent it from snapping. No part of the crane or crane load should be closer than 4 Mts. to live

overhead power lines. For movement of crane or other material handling equipment ,ramp gradient

should not exceed 1 in 10 No person should be allowed to stand or work under lifted load.

108 29.3 MANUAL HANDLING Assistance should be obtained if the load is too heavy or awkward for manual handling. Clear walkway to the destination and safe stack should be ensured before handling the load manually. Following procedure should be followed while lifting a load manually: Stand close to the load on a firm footing and with feet about 30 cm apart Bend the knees and keep your back as straight as you can Take a firm grip on a load .. Breathe in and throw the shoulders backwards Straighten the legs & continue to keep the back as straight as you can

Make sure that your view is not obstructed by the load Keep the load close to the body Lift slowly and smoothly When carrying the load ,avoid twisting spine to turn, move your feet instead One person shall not pull more than 63 kg. The weight unit for lifting by a worker is 18 kg and hence should be fixed as

upper limit of load to be lifted by worker If two or more workers are lifting, one should give instructions to ensure that

the team works together Type of clothing is very important in manual handling of material. Clothing

should be such that it allows easy movement of arms and will not catch in machinery or on a load. 30 VEHICLE SAFETY All vehicles used for carrying workers and construction materials must

undergo preventive maintenance and daily checks. Contractor shall maintain a register for this purpose for each vehicle. All documents related to the vehicle shall be kept in vehicle for checking. - Driver with proper valid license shall only be allowed to drive the vehicle. Routes shall be leveled, marked and planned in such a way so as to avoid

potential hazards such as overhead power lines and steep sloping ground. Speed limit shall be specified. While reversing the vehicle, help of another worker should be enlisted and his

instructions should be complied at all times during reversing and sound signal should be provided before reversing An unattended vehicle should have the engine switched off. Foot injuries to drivers and their assistance during loading and unloading are

common and they should wear safety boots and shoes. Wherever possible one-way system shall be followed. Head clearance must be ensured on the route of the vehicle and no vehicle

shall be allowed to deviate from its route. Overloading, carrying unauthorized passengers etc. shall not be allowed. Load on vehicle should be evenly distributed, properly secured and normally

should not project beyond the plan of vehicle. If some degree of projection is unavoidable, it should be clearly shown by the attachment of red flags. Load should be properly secured

109 The body of a tipper lorry should always be lowered before driving the vehicle

off. Signs/signals/caution boards etc. should be provided on the routes.

31 SAFE OPERATION OF PLANT, TOOLS AND EQUIPMENT The following four basic principles shall be applied for the safe use of hand and power tools. 1. To choose right tool for the job 2. To use only tools in good condition 3. To use tools correctly, and only for the purpose they are intended 4. To maintain and store tools properly. Electrical tools shall be checked to ensure that the supply voltage is as per

requirement. Electrical tools shall always be properly earthed.

High speed rotating equipments such as grinders shall be fitted with protective guards. Static load on shoulder or arm due to continuous holding of a tool at a raised

position or gripping of a heavy tool should be avoided Awkward wrist angles to be avoided Uncomfortable posture and pressure on the palm or joints of the hand should

be avoided. Repair or discard the tool, if tool heads mushroom, tool jaws open out and

cutting tools loose their edge Tools handle should have a firm grip Tools should be properly cleaned and stored Air connection to pneumatic tools should be clamped and secured properly. Electrical cable/pneumatic tube should be protected against damage Socket, terminal boxes, fuses etc. must be of high quality and properly

covered and protected Correct fuse should be used for the electrical tools. Power tools shall never be left operating unattended. Spark arrestor shall be fitted to all equipment exhausts where risk of

presence of combustible gases exists. Periodical inspection shall be done.

32 WORKING OVER WATER Falling into water and drowning and getting carried away by water current is an ever-present danger when working over or adjacent to large water bodies. The following precautions should always be followed: Working platform should be made secured and there shall be no tripping

hazards such as tools, wires, timbers, bricks etc. Surface should not be slippery. Access ladders, guard rail and toe board for the working platform should be

firmly held. Safety helmet should always be used.

110 A life jacket should be used A safety harness or net shall be used. Lifebuoys fitted with lifelines should be kept ready in hand for immediate use. Availability of safety boat (motor driven with self-starter for tidal/fast flowing

river) should be ensured. Availability of alarm system should be ensured

33 PIPELINE CONSTRUCTION SAFE PRACTICES I. Handling and storage of pipes a) Bare Pipes * Unloading, loading, stockpiling and transportation of bare pipes should be done using suitable means and in a manner to avoid denting, flattering or other damages to pipes * Pipes should not be allowed to drop but should be lifted or lowered from one level to another by suitable equipment * Lifting hooks when used, should be equipped with a plate curved to fit the curvature of the pipe * Pipe when stockpiled, should be placed on a suitable skid to keep it clear of the ground. * The stacks must be properly secured against sliding and should consist of

pipes of the same diameter and wall thickness * Personal Protective Equipment like safety shoe and glove should be used by worker while handling pipes. b) Coated Pipes * Coated pipe shall be handled by means of slings and belts of proper width made of non-metallic/ non-adhesive materials * Belts/slings when used should be cleaned to remove hard materials such as stone, gravel etc. * Coated pipes should not be bumped against any other pipe or any other objects * Rolling, skidding or dragging of coated pipes should be strictly avoided * Coated pipes at all times should be stacked completely clear from the ground so that the bottom row of pipes remains free from any ground contact. Pipelines should be stacked at a slope so that during rain, water does not collect inside the pipe. 111 * The coated pipes may be stacked by placing them on ridges of sand and covered with a plastic film. * Stacks should consist of limited number of layers so that the pressure exercised by the pipe's own weight does not cause damages to the coating * The weld lead of pipes should be positioned in such a manner so as not to touch adjacent pipes * Coated pipes stacked in open storage yard should be suitably covered on top to decrease direct exposure to sunlight * The ends of the pipes during handling and stacking should always be protected with end protectors II. Swabbing and Night capping To ensure that all dirt and objects likely to cause obstruction in the interior of the pipe are removed, each length of pipe should be thoroughly scrabbled prior to alignment and welding. At the end of each day's work a steel plate or nightcap should be adequately secured over open ends of incomplete section of the pipeline to prevent ingress of extraneous objects and ground or floodwater. . III. Inspection of field welds In case of cross-country pipeline and where specifically specified, all weld joints should be radiographed to ensure the soundness of welding joints to avoid failure of joints, which may create serious pollution or environmental problem. IV Coating Inspection in the field Where pipeline coating is carried out in the field, all bare and primed pipe should be kept free from dust and grease, oil etc. Before the pipeline is lowered into the trench the coating should be thoroughly inspected both visually and by using holiday detector. Any visible damage should be repaired and the pipeline shall be retested. V. Lowering and Backfilling Equipment used for lowering the pipeline from the skids and positioning it finally in the trench should be sufficiently padded at points of contact with the pipe to prevent damage to the protective coating * Slings used for lowering the pipe should be made of canvas or equally non-abrasive material and of a width not less than the diameter of the pipe. * The trench should be clear of loose rocks, lumps or other objects that

might prevent the coated pipe from bearing evenly on the trench bottom. 112 * When digging soil from beneath the pipe in order to remove slings, care should be taken to avoid damage to the protective coating. The coating should subsequently be inspected and any damage shall be repaired. * In waterlogged areas it may be necessary to provide additional weighting or screw anchors to prevent floatation of pipeline. * No lowering should be done after sunset without proper lighting arrangement * Minimum 3 side booms should be used and mounting of counter weights should be ensured on side booms for lowering the pipes. VI. Road, Rail and Water Crossing * Where work being done either adjacent to or any public or private road; warning signs and night time warning lights should be provided and maintained. * Crossing will frequently necessitate laying the pipeline at greater depth than normal and may therefore call for special measure to support the trench or boring pit. * Where crossings are made by open cut, the work should be programmed so as to minimise the amount of time that the normal traffic or flow is interrupted. Where necessary temporary conduits or pumping system should be provided to maintain the flow in water courses VII. Trenching * Barricading should be made while trenching in heavy traffic area. * Sign boards should be provided while trenching in heavy traffic area * Trench cross over shall be provided at every 30 Mts. of its length while trenching * Lighting should be provided for night working * Shoring should be provided for trench support * Underground service connections should be identified and marked prominently * Excavation tools should be properly insulated to avoid electric shocks * Evacuation of workers should be ensured before blasting * Entry of workers in site, where blasting is planned to be done, should be allowed after inspection and clearance from qualified Blaster Requirements of safe procedure as stipulated in BIS Code IS:4081-1986

for blasting and drilling must be observed during blasting operation. VIII. Pipeline Marks Distinctive markers should be created at all crossings to indicate the alignment of the pipeline and should give information about ownership, diameter, the nature of content, the normal direction of flow and the location of the crossing. A telephone number for use in emergencies shall also be displayed. 113 34.0 STORAGE OF HAZARDOUS MATERIALS Harmfulness of materials shall be identified and proper care shall be taken against fire/health hazards e.g. against asbestos fibre/rope, sand/shot blasting, paints, handling leaded container and tank, furfural liquid etc. Waste materials and consumables like woods, papers, and plastic pieces etc. shall be cleared on regular basis. Petroleum products/solvents used for cleaning etc. shall be kept away from working site specially when hot work is in progress. No smoking board/signs etc. shall be used in sites where such materials are stocked. Paints

shall be stored in separated areas. The quantity of paint stored in actual working areas shall be as minimum as practicable. The ingestion of paint shall always be avoided. Food and drink shall not be brought, stored, prepared or consumed in areas where paints are stored, handled or used. Smoking in such areas shall be prohibited. The inhalation of paints, dusts or fumes shall always be avoided by the use of local ventilation or extraction. Where fumes or dusts are unavoidable, then suitable approved respirators or facemasks shall be worn. All personnel who handle and use paints shall wear appropriate protective clothing (such as, gloves, eye protection and overalls). Splashes of paint on skin shall be treated promptly by copious washing with water or an approved cleaning agent. (Solvent shall not be used for personal cleaning). 35 CLASSIFICATION & WORKING IN HAZARDOUS ZONES Hazardous (flammable atmosphere) zones are classified as zone-O, zone-1 and zone- 2. All other areas are unclassified but not necessarily non-hazardous. In these areas, safety precautions must be observed in order to eliminate risk of explosion. Zone-O is defined as the vapour space in and directly around product storage tanks. Zone-1 is defined as an area where vapours, may be expected at all times. For zone 2, flammable vapours may be expected to be presently when a failure to equipment or plant occur. Unclassified areas cannot be assumed to be always non-hazardous, therefore must be checked prior to issue of work permits, Following precautions shall be taken while working in hazardous areas. 35.1 NON-SPARKING EQUIPMENT Sparks can be produced from electrical tools/devices, and where two surfaces collide. In order to avoid risk of sparking, only tools approved for use in hazardous zone-1 shall be used. The condition of all equipments used within hazardous zones shall be checked by BPCL Engineer. Where chipping or scraping is necessary in a hazardous area, several precautions shall be taken such as; the surface being chipped or scraped shall be kept moist with water at all times ; Air driven jackhammers may be used where atmosphere has been certified to be safe and the impacting surfaces must be submerged in water. 35.2 CHECKING OF WORKERS Workers are to be checked for matchboxes, lighters and other spark producing items. If workers are found to be carrying any such item, the same shall be taken into custody by security at the entry point. 114 35.3 SAFETY CHECKS In all cases where work is to be carried out within hazardous zones, BPCL Engineer shall check the area using an explosimeter for the presence of flammable vapours. The explosimeter shall be verified before each use, for its smooth functioning. Should there be any indication of flammable vapours, steps shall be taken to reduce the vapour content of the surrounding atmosphere. If found safe after re-checking by explosimeter, the work permit shall be issued. 35.4 FIRE SCREEN WALL Fire screen shall be provided to segregate area where hot works, such as welding & cutting, is planned to be done from surrounding. To construct fire screen, the following shall be complied with: Members shall be made of appropriate size MS pipes, MS structurals, strong

enough to withstand the wind, live and dead loads. The bottom of columns shall be properly grouted. Good quality G.I. Sheets free from damage and holes shall be used as

screening wall. G.I. Sheets shall be properly tied up with the structure.

The height of fire screen wall shall be decided based on the level at which hot work is supposed to be carried out. For example, in case of above ground tanks fabrication by jacking up method, a fire screen of 6 M height is sufficient where as in the other case it is required to have a height equal to height of structure to be fabricated. 36. WORK PERMIT SYSTEM If work is to be performed in a hazardous area, a duly authorized written work permit shall be obtained by the contractor from BPCL or any official duly authorized by BPCL for this purpose. This is a document authorizing contractor to carry out the work concerned, warning him of the possible hazards and spelling out precautions needed for the job to be done safely. The contractor shall be fully aware of the details of the work permit system and shall obtain the same signed by authorized person before starting the job. Based on the nature, the work shall be undertaken either under Cold Work Permit or Hot work / Entry to confined space permit or Electrical isolation and energisation permit. Permits and certificates are to be issued by BPCL Engineer or any official duly authorized by BPCLfor this purpose with overall responsibility for the work area. All work permits shall carry serially printed numbers. The printing of all work permits shall be done by the contractor in adequate quantity at his own cost. 36.1 COLD WORK PERMIT: Work falling under the category of cold work such as opening process machinery, blinding & deblinding, tightening of flanges, hot bolting, painting etc. shall be performed through Cold Work Permit. 115 This Permit shall be in minimum two copies. The original should be in yellow colour and the copy should have the word "Copy" printed in large yellow letters. Original shall be issued to the contractor, retaining the duplicate in the book. (Ref. Annexure-I) 36.2 HOT WORK / ENTRY TO CONFINED SPACE PERMIT: All hot work such as welding, grinding. gas cutting, burning, shot blasting. soldering, chipping, excavation, open fire, use of certain non-explosion proof equipment etc. shall be carried out through Hot Work Permit. Entry and operation of petrol or diesel driven vehicles or equipment without spark arrester in hazardous area also falls in the category of hot work, and shall be performed under the hot work permit. The confined space entry permit is required for the protection of personnel entering a confined space such as Vessels, boilers, storage tanks, large diameter piping etc against hazards such as oxygen deficiency, toxic and flammable materials, falling objects, power driven equipment etc. Excavation more than 1.2 meter deep, entry on floating roof tank when the roof is more than 3 meter down from the top, space located below ground level such as pits, drain, channels etc. also fall under the confined space. For excavation work regardless of the depth, permission from various sections shall be obtained with precautions to be taken for the underground facilities viz; sewers, telephone lines, cables, pipelines etc. This work permit shall be in minimum three copies. The original should be in pink colour and copies should have the word "COPY" printed in large pink letters. Original shall be issued to the contractor, duplicate to the Safety Section and triplicate retained in the book. (Ref. Annexure-II) 36.3 ELECTRICAL ISOLATION AND ENERGISATION PERMIT Before issuing any work permit, it is essential that the equipment / facility to be

worked on is electrically safe and electrical power is isolated to the extent necessary for the safe conduct of the authorized work.. Permit for electrical isolation and energisation shall be in triplicate and in two sections with tear off facility. Section-A shall be used for electrical isolation and Section-B for energisation. The original should be in light blue color and copies should have the word "COPY" printed in large letters in light blue colour. Original along with a copy shall be issued to the electrical section for electrical isolation / energisation. Electrical section authorized person on isolation / energisalion of the equipment / circuit shall return the original to the issuer keeping copy for record. (Ref. Annexure-III) 36.4 SCAFFOLDING FITNESS CERTIFICATE For all temporary scaffolds erected by contractor, fitness certificate, in format given in Annexure IV, shall be issued by BPCL site in charge after due checking to his satisfaction . 116 36.5 TEMPORARY ELECTRICAL CONNECTION FITNESS CERTIFICATE For all temporary electrical connections taken by contractor including diesel generating sets, fitness certificate, in format given in Annexure V, shall be issued by BPCL site in charge after due checking to his satisfaction. 37. ACCIDENT REPORTING AND CLASSIFICATION 37.1 ACCIDENT REPORTING All employees must be encouraged to report any near miss incident that has or could have caused injury, illness, damage to property, or interruption in work. The reporting of such incident helps in analyzing what went wrong and enables steps to be taken to prevent recurrence. The accident reporting forms the basis for objective investigation of the accident and will bring out essential and contributory factors leading to It. The necessary decisions then can be taken to prevent recurrence in future. 37.2 CLASSIFICATION OF ACCIDENTS Accidents are classified as follows: a) Near Miss It is a 'narrow escape' where accident, major loss or injury did not occur. Such incidents must be reported locally and the working conditions leading to it must be investigated. b) Fatality A death resulting from work injury is covered under this category irrespective of the intervening time between injury and death. c) Permanent total disability Personal injury which incapacitate a person completely and results in termination of employment. d) Permanent partial Disability Any injury which results in complete loss or permanent loss of use of any part of body or any permanent impairment of the function of the body. e) Lost Work-Day Case Any injury excepting permanent partial disability which renders the injured person unable to perform any regular job on any day after the day of receiving the injury. 117 f) Restricted work case After the injury, the injured person can not perform his normal duties or regular job.

g) Lost work days The number of calendar days on which the injured person was temporarily unable to work. h) Restricted Work days The total number of calendar days from the start of Restricted work, by the injured persons, till he returns to his regular job. i) Medical treatment cases The injury requiring medical treatment under order from a physician but does not involve Lost work Days, or restricted workdays. 37.3 REPORTING Contractor shall notify BPCL as under: Lost time injuries / Fatality / Injury which may cause total or partial disability to injured etc -immediately. Fire and Miscellaneous Events- immediately. First Aid injuries-Within a day. 38 SAFETY TRAINING Training is a pro-active measure. The contractor shall engage only those workers who are proficient in their respective jobs. It is responsibility of contractor to impart job knowledge to all workers and supervisors before engaging them for any work. It is also binding to the contractor to depute persons for safety training, if arranged by BPCL. 39 DOCUMENTATION Following documents shall be maintained by contractor at site: _ Safety & Environment Policy _ Safety committee minutes of meeting _ Critical machinery/equipment fitness certificate. _ Stock register of Personnel Protective Equipment. _ Maintenance registers for major machineries/equipment. 118 _ Accident / incident investigation reports. _ Various work permits. _ Earthing test certificates. _ Materials test certificates. _ P.F., Contract Labour, ESI registration. _ All records & registers as required under Contract Labour (Regulation & Abolition Act) 1970 and Building & Other Construction Workers Act 1996. 40 ENVIRONMENT PROTECTION Contractor should ensure that the work carried out by him does not change the quality of air, water & soil at the work site & surrounding areas. Disposal of surplus earth, rubbish, scrap etc. shall be done in Eco-friendly manner. The contractor shall ensure that the greenery is protected to the extent possible while executing the work. 41 ENVIRONMENTAL IMPACT MITIGATION MEASURES The best way of impact mitigation is to prevent the event occurring. All efforts should be made to locate the developmental activities in a area free of agricultural lands, cyclones, earthquakes, ecologically sensitive, erosion, forests, flooding, human settlements, land slides, natural scenic beauty, water logging. In case this is not feasible, the next step is to look at the raw materials/technologies/processes alternatives which produce least impact i.e. adopting or using processes or technologies which are efficient and produce recyclable wastes/minimum waste/wastes that can be easily disposed, without

affecting the environment. However if the developmental activity produce the adverse impact, action has to be taken to mitigate the same. Following are the suggested methods, which shall be taken in to consideration by the contractor to choose right technology for executing the work: 41.1 AIR Attenuation of pollution on pathway or protection of receptor through green

belts. Particulate removal devices such as : cyclones, setting chambers, scrubbers,

electrostatic precipitators, and bag houses. Gas removal devices using absorption (liquid as a media), adsorption

(molecular sieve), and catalytic converters. Uses of protected, controlled environment, such as oxygen masks, Houston

Astrodome, etc. Control of stationary source emission (including evaporation incineration,

absorption, condensation and material substitution) Use of masks Dilution of odourant (dilution can change the nature as well as strength of an

odour) Odour counteraction or neutralize (certain pairs of odours in appropriate

concentration may neutralize each other) 119 Odour masking or blanketing (certain weaker malodours may be suppressed

by a considerably stronger good odour) 41.2 NOISE The mitigation measure may include damping, absorption, dissipation and

deflection methods. Common technique involve constructing sound enclosures, applying mufflers, mounting noise sources on isolators, and/or using materials with damping properties. Performance specifications for noise represent a way to insure the procured

item is controlled. Ear protective devices should be used. When an individual is exposed to

steady noise levels above 85-dB (A), in spite of the efforts made to reduce noise level at the source, hearing conservation measures should be initiated. 41.3 WATER Conjunctive use of ground/surface water, to prevent flooding/water

logging/depletion of water resources. Included are land use pattern, land filling, lagoon/reservoir/garland canal construction and rainwater harvesting and pumping rate. Minimize flow variation from the mean flow. Segregation of different types of wastes. Storing of oil wastes in lagoons should be minimized in order to avoid

possible contamination of the ground water system. Surface runoff from oil handling areas should be treated for oil separation

before discharge into the environment. If oil wastes are combined with sanitary sewage, oil separation will be necessary at the waste water treatment facility. All effluents containing acid/alkali/organic/toxic wastes should be processed

by treatment methods. The treatment methods may include biological or chemical processes. The oil water separator of appropriate size based on catchment area shall be provided.

The impact due to suspended solids may be minimized by controlling discharge of wastes that contain suspended solids; this includes sanitary sewage and industrial wastes. Also, all activity that increases erosion or contributes nutrients to water (thus stimulating alga growth) should be minimized. Waste-containing radioactivity should be treated separately by means of

dewatering procedures and solids or brine should be disposed of with special care. 41.4 LAND The environmental impact of soil erosion can best be mitigated by removing

vegetative cover only from the specific site on which construction is to take place and by disturbing the vegetation in adjacent areas as little as possible. Land clearing activities should be kept to the absolute minimum. 120 Disturbing the existing vegetation and natural contour of the land as little as

possible can mitigate increases in surface runoff. Vegetation along watercourses should not be cleared indiscriminately. Neither should potholes or swamps be drained unless absolutely necessary for successful completion of the activity. Construction activities that result in the soil being laid bare could be

scheduled in such a way that some type of vegetative cover appropriate to the site could be established prior to the onset of intense rain or windstorms. If grass is to be seeded, mulch of straw will help to protect the soil from less extreme erosive forces until vegetative and root development begins. Natural drainage patterns can often be maintained by preparing sodden

waterways or installing culverts. Steep slopes can be terraced, thereby effectively reducing the length of

slope. Check dams built near construction sites can reduce the quantity of eroded

soil particles reaching free-flowing streams or lakes. Use of “floating” foundations and height restrictions in earthquake zones and

increased foundation height, wall strength and roof support in areas periodically subject to cyclones can reduce the hazards. All forms of temporary structures should be avoided from the flood plain and

all permanent structures should be raised to a height above the level which flood waters can be expected to reach once very 100 years (100-year flood). Installation of underground drainage structures helps to reduce sediment

loads. Engineering plans can be drawn to reduce the area of earth cuts on fills

below what might otherwise be acceptable, provide physical support for exposed soil or rock faces, concentrate or distribute-as appropriate the weight loading of foundations to areas or state better able to support that weight. Use small charges for mining/blasting. Restricting the number, frequency and area of movement of heavy

machinery. Compatibility between adjacent land uses can best be assured by providing a

green belt between the proposed activity and nearby properties where any significant degree of incompatibility is likely to result. 41.5 ECOLOGY

Intruding as little as possible on their habitat can best mitigate the impact of activities on animals. If such animals use the area where the activity will take place, the activity should be concentrated to the maximum extent possible in those parts of the area that they least often frequent. During the planning phase of an activity, an attempt should be made to avoid

extending into the home range wild animals. If this is not feasible, the activity should be completed, as quickly as possible, and regular and sustained use of the area over time should be minimized. Regular or sustained intrusions of men or equipment into nesting areas of

birds should be avoided to the maximum possible extent, especially while are being incubated by the adults and until the young have left the nest. The 121 sanitation cuttings of non-commercial individual trees should destroy no known nests. Restricting the input of polluting substances into watercourse, estuaries and

the open sea can mitigate impacts upon fish and shellfish populations. Additionally, when a part of the activity involves water level control, changes in such levels should be programmed to be extent, it is possible to do so in a way that will minimally disturb nesting and feeding habitat. 122 APPENDIX-I COLD WORK PERMIT Sl.No.______________ Work clearance from_ ________hrs of date_________ To _________hrs of date ________(Valid for the shift unless renewed) Issued to (Department / Section / Contractor) ______ ______________________________________________________ Exact Location of work (Area / Unit / Equipment no. etc)_____________________________________________________________ Description of work _____________________________________________________________________________ _____________________________________________________________________________ THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE PERMIT (Tick mark in the appropriate box. Checklist items marked with asterisk ( * ) shall be complied by receiver) Sr no. item Don e Not Reqd. Sr no. Item Done Not Reqd . 1 Equipment / Work Area inspected 6 Equipment water flushed 2 Surrounding area checked, cleaned and covered 7 Equipment properly steamed / purged

3 Equipment blinded/disconnected / closed / isolated / wedge opened 8 Proper ventilation and lighting provided 4 Equipment properly drained and depressurized

9* Area cordoned off & caution boards / tags provided. 5 Equipment electrically isolated and tagged vide Permit no. -------------------------- - 10 Gas test: HCs / Toxic etc. HCs = % LEL Toxic gas = ppm Remarks: 1. The activity has the following expected residual hazards (Tick the relevant items): Lack of Oxygen / H2S, Toxic Gases / Combustible gases / Pyrophoric Iron / Corrosive Chemicals / Steam – Condensate / Others _____________ 2. Following additional PPE to be used in addition to standards PPE (Helmet, Safety Shoes, Hand gloves, Boiler suit): Face Shield / Apron / Goggles / Dust Respirator / Fresh Air Mask / Lifeline / Safety Belt / Airline / Earmuff etc. 3. Additional precaution if any: _____________________________________________________________________________ Issuer Name & Designation Issuer Signature Receiver Name & Designation Receiver Signature 123 Closing of the work permit: Receiver : Certified that the subject work has been completed / stopped and area cleared Issuer: Verified that the job has been completed and area cleared and is safe from any hazard. Date & Time Name & Designation Signature Date & Time Name & Designation Signature Clearance renewal Time Date From To Additional precautions if any, Otherwise mention “NIL” Issuer's Name, Designation & Signature Receiver's Name, Designation and

Signature 124 General Instructions: 1. The work permit shall be filled up carefully and accurately in clear handwriting ensuring that complete information is provided in all the sections / subsections. Sketches should be provided wherever possible to avoid miscommunication. 2. Appropriate safe guards and required personnel protective equipment (PPEs) shall be determined by a careful analysis of the potential hazards and the operations to be performed prior to starting the work. 3. Requirement of standby personnel from Process / Maintenance / Contractor / Fire / Safety etc if any shall be mentioned in the additional requirement. 4. In case of fire alarm / siren, all work must immediately be stopped. 5. For renewal of work clearance, the issuer shall ensure that the conditions are satisfactory for the work to continue. If the conditions have changed, it may be necessary to issue a new permit or amend the existing permit. 6. This clearance on the same permit can be renewed / extended upto a maximum of seven calendar days. 7. This permit must be available at work site at all times. 8. On completion of the work, the permit shall be closed. The industry may add other relevant instruction based on their operating and maintenance practices. 125 APPENDIX -II WORK PERMIT for HOT WORK / ENTRY TO CONFINED SPACE Sl.No._ ________ Work clearance from __________hrs of date__________To________hrs of date __________(Valid for the shift unless renewed) Issued to (Department / Section / Contractor) ______________________________________________________ Exact Location of work (Area / Unit / Equipment no. etc)___________________________________________________ Description of work ____________________________________________________________________________ _____________________________________________________________________________ THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE PERMIT (Tick mark in the appropriate box. Checklist items marked with asterisk (*) shall be complied by receiver) Sr no Item Done Not Reqd . Sr no . Item Done Not Reqd A General points B For Hot work / Entry to confined Space 1 Equipment / Work Area inspected 1 Proper ventilation and Lighting providing 2 Surrounding area checked, cleaned and covered

2 Proper means of exit / escape provided 3 Sewers, manholes, CBD etc and hot surfaces nearby covered 3 Standby personnel provided from Process / Maint / Contractor / Fire / Safety dept. 4 Considered hazard from other operations and concerned persons alerted. 4 Checked for oil and Gas trapped behind the lining in Equipment 5 Equipment blinded/disconnected / closed / isolated / wedge opened 5* Shield provided against spark 6 Equipment properly drained and depressurized 6* Portable equipment / nozzles properly grounded 7 Equipment properly steamed / purged 7* Standby persons provided for entry to confined space 8 Equipment water flushed 9 Iron sulfide removed / kept wet C For Vehicle Entry 10 Equipment electrically isolated and tagged vide permit no. 1* Spark Arrestor on the mobile equipment / vehicle provided. 11 Gas test : HCs = %LEL Toxic gas = ppm, O2 = % 12* Running water hose / Fire extinguisher provided. Fire water system available. D For Excavation works 13* Area cordoned off and Precautionary tags / Boards provided. 1 Clearance obtained for excavation / road cutting / Dyke cutting from concerned depart. 126 REMARKS: 1. The activity has the following expected residual hazards (Tick the relevant items): Lack of Oxygen / H2S, Toxic Gases / Combustible gases / Pyrophoric Iron / Corrosive Chemicals / Steam – Condensate / Others 2. Following PPEs to be used in addition to standards PPEs (Helmet, Safety Shoes, Hand gloves, Boiler suit): Face Shield / Apron / Goggles / Dust Respirator / Fresh Air Mask / Lifeline / Safety Belt / Airline / Earmuff etc. 3. Additional precautions if any:.____________________________________________________________ __________________________________________________________________ _____________________________________________________________________ Issuer Name & Designation Issuer Signature Receiver Name and Designation Receiver Signature Clearance renewal Time Date From To Gas Test Values for HC's, Toxic, O2 etc Additional precautions if any, Otherwise mention “NIL”

Issuer's Name, Designation & Signature Receiver Name, Designation and Signature 127 Closing of the work permit: Receiver: Certified that the subject work has been completed / stopped and area cleaned. Issuer: Verified that the job has been completed and area cleaned and is safe from any hazard. Date & Time Name & Designation Signature Date & Time Name & Designation Signature General Instructions: 1. The work permit shall be filled up carefully and accurately in clear handwriting ensuring that complete information is provided in all sections / subsections and none of column is left blank. Sketches should be provided wherever possible to avoid miscommunication. 2. Appropriate safe guards and required personnel protective equipment shall be determined by a careful analysis of the potential hazards and the operations to be performed prior to starting the work. 3. In case of fire alarm / siren, all work must immediately be stopped. 4. Only certified vehicle / engines and permitted type of electrical equipment and tools are allowed in operating areas. 5. Welding machines should be located in non-hazardous and ventilated areas. 6. No hot work should be permitted unless the explosive meter reading is Zero. 7. When a person is entering confined space, the receiver must keep minimum two standbydesignated persons at the manhole or entry point. 8. Before box up of any vessel manhole cover, ensure that no men / materials are inside the vessel. 9. For renewal of work clearance, the issuer shall ensure that the conditions are satisfactory for the work to continue. If the conditions have changed, it may be necessary to issue a new permit or amend the existing permit. 10. This clearance on the same permit can be renewed / extended upto a maximum of seven calendar days. 11. This permit must be available at work site at all times. 12. On completion of the work, the permit must be closed and kept as record. 13. The industry may add other relevant instructions based on their operating and maintenance practices. 128 APPENDIX -III Electrical Isolation / Energisation Permit Section-A: Isolation Permit. Sl.No.______________ Request for Isolation: Date: ___________________Time:___________________ Department / Section / Area issuing the permit _________________________________________________

Equipment number to be isolated: ________________________________________________ Name of the equipment / circuit to be isolated: _______________________________________________ The above-mentioned equipment / circuit shall be de-energized and isolated from all live conductors to carry out the maintenance work by ____________________________ section / for operational requirement. _____________________ ______________________ ________________ Issuer Name Designation Signature Certificate of Isolation: Date: ____________________Time:__________________ Certified that Equipment / Circuit no. _____________________ of _____________________________plant has been electrically isolated by switches / isolators / links / fuses (tick as applicable) and the danger tag is put on the supply panel. Actions in respect of electrical isolation have been recorded in the electrical shift logbook. ____________________ ___________________ _______________ Name of Authorized Person Designation Signature 129 Section-B: Energisation Permit. Sl.No.______________ Request for Energisation: Date: _____________________Time:__________________ Department / Section / Area issuing the permit_________________________________________________ Equipment number to be energized: _________________________________________________ Name of the equipment / circuit to be energized:________________________________________________ Work on the above mention equipment / circuit has been completed and all the applicable permits closed. This equipment / circuit may be energized. _________________________ ___________________ _____________________ Issuer Name Designation Signature Certificate of Energisation: Date: ___________________Time:_____________________ Certified that Equipment / circuit no._______________________ of _____________________plant has been electrically energized and the danger tag removed from the supply panel. This is also recorded in the electrical shift logbook. __________________ _______________ _____________ Name of Authorized Person Designation Signature 130 APPENDIX -IV Scaffolding fitness certificate (Name of contractor ) Project___________________________ Exact location of scaffolding ____________________________________ Date of inspection _____________________ Type of scaffolding & height _________________________________ Purpose ____________________________________________________ We have personally checked the scaffolding and declare it as fit for use. Signature of site in-charge __________________ Signature of contractor’s representative __________________ Date: 131 APPENDIX -V

Temporary electrical connection fitness certificate (Name of contractor ) Project___________________________ Exact location of electrical temporary connection ______________________ Date of inspection _____________________ Purpose ____________________________________________________ We have personally checked the temporary electrical connection and workability of ELCB/RCCB and declare it as fit for use. Signature of site in-charge __________________ Signature of contractor’s representative __________________ Date: 132 GRIEVANCE REDRESSAL MECHANISM PREAMBLE Grievance Redressal Mechanism aims at speedy resolution of grievance of tenderes and prospective tenderes by providing them with a platform to refer their grievances and to seek appropriate remedy to the same. 1.0 Definitions In this mechanism, unless repugnant to the meaning or context thereof, the following expressions shall have the meaning given to them below :- 1.1 ‘Company’ shall mean Bharat Petroleum Corporation Ltd. 1.2 ‘Grievance’ shall mean a representation complaining of an interference in the rights of a Tendering party or represetation complaining of an oppression on a Tendering party by Bharat Petroleum Limited(BPCL) or its representatives, resulting in denial of his rights as a Tendering party. 1.3 ‘Tendering party’ shall mean a party or parties as a group who has / have participated in the tender process and submitted his / their tender in response to an invitation to participate in the tender or a party / parties who is / are prospective tenders qualified to participate in a tender based on notice issued by the Company inviting tender. 1.4 ‘Tender Inviting Authority’ shall mean an employee or committee of BPCL employees authorised to invite and / or to accept a particular tender. 1.5 ‘Grievance Redressal Officer’(GRO) shall mean respective Functional Director to whom the originator of Tender reports. 2.0 Authorities to handle grievances 2.1 Their will be a two -tier mechanism to handle the grievance received from a Tendering party. 2.2 The first level of Grievance Redressal Mechanism (GRM) shall comprise of a Grievance Redressal Committee(GRC) consisting Tender inviting authorities as the Co-ordinator,head of SBU/Entity orginating the Tender and the ED (Finance).All the grievance shall be lodged with the Coordinator of the GRC with a copy to the Tender Inviting Authority. 2.3 The second level of GRM shall be Standing Committee of the Board for Tenders (SCBT) to whom appeal against the Orders of the GRO can be filled by the Tendering party in case he is not satisfied with the decision of the GRC. 133 3.0 Contact details co-ordinator Telephone No. Address: Fax: Our Ref: