technical specification for erection of items

EPC-03

TENDER No. CMM/MEQ/25-26-2-1142

SECTION – C

SECTION-C CONSIST OF:-

1. SECTION C-2: TECHNICAL SPECIFICATION

FOR ERECTION OF ITEMS

rohitdwivedi

Typewriter

0

Kudankulam Nuclear Power Project 3&4 Document No.I01.KK34.0.0.MRR.TS.P001

Date of issue Revision No Page Number 28 February 2018 2 Page 2 of 50

TECHNICAL SPECIFICATION FOR

ERECTION OF MATERIAL HANDLING EQUIPMENTS (MHE)

REVISION CONTROL SHEET

Document Number

I01 KK34 0 0 MRR TS P001

Title


ERECTION OF MATERIAL HANDLING EQUIPMENTS (MHE)

Details of revision

Sr.No.

Revision

No.

Date of issue

No.of pages

Reasons for revision

1

0

15.05.2017 49

2 1 03.08.2017 49 SOQR item numbers and Annexure-2 list of Free issue materials are revised.

3 2 28.02.2018 51

Inclusion of Trestle metal structure erection specification, Annexure-2 list of Free issue materials and Annexure-3 QAP format for guidance are revised due to revision of TTS.




ERECTION OF MATERIAL HANDLING EQUIPMENTS (MHE) Content:

1. INTRODUCTION 2. SCOPE OF WORK 3. REFERENCE DRAWINGS, DOCUMENTS & SPECIFICATIONS 4. RECEIPT, TRANSPORATATION & STORAGE OF FREE ISSUE MATERIALS 5. SEQUENCE OF ERECTION ACTIVITIES 6. INTERFACING WITH OTHER AGENCIES 7. PREPARATION OF PROCEDURES & QAP 8. MANUFACTURER’S INSTRUCTION AND SUPERVISION 9. ASSEMBLY, WELDING AND ERECTION OF EQUIPMENT 10. ERECTION OF STRUCTURAL STEEL INCLUDING TRESTLE STRUCTURES 11. WELDING REQUIREMENTS 12. QUALITY ASSURANCE 13. COMMISIONING AND TESTING OF EQUIPMENT 14. GRIT BLASTING AND PAINTING 15. ELECTRICAL GROUNDING OF EQUIPMENTS 16. GENERAL TECHNICAL REQUIREMENTS 17. HOUSEKEEPING & CLEANLINESS 18. RECORDS AND REPORTS 19. COMPLETION OF WORK AND SUBMISSION OF CCC & MATERIAL ACCOUNTING 20. CONFIDENTIAL INFORMATION 21. PATENTS AND PATENT RIGHT INDEMNIFICATION

Annexure-1--- List of sample drawings Annexure-2--- List of free Issue Materials Annexure-3--- QAP format for guidance




ERECTION OF MATERIAL HANDLING EQUIPMENTS (MHE) 1. INTRODUCTION:

This section defines the general technical requirements for “Handling, transportation, pre-fabrication, pre-assembly, assembly, welding, erection, inspection, commissioning, load testing and handing over of the material handling equipments which are in supply scope of contractor and handling, transportation, pre-fabrication, pre-assembly, assembly, welding, erection, inspection, commissioning, load testing and handing over of free issue material handling equipments for KKNPP-3&4".

2. SCOPE OF WORK:

The scope of work includes “Handling, transportation, pre-fabrication, pre-assembly, assembly, welding, erection, inspection, commissioning, load testing and handing over of the material handling equipments which are in supply scope of contractor and handling, transportation, pre-fabrication, pre-assembly, assembly, welding, erection, inspection, commissioning, load testing and handing over of free issue material handling equipments for KKNPP-3 & 4".

The erection work includes the MHE issued as free issue materials by NPCIL as well as the MHE supplied by the contractor under supply scope of contract.

2.1 NPCIL SCOPE OF WORK:

NPCIL scope of work is limited to the following:

1. Issue of drawings for fabrication & erection of cranes and its components,

manufacturer’s manual & guidelines for installation of MHE and for carrying out commissioning checks for free issue MHE.

2. Issue of free issue materials at delivery point. 3. Issue of fabricated support brackets and anchor fasteners. 4. Erection of LT girder and crane rails for cranes. 5. Release of work front. 6. Power supply sources for commissioning of electrical operated travelling cranes and

hoists at free of cost.



7. Release of test loads for load testing as identified by the contractor. 8. Providing land/area for establishing contractors work shed/office within KKNPP. 9. Providing power supply at one point for establishing construction power supply

network by contractor on chargeable basis. 10. Heavy duty crane for the erection of assembled polar crane, trestle crane and turbine

hall crane will be provided by NPCIL. NOTE: “Delivery point” means NPCIL stores or any other point within KKNPP site.

2.2 CONTRACTOR’S SCOPE OF WORK:

Contractor’s scope of work comprises but not limited to the following:

1. Handling, Transportation, Pre-fabrication, Pre-assembly, Assembly, Ground assembly of component parts, cleaning, hoisting, fabrication, welding, erection and placing of MHE on rails, alignment of span girder, erection and alignment of cross travel trolley and all the MHE, greasing or filling with oil, checking for free rotation/movement as applicable, inspection including NDT, commissioning, functional check, load testing and handing over of “Material Handling Equipments" (MHE) such as cranes, hoists and lifts as per drawings / manufacturer instructions.

2. Preparation and submission of detailed work schedule to meet the specified targets and work progress reports (daily, weekly, monthly etc.).

3. Receipt of free issue materials from NPCIL stores or at the delivery point, uncrating, inspection and preparation of incoming material inspection report (IMIR), reporting deficiency if any to NPCIL, transportation from NPCIL'S store to contractors store, storage, transportation from contractor's storage to erection site, handling of materials during erection/construction and inspection before erection of items.

4. Loading, transportation to place of erection/ contractor stores, unloading, uncrating, inspection & acceptance of materials as per WD & packing list.

5. Material management, storage, and preservation of the material while at contractor's store. Returning of empty crates of equipments to engineers store at designated location specified by the Engineer-in-charge (ENC) shall also be in the scope of contractor.

6. Fixing of anchor fasteners- Hilti make as specified in drawing (wherever embedded fasteners/plates are not available).

7. Erection of support brackets. 8. Study of working drawings, inspection of work front, preparation and submission of

various work procedures, quality assurance plans, safety job hazard analysis for all the equipment for NPCIL acceptance including preparation of erection methodology for critical equipments.



9. Preparation, submission of welding procedure specification (WPS) & conducting Procedure qualification record tests (PQR) as per relevant standards.

10. Preparation of various procedures, QAP etc., arranging & carrying out inspections as per approved QAP, submission of various reports concerning the quality assurance.

11. Non-destructive examination (NDE) and testing as per drawings and specifications. 12. Arrangement of welding machines and apparatuses, all equipments and consumables

for welding as well as for all the tests at site. 13. Supply of welding consumables, argon gas and other gases, for welding purposes,

with required purity & accessories (except welding electrode, filler wire) for erection of free issue materials.

14. Supply of electrodes and filler wires and welding consumables, accessories for erection of the material under supply scope of contractor.

15. Arrangement of necessary equipments, P&M, material handling devices such as cranes, winches & chain pulley blocks etc of required capacity, lifting, rigging, transporting arrangements, tools & tackles, scaffoldings, platforms, ladders etc. required to execute entire works of the subject tender as a whole.

16. Deployment of qualified, skilled and unskilled manpower, experienced and qualified supervisory and technical staff and competent management fully backed by latest project management tools and facilities, training and qualification of required personnel for efficient & safe execution of work, committed to total quality management. The contractor personnel shall be conversant with Russian codes and standards.

17. Preservation of free issue material at contractor’s store as well as in situ (till handing over back to NPCIL) shall be done by the contractor. Further, any de preservation of the free issue material for erection purpose (including but not limited to removal of caps, protective tapes, de greasing, primer/peel off, paint removal etc.) shall also be done by the contractor. All the resources including consumables/ non consumables required for the purpose shall be arranged by the contractor at no extra cost.

18. Adherence to safety guidelines, security guidelines, various work permit system and compliance of all statutory requirements of the project. Performance of all the activities with necessary safety precautions. Obtaining necessary permits pertaining to the safety, field work, load testing and other permits as per the requirement.

19. Arrangement of safe working conditions in the area of work to ensure the protection of the already erected equipments, pipe lines & other property of NPCIL by proper protection arrangements. These arrangements shall be elaborated in the work procedure/ Job hazard analysis.



20. Electrification of crane including installation of down shop leads and connection to main switch, pre-commissioning, load testing including electrical grounding and handing over the MHE as per drawing, tender specification and instructions of ENC.

21. Touch up painting after erection of MHE. 22. Keeping the working area clean and materials segregated neatly in coordination with

other contractors. 23. Generating, maintaining and submitting reports concerning the quality assurance,

progress and completion of work and various records such as alignment reports, progress reports, test certificates, inspection reports, welders qualification records, all procedures, hand over reports, CCC etc. in order for any reference and scrutiny.

24. Along with the hard copy of final CCC the contractor shall submit scanned copy in soft form (.pdf format).

25. Material accounting for the free issue materials as well as contractor’s supplied materials under supply scope of contract and submission to NPCIL for acceptance.

26. In general all materials, plant and machinery and services whatsoever necessary for satisfactory completion of the work unless specifically provided as the free issue material by the engineer are deemed to be included in the contractor scope of work.

3. REFERENCE DRAWINGS, DOCUMENTS & SPECIFICATIONS:

1. The KKNPP-3&4 units are designed by Russian Federation. Accordingly assembly, fabrication, erection, inspection, testing and commissioning activities of all the MHE and all other technical requirements shall be as per the Russian Standards and Codes. This Technical Specifications are compiled based on the Russian Standards and are only for the guidance of the contractor. Erection of MHE shall be done based on the Working Documents and for more details contractor shall have to follow Russian NTD/GOST/PB/PNAEG/AERB codes as specified in Working Drawings (WD) released for construction and manufacturer documents which will be progressively issued to the contractor during execution of work. The Russian Standards and codes are available with Engineer In-charge’s library for reference. Working documents (set of drawings and documents) will generally contain necessary information for erection and testing of MHE.

2. One set of sample drawings listed in Annexure- 1 of this tender are attached to give an idea of the nature of the documents on the basis of which the erection would be carried out. These listed drawings are made from the MHE function point of view and certain changes are expected in the drawings with respect to detailing. The work shall be executed as per WD released for construction issued by engineer after award of contract.



3. It is the responsibility of the contractor to study & understand all the pre-requisites & conditions like availability of work front, labour, material, consumables etc before the start of the work. Contractor shall ensure safe storage of all the WD’s issued during the period of work, till the completion. Along with the hard copies, NPCIL will issue Soft copies of the WD’s from time to time to the contractor.

4. The specifications listed below are compiled based on Russian standards. These specifications are available at KKNPP site for reference. The copy of these specifications will be issued only to the successful bidder. These specifications are for guidance of contractor. The actual work shall be carried out based on working documents and Russian standards to be provided to the successful bidder. The contractor personnel shall be conversant with Russian codes and standards.

Sl. no.

Specification Designation

Description

1 I.02.KK.0.0.QA.TU.WD.001

Specification for Liquid Penetrant Testing of weld joints of equipments and piping during construction of KKNP.

2 I.02.KK.0.0.QA.TU.WD.002

Specification for Magnetic particle testing of weld joints of equipments a piping during construction of KKNPP.

3 I.02.KK.0.0.QA.TU.WD.003

Specification for radiography examination of weld joints of equipments and piping during construction of KKNPP.

4 I.02.KK.0.0.QA.TU.WD.004

Specification for ultrasonic examination of weld joints of equipments and piping during construction of KKNPP.

5 I.02.KK.0.0.QA.TU.WD.006

Specification for shop and field welding of piping and equipments during construction of KKNPP.

6 GOST 27584-88 Electric Overhead Travelling Cranes and Gantry Cranes 7 AERB/NPP-

PHWR/SG/D-1 Safety classification and seismic categorization for systems, structures and components of pressurized heavy water reactors

8 AERB/NPP-LWR/SG/D

Design of Light water reactor based nuclear power plants

9 2.01.07-85 Construction Norms & Rules (Loads & Effects) 5. In the event of conflicting requirements between the specification and drawings, the

governing requirements shall be at the discretion of the ENC of the work. In the instance where contractor is unable to achieve the required technical parameters, he must apply to the ENC with full justification for the regularization of non conformance. Any deviation from technical requirements must be recorded and duly approved by the Engineer in-charge.

6. Working drawings will be issued during the course of execution of work to match the progress of the work in the phased manner. The Contractor shall prepare detailed



fabrication / shop drawings where ever required based on the design drawings supplied by NPCIL.

7. Any discrepancies or contradictions in, or omissions from drawings, specifications or other documents or any doubt arising as to the meaning or intent of any part thereof, shall refer to the Engineer in-charge. Written instructions or explanations will then be issued by the engineer as soon as possible.

8. In case the Contractor feels that the drawing issued by the Engineer does not provide sufficient details required to prepare shop drawings, the Contractor shall obtain the Engineer’s consent in writing, to design the additional details and prepare the shop drawing from the design drawings issued to him. Where standard joints are not available, the Contractor shall design connections as per standard practice of design and shall get Engineer's approval prior to fabrication.

9. Inadequacy in detailing in Engineer’s drawing shall be brought to the notice of the Engineer within 3 (Three) days of receipt of drawings by the Contractor. Time consumed beyond the above time frame will not be considered for completion of schedule of the particular activity.

10. Whenever the contractor is unable to comply with the Engineer’s requirements, whether it is dimensional or technical, or whenever field changes are inevitable for any reason, the Contractor must obtain the appropriate authorization from the engineer.

11. Design Concession Request (DCR) shall be raised for non-generic deviation and non-conformances and it has to be regularized as per Quality management system.

4. RECEIPT, TRANSPORATATION & STORAGE OF FREE ISSUE MATERIALS:

All the MHE and other associated materials to be issued as free issue materials to the contractor for erection in this scope of tender are stored in NPCIL designated central stores hereafter referred to as NPCIL stores. The materials received in stores will be assigned Item no’s to each packing list of MHE, components and equipment. All the materials received in the NPCIL stores are subjected to inspection by a Joint Inspection Team (JIT) constituting of personnel from NPCIL and deviations if any are noted, are recorded. The materials cleared of any deviation are accepted and are ready for issue to the respective contractor on requisition. NPCIL stores are maintained by a separate agency.

The materials supplied by contractor shall be stored in contractor's stores after inspection and acceptance by NPCIL.

4.1 RECEIPT OF MATERIAL FROM NPCIL STORES AND TRANSPORTATION:



1. All such materials which are issued to the contractor by NPCIL during the contract period shall be treated as Free Issue Material (FIM). A list of all the free issue materials is given in Annexure-2. The WD’s issued to the contractor contains the list of the items required for erection MHE. The contractor shall make note of such items and draw from NPCIL stores on requisition. The free issue material will be issued against contractor issue voucher (CIV) at NPCIL stores. The contractor shall prepare Contractor Issue Voucher (CIV) either using NPCIL certified software’s like IPMIS, IBA-CMM or manually using CIV book which shall be issued to contractor during the execution of work. Contractor shall establish facility for soft ware based material management system for free issue materials, compatible with the NPCIL's software. The CIV should contain all the details of the requested material and the same shall be submitted to department of stores through ENC. It is the responsibility of the contractor to collect the requested material from the designated location of the NPCIL stores once the materials is issued.

2. Any deficiencies in the materials received shall be reported to ENC within two days

of receipt of material. Incoming material inspection report (IMIR) shall be prepared after inspection with NPCIL engineer. Further loading, transportation to the actual place of erection and unloading shall also be done by the contractor. In no case the material will be delivered by NPCIL at the actual place of erection. All the resources required for the purpose shall be arranged by the contractor. Empty crating shall be returned to engineers store at designated location specified by the Engineer-in-charge

3. The Contractor shall draw the FIM from the NPCIL's stores located within the plant

premises or in the vicinity of the plant premises. The contractor shall receive the FIM from the NPCIL at the delivery point (The delivery point can be a designated loading point at NPCIL stores or either at the contractor’s stores or near and outside the respective building where the equipment is to be installed). The contractor may also note that the ENC will decide the delivery point depending upon the practical feasibility of the access of tractor trailer carrying the cargo outside the nearest point of actual erection of the respective equipment, size of cargo and weight of the component.

4. The Contractor shall be responsible for transportation of all the items / general

equipment / material from the NPCIL’s store / Contractor’s store / shop to the place of work/ installation, except for the materials indicated in the free issue material list, which will be shifted by NPCIL to outside the building. In no case the equipment will be delivered by NPCIL at the actual place of erection.



5. Loading and unloading of materials and equipment shall be hoisted or skidded so as

to avoid shock or damage. Under no circumstances materials shall be dropped. Dragging of unprotected equipment on the ground shall not be permitted.

6. Many rooms (floor & walls) are provided with stainless steel & carbon steel liner.

Contractor shall take extreme care while shifting and erecting the MHE to avoid damage to the room liners. The scaffolding used in the area shall have rubber bushing to avoid scratch & dents on the liner.

7. The FIM shall be issued in a lot, in packed/as received condition. No piecemeal

issue/delivery shall be permitted. After the material is issued, the contractor shall be responsible for uncrating of the free issue material, inspecting the contents for deficiency if any, checking for the completeness, proper storage, safekeeping, preservation and handling as per approved procedure while materials are in his custody, safe transportation and handling from his workshop to the erection point etc.

8. The contractor shall arrange all tools & tackles, machinery and hoisting required for

loading, transportation and unloading of the materials. Wherever the contractor has to attach his hoisting equipments to project’s existing structure written procedure of rigging operation must be submitted for the engineer’s approval. In the work area where the engineer may have installed hoisting equipments in time, which is part of the project as permanent installation, the contractor may be permitted to utilize it free of charges for the execution of his work. The engineer will provide competent operator. The same does not apply in the event of the engineer’s permanent hoisting equipment if the operator is not available or engaged for his work or being out of order. This shall not be the cause for claims of extra payment or an excuse for delays in executing the work. This facility is offered purely on the ground to increase safety of hoisting operations and to remove unnecessary congestions, if and where possible. The contractor shall check the lifting capacity of various hoisting equipments before taking up any erection.

9. Briefly the scope of material transportation covers identification of material,

preparation of CIV, clearance from ENC and its submission to NPCIL's Stores, receipt, handling, loading on to the truck/trailer, transportation of materials from NPCIL's stores to contractor's store or erection site, unloading the material at contractor's store or erection site, uncrating, checking the completeness of items/physical damage(if any), preparation and submission of incoming material



inspection report (IMIR) and its clearance from ENC, further shifting of materials from contractor's store to erection site and disposal of the crating/packing material at the designated place of the NPCIL's stores, returning of un-erected materials to NPCIL's stores. This work also includes arranging all the necessary tools and tackles, truck/trailer, plant and machinery, man power and consumables.

4.2 TRANSPORTATION OF HEAVY AND CRITICAL EQUIPMENTS:

In general for packages/Equipment weighing greater than 20 MT Gross Weight, the delivery point is either at the contractor’s stores or near and outside the respective building, where as for all other packages/Equipment the delivery point shall be a designated loading point at NPCIL stores. In no case the equipment will be delivered by NPCIL at the actual place of erection. Contractor shall do subsequent handling and transportations where ever required. Equipment placement on to designed location, alignment, adjustments and grouting for final erection shall be carried out by the contractor.

4.3 STORAGE OF MATERIALS:

1. The contractor shall make his own arrangements, for constructing a covered storage area on earmarked open space made available to the contractor at site. Attention is drawn to the fact that the environment at KK site is corrosive and therefore proper storage and its periodic monitoring by contractor has to be done at no extra cost. Contractor shall make warehouse in his own arrangements to provide appropriate storage at site (in accordance with manufacturer’s recommendation and taking into account climatic and other relevant conditions at the warehousing site) for all NPCIL issued FIM’s, Contractor’s Plant & Machinery and Contractor’s Equipments till the completion of the work. All the Plant & machinery, tools & tackles, hoisting, manpower etc required for handling the materials at contractor’s store, are in the scope of the contractor. Watch and ward shall be the responsibility of the contractor.

2. Once materials are issued to the contractor it is the responsibility of contractor in

storing of any materials and pre-fabricated items at erection location in the building or enclosures providing adequate protection. All storage shall be orderly and executed in a way so as to eliminate mixing up of materials and possibility of damage prior to their installation in the field. No material shall be stored directly on the floor. Supports shall be provided below to ensure Gap of 100 to 150 mm from ground.

3. The Contractor shall be responsible for security of all the FIM’s stored at the

contractor’s stores till the completion of the work and acceptance by NPCIL. It is the



responsibility of the contractor to maintain complete record of the list of materials at stores, maintain log books and entry/exit records for the material movement in and out of the contractor’s warehouse/ store. All such records which are required for material accounting and billing shall be prepared, recorded and maintained by the contractor either manually or by using licensed software’s with prior approval of ENC. NPCIL approved committee has every right to audit Contractor stores, records and his logbooks time to time during the execution of work, for which Contractor shall ensure and provide all such information and facilities on demand.

4.4 IDENTIFICATION, MARKING AND SEGREGATION OF MATERIALS:

1. In NPCIL stores, all MHE are identified by their KKS codes and Item no’s. It is the

responsibility of the contractor to get the details of KKS codes, package no’s, Item no’s for such materials from NPCIL. All the FIM’s shall be stored at appropriate locations in contractor's stores, properly tagged and identified for segregation from other goods, properly protected and preserved as per manufacturers recommendations, properly marked with their KKS code, system Code, Item no. and item description like weight, material, type etc and the material locations shall be marked properly for easy identification and retrieval of the material at stores.

2. The contractor shall visually examine all materials being erected or being used in the

fabrication and shall report any defects to the engineer. Any repair of materials shall be as per approval of the engineer’s instructions. Any material not conforming to the specification and subsequently rejected should be suitably identified, stocked and disposed off as per the instructions of the engineer.

5. SEQUENCE OF ERECTION ACTIVITIES:

1. The sequence of erection shall be decided by Engineer based on availability of erection fronts, drawings and equipments. In general the sequence of the erection shall follow the overall project schedule of KKNPP-3&4. Generally installation of support structures shall be taken up first followed with installation of Material Handling Equipments, electrical and instrumentation components. The following shall be the preferred sequence of installation.

a. Support structure installation and inspection b. Installation and inspection of material handling equipment.



c. Installation and inspection of electrical and instrumentation components. d. Commissioning and load testing of material handling equipment.

6. INTERFACING WITH OTHER AGENCIES:

1. The MHE contractor shall note that the construction of civil works will be continuing by other agencies in the same building where this MHE will be erected. This type of parallel working shall not be considered as disturbance or hindrance to erection work. Also other mechanical/electrical agencies related to ventilation, equipment and piping, common services, cable laying, ducting etc may also work in the same area. Hence for carrying out the above activities the co-operation and co-ordination with other contractors/agencies working in that area for erection of ducting, cable tray, etc., will be required from MHE contractor.

2. All MHE erection work covered under this specification shall be planned and

executed as combined nature of civil, mechanical, electrical and instrumentation work. The civil construction and mechanical erection works shall be done in a sequential/combined manner. The work front for civil and MHE contractor shall be available or released on completion of specified activities by each contractor on every activity and both contractors shall ensure that their part of work is completed in time. The rate quoted by bidder shall include such combination of civil, mechanical, electrical and instrumentation work. No extra claim on account of any misunderstanding or not understanding the nature of work shall be entertained by NPCIL.

7. PREPARATION OF PROCEDURES & QAP:

The contractor shall prepare and submit the Erection/QAP/NDT/Testing procedures for all the MHE erection works in his scope to ENC for approval. A sample format for guidance for preparation of QAP is enclosed as Annexure-3 of section. The procedures shall be prepared in line with the general Industry practice, Working Documents, acceptable codes and standards and to the requirements of Equipment Manufacturer/Designer. The procedures shall clearly define all the details pertaining to the type of testing, process of testing, the methodology adopted, special requirements, sequence of steps, assembly requirements, alignment process, quantum of testing, testing tools & consumables required, calibration requirements, testing parameters, interpretation of results, defect rectification methodology.



Some of the major procedures to be prepared by contractor are,

1. Quality Assurance Manual 2. Welding Procedures like Welding Procedure specification (WPS), Procedure

Qualification Record (PQR). 3. Welder’s qualification Procedure 4. Qualification certificates of the personnel performing non-destructive examination 5. Assembly procedures 6. Erection procedures for MHE 7. QAP 8. NDT procedures 9. Testing procedures

10. Cleaning procedures 11. Commissioning procedures 12. Mock up procedures 13. Safety Manual

Further, where complexity of the work or safety is involved, the contractor shall submit such work procedures when requested by the ENC. Any other procedure deemed necessary for work shall be submitted to ENC for acceptance.

8. MANUFACTURER’S INSTRUCTION AND SUPERVISION AT SITE:

1. Manufacturer’s instructions are special/specific instructions issued by the equipment manufacturer. Any such installation requirement specified by the Manufacturers, such as alignment adjustments, greasing, turning of motors, mounting of particular items on the equipment etc. is included in contractor’s scope of work. Adequate care shall be taken during welding of MHE components. For any equipment or items (supplied by the engineer) of proprietary nature, the Engineer will issue the Manufacturer’s data or instructions to the Contractor. Contractor shall follow the manufacturer’s instructions/data for equipment/items supplied by the contractor under supply scope of contract. The manufacturer's manual should be returned to NPCIL with deviation marked by the contractor on completion of work.

2. Wherever deemed necessary NPCIL may arrange supervisors of manufacturer

representative during erection, testing and commissioning of the equipment for pre determined period. The contractor is required to complete the erection of such equipment in a fixed time frame as per agreed schedule. Any delay in completion of



work by the contractor within the agreed schedule shall be considered as delay in work. If any additional expenditure incurred by NPCIL on account of delay by the contractor on account of supervision front, shall be deducted from the contractor.

9. ASSEMBLY, WELDING & ERECTION OF MHE:

9.1 GENERAL REQUIREMENTS:

1. The general instructions and requirements for erection are detailed in WD or manufacturer’s documents. All the equipments shall be erected as per the equipment installation drawings and specification and other details to be furnished to Contractor.

2. All required manpower for the erection of equipments shall be provided by the

contractor. Erection and alignment of all machineries shall be carried out by experienced fitters and technicians. Contractor shall deploy experienced erection supervisors and crews who have done similar type of jobs. Contractor shall ensure performance by qualified electricians / technicians to the best industrial practice. Proper sequence for assembly and erection / installation shall be adhered to in accordance with drawings, catalogue and manufacturers instruction.

3. All necessary handling equipments, tools, tackles and precision instruments for carrying out the works as specified shall be provided by the contractor at his own cost. Contractor shall provide all tools and gauges for erection and alignment. Special tools, if any, received as part of equipments shall be used by the contractor for erection purposes, which shall be returned in good condition after use. While handling, transporting or erecting the equipments, care shall be taken not to damage any parts of the equipments.

4. Rigging procedures and erection schemes for all the heavy lifts shall be prepared by the contractor and got approved by ENC before starting work. Approval by ENC shall not relieve contractor of his responsibilities. The details to be submitted will include the location of equipment from where it will be lifted, location of crane(s), details of crane(s) (like configuration, boom length, operating radius, boom point elevation, clearance underside the boom and the equipment, lifting capacity, counter weights to be deployed, holds on any neighbouring foundations, structures, equipments etc.), the load chart of the crane(s), design of the lifting tackles like spreader beam, D-shackles, wire rope slings etc.

5. Contractor shall produce valid test certificates of the lifting tools and tackles including slings used for erection work. However, retesting shall be done by



Contractor, as and when required for revalidation. Tested slings will be punched for test loads and date of testing. Also, the D shackles, EYE bolts and other tackles shall be inspected at regular intervals.

6. Before taking up the equipment for erection, the contractor shall check the readiness of front release. Discrepancy, if any, should be brought to the notice of the ENC before actual erection is started. Before start of erection activities contractor shall ensure crane rail clamps are properly aligned and tightened.

7. All equipment shall be thoroughly cleaned, oiled and greased and presented for

inspection to the owner before placing in for operation. While filling lubricants and oils, care shall be taken that they conform to manufacturer’s recommendations. The required quantities of oils and lubricants shall be supplied by the NPCIL.

9.2 DE-PRESERVATION:

1. De-preservation shall be carried out as per manufacturer’s recommendation. After

shifting the equipment from the store to site the equipment shall be placed safely. Steel structures/ wooden blocks used for the packing and transportation shall be removed carefully. Equipment Manufacturer's recommendations regarding de-preservation/preservation during storage at site store and after erection at designed location shall be strictly followed by the contractor till the completion and handed over to the NPCIL.

2. De-preservation of bogie pin and pin bearing surfaces shall be done by appropriate paint remover. Before installation of bolts it is necessary to remove preservation coating and shall be cleaned by using steel brushes. The high-strength bolts and washers before installation shall be cleaned with petrol and wiped dry. De-preservation of bolts, nuts and washers by immersing in boiling water for 10 minutes and rinsing it in hot condition with mixture of 85% clear petrol and 15% of machine oil mixture to clean them. Surface contact area and fasteners shall be de-preserved by gas burning for removal of primer coating as instructed by the manufacturer. De-preservation of surface of the plates wherever necessary and shall be done by gas burning for removal of primer as instructed by the manufacturer. Necessary crates, tank and gas burner including industrial LPG cylinder for the above activity shall be arranged by the contractor and the quoted rate is inclusive of making such arrangements. The thread of nuts shall be applied with mineral oil. De-preservation of rope shall be done by wiping with brush and cleaning with cloth.



General sequence of erection procedures of major equipments are given below only for reference. The contractor shall prepare erection procedure and QAP for erection based on manufacturer manual and submit for approval of NPCIL before start of erection. All the component parts of the equipments shall be shifted to the respective locations including the erection devices.

9.3 ERECTION OF POLAR CRANE (FCA07AE071) :

A. General: 1. The Polar crane is a circular crane of lifting capacity 350/190 T with a working

range from 0o to 370o with full capacity at all ranges and located at an elevation of +43.900 m inside the Reactor Building (UJA).

2. The polar crane is free issue material to the contractor for assembly, erection, commissioning and testing. There are two nos. of polar cranes (one no. per unit) under this scope of contract.

3. SOQR of this tender is for measurement and billing of polar crane work.

B. Ground assembly: The following are the major steps involved in assembly of Polar crane.

1. Assembly of Bridge Metal Structure - L.H. & R.H.: Turn the pieces wherever they

are kept upside down. Place the bridge metal structure pieces on concrete blocks / wooden sleepers for leveling. The straps and bridge metal structure contact surfaces shall be prepared by shot / grit blasting to required surface finish as per the instruction of the manufacturer. After surface preparation, match the straps and Bridge Metal Structure as per the match marks punched on them. Matching of component or part holes and their fixation in conformity with the working drawings shall be done with the help of taper mandrels (assembly plugs). The taper mandrels (assembly plugs) required for matching the holes are in the scope of the contractor. Number of assembly plugs required shall be at least 10 % of the holes but not less than two in one joint. The bolting area shall be cleaned and kept free from dust. During installation of high strength bolts, make sure that nut turns easily on the bolt by hand or replace either nut or bolt. Lubricate nut thread with mineral oil while tightening, never lubricate bolt thread. The HSFG (High Strength Friction Grip) bolts supplied along with the crane shall be tightened in a sequence as recommended by the manufacturer with the help of calibrated torque wrench to the adequate torque as per the instruction of the manufacturer. If any bolt or nut slips during tightening, it should be replaced by a new bolt. Each bolt is installed in combination with two high-strength washers (one of them is placed under bolt head and the other under nut). After completion of tightening, the gap between the contact surfaces should be



checked using feeler gauge. Trolley rails are to be fixed on the Bridge Metal Structure and the clearance between the rails should not exceed 1.5 mm.

2. Assembly of Roller Pedestal with Bridge Girder: Assembly of Roller Pedestal with

Bridge Metal Structure shall be done by Bolting joint at one end and Welding joint at other end. After alignment, bolting and tightening of HSFG bolts shall be done as per the same procedure followed for Bridge Metal Structure assembly. After bolting, prior to performing welding works, each side of welding surfaces shall be ensured for free from grease, loose scales, moisture and paint etc. The qualified welding procedure and qualified welder shall be used. Welding shall be inspected and accepted by the respective NDT techniques as recommended by the manufacturer.

3. Assembly of Bridge Drive Mechanism: Place one piece of drive carriage and idle

carriage on concrete blocks / wooden sleepers to the working height. Align both the carriages to match the pin centre of the balancing beam and ensure that they are lying on same plane. Before assembly, ensure all pins and pin housings are cleaned properly by using appropriate Solvent recommended by the manufacturer. Place the balance beam above the carriages and insert the pin into the pin housing with appropriate lubrication as instructed by the manufacturer. Check the alignment of motors and brakes. Repeat the above for the remaining three bridge drive mechanisms assembly. Temporary locking of bridge to drive mechanism has to be done by welding using channels for handling purposes. The welding shall be done as per the instruction of the manufacturer.

4. Assembly of Main Hoist: Assemble the Main Hoist drive mechanism with the Main Hoist Trolley. Installation of motor and gear box shall be carried out and alignment of Motor to the gear box is to be done using dial gauges. Gearbox shall be de-preserved and filled with lubricating oil. All the handrails and platforms shall be installed with the main hoist trolley assembly.

5. Auxiliary Hoist Trolley: Alignment of Motor is done by connecting the motor with

gear box by using key and alignment is checked by means of feeler gauge. Alignment of Brakes is done by setting manually and physical checks shall be carried out. All the handrails and platforms shall be installed with the auxiliary hoist trolley assembly.

6. Assembly of Main Gantry: Place the two stands of the gantry on the ground. After

checking the span of stands as per drawing, horizontal piece is bolted with HSFG



bolts and tightened as per manufacturer instructions. Cantilever beam is attached with this assembly by means of HSFG bolts and tightened as per manufacturer instructions. Main Gantry hoist shall be installed and locked for movement during erection activities.

7. Assembly of Auxiliary hoist Gantry with Monorail: Place the two stands of the

gantry on the ground. After checking the span of stands as per drawing, horizontal piece is bolted with high strength friction grip (HSFG) bolts and tightened as per manufacturer instructions. Monorail is attached with this assembly by means of HSFG bolts and tightened as per manufacturer instructions. Auxiliary Gantry hoist shall be installed and locked for movement during erection activities.

C. Erection sequence:

The following are the sequence of activities in erection of polar crane.

1. Before start of erection activities ensure crane rail clamps are properly aligned and tightened.

2. Erect the assembly of Bridge Metal Structure with Roller Pedestal and Bridge Drive mechanisms (R.H & L.H) on rail using Heavy duty crawler crane.

3. Erect the end beams, align with the respective bridge beam assemblies and bolting of end beam by HSFG bolt is carried and tighten the bolts with Torque Wrench with specified torque. Check the elevation and level between the two bridge metal structures and check the span, diagonal of the crane.

4. Erect the Main hoist (MH) & Auxiliary hoist (AH) trolleys on girders separately and connect two trolleys with main hoist carriages by pin and bolts.

5. After cleaning the bolting surface of Fixing Device, four pieces of fixing device shall be aligned and fitted under the bridge metal structure by HSFG bolts as per specification.

6. Grapples (four pieces) shall be erected and fixed under the trolley frame as per drawings.

7. The assembled main gantry shall be erected over the pedestal on the Bridge metal structure. The assembled Auxiliary hoist gantry shall be erected over the pedestal on the Auxiliary hoist trolley.

8. Erect and align the dome maintenance platform on roller pedestal units. 9. Rope reeving of main hoist suspension and auxiliary hoist with rope drum shall be

done.



10. Fixing of permanent current supply platform is to be done after completion of dome erection. For erection of this platform weld the erection lugs on Reactor building dome with which the platform will be erected and fixed with dome.

11. After completion of erection lubrication at all specified points, oil filling in gear boxes, thrusters, application of rope preservative compound shall be done.

12. Complete electrification & charging of polar crane.

9.4 ERECTION OF TRESTLE CRANE (FCJ07AE041)

A. General: 1. The trestle crane of 350/190 T is installed over the transport portal beam (UJG) at an

elevation of +52.850 m outside the Reactor Building. 2. The trestle crane is free issue material to contractor for assembly, erection,

commissioning and testing. There are two nos. of trestle cranes (one no. per unit) under this scope of contract.

3. SOQR of this tender is for measurement and billing of trestle crane work.

B. Ground assembly: The following are the major steps involved in assembly of Trestle crane.

1. The frame parts shall be placed on supports (concrete blocks/ wooden sleepers) with

sufficient heights accommodating bogies assembly and leveled to ensure the bolting position.

2. The joining of frames shall be done by bolting using HSFG bolts to the adequate torque value as instructed by the manufacturer. After completion of torque tightening the exposed surface area shall be painted manually.

3. Fixing of Trolley hand railings, ladder and platform shall be done as ground assembly.

4. Depot installation along with gantry and shelter shall be done in two stages as partial ground assembly and assembly at actual place. Metal structures for above mentioned assembly are welded / bolted joints and partial ground assemblies shall be taken up suitably to facilitate further assembly after erection.

5. Gantry frame metal structure shall be assembled at ground with bolts and geometric dimensions shall be checked with reference to working drawing.

6. Similarly trolley shelter with metal sheeting shall be taken up at ground assembly. After erection of gantry & shelter at their place, necessary tie beams as per working drawing shall be fitted for preliminary completion of Depot erection.



7. Metal structure for Shelter for Hoist shall be taken up at ground prior to erection of gantry metal structure.

8. Above activities completes partial ground assembly of Depot. Once Depot erection is completed necessary erection for current supply line to gantry shall be done manually at its place.

C. Erection sequence:

The following are the sequence of activities in erection of Trestle crane.

1. Once the trolley frame is assembled at ground level along with bogies and hand railings fitted in place shall be secured by proper welding and rope tying.

2. The Trolley frame with wheels and bogies shall be erected on to the Trestle crane girder rail.

3. Further erection of reduction gear unit, hoist drum, sheaves, pulleys, rope reeving, suspension block, motors ,brakes, floating shafts, load cells, security holds, fixing devices for main hoist & aux. hoist drive assembly are to be completed.

4. Erection of cabin with top structure 5. Alignment of motor to the gear unit shall be done on the erected trolley. 6. Part assembly of the gantry and shelter shall be erected and fixed by bolting on the

crane beam. 7. Erection of balance structural assemblies, Monorail I beam, laying and termination

of power supply line to trolley. 8. Erection of the tie beams and structures including current supply line to trolley

including depot erection, cable tray & conduit fixing, foundation brackets for electrical & instrumentation items etc., with wiring & termination and electrical grounding work.

9. Rope reeving with Fork assembly, Fork swing mechanism and Aux. Hook. 10. In the meanwhile platform & ladders fitments with bolts & welding wherever

necessary shall be carried out. 11. Fixing of cabin structure to the crane beam by welding and the operator cabin to the

structure by bolting and fixing pins. 12. Complete electrification & charging of trestle crane.

9.5 ERECTION OF TURBINE HALL CRANE (SMM20AE001) - 180+180/32 T

A. General:

1. The turbine hall crane is an Electrical Travelling crane of load capacity 180+180/32 T. The crane is located at an elevation of +29.205 m of Turbine Building (UMA).



2. The turbine hall crane is free issue material to contractor for assembly, erection, commissioning and testing. There are two nos. of turbine hall cranes (one no. per unit) under this scope of contract.

3. After completion of above activities an additional mounting trolley of load lifting capacity 180/32 T shall be mounted on each of the turbine hall crane. The scope covers assembly, installation, inspection and combined load testing of additional (mounting) trolley.

4. After use of the above arrangement the additional mounting trolley of load lifting capacity 180/32 T shall be dismantled and removed from the turbine hall crane.

5. SOQR of this tender are for measurement and billing of above activities of turbine hall crane erection, mounting of additional trolley and dismantling of additional trolley.

B. Ground assembly:

The following are the major steps involved in assembly of Turbine hall crane.

1. The single span shall be placed on supports (concrete blocks/ wooden sleepers) with sufficient heights to enable easy assembly of the end carriages.

2. The other single span shall be placed parallel on supports (concrete blocks/ wooden sleepers) with required gap between the spans as per drawing.

3. The end carriages with the travel mechanism shall be fixed to the span with bolting to form a solid bridge.

4. The crane rails shall be assembled and erected over the bridge span by welding. 5. The metal platforms and hand railing shall be assembled and erected around the

bridge by welding.

C. Erection of turbine hall crane: The following are the sequence of activities in erection of Turbine hall crane.

1. The assembled bridge structure of the beam with travel mechanism shall be lifted and

erected over the crane rails using heavy duty crane. The erected beam structure shall be locked temporarily in order to prevent movement of the crane over the rails during the due course of erection activities.

2. The Erection of main trolley with travel mechanism and hoisting mechanism shall be carried out. The erection of mounting trolley with travel mechanism and hoisting mechanism shall be carried out. The joining together of both the trolleys shall be done in the design position by attached arms with elements of the clutch device which operates under convergence of trolleys.



3. The erection of seismic bracket shall be carried out after completing the trolley erection.

4. The metal platforms and hand railings intended for the maintenance of the crane shall be fixed in position by welding.

5. The operator cabin shall be fixed on the beam structure by welding. The welding shall be inspected as per the manufacturer recommendations. The cabin structure shall be fixed to the crane beam by welding and the operator cabin shall be fixed to the structure by bolting and fixing pins.

6. Rope reeving with Fork assembly, Fork swing mechanism, Aux. Hook 7. In the meanwhile platform & ladders fitments with bolts & welding wherever

necessary shall be carried out. 8. Complete electrification & charging of turbine hall crane. 9. After the use of the turbine hall crane with additional mounting trolley in Unit-3, the

additional mounting trolley shall be de-coupled and removed from Unit-3 and shifted to Unit – 4 for similar work. After completing the similar work in Unit-4 the additional mounting trolley shall be returned to NPCIL stores through Contractor Credit Voucher (CCV).

9.6 ERECTION OF ELECTRICAL OPERATED TRAVELLING CRANES:

A. General: 1. Erection of the following type of MHE is covered under this clause.

a. 20/5 T capacity crane (0SMU20AE104) b. 32/5 T capacity crane (FCD02AE121) c. 30/5 T capacity crane (FCD01AE071) d. 1 to 32/5 T capacity cranes

2. The Electrical operated Travelling crane of lifting capacity of 20/5 T (0SMU20AE104) is located at an elevation of +18.5 m inside the UKS building. The crane is free issue material to contractor for assembly, erection, commissioning and testing. SOQR of this tender is for measurement and billing of this crane.

3. Electrical operated Travelling crane of lifting capacity of 32/5 T (FCD02AE121) is located at an elevation of +16.5 m inside the UFC building. The crane is free issue material to contractor for assembly, erection, commissioning and testing. SOQR of this tender is for measurement and billing of this crane.

4. The special Electrical travelling crane of lifting capacity of 30/5 T (FCD01AE071) is located at an elevation of +16.5 m inside the UFC building. The crane is free issue material to contractor for assembly, erection, commissioning and testing. SOQR of this tender is for measurement and billing of this crane.

5. Electrical operated Travelling cranes of lifting capacity varying from 1 T to 32 T are located in various buildings and various elevations. These cranes shall be assembled,



erected, commissioned and tested by the contractor. The following SOQR of this tender are for measurement and billing of the cranes for assembly, erection, commissioning and testing.

SOQR for the electrical cranes with capacity 5 T, SOQR for the electrical cranes with capacity 2T, SOQR for the electrical cranes (contractor scope of supply) of capacity

varying from 1 T to 32 T.

B. Assembly and erection: 1. The crane span beam shall be placed on the supports (concrete block/ wooden

sleepers) with enough height for end girders assembly with travel mechanism. The end girders are fixed to the span beam with bolted joints. The metal platforms and hand railing shall be assembled and erected around the bridge by welding.

2. The assembled bridge structure of the beam with travel mechanism shall be lifted and erected over the crane rails by crane with required capacity (The required crane for lifting and erection shall be the contractor scope). The erected beam structure shall be locked temporarily in order to prevent movement of the crane over the rails during the due course of erection activities.

3. The Erection of trolley with travel mechanism and hoisting mechanism shall be carried out. The operator cabin shall be fixed on the beam structure by pin and bolting. The metal platforms and hand railings intended for the maintenance of the crane shall be fixed in position by welding. The suspension of flexible cable is fixed on monorail with brackets on the side wall of the span girder.

4. For double girder and single span cranes, the operator cabin shall be fixed on the beam structure by pin and bolting. Anti-seismic restrainers shall be fixed on the trolley and the span beam by fixing bolts.

9.7 ERECTION OF HOISTS, GRAPPLERS & MANUAL CRANES:

A. General: 1. Erection of the following type of MHE is covered under this clause.

a. Manual Stationary Gear Hoists (Capacity 0.5 T to 5 T) b. Gear mobile hand operated hoists (Capacity 0.5 T to 5 T) c. Hand operated Grapplers (Capacity 0.5 T to 5 T) d. Electrical hoists (Capacity 0.25 T to 10 T) e. Manual Cranes with capacity of up to and including 5 T



2. Manual Stationary Gear Hoists (Capacity 0.5 T to 5 T) are located in various buildings and various elevations. These hoists shall be assembled, erected, commissioned and tested by the contractor. The following SOQR of this tender are for measurement and billing of the hoists for assembly, erection, commissioning and testing.

SOQR for the hoist (contractor scope of supply) of capacity varying from 0.5 T to 5 T.

3. Gear mobile hand operated hoists (Capacity 0.5T to 5T) are located in various buildings and various elevations. These hoists shall be assembled, erected, commissioned and tested by the contractor. The following SOQR of this tender are for measurement and billing of the hoists for assembly, erection, commissioning and testing.

SOQR for the hoists (contractor scope of supply) of capacity varying from 0.5 T to 5 T.

4. Hand operated Grapplers (Capacity 0.5 to 2T) are located in various buildings and various elevations. These grapplers shall be assembled, erected, commissioned and tested by the contractor. The following SOQR of this tender are for measurement and billing of the grapplers for assembly, erection, commissioning and testing.

SOQR for the grapplers (contractor scope of supply) of capacity varying from 0.5 T to 2 T.

5. Electrical hoists (Capacity 0.25T to 10T) are located in various buildings and various elevations. These hoists shall be assembled, erected, commissioned and tested by the contractor. The following SOQR of this tender are for measurement and billing of the hoists for assembly, erection, commissioning and testing.

SOQR for the hoists with capacity 5 T. SOQR for electrical hoists (contractor scope of supply) of capacity varying

from 0.25 T to 10 T.

6. Manual Cranes with capacity of up to and including 5 T are located in various buildings and various elevations. These cranes shall be assembled, erected, commissioned and tested by the contractor. The following SOQR of this tender are for measurement and billing of the hoists for assembly, erection, commissioning and testing.



SOQR for the manual cranes (contractor scope of supply) of capacity varying from 1 T to 5 T.

B. Assembly and erection:

1. Prior to start of the erection activities the area of erection shall be inspected for cleanliness and availability of necessary structural arrangement for fixing the hoist in position and the runway beam for hand operated grapplers and manual cranes. If the structural arrangement is not available the same shall be erected at site as recommended in the drawing. In addition, if the embedded structural part is not available the same shall be fixed by using adequate Hilti bolts as per the drawing/ FE recommendation. Necessary scaffolding to the height required for erection shall be made by the contractor at site following the safety norms and requirements.

2. Necessary arrangement for lifting and erecting the support bracket, runway beam and the hoist shall be made at location. The hoist shall be lifted and erected on its position with the top hook of the assembly in the erection position. The runway beam shall be lifted, aligned and erected on the brackets. The hand operated grapplers shall be lifted and erected on the runway beams. The stopper shall be fixed on the runway beams at both the ends on either side of the beam by welding/bolting as per the drawing requirements. The gear operated hand hoist shall be lifted and erected on hand operated grapplers with the top hook of the assembly in the working position.

3. The travel mechanism shall be assembled to the electrical hoisting device at ground level. Before erection of the electrical hoist check the voltage and frequency, indicated on the name plate.

4. The stopper shall be fixed on the runway beams at both the ends on either side of the beam by welding/bolting as per the drawing requirements. The electrical hoist with travel mechanism shall be lifted and erected on monorail assembly in the working position. The current carrier from the circuit breaker to the hoist is done by electrical cables. Pendent type control shall be used for controlling device of electrical hoist.

5. Both the end girders with travelling mechanism shall be lifted aligned and erected over the crane runway beams. The span girder shall be lifted and erected over both the End girders by bolting / welding as recommended by the manufacturer. The assembled travelling hoist shall be erected under the span girder. The end stops shall be fixed in span girder and crane runway beams by bolting or welding as specified in the drawing.

9.8 ERECTION OF PASSENGER AND FREIGHT LIFTS

A. General:



1. Erection of Passenger and Freight lifts of lifting capacity ranging from 400 kg to 5000 kg is covered under this clause.

2. The above Passenger and Freight lifts are located in various buildings and locations. These lifts are free issue materials to the contractor for assembly, erection, commissioning and testing. The following SOQR of this tender are for measurement and billing of the lifts.

SOQR for the lifts with capacity of 400 kg, SOQR for the lifts with capacity of 630 kg, SOQR for the lifts with capacity of 5000 kg.

B. Assembly and erection: 1. Before starting of installation the dimension, verticality and availability of EP’s for

fixing the cabin and counter balance guides of the lift shaft shall be measured and ensured. Necessary scaffolding arrangements and temporary lifting arrangements shall be made available in the lift shaft for the entire height of the lift shaft. The bottom of lift shaft shall be ensured for cleanliness.

2. If EP plates are not available in their respective location the same shall be fixed with the help of Hilti bolts. The bracket for fixing the guide shall be erected on the respective locations over the EP plates. The guide for the cabin and the counter balance shall be erected and aligned over the guide brackets. The lift shaft door shall be fixed starting from the bottom floor with its mechanism. The buffer supports for the cabin and the counter balance shall be erected at the bottom of the shaft over the concrete pedestals.

3. The counter balance frame shall be erected and the counter weights blocks shall be added to the frame to the designed value and fixed to the frame. The cabin shall be assembled and erected inside the lift shaft. The machine room equipments shall be erected over the foundation pedestal of the equipment with rope driving pulley.

4. The electrical panels shall be erected inside the machine room in their respective pedestals. The driving ropes reeving shall be done in accordance with the schematic diagram of the erection drawing / manufacturer instruction. All the electrical and control wiring shall be done in accordance with the instruction manual of the manufacturer.

10. ERECTION OF STRUCTURAL STEEL INCLUDING TRESTLE STRUCTURE:

10.1 Support brackets and EP plates:

1. Support brackets and EP plates shall be fixed on concrete ceiling/beam at different locations and buildings to provide support to MHE.



2. Receipt of fabricated supports brackets and EP plates from NPCIL stores or from any other designated place within the project premises as free issue materials, shifting to the location and fixing of same as per the drawings and documents.

3. Arrangement of required man power, tools & tackles, plant & machinery, special tools, consumables including NPCIL approved electrodes and filler wires, cleaning aids etc., to complete the work as per drawings and tender specifications.

4. Arrangement of scaffolding material, preparation of staging, platforms, Installation and de-installation of scaffolding.

5. Preparation of reports, documents required at various stages of the work.

6. Erection in general shall conform to the relevant clauses in IS: 800. In case of any faulty erection, all such dismantling and re-erection required will be at the contractor's cost. Any rework / rectification required on the place of erection (roof EP’s) are to be carried out by the contractor for proper placement of fabricated plates to the satisfaction of the Engineer by chipping and additional EPs /plate provided with proper approval issued by ENC. This shall also include any additional inspection requirements as decided by the Engineer.

7. All Erected structures (EP's and support brackets), assembly and welding executed in accordance with the WD requirements are to be checked and offered for inspection by NPCIL Engineer and recorded in a protocol.

8. The works shall be executed as per the drawings, specifications, approved procedures and to the Instructions of Engineer In-charge.

9. The contractor shall protect all existing plants, embedded parts, all permanent and temporary structures, piping, conduits, equipment and facilities against damage during erection. The contractor shall perform his work in a manner, in no way endangers the operations of any existing plant or structures or hinders other construction activities.

10. All the support brackets and EP plates will be issued as free issue materials to the contractor. The SOQR of this tender are for measurement and billing of structural steel erection.

10.2 Fixing of anchor fasteners for supports:

1. The Hilti or equivalent anchor fasteners shall be fixed on ceiling at different locations and buildings to fix the EP and provide support to MHE.

2. The scope includes receipt of bolts from NPCIL stores, marking of holes, drilling of concrete to depth specified in drawings, cleaning the holes and fixing and tightening



of anchor fasteners to the required torque as per the manufacturer’s catalogue. 3. Extra holes may have to be drilled by the contractor if any obstruction of

reinforcement rods occurs in the location. Unused holes shall be filled with dry pack material.

4. All consumables, machineries power supply, approach platforms, scaffoldings, tools and tackles and works required for completion is in the scope of contactor.

5. All the anchor fasteners will be issued as free issue materials to the contractor. SOQR is for measurements of fixing of anchor fasteners for supports.

10.3 Erection of Trestle structures:

Trestle structure in general consists of arm shaped or П-shaped columns with arms supporting with bottom plates onto concrete base and fixed with foundation bolts. Monorail beam is fixed on columns arms. Working area with guard for maintenance of electric hoists is provided in one of columns bay. Shelter is provided for protection of electric hoists from direct solar radiation and atmospheric precipitation. Electric hoists with capacities ranging from 2T to 10T lifting capacity are mounted on the trestle structures erected at UPU, UPX and UQX.

The details of trestle structures are as follows;

KKS Code Designation Attached implements UPX17BQ800 Trestle L=33,0 m Electrical hoist, 5 T (SMQ24AE300) UQX17BQ800 Trestle L=22,2 m Electrical hoist, 2 T (SMP24AE200) UPU17BQ801 Trestle L=21,5 m Electrical hoist, 10 T (SMP24AE100)

The scope of work includes, but not limited to the following;

1. Fabrication and erection of trestle structure works like posts, beams, bracing,

monorails, stops, platforms, handrails, gratings, ladder, anchor bolts and other structural items for Fore bay (UPU), Fish protection facility (UPX) and Siphon well (UQX).

2. Contractor shall prepare detailed erection drawings and get approval from NPCIL before starting the erection.

3. Unless specified in the relevant drawing and specification, all erection work shall be carried out in accordance with the latest edition of Standard code of practice for use of structural steel.

4. Tolerances: Standard tolerances as per relevant specifications/ drawing shall be



followed. 5. Work of fabrication & erection as per approved drawings includes, handling,

transportation, storage, drilling, bending, straightening, cutting, bolting, welding grinding, erection, fixing and aligning in line & level and concreting/grouting of anchor/foundation bolts.

6. The contractor shall also be responsible for drilling of holes in structures and matching of holes.

7. Cutting may be done by shearing, sawing or machine flame cutting. All re-entrant corners shall be shaped notch free. Sheared or gas cut edges shall be dressed to a neat workmanlike finish and shall be free from distortion and burrs.

8. Hand flame cutting shall be undertaken only if so permitted by the Engineer and shall only be carried out by an expert in such work. Hand flame cut edges shall be ground smooth and straight.

9. All the fabricated structural steel members shall be inspected at all stages of fabrication and assembly to verify that dimensions, tolerances, alignment and surface finish in accordance with the requirements shown on the Contractor's shop drawings approved by NPCIL.

10. In case of any faulty erection, all such dismantling and re-erection required will be at the Contractor's cost. Erection in general shall conform to the relevant clauses in IS: 800.

11. No dragging of fabricated items is permitted. 12. After completion of erection, the contractor shall carry out in-situ touch up painting

wherever paint coating is removed or damaged trestle structures. 13. The Contractor shall protect all existing plants, embedded parts, all permanent and

temporary structures, piping, conduits, equipment and facilities against damage during erection. The Contractor shall perform his work in a manner, in no way endangers the operations of any existing plant or structures or hinders other construction activities.

14. All the erected structures, assembly and welding executed in accordance with the approved drawing requirements are to be checked and offered for inspection by NPCIL Engineer and recorded.

15. Arrangement of required man power, tools & tackles, plant & machinery, special tools, consumables including NPCIL approved electrodes and filler wires, cleaning aids etc., to complete the work as per approved drawings and tender specifications.

16. Arrangement of scaffolding material, preparation of staging, platforms, installation and de-installation of scaffolding.

17. Inspection, testing and making arrangements for the acceptance of the structures by NPCIL.



18. Preparation of reports, documents required at various stages of the work. 19. Completion of work in all aspects, as per tender specification, drawings. 20. The contractor shall supply and install the anchor bolts by concreting/grouting at no

extra cost. 21. SOQR of this tender is for measurement and billing for erection of trestle structure.

11. WELDING REQUIREMENTS:

11.1 GENERAL 1. No welding shall be done on surfaces which are wet or exposed to rain or excessive

draft. Surfaces to be welded shall be free from paint, rust, oil, grease, dust or any other contamination. Weld edge preparations shall be cleaned by use of approved solvents only.

2. Welds shall be cleaned between passes to remove all traces of slag and flux before successive beads or layers are deposited. Completed weldments shall be cleaned to the same extent. The craters at the starting and stopping points of each individual bead shall be carefully examined and any defects shall be removed by grinding.

3. Inspection and Quality Surveillance shall not be limited to examination of the finished weld. All dimensions specified for welding including weld size, reinforcement, edge preparation, fit up etc. shall be checked by gauges approved by the Engineer. All aspects of the materials, fabrication procedures and examination procedures used, that could affect the quality of the finished weld, shall be subjected to the approval of the Quality Surveyor. The equipment to be used shall be suitable for the quality of the work specified and the technique employed shall be based on methods which are known to produce good results and which have been verified at site by actual demonstrations. All stages of fit-up to final welding shall be checked and cleared by qualified inspectors/engineers of contractors. Random inspection shall be carried out by QA representative of NPCIL.

4. The welding technique and arc manipulation shall be controlled to ensure the following:

a) Full Penetration for groove welds. b) Full fusion into the preceding bead or layer. c) Full fusion into the base metal without undercutting along the sides of the weld. d) Uniformity of surface in both single run passes and beaded layers. e) Floating all slag, oxide and gases to the surface behind the advancing arc. f) Delay in electrode travel until base metal fusion at the starting point is assured

and until the crater is well filled at the completion of the weld. 5. Haphazard striking of the electrode on the base metal in establishing the arc shall not

be permitted. The arc should be struck either in the joint where the metal surface will



be fused into the weld or on a starting tab. Starting tabs shall be of the same material or a material compatible with the base metal being welded. When inadvertent arc strikes occur, the areas affected shall be ground flush and then examined by the magnetic particle or liquid penetrant method. High frequency arc starting devices shall be used for GTAW process.

6. Care must similarly be taken when stopping the arc to avoid an unfilled crater and crater cracks.

7. The arc should be drawn off to the side of the joint and stopped on the beveled surface of the joint while extending the arc length rapidly.

8. In GTAW, the machine should ideally be equipped with a foot or hand control to permit a gradual decrease of current. It is then easier to fill the crater completely and prevent crater cracks. Alternatively the arc shall be extinguished as mentioned above.

9. When welding carbon steel with covered electrodes, the width of the deposited pass shall not exceed three times, the nominal core wire diameter. For vertical position stringer bead is preferred.

10. In GTAW the electrode must be correctly shaped i.e. pointed for DC welding and a spherical end for AC welding. The electrode extension beyond the gas cup should be kept as short as is consistent with the joint being welded. The welding torch should be inclined slightly in the forehand welding position and the filler metal added carefully to avoid contact with the consequent contamination of the tungsten electrode. If contamination does occur, the tungsten electrode shall be cleaned and redressed. Similarly, if the tungsten electrode comes into contact with the weld pool the operator shall break the arc and grind out the tungsten deposit.

11. Joint design: In all instances the edge preparation for welding shall be as per the Engineer’s drawings.

12. Fit-up: Before fitting up the weld joint, the profile and dimensions of the weld edge preparation shall be checked. If the specified tolerances are exceeded this shall be corrected with prior approval, by grinding, machining or any other method acceptable to Engineer. All fit-ups shall be examined by the Quality Surveyor prior to welding the root pass.

13. Weld profile: The surface smoothness of the finished weld shall be suitable for proper interpretation of the non-destructive examination of the weld. If grinding is necessary, the weld shall be blended into the parent metal without thinning the basic wall thickness of the parent or weld metal in any way. Uneven or excessive grinding may be cause for rejection or re-work at the discretion of the Quality Surveyor. Fillet welds shall preferably be slightly convex and shall be free from undercutting and over-lap at the toe of the weld. Convexity shall not exceed 1.6mm Full fusion shall be obtained at the root of the fillet and in no case shall the leg length of the fillet be



less than the nominal weld size stated in the drawings or specification.The leg length shall not exceed the specified size by more than 1.6mm. Dimension specified in the drawing and codes shall be adhered.

14. Tack welds: The number and size of the tack welds shall be kept as small as is consistent with adequate strength and joint alignment. All tack welds shall be examined visually for defects and if found defective shall be completely removed. As the welding proceeds, tack welds shall be either removed completely or shall be properly prepared by grinding or filling their stopping and starting ends so that they may be satisfactorily incorporated into the final weld.

11.2 WELDING MATERIALS

1. Contractor shall supply all the welding consumables (including electrodes, welding

wire, inert gas etc.) required to execute the works of subject tender. All these shall be procured for NPCIL approved vendors only. Copy of list of present approved suppliers of electrode is enclosed. The following electrodes and wires shall be used:

- E7018 as per ASME section-II part C SFA-5.18

- ER70S2 as per ASME section-II part C SFA-5.9

2. The contractor shall store electrodes and filler wire in a specially developed controlled atmosphere. The temperature of room shall be maintained not lower than +200C and not more than 500C. The relative humidity of room should not exceed 50%.

3. The electrode of different type needs to be baked at different temperature. The contractor shall have mother baking oven of heating capacity not lower than 4000C. The baked electrode shifted to site should be stored in a transfer oven at 1500C to 2000C. Electrode should be send to site only through portable oven having heating range of 1000C and above. Electrode should never be taken to site without ovens.

11.3 WELDING TECHNOLOGY

The contractor may use following welding technologies

a. Manual arc welding with coated electrodes; b. Manual argon-arc welding with non-consumable (tungsten) electrodes (TIG

welding); c. Combined welding (root and hot pass by argon-arc welding; final run by manual arc

welding).

11.4 REPAIRS



1. Any weld repair shall be subject to the approval of the Quality Surveyor. 2. Unacceptable defects shall be removed by grinding, machining or chipping. Arc

gouging or flame cutting are also permitted provided gouged surfaces are ground back at least 1.6mm below the deepest indentation.

3. If preheat is specified in the appropriate welding procedure then the same preheat must be maintained during flame outing or arc gouging.

4. Dye penetrant examinations shall be used to check that the defect has been completely removed prior to weld repair. In the event of any doubt regarding complete removal of a defect, radiography may be required at the discretion of the quality surveyor.

5. Weld repairs shall be made using qualified procedures and welders. The preparation for the weld repair shall have the prior approval of the Quality Surveyor.

6. In the event of several unsuccessful repair attempts or if the Quality Surveyor feels that a satisfactory repair is not feasible, the joint shall be completely remade. Due consideration should be given to check the damage to the parent metal.

7. The re welded area shall be re-examined by the methods specified for the original weld. Where radiography is required, a minimum amount of 50mm film overlap beyond the repair edges must be ensured.

8. Repairs of any base material utilized in fabrication of MHE components shall not be undertaken unless specifically permitted by the Quality Surveyor.

12. QUALITY ASSURANCE:

12.1 QUALITY CONTROL OF WELDED JOINTS:

Contractor shall prepare QAP for all the erection activities at site and submit for approval of NPCIL. A sample format for guidance for preparation of QAP is enclosed as Annexure-3 of this section. The operational control includes inspection of technology compliance in the course of preparation of details, fit-up, heating, welding process etc

Notwithstanding with the quality control requirement given in referred normative document /specification, the following shall be applicable during the quality assurance & testing:

a. Certification of inspectors; b. Inspection of fit-up and weldment; c. Incoming control of main materials; d. Quality control of welding materials; e. Operational and process control; f. Non-destructive inspection; g. Destructive inspection;



h. Load testing;

The contractor shall note the following:

1. The MHE erection covered by this contract shall be subjected to stage inspection and final inspection and testing as per QAP. The Contractor shall provide all required services and resources to establish and maintain quality of workmanship during erection.

2. The contractor shall perform his internal inspection / NDT testing before offering the MHE for NPCIL’s inspection. Only after ensuring that his inspection/test results are satisfactory, contractor shall offer the MHE for NPCIL’s inspection.

3. The minimum inspection requirements for all components/equipment shall DPT, UT and RT shall be witnessed by NPCIL as per approved QAP.

4. All MHE / structures erected shall be checked for proper alignment, orientation, bolting/ welding, torquing etc. The inspection requirement shall be as per WD.

5. Destructive examinations such as mechanical test, inter-crystalline corrosion test, IGC test, metallographic analysis, determination of chemical composition, and determination of ferritic phase shall also be carried out to ascertain the quality of the weld and base. The inspection requirements will be indicated in detail in the final erection specification.

6. The scope of work under this contract covers erection work which demands highest degree of quality and reliability standards. In line with these requirements, the Contractor shall have a dedicated group of experienced and qualified inspection engineers and inspectors responsible for assuring quality assurance and quality surveillance program at their work. Further, persons deployed on the job shall be subject to approval of NPCIL for their technical capabilities.

7. NPCIL shall carry out audit in all phases of the work i.e. procurement, pre-fabrication, erection, inspection, examination and testing.

8. NPCIL or its authorized representative(s) shall carry out Quality surveillance in all phases of the work. They will have free access to all areas where works involving the concerned contracts/purchase orders are in progress. This includes access necessary to verify the implementation of all aspects of the Quality Assurance Program as well as access to Sub-contractor’s facilities.

9. Quality surveillance by NPCIL or its authorized representative includes, but is not limited to, Witness and Hold Points.

10. ‘Witness Points’ are critical steps in examination/ inspection/testing where the contractor is obliged to notify in sufficient advance of the start of operation/test so that it may be witnessed. The supplier may proceed with the work past a Witness



Point if the NPCIL QS or its authorized representative is not available at the appointed time.

11. ‘Hold Points’ are critical steps in examination/ inspection/testing where the contractor is obliged to notify NPCIL or its authorized representative in sufficient advance of the start of operation/test so that it may be witnessed. The contractor is not to proceed with the work past a Hold Point except by written waiver/agreement by NPCIL.

12. The performance (or waiver) of quality surveillance activities by NPCIL, QS or its authorized representative does not relieve the contractor of any obligations to meet all requirements of the drawings/specifications.

12.2 NON DESTRUCTIVE EXAMINATION (NDE):

Non Destructive Examinations of welded joints of MHE shall be performed by the methods prescribed in working documents The following Non Destructive Examinations shall be performed by the contractor on the MHE as per the requirements of working documents. Contractor shall prepare procedure for each NDE method and submit to NPCIL for approval before carrying out the examinations.

a. Visual and measuring methods; b. DPT method; c. Radiographic method; d. Ultrasonic method; e. MPT method;

1. Visual: Includes visual inspection of the weld joints and erected components of MHE

as per the approved standards and procedures by qualified and authorized QA personnel of contractor and NPCIL.

2. DPT: Performance of Dye Penetrant Test of weld joints of MHE, supports brackets

and other structures as per working drawing and documents includes activities like identification of the test area/joints, Pre-cleaning of joints (test area) and post cleaning after testing, shifting of DPT consumable to location, Carryout dye penetrant Testing by ISNT/ ASNT level-II qualified personnel as per the approved procedure, generating reports, report analysis and submission to NPCIL for acceptance including arrangements of equipments, manpower, tools tackles materials & consumables and



completion of work as per the tender specification, drawings and as per the instructions of the Engineer-in-charge.

3. RT: Performance of Radiographic examination of weld joints of MHE, support

brackets and other structures as per the working drawings including providing necessary machinery, radiographic sources, radiographic cameras, storage including storage of source at concrete pits, handling, safety arrangements, surface cleaning of welded joints, removal of paint, grease, slags, burrs, spatters both in CS & SS materials, installation and dismantling of scaffolding /platforms, arranging materials, consumables such as radiographic film, developer, fixer etc., Carryout Radiographic Testing by ISNT/ ASNT level-II qualified personnel as per the approved procedure, developing the films, marking, generating reports, report analysis and submission to NPCIL for acceptance including arrangement of manpower, tools, tackles and completion of work as per the tender specification, drawings and as per the instructions of the Engineer-in-charge.(Radiographs shall be submitted to Engineer-in-charge along with RT reports after interpretation).

4. UT: Performance of Ultrasonic Test of weld joints of MHE, support brackets and

other structures as indicated in working drawings and documents. includes activities like identification of the test area/joints, Pre-cleaning of parts and components on test area and post cleaning after testing, Sourcing and calibration of the UT machines with calibration block, shifting of the Ultrasonic flaw detector along with probes and accessories to location, Carryout Ultrasonic Testing by ISNT/ ASNT level-II qualified personnel using both normal and angle probes, generating reports, report analysis and submission to NPCIL for acceptance including arrangements of equipments, tools tackles, materials & consumables and completion of work as per tender specification, drawings and as per the instructions of the Engineer-in-charge.

5. MPT: Involves carrying out Magnetic Particle Testing on equipment and supports

which includes activities like identification of the test area/joints ,Pre-cleaning of parts and components on test area and post cleaning after testing, shifting of MPT consumables to location, Carryout Magnetic particle Testing by ISNT/ ASNT level-II qualified personnel as per the approved procedure, generating reports, report analysis and submission to NPCIL for acceptance and including arrangement of plant & machinery, manpower , tools tackles & consumables and completion of work as per the tender specification, drawings and as per the instructions of the Engineer-in-charge.



13. COMMISSIONING AND TESTING OF EQUIPMENTS:

13.1 PRE-COMMISSIONING CHECKS AND PREPARATION FOR TESTS:

1. After completion of erection as per drawing and manuals contractor shall carry out visual checks on the MHE as part of pre-commissioning checks to ensure that all parts of mechanical, structural, electrical fitting, lights, limit switches including earthings, buffers, bell/hooter, fasteners, welding, touch up painting, safety devices or if any are in place signifying readiness of the crane for testing.

2. The temporary arrangements made for erection of MHE and inside the lift shaft shall be removed.

3. The erected hoists grapplers shall be re-preserved and the lubrication shall be applied on the lubrication points as per the manufacturer’s instruction.

4. All the commissioning works shall be properly documented as commissioning reports and shall be submitted to NPCIL. Check lists, data sheets, commissioning procedures etc., shall be prepared before the start of commissioning works and approval shall be obtained from NPCIL.

5. The checks shall be carried out for the load testing as per the WD requirements. The requirements of relevant Indian standard/ AERB safety guides shall also be followed. The stringent of either of these requirements have to be met when there are variations in the requirements of the standards. Some of the checks to be performed on the crane subsequent to completion of work prior to load test is given below.

6. All the checks shall be recorded in a format to be agreed to the ENC and submitted as a part of CCC.

7. The test loads shall be transported from NPCIL stores to the testing location and contractor shall make necessary arrangement for load testing of the crane. All lifting tools and tackles including arrangement of competent person for certifying the Load Test shall be arranged by the contractor.

13.2 PRE-COMMISSIONING OF MECHANICAL WORKS:

1. Installation of girders for EOT cranes, fixing of rails, checking their alignment, elevation and central line with respect to the building, clearances with respect to building to be within the specification and recording the data.

2. Installation of I-beams and their supports for trolleys, checking their elevation, central line, alignment and position with respect to building / equipment and recording the same.



3. Installation of Chain pulley blocks and their supports, checking their elevation, central line, height of travel, alignment and position with respect to building / equipment and recording the same.

4. Installation of elevators car shaft, alignment, fixing, car cabin, landing door, gear box machines alignment in machine room.

5. Completion of all drive elements, lubrication of gear boxes, gears, bearings, installation of all protective guards, installation of approach platforms, etc.

13.3 PRE-COMMISSIONING OF ELECTRICAL WORKS:

Contractor shall carry out the following general checks on the electrical equipments of the cranes as part of pre-commissioning / commissioning checks.

1. Any physical damage to the control panels, proper tag number, healthiness of the

terminal blocks used inside the panel, healthiness of the gasket, insulation resistance, connection of two earthing terminals suitable for grounding, proper glanding, etc shall be checked on the control panels and rectified by the contractor.

2. Any physical damage to the pendent, healthiness of the terminal blocks used inside Pendent, healthiness of the gasket, healthiness of the push buttons, insulation, earthling connection, etc shall be checked on the crane operating pendent and rectified by the contractor.

3. Installation, access to motor, proper illumination at the motor location, proper cleanliness of the motor surface, foundation bolt tightness, level of foundation, bearing lubrication, free rotation of motor after de coupling the motor, motor frame grounding, proper power cable support, earthing connection for continuity and tightness, overload relay setting, healthiness of control supply fuses if any, any physical damage to the power cable, availability of tag number for the cable, insulation resistance of the cable, terminal box of the motor, etc shall be checked on the motors and rectified by the contractor.

4. After completion of the erection activities the power and control cables shall be checked for its routing and termination and continuity as per the circuit diagram. Layout of the power and control cables shall be ensured to be in a protected route to avoid physical damage due to movement of personnel, crane movement etc. along with necessary support clamping and arrangement. Ends of the cables shall be crimped with cable lugs with cable crimping tool. Proper tagging of cables shall be done. Ferrules shall be provided for the internal wiring and identification of the wires shall be printed in the ferrules using ferrule printer. The internal wiring of the panels



shall be checked for continuity. Shielded cables of the encoders shall be laid carefully without any sharp bends.

5. Contractor shall ensure the continuity of control cables from equipment junction box to individual control panels, power cables from equipment junction box to MCC/switchgear and installation of down shop leads/ insulated bars for the electrical supply and electrical grounding of equipments.

6. The internal components like relay, contactor and meters of the panel shall be checked for healthiness.

7. The software for PLC & variable frequency drives of the cranes shall be installed and necessary assistance shall be provided by the contractor to the crane manufacturer for the same.

8. Contact resistance of DSL shall be checked by micro ohm meter. 9. All the interlocks, logic and functional tests shall be carried out by the contractor.

10. Contractor shall check the main distribution board / switch fuse unit and cable laying from main distribution board to the local distribution board and further distribution to the respective loads.

11. Contractor shall carry out the measurements of IR value of all the motors of driving system and braking system, resistance and inductance measurement, the no-load operation of the motor and measure parameters like running current, voltage, speed, winding temperature, bearing temperature etc and corrected if necessary.

13.4 CHECKING OF CONFORMITY OF MHE: The following should be checked for compliance to the working documents.

1. Lifting capacity of the crane 2. Lifting height of MHE 3. Hoisting speed of MHE 4. Lowering speed of MHE 5. Travelling speed of the crane (longitudinal travel and cross travel). 6. The functions of the limiting devices 7. The working characteristics of the power drive means, for example, electric current

in the electric motors under the conditions of the test loads.

13.5 VISUAL CONTROL: The visual control is carried out to establish the conformity of the crane to passport data of the parameters the important one are listed below.

1. Mechanism, electric equipment, safety devices, brakes, control apparatus, lightening and signaling.



2. Metal constructions and their connections, ladders, the approach means. 3. The repair platforms must provide convenient approach to the mechanisms and

electric equipment. 4. Check the headroom available from the crane girder to roof structures to be within

requirements. 5. Protective measures – Fencing especially for current supply devices. 6. Hook or another load handling fixture and the parts for their suspension. 7. Ropes and their fixing – clamping devices are fitted properly. 8. Fixing of the rope to the drum must be done with the reliable means, which allows

substituting the rope. In case of usage of the clamp bars there must be at least two of them. The length of the free end of the rope after the last clamp must be at least two rope diameters.

9. Check that the rope capacity of the drum must be such, that at lowest possible position of the load fixing device the rope shall remain rolled on the drum at least 1.5 turns of the rope or chain, not taking into consideration the turns under the clamping device.

10. Check that the load hoists with two drives must have the rigid connections between them, preventing the spontaneous going of the load down in case of failure of one of the devices.

11. Cranes, running over the railways in the open must be equipped with the rail anchors. 12. Blocks, axles and the parts of their fixing. 13. Limit Deviations of the Rail Tracks (in the plan and profile). 14. Difference of the rail heads elevation in one cross section, Difference of the rail

elevations at the neighboring columns, Tapering or widening of the rail-way gauge (deviation of the rails from the project position in the plan), Mutual displacement of the butt ends of being connected rails in the plan and in the height, Gaps in the joints of the rail shall be measured and recorded in mm.

13.6 CONDITIONS OF THE TESTS ON MHE:

1. For the tests, the crane must be equipped with the working equipment for the

operation with the nominal load in accordance with technical documentation. 2. Test of the crane moving over the rail way, should be conducted on the track,

executed and laid in accordance to the conditions established in the technical documentation.

3. During the test, the speed of the wind should not exceed 8.3 m/s where ever applicable.



13.7 FUNCTIONAL TESTS ON MHE: 1. The functional test on all MHE shall be conducted at no-load condition and adjusted

if necessary. The test must include the repeated start and stop for each movement in the whole range of the given movement and they must continue for at least 1 hour in the cycle of work.

2. The operational check of the hoist shall be checked as per the manufacturer operational check list. The hoist shall be checked for free movement without load.

3. The gear mobile hand operated hoist shall be checked for free movement of rising and lowering of hoist and the movement of grapplers along the axis of the hoist runway beam without load. Also the movement of hand grapplers along the longitudinal axis of runway beam shall be checked.

13.8 LOAD TESTS ON MHE:

Static load test, dynamic lest and stability test shall be conducted on MHE for its suitability of the work. Prior to load testing the dimensions of the identified chain link shall be noted and also the throat opening dimension of the hooks (Top & Bottom) shall be noted and recorded.

1. Static tests are executed to control the design serviceability of the crane and its

assembly units. The tests are considered successful in case during their execution; there have been no cracks, no residual deformation, peeling of the paint or damages and no slackening or damage of the joints. Static test should be conducted for each MHE in the positions and execution variants such that the gradually increased test load is elevated from the ground by 100-200 mm and kept in this position during the period necessary for conducting the tests not less than 10 min. The test load for all the cranes must be at least 1.25 times of the rated capacity if no higher value is to be applied as per norms/ standard.

2. Dynamic tests are conducted to control the functioning of the crane mechanism and brakes. The crane is considered as having successfully passed the tests in case the elements of the crane fulfill their functions and there will not be any discovered damages of the mechanisms or of the construction elements and no slackening of the joints. The test load for all the cranes must be at least 1.1 times of the rated capacity if no higher value is to be applied as per norms/ standard.

3. Stability Test: The test for the load stability is conducted to control the stability of the crane. The crane is considered as having successfully passed the test, if it does not overturn at the static application of the load to the hook.

4. The Load Test of polar and trestle cranes shall be performed at different stages as detailed below.

Safe working load at 100% (350T)



Static load test at 125% of the rated capacity (437.5T) Dynamic load testing at 110% of the rated capacity (385T)

5. The Load Test of Turbine hall crane shall be performed at different stages as

detailed below. Static test of erection (Load) trolley at 125% (225T) Static test of mounting trolley at 125% (225T) Combined static test using the lifting beam of capacity 419 T Combined dynamic test using the lifting beam of capacity 369 T

6. The Load Tests of Hoists & grapplers shall be performed at different stages as

detailed below.

Static test at 125% of the rated lifting capacity of the hoist. The load shall be lifted to a height of 200mm to 300mm and hold it for 10 minutes. During the static test the initial height and final height of the load from ground level is measured and recorded. After lowering the load the dimension of the identified chain link and the throat opening of the hooks (Top & Bottom) shall be measured and recorded. The deflection of the beam shall be measured and also the tightness of the fasteners of the bracket shall be ensured. The measured dimensions shall be within the acceptance range.

Dynamic test at 110% of the rated lifting capacity of the hoist. The load shall be raised and lowered to check the free movement of the hoist and also the brake of the hoist with load shall be ensured by releasing the hand chain at any point during raising or lowering for holding the load at any point.

7. The Load Test of the Lifts shall be performed at different stages as detailed below.

Safe working load at 100% Static load test at 200% of the rated capacity Dynamic load testing at 110% of the rated capacity

After completion of the load test the temporary arrangements made for erection of the MHE shall be removed.



14. GRIT BLASTING AND PAINTING: Grit blasting & Painting has to be performed for the various components of MHE surfaces as

mentioned in the working drawings. Material shall be inspected for any damage, lamination etc. Grit blasting: Grit blasting of the MHE component surfaces shall be carried out on the surfaces wherever painting is to be removed to meet the surface finish requirements of friction grip joints. After grit blasting the surface shall be cleaned by blowing dry air / vacuum cleaner to remove the dust etc. Grit blasting shall be carried out to meet the surface finish requirement of the manufacturer. Painting: After completion of erection of MHE the contractor shall carry out touch up painting in-situ as per the manufacturer recommendation.

15. ELECTRICAL GROUNDING OF EQUIPMENTS:

Contractor shall provide grounding connection for all the MHE to the grounding grid of the project as part of the main erection work of MHE without any extra cost. This shall be executed as per approved procedures and document. Procedure shall be prepared by contractor and approved by NPCIL. The scope shall include supply of materials required for electrical grounding of MHE and fixing of same.

16. GENERAL TECHNICAL REQUIREMENTS:

The general technical requirements are based on norms, standards and practices followed for such jobs. The engineer shall have the right to amend the existing and to issue additional specifications whenever the need arises. In the event that certain technical requirements are not described in the engineer’s specification, the contractor shall request the engineer, prior to starting any fabrication to clarify governing requirements.

16.1 Threading: The contractor shall be responsible for threading all mating components wherever

required. Prior to making a screwed joint, the threads shall be thoroughly cleaned of all foreign matter, oil, grease etc. Any thread that has become blurred or deformed shall be repaired prior to assembling the joint. No lubricants or sealants shall be used on threaded joints.

16.2 Tightening of bolts: All bolts shall be engaged in such a way that there is visible evidence of complete threading through the nut or threaded attachment. At least two threads on bolt should project beyond nut. The bolt stress in all flanged joints shall be relatively uniform. All threads of bolts and nuts shall be cleaned by suitable means so as to be free from any foreign materials and suitably approved lubricant whenever specified shall be used prior to tightening of bolts.



Torque Wrenches shall be used for tightening of bolts to ensure controlled tightening. Torque values for various sizes of bolts for tightening shall be as per specification in drawings.

16.3 Removal of caps: Removal of caps and other closures from all MHE components supplied

with temporary caps is included in contractor’s scope of work. This shall be considered as part of edge preparation and job shall be done without any extra charges. The removal of caps shall be done by grinding or sawing off only. Any damage to the equipment during the process of removal of the caps shall have to be made good by the contractor’s at his own cost.

17. HOUSEKEEPING & CLEANLINESS:

Project instruction for housekeeping enclosed in the tender shall be complied. The contractor shall thoroughly check and remove the extraneous materials, if any, like electrodes, welding rods, helmets, bolts/nuts, etc. left in the working place. Cleaning shall be done on day to day basis. All the waste collected shall be stored in sealed container and to be removed on weekly basis. All wastes generated like surplus earth after use/surplus construction materials to be disposed off from time to time to the disposal locations as directed by the site Engineer In-Charge. Handling, Transportation & Disposal of the waste generated during construction, installation, commissioning, etc shall be a part of the contractor’s scope of work. Contractor to collect such waste generated within battery limit and then transport and dispose to the locations as directed by the site Engineer In-Charge. Also, housekeeping of the area under the control of the contractor shall be a part of the contractor’s scope of work.

Scope includes but not limited to:

a. Debris Disposal:

Involves collection of debris from various floors of buildings, transportation and disposal to waste yard which includes activities like survey of the buildings, identification, collection and removal of dust, electrode waste, welding waste, cutting waste, grinding waste, packing material, cement debris, aggregate, waste sheets, cut pieces of wires/cable etc. from working place and disposal at designated dump yard with in 2 Km distance. This work also includes providing man power, P&M, all tools & tackles required for completion of work, making & maintenance of reports as per tender specification and as per the instructions of the Engineer-in-charge.

b. Surface Cleaning of MHE: Involves cleaning of external surfaces of all MHE which includes activities like removal of dust, unwanted sticking, foreign particles and other forms of dust, from the surface of



MHE including providing all necessary cleaning aids and appliances. This work also includes arranging manpower, consumables and all other required tools and tackles required for the completion of work as per tender specification and as per the instructions of the ENC.

When work is going on it is the responsibility of the contractor to maintain clean environment by maintaining good housekeeping. Project instruction for housekeeping enclosed in the tender shall be complied. It is necessary to identify the person who is responsible for the same.

18. RECORDS AND REPORTS:

18.1 Records: The contractor shall maintain records pertaining to the storage, welding, erection, alignment, inspection and testing work in compliance with all drawings and technical requirements. The records shall be in a proper format as indicated by the Engineer. The contractor shall submit the copies of such-records to the Engineer within 7 days from completion of any particular work, and prior to submitting bill for progressive payments. The report concerning welding, alignment of the MHE is included in this category. The Engineer shall need certain records for verification viz. weld inspection report, consumable certificate, etc. The contractor will have a system of record to facilitate easy traceability of all such records. These records shall be subjected to the inspection of engineers, auditing group, AERB, Russian representatives etc. Soft (scanned) copies for the all the reports, records shall be made and submitted to NPCIL

18.2 Reports:

The contractor shall submit on weekly basis, to the ENC three (3) copies of following reports indicating the details of MHE erection progress, testing status, QA activities, etc.

(i) MHE erection progress report (ii) General statement of activities (iii)Welders performance & qualification records (iv) Weekly report on items on critical paths

In addition to above, the following reports shall be submitted to the engineer every month:

(i) Daily, weekly, fortnightly and monthly progress reports (ii) Monthly planning report (iii) Three and Six months rolling schedules

All reports shall be statistical and on tabulated form indicated by the engineer.



19. COMPLETION OF WORK AND SUBMISSION OF CCC & MATERIAL

ACCOUNTING:

1. Completion of work: As far as technical requirements are concerned, the contractor’s work shall be considered as completed when all the MHE are installed and have passed all examination, inspection and tests requirements and painted and complete in all respects in accordance with drawings and specifications. The contractor shall be responsible for rectifying the defects and deficiencies revealed during testing or commissioning of the MHE, on the joints, in consultation with the Engineer and QS so as not to delay other works or testing.

2. Construction Completion Certificate (CCC): The contractor shall submit CCC

attaching all relevant documents needed for attesting the completion of work for each MHE. The CCC in the approved format shall be submitted to the ENC and shall be subject to endorsement by the ENC. The CCC for each MHE shall contain the following.

1. MHE descriptions 2. Manufacturers instruction / literature 3. As-built drawing information 4. Important correspondence 5. List of WD (with rev. no.) including FCN, ECN & DCN certified 6. Weld inspection reports & radiographic test final results 7. Weld procedures (welding and fabrication procedures, WPS & PQR) 8. Erection procedures for mechanical components (including forming and

assembly procedures) 9. Mechanical joint inspection report [ blasting / painting ] 10. Equipment erection & alignment report 11. Commissioning and testing procedures 12. Commissioning and testing reports

Final completion certificate will be issued only after the ENC has accepted all CCC’s and after other provisions of general contract conditions are duly met. Along with the hard copy of final CCC the contractor shall submit scanned copy in soft form (pdf format).

3. Material accounting: Contractor shall establish facility for soft ware based material

management system for the free issue materials, compatible with the NPCIL's software. Contractor shall prepare material accounting taking into the consideration of materials issued through various CIV, consumed through various erection reports, returned back to NPCIL’s stores through CCV and tally the quantities and submit to NPCIL for acceptance.



20. CONFIDENTIAL INFORMATION:

The drawings, specifications, proto-type, samples and such other information furnished to the contractor relating to the supply/works/equipments etc. are to be treated as confidential, which shall be held by the contractor in confidence and shall not be divulged to any third party without the prior written consent of the engineer. The contractor, therefore, binds himself, his successors, heirs, executors, administrators, employees and the permitted assignees or such other persons or agents directly or indirectly concerned with the works/supply to the confidential nature of the drawings, specifications, proto-type samples etc. It is a further condition of the contract that the Contractor shall not, without prior written permission from the Engineer, transmit, transfer, exchange, gift or communicate any such confidential information and also the component, sub-assembly, products, by-products, non-conforming/rejected equipment/components, etc. to any third party.

21. PATENTS AND PATENT RIGHT INDEMNIFICATION:

All specifications, drawings, patents and such other relevant information furnished to the contractor by the engineer shall be the property of the engineer. If, during the process of execution of the contract, any improvement, refinement or technical changes and modifications are affected by the Contractor, such changes shall not affect the title to the property of the engineer and the information, specifications, drawings, etc. including the improvement/modifications effected by the Engineer. The Engineer shall also have the absolute right to assign, transfer, sublet, use and transmit all such information and details to the Engineer’s consultants. Contractor shall not have any claim or rights whatsoever in respect of the Engineer’s drawings, specification, patents, proto-types etc. even where improvement refinement, modifications etc. were affected by the contractor.

All drawings, specifications, patterns, models and prototypes furnished to the contractor by the Engineer are intended to be complementary and to provide for and comprise everything necessary for the completion of work/supply and are the property of the Engineer. These are not to be used for any works or purpose other than those for which these have been provided and shall be returned to the Engineer immediately on completion of work/supply in good condition.



1. DISTRIBUTION

Sl. No. Copy Holder Copy No.

1 Master copy with Doc centre Original

2 All CEs / ACEs / PEs / ENCs #

# Soft copies issued through IPMIS

Sl.

No

Building

KKS codeDrawing No Drawing Name

No of

sheetsRemarks

1 UJA R01.KK.1 UJA.0.MRR.OK.WD001Installation Drawings for whole load lifting

equipment.17

2 UKC R01.KK.1 UKC.SMK.MRR.OK.WD001Installation drawing for load lifting equipment

upto el. +14,00025

3 UKC R01.KK.1 UKC.SMK.MRR.OK.WD002Installation drawings for load lifting

equipment above to el. +14.000.9

4 UKC R01.KK.1 UKC.SMK.MRR.OKU.WD003Installation drawings for load lifting

equipment.8

5 UMV R01.KK.1 UMV.SMM.MRR.OK.WD001Installation drawing for whole load‐lifting

equipment8

6 UMA R01.KK.1 UMA.SMM.MRR.OK.WD001Installation drawings of the electrical bridge

crane ith a capacity of 180+180/32 ton4

7 UMA R01.KK.1 UMA.SMM.MRR.OKU.WD002

Installation drawings for load lifting

equipment except cranes for load lifting

capacity of 180Te

19

8 1‐4 UKD R01.KK.1 UKD.SMK.MRR.OKU.WD0011‐4 UKD Installation drawing for whole load

lifting equipment12

9 USA R01.KK.1 USA.SMS.MRR.OKU.WD001Installation drawing for all load lifting

equipment3

10 UBA R01.KK.1 UBA.SMB.MRR.OKU.WD001Installation drawing for all load lifting

equipment6

11 05 UKD R01.KK.0 5UKD.SMK.MRR.OKU.WD001Installation drawing for whole load lifting

equipment5

12 UFC R01.KK.0 UFC.FCD.MRR.OK.WD001Installation Drawings for whole load liting

equipment3

13 UBA R01.KK.1 UBA.SMB.MRR.OKU.WD001Installation drawing for all load lifting

equipment6

14 UQA R28.KK.1 UQA.PA.KM.OK.WD016

1 UQA, UQC, UPU, UQX Installation drawing

for all load lifting equipment. Main pump

station. Superstructure

2

15 UQC R28.KK.1 UQC.PE.KM.OK.WD009


for all load lifting equipment. Essential loads

pumps houses

5

16 UQX R28.KK.1 1UQX.0.KM.OK.WD002


for all load lifting equipment.1 1UQX...1 4UQX

Siphon wells

3

17 UPU R28.KK.1 UPU.0.KM.OK.WD0031 UQA, UQC, UPU, UQX Installation drawing

for all load lifting equipment. Forebay3

18 UPX R28.KK.1 UPX.0.KM.OK.WD0071 UPC UPX Installation drawing for all load

lifting equipment. Fish Protection Facilities4

19 UPC R28.KK.1 UPC.0.KM.OK.WD0061 UPC UPX Installation drawing for all load

lifting equipment. Water intake.4

20 02UGW R01.KK.0 02UGW.SMG.MRR.OK.WD001Installation drawings for load lifting

equipment2

21 UKS R25.KK.0 UKS.SMU.RO.OK.WD001Installation drawing for whole load‐lifting

equipment10

22 UBZ R01.KK.1 UBZ.SMU.MRR.OKU.WD001Installation drawing for load lifting

equipment.7

23 UKZ R01.KK.1 UKZ.SMU.MRR.OKU.WD001 Installation drawing for load lifting equipment 4

24 UUQ R37.KK.1 UUQ.PE.KZ.OK.WD0011‐7UUQ Doors,manholes,ladders,gratings,

hoisting gears31

25 UUP R37.KK.0 UUP.PE.KZ.OK.WD0011‐7 UUP Doors, manholes, ladders,gratings,

hoisting gears.25

Annexure‐1LIST OF SAMPLE DRAWINGS

Sl.NoKKS code of

buildingKKS code of MHE Description of MHE Qty Remarks

1 UJA FCA07AE071Crane of circular operation(Polar) with

Load lifting capacity 350/190+32T2

2 UJG FCJ07AE041Trestle crane with Load lifting capacity

350/190/32T2

3 UMA SMM20AE001 Travelling supporting electric crane

with Load lifting capacity 180+180/32T

2

4 UKS SMU20AE104Bridge support electric crane with Load

lifting capacity 20/5T1

5 UFC FCD02AE071Special electrical bridge crane with Load


6 UFC FCD02AE121Special electrical bridge crane with Load


7 UKS 00SMU20AE101

Electrical operated travelling

crane with Load lifting capacity 5 T 1

8 UKS 00SMU20AE106



9 UKS 00SMU20AE100



10 UKS 00SMU20AE102



11 UKS 00SMU20AE103



12 UKS 00SMU20AE109



13 UKS 00SMU20AE105



14 UKS 00SMU24AE104Electrical hoist with Load lifting capacity

5 T1

15 UJA UJA21AE601 Passenger lift capacity 400Kgs 2

16 UJG UJG11AE601 Passenger lift capacity 630Kgs 2

17 UKC UKC06AE602 Passenger lift capacity 400Kgs 2

18 UKC UKC06AE603 Passenger lift capacity 400Kgs 2

19 UKC UKC06AE601 Freight lift capacity 5000Kgs 2

20 UMA UMA02AE601 Passenger lift capacity 400Kgs 2

21 UMA UMA10AE601 Passenger lift capacity 400Kgs 2

22 UBA UBA02AE602 Passenger lift capacity 400Kgs 2

Annexure ‐ 2LIST OF FREE ISSUE MATERIALS

SL.No Hitli bolts & Type UOM QTY REMARKS

1 HDA T-M12X115/20 Nos. 36

2 HDA T-M12X125/30 Nos. 268

3 HDA T-M12X125/50 Nos. 80

4 HDA T-M12X190/30 Nos. 576

5 HDA T-M12X190/40 Nos. 176

6 HDA T-M16X190/40 Nos. 576

7 HSL 3G M10/20 Nos. 20

8 HSL 3G M12/15 Nos. 192

9 HSL 3G M12/25 Nos. 232

10 HSL 3G M16/25 Nos. 360

11 HST M16/140 Nos. 8

12 HST M16/25 Nos. 16

13 HST M10 Nos. 8

LIST OF FREE ISSUE HILTI BOLTS

Annexure ‐ 2

Sl.No Description of MHE Qty (MT) Remarks

1 Brackets, anchor plates etc., 130

Annexure ‐ 2LIST OF FREE ISSUE BRACKETS & ANCHOR PLATES

ANNEXURE‐3

QAPFORMATFORGUIDANCE

Contractor Item: MaterialHandlingEquipment(MHEPackage)

KudankulamNuclearPowerProject DrgNo:

QualityAssurancePlan(Indicative) QAcategory: QA2 KKSNo:

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

No Description(Component/Operation)

Attribute(Characteristicofinspection/test)

CategoryofAttribute

Typeofcheck Quantumofcheck

Referencedocument

Acceptancenorm

Formatofrecord

AgencyContractor

AgencyNPCIL

Remarks/Annex.Exe. QA Exe. QA

1 Incomingmaterial&RawMaterialcheck

1.1 Identification,Marking,Unpacking&Quantityverification Physical Major Packinglist/SSIR 100% Manufacturer

document

Aspermanufacturerdocument

IMIR P H W H

1.2 IdentificationofweldingandNDTconsumables

Physical&ChemicalProperties Major TCReview 100% MTC Asperref.standard Testreport P H S H

2 Qualification

2.1 WPS,PQRrequirementsWeldingprocessparameters

MajorVisual,NDT,destructivetesting

100%PNEAG‐07‐003‐89ASMESECIX

Asperref.standard WPS&PQR P W H H

2.2 Qualificationofwelders Skill,performance Major Visual,NDT 100%PNEAG‐07‐003‐89ASMESECIX

Asperref.standard WQR P W H H

2.3 Procedurequalificationofgritblasting

Meetingthetender/drawingspecification Major TCreview,trial

testing 100% Drgs&Documents Asperref.standard Qualificationrecord P W H H

2.4 Qualificationofgritblasters surfaceprofile,cleaningvisual Major visual,

measurement 100% Drgs&Documents Asperref.standard BPQR P W H H

2.5 QualificationofAnchorboltinstallation(HILTI)operator Skill,performance Major Visual,

Measurement 100%PerformanceCertificate,Procedureforqualification

Asperref.standard PerformanceReport P W H H

3 Preassembly&ErectionofMHE

3.1WorkfrontclearanceforMHEerection

CheckthereadinessofMHE,civilfrontetc,withreferencetodrawing.

MajorVisual,Measurement&Recordverification

100% Civilfront&MHEdrawings Protocol Completion

protocol P H H H

3.2

IdentificationofMHEanditscomponents

Identification,verificationofQty,marking,itemNo.anddimensions

MajorVisual,Measurement&Recordverification

100% Drgs&DocumentsasapplicableandWP

Asperdrawingsandpackinglist IMIR P H H H

3.3 Depreservation,Handling&storage

CleaningofMHE,removaloftemporarycovering,degreasingetc.

Minor Visual 100%Drgs&DocumentsasapplicableandWP

Asperthemanufacturer’sdocument

InspectionReports P H W H

3.4 Transportationofmaterialstoerectionsite

Checkingofproperloadingintruck,properstackingandpackingetc.

Minor Visual 100% Drg&Documentsasapplicable&WP

Asperdrawingsandpackinglist MMR P H W S

3.5

Fitup,alignmentanderectionofTrestlestructures,Bracketsofmonorail,carrail,CWrail,CTrailclamp,Lugetc.,

Checkingoflevel,elevation,verticality,span&diagonalsasperdrawing.

MajorVisual,Measurement

100% Drgs&Documents Asperdrawings Alignmentreports P H W H

3.6

Assemblyanderectionofgirders.Endcarriages,Hoistingmechanismandtravellingmechanismoftheelectrically/manuallyoperatedcrane

Checkingoflevel,elevation,span&diagonalsasperdrawing.

Major

Visualanddimensionalmeasurement

100% Drgs&DocumentsAsperdrawingsandmanufacturesdocuments

Alignmentreports P H W H

3.7 Assemblyanderectionofelectrical/manualhoists

Checkingoflocationandelevation Major

Visualanddimensionalmeasurement

100% Drg&Documentsasapplicable&WP

Asperdrawingsandmanufacturesdocuments

Alignmentreports P H W S

3.8

Assemblyanderectionofcarcabin,landingdoors,counterweightandwinchwithmotorofpassenger/freightlifts.

Checkingoflevel,elevation,verticality,diagonalandalignment

MajorVisualanddimensionalmeasurement


Asperdrawingsandmanufacturesdocuments

Alignmentreports P H W S

3.9 weldingprocessEnsurerequiredprocess,Welder&WeldingParameters.

Major Visual,Recordverification 100% Drg&Documents

asapplicable&WP AsperWPS WIR P H S H

3.10

Weldingofbrackettotheembeddedplate(EP),Monorail,CTrailclamp,Lugetc.,

AvailablityofWPS,PQR&WPQEnsuringweldingparameter

MajorRecordverfication,Visual&Measurement

100% Drgs&Documents Asperdrawings WIR P H W S

3.11 weldroot&finalvisualinspection welddefects Major Visual,Recordverification 100% Drg&Documents

asapplicable&WP Asperref.standard WIR P H S W

3.12 Erectionofelectricalcableandwiringsystem

Routingofelectricalcablesasperdrawing Major

Visual,Measurement

100% Drgs&Documents Asperdrawings IR P H S W

4 NDTandTesting

4.1 RT/UT(plate,Ibeambuttjoints) Defects Major Test *20% ApprovedProcedure ApprovedProcedure IR P H S W

4.2 DPT Surfacedefects Critical Test 100% ApprovedProcedure ApprovedProcedure IR P H S W

4.3 MPT Surfacedefects 100% ApprovedProcedure ApprovedProcedure IR P H S W

5 Commissioning&Loadtesting

5.1 Continuitycheckofelectricalcircuits Multimeter Major Verification 100% Asperthe

manufacturer’sdocument NA Protocol P W H W

5.2 IRvalueofelectricalmotors Megger,Multimeter Major Measurement 100% Asperthemanufacturer’sdocument

NA Testreports P W H W

5.3 Couplingofmotor&gearbox Alignment Major Visualandmeasurement 100% Drg,Documents Asperdrawings

Couplingalignmentreport

P H S W

5.4 Preparationofloadtestingprocedure

Preparationandsubmission Major

VerificationofWDwithmanufacturerdrawing

100% W.D&manufacturerdocuments

ApprovedProcedure Testreport P W H S

5.5 Finalacceptanceclearanceofloadtesting

Verificationoferection&alignmentreports Major

Recordverfication,Visual&Measurement


ApprovedProcedure

Alignmentreports P H H H

5.6 Noloadtrailsforelectricallyoperatedhoistandcranes

Checkingfordirectionofmotors,operationofbrakes,hooksapproach,heightoflift(max&Min)

Critical Visual,Measurement 100% Drg&Documentsas

applicable&WPApprovedProcedure Testreports P H W W

5.7 a)ManuallyoperatedHoists(stationery&movable)/cranes/grapplers

5.7.1 Statictest(125%ofSWL) Checkingforslippageofbrakes Critical Visual,

Measurement 100% Drg&Documentsasapplicable&WP

ApprovedProcedure Testreports P H W W

5.7.2 Dynamictest(110%ofSWL) Checkingformovementofhoist Critical Visual,



5.8 b)Electricallyoperatedhoist/cranes

5.8.1 Statictest(125%ofSWL) Checkingforslippageofbrakesanddeflection Critical Visual,



5.8.2 Dynamictest(110%ofSWL)CheckingofCT,LTmotionandhoistupanddownmotion



5.9 c)Passenger/FreightLifts

5.9.1 Statictest(125%ofSWL) Checkingforslippageofbrakes Critical Visual,



5.9.2 Dynamictest(110%ofSWL)

Checkingforoperatingspeed,limitswitchesfunctioninganddooropen/closeatstops.



6 FinalCompletion

6.1 FinalInspectionaftererection&Documentation Finalandreporting Major

Visual,FinalMeasurement,ReviewoftestDocuments

100% Aspertheapprovedprocedures

Aspertheapprovedprocedures

Erectionreports P H R H

6.2Constructioncompletioncertificatesubmission

Verificationofrecords Major DocumentVerification 100%

CompletionofallErection&QADocuments

Aspertheapprovedprocedures CCCFormat P H H H

Note:

TheaboveQAPiscomprehensivecoveringmajorworksofthepackageandisindicativeonly.SeparateanddetailedQAPshallbepreparedbythecontractorbasedonactualprojectrequirementsanddocuments.ThepercentageofinspectionmayvaryasperWDandspecifications.1.W‐Witness;ContractorshallgiveadvanceinformationtowitnessingagencyofNPCIL,whenthisstageisreached,andproceedtonextstage.Dependingontheperformanceoftaskperformer,NPCILmaydecidetowitnessorwaivethewitnessing.

2.H‐Hold;ContractorshallgiveadvanceinformationtoNPCIL,whenthisstageisreached,andcanproceedfurtheronlyafterobtainingclearancefromNPCILQA.

3.R‐ContractorshallsubmitallrecordsuptothisstageforreviewbyNPCIL,notlaterthanoneweekfromthedateofactivity.

4.P‐Perform;Ex‐executionagency;5.S‐Surveillanceinspection6.IR‐Inspectionreport.

EPC-03

TENDER No. CMM/MEQ/25-26-2-1142

SECTION – C

1. CONSTRUCTION MANAGEGMENT

REQUIREMENTS FOR CONTRACTORS

NUCLEAR POWER CORPORATION OF INDIA LIMITED

KUDANKULAM NUCLEAR POWER PROJECT - 3&4

CONSTRUCTION MANAGEMENT REQUIREMENTS BY

CONTRACTOR PAGE NO. : Page 2 of 30

REV. NO. : R0

November 2016


CONTRACTOR

DOC NO. : I01.KK 3 4 .0.0.MP.EP.P003

REVISION NO. : R0

DATE OF ISSUE

: 29.11.2016

TOTAL NO. OF PAGES

(Including Cover

Sheet+Appendix+Annexures)

: 30

REVISION CONTROL SHEET

Rev. Description NPCIL

No. & Date of Revision Revised By Checked By Approved By

R0





REV. NO. : R0

November 2016

TABLE OF CONTENTS

CLAUSE NO. TITLE PAGE NO.

1.0 General 4

2.0 Execution of works 6

3.0 Construction management plan 9

4.0 Temporary Facilities 11

5.0 Records, procedures and reports 12

6.0 Schedule 13

7.0 Warehouse Management & Material Control 13

8.0 Field Engineering 22

9.0 Field Tendering 22

10.0 Field Purchase 22

11.0 Patents and patent right indemnification 22

12.0 Industrial Labour Relations 23

13.0 Construction Equipments 23

14.0 Construction Manpower 25

15.0 Interface with other CONTRACTORS 26

16.0 Colour Coding of Piping Material 26

17.0 Security Requirements 27

18.0 Approval of Erection testing & Commissioning Procedure 27

19.0 Layout and Measurement 27

20.0 Access Roads & Temporary Buildings 29

21.0 Notices 29

22.0 Pattern, samples and models 30





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NOT FOR PUBLICATION / PRESENTATION OUTSIDE NPCIL

1.0 GENERAL

1.1 The Contractor shall construct Plant/Facilities in accordance with the requirements of the

Technical Standards/ Specifications, with proven/good engineering practices and procedures. Such facilities shall be safe, reliable and suitable for their intended purpose.

1.2 It is to be understood and agreed by CONTRACTOR, that the work described shall be

complete in detail, even though every item necessarily involved is not particularly mentioned. The Contractor shall provide all supervision, labour, construction equipments, tools & tackles, materials and consumables, temporary facilities, supply monitoring and supply chain management etc. and render all support services necessary for the construction. Provision of construction power and water shall be as per Special Conditions of Contract (SCC)/ General Conditions of Contract (GCC).

1.3 The Contractor shall plan, execute, manage and control all the construction activities for

the facilities forming a part of this contract.

1.4 The Contractor to ensure mechanizing the construction activities to the maximum extent

possible.

1.5 The Contractor is deemed to have full knowledge of the applicable laws, statutory requirements, and regulations, conditions of labour, local conditions, the SITE conditions, environmental aspects and shall comply with the requirements thereof.

1.6 The Contractor is required to organize and mobilize Construction Management

Services in a systematic and sequential manner to ensure that the Plant installation is carried out in accordance with the approved engineering drawings, specifications, standards, QA/QC, safety procedures etc. and its completion is achieved within targeted time schedule. Construction Management and Supervision is to be carried out by the Contractor himself by deploying competent persons who are on his rolls and this activity is not to be sub- contracted in any case.

For this purpose, the Contractor shall deploy a Construction Management Team headed by a qualified & experienced person at site. The Construction Management team shall include engineers/ specialists in QA/QC, Project Control (Planning, scheduling, monitoring), contract execution, material handling construction supervision, progress measurement/billing, safety, warehousing, purchasing etc. Key personnel including the Head should have suitable qualification/ sufficient experience and should not be changed without concurrence from NPCIL.

Curriculum vitae (CV) of all key Construction Personnel shall be submitted to NPCIL at least 3 months before deployment. NPCIL reserves the right to assess/ interview these personnel before their mobilization, where ever and when ever felt necessary.

1.7 The Contractor shall ensure delegation of adequate and sufficient powers (including

financial) to the Head of his Construction Team for effective and smooth functioning of the construction management. HO support shall be provided to the Head of Construction Team at site during construction on all matters of project execution including the following:

- Field engineering.

- Rectification/replacement of defective supplies, if any, noticed during construction.





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- Expediting replacement of imported items found short/damaged.

- Required documentation for the material inspection at site

- Compilation and submission of Field Inspection documents in requisite copies

hard and soft form as per contract

- Documentation to meet statutory requirements.

- Any support needed from HO to improve safety.

1.8 The construction supervision, co-ordination and management activities shall be carried out by the Contractor in accordance with the construction procedures developed and submitted by the Contractor and approved by NPCIL. Contractor shall prepare construction schedules within the framework of overall contract schedule and submit to NPCIL for approval. Contractor shall plan, execute, monitor and control construction activities as per the approved construction schedule.

Contractor shall depute a project team at site during construction phase under a project coordinator for providing above-mentioned support to the Head of Construction Team.

1.9 In case of civil works/ requirements, most of the civil construction materials like cement, reinforcement bars, aggregates, bricks, and structural steel are available locally. However, the material like cement, reinforcement bars and structural steel shall be procured from approved vendors only. The Contractor shall establish and maintain a material testing laboratory for carrying out field tests during execution of contracts under different disciplines at no extra cost to NPCIL. The entire test equipments deployed shall have valid test/calibration certificates traceable to relevant national/ international standards. Such material tests, for which testing facility at site is not established, shall be carried out by Contractor at testing laboratories approved by NPCIL at no extra cost. Contractor shall maintain the test records and the same shall be made available for review/ inspection of NPCIL. Further, NPCIL reserve the right to witness / inspect testing at the laboratory at no extra cost to NPCIL.

The concrete testing lab established at site by KKNPP shall be used with NPCIL

concurrence, if provided as per the terms of the contract. However the manpower, consumables etc for the testing shall be arranged by the contractor at his own cost.

1.10 Construction supervision and management functions to be performed by the Contractor shall

include the following as key functions for effective execution, monitoring and control:

- Planning, scheduling, monitoring & reporting. - Construction & erection supervision discipline wise. - Quality assurance and quality control, discipline wise. - Shipping, custom clearances, inland transportation - Warehouse management and material control / material handling at site. - Field engineering/field purchase. - Health, Safety and Environment (HSE) Management - Statutory clearances and enforcement of statutory rules/ regulations and Labour

Laws - Personnel/administration/Industrial Relations - Finance and Accounts - Security, insurance, Housekeeping & preservation





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- Transportation and material handling management - Coordination with other contractors - Preparation of procedures, reports and their up keeping

1.11 Whenever the hook up is to be done with the facilities under operation, efforts shall be made by the Contractor to complete the work and restore the system expeditiously. If required the work shall be continued round the clock.

1.12 Over Dimensional cargo (ODC) movement to the erection site is included in the scope of the Contractor. The Contractor shall carry out the route survey and report shall be submitted to NPCIL well in advance. All the clearances, approval from government agencies, local bodies, private parties, police, electricity / telephone departments, Railway authorities, PWD, Highway authorities, various departments of NPCIL etc. for moving the ODC cargo is included in the Contractor’s scope. Before each movement, copy of the major clearance obtained shall be forwarded to NPCIL. The cost /deposits of such approval, which may be incurred by the Contractor, shall be included in the contract price.

1.13 Any modification, dismantling, re-routing etc. of the permanent / temporary facilities

belonging to NPCIL, private parties, public / government facilities including provision of ramps at bridges to enable the ODC movement are in Contractor’s scope.

1.14 Restoration of the all the modified, dismantled facilities to original condition is in the scope

of the Contractor. Contractor shall obtain no claim certificates from such parties.

2.0 EXECUTION OF WORKS

The Contractor’s work during construction & erection shall include but not be limited to the following: i) Prepare and submit all the Plans, Procedures and documents to NPCIL as

specified in the contract. ii) Establish requisite site organization staffed by competent and experienced

specialists, supervisors and inspectors. iii) Supervise, Coordinate and manage the activities performed at site by him and by

his sub-contractors for execution of work and render all technical/specialist services. iv) Plan and schedule the construction work, monitor and take timely corrective action

when required to adhere to approved execution schedule. v) Plan, allocate and mobilize required resources, manpower, and construction

equipment/materials, commensurate with construction plan/schedule. vi) Provide all temporary facilities required for Construction including drinking water,

lighting, office space, electronic transmission of drawings & documents, printing facilities, rest rooms, crèches, first-aid, fire protection system, toilets, canteen facilities, labour hutments, transport facilities for the workers and staff.

vii) Prepare & implement Quality Control and Quality Assurance plan. viii) Prepare & implement Health, Safety & Environment (HSE) plan. ix) Report beforehand and take approval from NPCIL regarding use of any

equipment and/or material not conforming to the contract, drawings and specifications.

x) Execute and supervise all additional works and modification works as required or suggested by NPCIL as a part of approved change orders.

xi) Erect and install the equipments and materials according to the approved Specifications and procedures.





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xii) Establish required Field Inspection and Testing Laboratories at site to carryout tests as specified in the standards/specifications of the contract.

xiii) Transferring levels and coordinates from the master benchmarks provided by NPCIL.. xiv) To organize and obtain all applicable clearances/approvals from statutory

bodies/ authorities, as required by the laws of land for the work executed at site. xv) Obtain approval of NPCIL for Welding Procedure Specifications (WPS) /

Procedure Qualification Records (PQR) as required. Carry out inspection, non- destructive tests and analyze and certify acceptability of all welds and materials in accordance with specified Technical Standards. Carry out inspection and testing of incoming materials as per agreed procedures.

xvi) Prepare detailed schemes for Heavy / Critical Equipments' movement / erection / lifting / rigging and submit the same for review / approval to NPCIL before undertaking such Critical/Heavy lifts/movements. Any modifications required including dismantling and re-erection of structures/piping, etc for the existing facilities for smooth flow of such heavy equipment shall be carried out by the contractor at his own cost. However, prior approval for such modifications shall be required from the NPCIL.

xvii) Organize and conduct Weekly Project Review meeting related to site construction activities.

xviii) Provide daily work progress reports and detailed weekly and monthly progress reports summarizing percentage completion of the work including status of drawings, materials and effects on approved schedule, areas of concern and corrective actions required thereof. Contractor shall also identify any foreseeable delays in any aspect of the WORK and take corrective actions to eliminate/minimize the effect on Overall Completion Schedule. All progress shall be quantified.

xix) Prepare and submit records of all site meetings and any other related documents to all parties concerned within two (2) days of the meeting.

xx) Prepare and submit safety and labour relation procedures in line with all applicable codes, regulations and NPCIL’s requirements.

xxi) Supervise and monitor all safety and labour relation functions as per agreed procedures and applicable laws of the land and report to NPCIL immediately for any violations and injuries.

xxii) If any part of the facilities is completed and is under operation, while other parts of the facilities are under construction, or work is to be carried in running Plant, it is essential that rigid safety rules be prepared and maintained for all WORKS in accordance with the requirements of NPCIL.

xxiii) Maintaining all the records generated during project execution up-to-date and made available to NPCIL whenever requested. These records shall be handed over to NPCIL on completion of the work in hard and soft form at no extra cost to NPCIL.

xxiv) Carryout warehouse management and material control in accordance with approved procedure.

xxv) Take all necessary precautions and required actions to protect construction work and materials from damage by local weather conditions and ongoing construction activities in the vicinity, theft and pilferage etc. till handing over of the plant to NPCIL.

xxvi) Take insurance policies for materials in transit and storage-cum-erection risk and other insurance covers required for men and materials at site as per SCC/ GCC in consultation with NPCIL.

xxvii) Undertake housekeeping including sweeping, clean up to maintain cleanliness, sanitation, removing excess materials, temporary facilities, scaffolding, etc. on





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Regular basis till handed over to NPCIL. xxviii) Prepare and submit to NPCIL the following reports for construction activities

covering the following: a. Manpower deployment category wise, including attendance details.

b. Construction Equipments c. Work Progress d. Safety report

xxix) Ensure the control of all works with regard to its impact on the surrounding environment.

xxx) Ensure all hot works are performed in compliance With NPCIL’s Safety Permit System requirements wherever applicable.

xxxi) Arrange and coordinate the visits of supplier’s representatives/specialists at site. xxxii) All material handling equipment, tools, tackles, hoisting and lifting

equipments/machineries should be subjected to required load test initially and then periodically, to ensure safe/stable operation.

xxxiii) Organize field engineering work, wherever required and ensure timely resolution of interface problems / site constraints in consultation with NPCIL.

xxxiv) Prepare and certify material reconciliation statement on completion of each work to enable NPCIL to take over the surplus materials, as applicable.

xxxv) Organize the codification and handing over of surplus materials (as applicable) and spares/ tools and tackles to the NPCIL on completion of work.

xxxvi) Provide weekly/daily activity plan for site inspection. xxxvii) Develop a phased erection program to facilitate sequential Pre-

commissioning/Commissioning activities (Whereever applicable) in a logical manner to meet the Overall Project Schedule.

xxxviii) Remove / demolish all temporary structures/ establishments/ facilities created by the contractor / his sub-contractors during the execution of the work and restore the site to its original condition.

xxxix) Estimate monthly consumption of following utilities (if provided by NPCIL): a. Industrial water b. Drinking water c. Electricity

xl) Organize and conduct Positive Material Identification (PMI) of incoming materials and of materials & welds after erection/installation, but prior to hydro testing of facilities. Any non- conformance detected shall be removed and replaced prior to final hydro testing.

xli) Colour coding of the pipe lines and equipments norms available with NPCIL shall be used for painting and identification.

xlii) Carry out tightening of flange joints by using hydraulic tensioner/torque wrench as per specifications. Contractor shall ensure that stud bolts are ordered extra long to facilitate tensioning.

xliii) Organize safety induction programme, training programme, Housekeeping and preservation for their manpower before deployment on work and at regular intervals thereafter.

xliv) Develop/ deploy software based supply monitoring systems to track the supply of materials for construction.

xlv) Execute all the civil, Mechanical, Electrical, Instrumentation and services related construction/ erection works as per the tender requirements.

xlvi) Supply of adequate quantity of all consumables of approved brands, required for the job, Viz., welding electrodes, welding gas, oil, grease, kerosene, cotton waste, etc,.





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xlvii) Supply and initial filling of various lubricants and control fluids of approved brands xlviii) Hydro-test of all piping erected by him as per the piping material specifications and

piping technical specifications attached with the tender. All temporary piping hangers and supports, fittings, strainers, valves, blanks for hydro testing of the pipelines, valves and equipment shall be supplied by the CONTRACTOR. It is the CONTRACTOR’s responsibility to arrange for pressuring pumps, tanks, relief valves, instruments and other accessories that would be required for testing operations. These are to be taken back by CONTRACTOR after successful completion of all hydro-testing operations. Contractor shall draw up a detailed activity list of pre shutdown activities and shutdown activities (wherever applicable) and submit the same for the approval of the NPCIL. All endeavours shall be made to maximize the pre-fabrication before the planned shut down and to minimize the work during shutdown period. All such activities shall be identified and appropriately planned for temporary supports, scaffolding, clamping arrangements, enabling works, etc. so that the quantum of the work during the shutdown can be minimized if applicable.

3.0 CONSTRUCTION MANAGEMENT PLAN

Contractor shall submit Construction Management Plan to NPCIL for approval during kick-off meeting. The Plan shall detail the management methodology to be applied during the construction phase of the Project, along with a list of procedures to be utilized in undertaking the work.

All reference procedures and detail work plans referred to in this document must be submitted for review and approval by NPCIL at least (4) four weeks in advance of actual commencement of the activity concerned.

3.1 Project Execution assurance Plan:

It shall include all the activities required for successful execution of the project as indicated in the document Project execution assurance plan enclosed elsewhere in the tender. Contractor shall be responsible for construction Planning, Scheduling, Monitoring and Reporting activities at site in line with the overall master schedule and procedure shall be submitted for approval of NPCIL and the same shall be followed after approval. Following shall be submitted as minimum:

3.1.1 Contractor’s manpower and man-hour histogram by major section and discipline and their

manpower deployment schedule on monthly basis.

3.1.2 Major equipment mobilization plan on monthly basis with short description. Contractor shall develop this plan with due consideration to maximize the mechanization of construction activities.

Other plans of Contractor and procedures to be submitted at least four (4) weeks prior to start of respective activity at site, include the following as a minimum:

a. Develop/ prepare construction/erection plan/procedures and submit to NPCIL for

approval.





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b. Temporary facilities, etc. c. Scaffolding plan d. Excavation and underground work plan e. Heavy transport and heavy lifting plan (Rigging Plan), If applicable f. Pre-fabrication plan g. Other activity plans e.g. piping, equipment and steel structure erection plan etc. h. Monsoon counter measures and preparation i. Emergency Evacuation Procedure j. Schemes to carry out works in inclement weather

Contractor shall ensure that lay down area (as applicable) given to him shall be utilized optimally.

3.2 Sub-Contracting Plan

All Engineering Consultants, Procurement Agencies, Commissioning Agencies, Plant Operating Agencies, Merchants, Tradesmen and others executing any work or supplying any goods, materials or service appointed by the CONTRACTOR shall be deemed to be sub-contractors.. If Contractor proposes to engage sub-contractor(s) for the execution of some of the activities at site, a preliminary sub-contracting plan along with the identified scope of work for each sub-contract shall be furnished by the Contractor to the NPCIL at the time of bid submission. The list of Major sub contractor shall be indicated in the bid. However for any new sub contractor the credentials of the sub contractor shall be submitted well in advance and NPCIL acceptance shall be taken before engaging them for this work. Contractor shall not be permitted to change the sub-contractor under any circumstances without prior approval of NPCIL. Non-compliance of the above shall be strictly dealt within relevant provision(s) of the contract. The sub-contracting plan shall cover i) Sub-contracting philosophy ii) List and scope of work of each subcontract

iii) Subcontract administration plan iv) Organization chart of each sub-contractor.

The list and major scope of each subcontract shall not be changed from those of the Contractor’s plan unless specially approved by NPCIL.

In respect of the work, goods, materials or services etc. specified in the sub-contract, the sub-contractor will undertake towards the CONTRACTOR the like obligations and liabilities as are imposed on the CONTRACTOR towards NPCIL by the terms of the contract and will save harmless and indemnify the CONTRACTOR from and against the same from all claims, proceedings, damages, costs, charges and expenses whatsoever arising out of or in connection therewith, or arising out or in connection with any failure to perform such obligations or to fulfil such liabilities.

3.3 QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC) Contractor shall be responsible for ensuring quality of construction (including materials)





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carried out by him/his approved sub-contractors in accordance with the requirements given in attached document “Quality Management System requirements from contractors” attached elsewhere in the tender.

3.4 HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT Contractor shall be responsible for Health, Safety and Environment (HSE)

Management at construction site for the construction activities to be carried out by the him/his approved sub-contractors in accordance with the requirements mentioned in GCC/SCC and AERB documents attached elsewhere in the tender.

All the personnel working at site shall be familiarized with the important and/or immediate

actions that may be called for e.g. the emergency announcements, siren, the emergency shelter areas, use of prophylactics, etc. Periodic lectures and audio-visual courses, etc. shall be organized to retrain once in a year and documented. All Contractor personnel shall be given training on Emergency Preparedness and also a briefing shall be given before Exercise. Personnel are to be re- trained on emergency preparedness after one year.

4.0 TEMPORARY FACILITIES

Contractor shall arrange the following temporary/ Infrastructure facilities as the minimum (including for his sub-contractors also) in sufficient quantity to meet the quantum of contract work:

1) Exact location of temporary work area, access and general layout inside the area.

2) Planning and Establishment of the temporary facilities:

a. Identification of borrow earth area (if required)/excess earth dumping yards b. Site office and Fabrication yards, Open storage area and Warehouse c. Miscellaneous workshops including maintenance area for construction

equipments. Grit blasting and Painting shops. d. Temporary roads including access road to Plant, fencing and gates e. Security, watch & ward, security gates, etc. f. Utility supply systems viz. Construction power with DG Sets, construction

water, drinking water etc. g. Area lighting h. Fire fighting equipments i. Drainage and Sanitation j. Camp Accommodation k. Field Testing Laboratory l. Radiography Source Pit as per BARC Guidelines m. Film processing and viewing labs n. Communication facilities viz. Telephone, Fax, E-mail, electronic transmission of

drawings./ documents, etc. o. Hutments, transport, Pantry and Canteen for staff and workers. p. Vehicle parking area including construction equipments. q. First aid arrangement/ medical and health care facilities r. Valve testing facilities, Instruments calibration lab, Work shop for

machining etc





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Contractor shall develop the temporary facilities layout for approval of NPCIL. Please refer Project execution assurance plan document enclosed elsewhere in the tender for more details.

5.0 RECORDS, PROCEDURES AND REPORTS

(A) RECORDS:

The Contractor shall maintain records pertaining to the Design, engineering, drawings,

approvals, procurement, storage, fabrication, construction, welding, erection, alignment,

cabling, instrumentation, inspection and testing work in compliance with all drawings and

technical requirements. The records shall be in a proper format as indicated by the

Engineer. The Contractor shall submit the copies of such-records to the Engineer within 7

days from completion of any particular work, and prior to submitting bill for progressive

payments. For material supplied by contractor, the contractor shall forward one copy of test

certificate to the Engineer pertaining to the origin and specification of material. The

Engineer shall need certain records for verification viz. weld inspection report, stress

relieving report, consumable certificate, etc. The Contractor will have a system of record to

facilitate easy traceability of all such records.

(B) PROCEDURES: The contractor shall submit construction procedures to the Engineer for review and

approval. Some of the major procedures are listed below:

(i) Welding Procedures (ii) Procedure for non-destructive examination (iii) Qualification certificates of the personnel performing non-destructive examination (iv) Fabrication procedures) (v) Erection procedures (vi) Q.A. plans (vii) Testing procedures (viii) Mock up procedures (ix) Cleaning, grit blasting, painting, insulation procedures (x) Procedures and testing of various civil constructions (xi) Procedures and testing of E&I equipments Further, where complexity of the work or safety is involved, the contractor shall submit such

procedures when requested by the engineer. Any other procedure deemed necessary for

work shall be submitted to Engineer for acceptance.

(C ) REPORTS: The contractor shall submit on weekly basis, to the engineer, one copy of report indicating the details like system wise progress, fabrication/erection progress, system testing status, QA activities, etc. Following are, indicative list of reports and other suitable reports shall be submitted as per the instructions of engineer.





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(i) Equipment erection progress report (ii) Piping erection progress report (iii) General statement of activities (iv) Welders performance & qualification records (v) Weekly report on items on critical paths (vi) Pipeline and support alignment and erection report (vii) Weld joint inspection report (viii) Grit blasting and painting report (ix) Reports on civil construction, testing and concreting. (x) Reports on E&I testing and erection. All reports shall be statistical and on tabulated form indicated by the engineer.

6.0 SCHEDULE (Mile stones indicated in SCC)

The required schedule of start and completion of various activities for all facets of work of

this tender viz. procurement and supply of materials, fabrication and erection of piping and

equipment at site, are given in this tender. The contractor is required to study the schedule

and prepare a detailed activity network and should enclose the same along with the bid.

The deviation from the schedule, if any, should be brought out clearly.

7.0 WAREHOUSE MANAGEMENT & MATERIAL CONTROL

CONTRACTOR shall provide closed/semi-closed /open storage facilities with approach road and shall ensure proper storage and maintenance of plant and equipment to be erected. CONTRACTOR shall indicate his space requirements for provision of closed, semi-closed and open storage areas to NPCIL. He should also indicate the space requirements for office, workshop, canteen etc., if any. The facilities shall include proper lighting, fire protection system, office/rest rooms/toilets for warehouse personnel.

Contractor shall obtain all statutory approvals from authorities concerned for all warehouse equipment, instruments etc. Contractor shall comply with statutory regulations for storage of any material covered under Explosives rules.

Contractor shall be responsible for carrying out the Warehouse Management and Material Control in accordance with the approved warehousing procedure and material control procedure, which is to be submitted by the Contractor during kick-off meeting. The activities shall include but not limited to:

- Transport Liaison, both for imported materials as well as materials procured

indigenously, from the time of dispatch up to receipt at site. - Transportation Plan (i) from source to site (ii) site to erection location. - Filing of insurance Claims and follow up. - Documentation for control and accounting of materials. - Generation and upkeep of Traceability Records for materials. - Materials Control & Issue. - Inventory Checks. - Field Requisition and Purchase. - Spare & Tools including handing over of mandatory Spares/Tools to the NPCIL as per





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the terms of the contract. - Material Appropriation and Handing Over of all items to NPCIL with NPCIL’s

Codification system. - Security. - Taking up with suppliers on short supplied items and placing replacement orders for

lost/damaged items. - Intimating short/lost/damaged items received at site and further replacement action, as

applicable. - Material handling plan and ODC movement plans. - Preservation of the materials in storage as per manufactures’ recommendation. - Proper up keeping of the outdoor storage area devoid of bushes, fire loads etc. - Housekeeping of the total ware houses. - Establishing special stores for electrode and other materials requiring heating or Air

conditioned storages. - Material stored is to be insured. Fire fighting and ventilation facilities to be provided in

storage places

Contractor shall generate and issue following reports: - Fortnightly statement of consignments in transit. - Daily report of material received. - Material receipt status and inventory status w.r.t. material delivery schedule - Material Inspection Report with respect to materials received at site - Report on material issue vouchers for erection works and material return vouchers - Report on Over/Short/Reject/Damage (OSRD) receipts against each consignment on

receipt at warehouse. - Weekly status of consignments, Material Receipt Report (MRRs) - Monthly status of field purchase. - Monthly status of over, short, reject & damage (OSRD) settlement. - Monthly status of piping material MTO V/s Actual receipt. - Log Register of Rotating Equipments maintenance - Daily Stock Position of Cement - Status of the purchase order and delivery schedules of the materials. - Imported materials list and its reconciliation (with customs) status. - Material accounting statements. - Any other report as desired by NPCIL.

The CONTRACTOR shall submit to the NPCIL a list of equipment he proposes to use

indicating their capacities and quantities as well as the scheme of handling for approval by NPCIL.

The various lifting / handling equipment and rigging tools proposed to be used by the CONTRACTOR shall be tested as per statutory and safety regulations and the latest test certificates shall be furnished to the satisfaction of NPCIL. In case NPCIL feels that the tools and tackles are inadequate or unsuitable, the CONTRACTOR shall arrange to provide such tools and tackles considered suitable by NPCIL in sufficient quantities acceptable to NPCIL.

The CONTRACTOR will be responsible for any damage caused due to his defective /

negligent handling of equipment and he shall make good such damages at no extra cost to NPCIL and without affecting the project schedule. Any repairs carried out shall be with the prior written approval from NPCIL and under CONTRACTOR supervision. A complete record of all such repair works shall be maintained by the CONTRACTOR at all times.





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Transport of equipment by dragging, pulling, skidding on rollers etc., will require the prior

written approval from NPCIL and are generally discouraged. In all cases where major components have to be handled, the detailed scheme shall be submitted to NPCIL for prior approval.

It is the responsibility of the CONTRACTOR to provide adequate weather protection and security for the equipment during the period they are transported from the unloading point to warehouses. The safe loading of equipment as well as transport up to warehouses shall be closely supervised by the CONTRACTOR.

7.1 STORAGE OF MECHANICAL AND ELECTRICAL EQUIPMENT AT SITE

Scope

The following specification details the general guidelines for storage of mechanical and electrical equipment at site from the date of receipt of equipment at site by the CONTRACTOR till the same are erected and handed over to NPCIL.

Storage Classification The types of storage are broadly classified under the following heads :

1. Closed storage 2. Semi closed storage 3. Open storage

The equipment covered under these specifications shall be stored in the type of storage as

recommended by the MANUFACTURER / NPCIL.

7.2 CONSTRUCTION OF STORES

Normally, NPCIL makes available the space (at terms specified) for the CONTRACTOR to construct the necessary stores as specified. The storage areas should have adequate unloading and handling facilities with adequate passage space for movement of material handling equipment such as cranes forklift trucks etc. The storage of materials shall be properly planned to minimise wasteful handling during retrieval of items required for erection. The outdoor storage areas as well as semi closed stores shall be provided with adequate drainage facilities to prevent water logging. The CONTRACTOR shall check the satisfactoriness of these facilities prior to monsoon. The storage sheds shall be built in conformity with fire safety requirements. The stores shall be provided with adequate lights and fire extinguishers. “No smoking’ signs shall be placed at strategic locations. Safety precautions shall be strictly enforced.

In case of storage of certain equipment / materials, it may be necessary to maintain specified temperature ranges. In such case, it is the responsibility of the CONTRACTOR to





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provide adequate heating / air conditioning facilities on round the clock basis. The CONTRACTOR shall check that space heaters, heating bulbs and air conditioners are kept energised continuously as applicable. In the event there is a prolonged failure of electric power, rendering such air conditioners / space heaters inoperative, the CONTRACTOR shall make alternative arrangements to ensure that items under storage do not suffer any damage / deterioration on this account. Adequate lighting facility shall be provided by the CONTRACTOR in storage areas and storage sheds and security personnel positioned to ensure enforcement of security measures to prevent theft and loss of materials. The CONTRACTOR shall carryout regular inventory of materials received, issued and erected and inform NPCIL of any loss when noticed. The CONTRACTOR shall provide adequate number of competent stores personnel including store keepers, clerical staff, inspection engineers, watchmen and security staff to efficiently store and maintain the equipment / material. Where necessary, the CONTRACTOR shall provide necessary space heating and other protective care to equipment in case it will take a long time to haul them to the stores. Any equipment, left in the open under such conditions shall be, if required, covered with tarpaulin.

7.3 MAINTENANCE DURING STORAGE

The CONTRACTOR is responsible for preservation/ maintenance of the equipment / materials in storage, during erection and until commissioning including protection of the same against theft, elements of nature and corrosion damages. In case commissioning of the equipment is delayed, the CONTRACTOR shall be responsible for maintenance of the erected plant and equipment as directed by NPCIL or as per the instructions from manufacturer. Contractor shall prepare procedure for storage of materials till erection and preservation of equipments till handing over to NPCIL and submit the same for NPCIL approval.

The CONTRACTOR shall repack the equipment after inspection and store the same in an orderly manner, preserving their identification slips, tags and instruction booklets, etc., required during erection. The storage of materials shall be equipment wise. Loose parts shall be stored in sheds on racks, preserving the identification marks and tags in good condition. Contractor shall store spares received along with main equipment separately with proper packing till handing over the same to NPCIL with Free issue material accounting. The group codes shall be displayed on the racks.

The CONTRACTOR shall carryout frequent inspection of materials stored and also extend necessary facilities to NPCIL to carry out such inspection, when considered necessary. The CONTRACTOR shall implement the suggestions, if any, of NPCIL in this connection.

At no time shall any material be stored directly on ground. All materials shall be stored minimum 200 mm above the ground by providing good wooden sleepers. Welded and cast units shall be stored in such manner that there is no danger of distortion. All special measures to prevent corrosion shall be taken by the CONTRACTOR. Materials, which carry a protective coating, shall not be wrapped in paper, cloths etc, as these are liable to absorb and retain moisture. The CONTRACTOR shall inspect the materials and in case of signs of wear or damages to protective coating, that portion shall be





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cleaned with appropriate solution and coated with an appropriate compatible protective paint. Complete record of all such observations and protective measures taken shall be maintained.

The rust preventive oil or grease for application on machined / fabricated components shall be adequate for the intended purpose and shall not cause any injury to the system, structure and components. Protective coatings/application of grease, oil etc shall be inspected from time to time and reapplication/ repair shall taken at appropriate frequency. While handling the equipment, no dragging on the ground is permitted. The CONTRACTOR shall submit his scheme for handling major pieces of equipment for approval by NPCIL prior to actual handling of the same. In cases where a scheme is recommended by the MANUFACTURER, it shall be strictly adhered to.

The CONTRACTOR shall periodically inspect materials with specific reference to. Ingress of moistures and corrosion damages. Regular inspection and renovation of silica gel is essential. Damage to protective coating. Open ends in pipes, vessels and equipment. In case any open ends are noticed, the CONTRACTOR shall get them capped. Insulation of electrical equipment. Regular insulation checks are essential and these values shall be properly logged.

Any damages to equipment / materials.

In case of any damages, these shall be promptly notified to NPCIL. In all cases, the repairs / rectification shall be carried out strictly as directed by NPCIL. In such repairs rectification is necessitated due to causes attributable to the CONTRACTOR, such repairs / rectification shall be carried out at no extra cost to NPCIL.

In case such damages are attributable to the CONTRACTOR and if, in the opinion of NPCIL, the CONTRACTOR is not competent to carry out necessary repairs / rectification, NPCIL shall get this done by any other agency and recover the expenditure incurred by him from the CONTRACTOR.

7.4 MODES OF STORAGE

Given below are the general guidelines for storage of various equipment under the broad storage classification listed in clause 7.1 above. Wherever the specific recommendations of the MANUFACTURER / NPCIL are at variance with what is indicated below, the former shall prevail.





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Special Storage – Air Conditioned :

The following materials are normally stored in air-conditioned storage. Welding ElectrodesThese deteriorate under adverse conditions of storage and are preferably stored in air-conditioned storage. As an alternative, if approved, these can also be stored in hot boxes / ovens. It is essential to regularly inspect the condition of electrodes and ensure that temperature is maintained within specified range at all times.

Ball, needle and roller bearings : These shall be stored in their original packing.Photographic materials and films These shall be stored in their original moisture vapour proof packages. Rubber Goods: These shall be protected against sunlight and artificial light as well as high humidity conditions.

Electronic Instruments and Components. These shall be stored in sealed packages.

7.4.1 CLOSED STORAGE

The following materials are normally stored in closed storage. Cement bags. All small parts / components liable to be misplaced / lost. These shall include the following :

a) Small structural cleats, bolts, nuts, washers etc.

High tensile bolts and nuts shall be stored in separate sealed boxes with proper identification to avoid mix up with other items

b) Pipe hangers, spring hangers etc.

The identification numbers on spring hangers shall be carefully preserved during storage.

c) Stainless steel and copper tubes, pipe fittings, etc

d) Electrical clamps, cable boxes, cable glands, ferrules, fuses, control cables, copper cable and grounding strips, push button switches etc.

e) Pilot valves, pull rods, keys, control valves. These shall be greased, wrapped in paraffin

paper and stored in packing boxes.

All loose parts, packing plates, bolts and studs. All indoor switchgear equipment. All instrument parts such as measuring instruments, controllers and regulators, interlock system, control drive units, gauges, instrument valves, thermocouples and leads Synthetic Paints. Normally in separate stores

7.4.2 Semi-closed Storage

The following materials are normally stored in semi closed storage.





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Large C.I. valves, butterfly valves, stop and control valves, expansion joints. Outdoor switchgear and panels, small transformers, cable tray parts, etc.

7.4.3 OPEN STORAGE The following materials are normally stored in open storage. Fabricated and un fabricated structural steel members.

Stairways and hand rails Gallery steel Steel members Reinforcement steel

Coarse aggregate and sand. Un fabricated pipes and fabricated pipe assemblies. Large diameter conduits / pipes in boxes. Cable drums 7.4.4 SPECIFIC GUIDELINES FOR STORAGE

Given below are guidelines for certain other major equipment / materials. These are broad guidelines only and storage shall be strictly as directed by the MANUFACTURER / NPCIL.

a. ROTATING EQUIPMENT SUCH AS PUMPS AND COMPRESSORS

These are normally stored in assembled condition in closed / semi closed storage. When stored in semi-closed storage, they shall be covered with tarpaulin and bedplates shall rest fully on sleepers.

The CONTRACTOR is responsible for proper lubrication of these equipments as directed. The gearboxes and oil sumps shall be kept filled with recommended lubricating gear oil. The couplings and bearings shall be covered with approved grease and nozzle flanges screwed with caps or suitably plugged. The shaft and internals shall be, if so directed, given a fresh coat of approved protective paint. Pump, if delivered in disassembled condition, shall be stored with the parts properly greased on wrapped in paraffin paper. Smaller parts are to be stored on racks whereas larger parts on sleepers in closed storage. Occasional flushing with hot lubricating oil may have to be carried out, if so directed by NPCIL. The shafts of rotating equipment shall be turned by 90 degree every week to avoid rotor journals from rusting and to ensure that shaft is free to rotate.





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The CONTRACTOR shall maintain record of lubrication with details of lubricants used as well as protective measures carried out. b. PIPING AND VALVES

All pipes shall be stored on sleeper beds with open ends securely capped. The bevelled ends shall be protected with a coating of approved greases. Pipes shall be neatly arranged and stacked for easy identification and retrieval. Pipes shall be blown with air prior to installation and it shall be ensured that there is no obstruction.

Valves shall be stored with the discs screwed down on the seat so that packing surfaces are not exposed to dust. All machined surfaces shall be covered with grease. Preservation of identification tags is essential to avoid installation in wrong services. Smaller valves shall be stored in closed storage whereas large CI valves may be stored in semi closed storage.

Pipe fittings shall be stored on racks in closed storage in packed condition, with openings suitably capped.

c. SWITCHGEAR & CONTROL PANELS

Depending on whether these are of indoor or outdoor design, these shall be stored in closed / semi closed storage. The space heaters where provided, shall be kept connected with power supply irrespective of mode of storage. Where space heaters are not provided, use of adequate number of heating bulbs is recommended. Insulation resistance shall be measured at regular intervals and megger values properly logged. d. CABLES

Cable drums if stored indoors shall be in dry ventilated stores. Cables are normally supplied with ends sealed. When a length is cut, the end should be resealed. The drums shall be stored with adequate spacing between them for better air circulation.

e. MOTORS

Motors shall be stored, preserved, inspected for IR and other checks as instructed in manufacturers recommendations.

f. INSTRUMENTS

These are stored on racks in closed storage and in air-conditioned storage if so recommended. These shall be stored in their packages in dry condition and shall be handled with extreme care.





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Instrument flanges and nozzles, if directed, shall be coated with technical Vaseline. In the case of fragile instruments, the storage shall be in a separate zone away from where heavy materials are stored to minimise danger of damage.

g. STRUCTURAL STEEL

Structural steel could safely be stored in open storage but with sufficient space in between for handling and crane movement. All steel shall be stored 300 mm above ground on suitable packing to avoid damage. It should be stored according to sizes and sections preferably in the order required for erection. The area for open storage should be properly graded to avoid water logging in the storage area. Steel shall not be stored in the vicinity of areas where excavation or grading will be done. Scratched or abraded steel shall be given a coat of primer for protection after unloading and handling prior to erection. All milled and machined surfaces shall be properly protected from rust / corrosion by suitable coating.

h. CEMENT

Cement shall be stored in bags in a separate closed shed away from where mechanical and electrical equipment are stored to minimise the possibility of cement dust settling on the equipment. The Contractor shall make necessary arrangements for the storage of cement to prevent deterioration due to moisture and/ or intrusion of foreign matter. If the storage arrangement is not to the satisfaction purchaser may direct the Contractor to make such arrangements as consider necessary, and in the event of non-compliance, purchaser would reserve the right to make proper arrangements at the Contractor’s risk and cost. The Contractor shall have adequate, weatherproof storage capacity for storing of cement as required.

The storage shed where cement is stored shall be absolutely watertight. The ground shall be such that water shall drain away from the shed to prevent accumulation of water in its vicinity.

The bags shall be neatly stacked with adequate passage in between for easy retrieval. The cement shall be issued on ‘First in-first out” basis.

In case different grades of cement are stored in the same shed, each grade shall be stacked separately to avoid mix up and clear indication boards shall be provided to identify different grades.

i. PAINTS

These have limited life and as a safeguard against possible deterioration, the drums shall be inverted at regular intervals as specified to minimise risk of hard settling of pigments.

j. SLINGS & WIRE ROPES

All slings and wire ropes shall be coated with approved grease and hung from racks in rolled condition.





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k. DOCUMENTATION

The CONTRACTOR’S store–keeping function will include maintaining various records as required by NPCIL. These records shall include but not be limited to the following. Supplier wise record of equipment / material received, stored and issued for erection as well as stock position. Record of inspection and repairs carried out, protective measure and lubrication of equipment in storage as well as erected until the same is taken over by NPCIL.

8.0 FIELD ENGINEERING

Where engineering is in the scope, contractor shall be responsible for controlling and issue of technical drawings and documents, preparation of field sketches, field modifications, checking/preparation of as-built drawings, etc. Contractor should have adequate facilities for incorporating field changes, preparation of As-built drawings, Printing machines and Drawing & Document Control System. Contractor shall establish Field engineering group at site for speedy resolution of field problems.

9.0 FIELD TENDERING

Contractor shall be responsible for carrying out field tendering activities, as required from the site itself. NPCIL- KKNPP registered sub contractors from the local area shall also be considered for tendering and award of work.

10.0 FIELD PURCHASE

Contractor shall be responsible for carrying out field purchase activities, as required. Field Purchase items are restricted to those required for running and maintenance of the field offices, items required to expedite construction work and items found short, missing or damaged against the main order when received at the site. Any material purchased from field for usage in the plant should have proper inspection certificate and should be purchased from NPCIL approved suppliers. If required by NPCIL, check testing of the material samples selected by NPCIL shall be carried out by Contractor without any extra commercial implication.

11.0 PATENTS AND PATENT RIGHTS IDENTIFICATION

All specifications, drawings, patents and such other relevant information furnished to the contractor by the engineer shall be the property of the engineer. If, during the process of execution of the contract, any improvement, refinement or technical changes and modifications are implemented by the Contractor, such changes shall not affect the title to the property of the engineer and the information, specifications, drawings, etc. including the improvement/modifications effected by the Engineer. The Engineer shall also have the absolute right to assign, transfer, sublet, use and transmit all such information and details to the Engineer’s consultants. Contractor shall not have any claim or rights whatsoever in respect of the Engineer’s drawings, specification, patents, proto-types etc. even where improvement refinement, modifications etc. were implemented by the contractor





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12.0 INDUSTRIAL LABOUR RELATIONS

Contractor shall be responsible for industrial relation functions and implementation of labour laws at site. Contractor’s staff shall be suitably trained and experienced in Labour Relation functions so as to ensure a good relationship with labour and to prevent the occurrence of industrial disputes resulting in subsequent delays or work stoppages. In particular, Contractor shall maintain close liaison with NPCIL.

Contractor shall maintain proper liaison with Statutory Authorities and local bodies and shall be responsible to implement and observe all statutory laws at site. Contractor must have in his staff; a well experienced Labour Relation Officer.

Contractor shall maintain the records of wages paid in a wage register, PF, etc. as per statutory regulations.

Contractor shall report immediately to NPCIL any problems including labour disputes, fight, and work stoppages. A written report shall be submitted to NPCIL within 24 hours of the incident.

Contractor must submit a Labour Relation Plan including their sub-contractor(s) prior to the start of the work/within one month of award of the contract, whichever is earlier, mentioning as a minimum:

a. A detailed estimate of the number of labour, indirect and direct.. b. Outline recruiting plans for all manpower requirements. c. Identify personnel involved with labour relations and outline procedures to mitigate

labour disputes & problems. d. Labour welfare plan

13.0 CONSTRUCTION EQUIPMENTS

Contractor is required to organize and mobilize the construction equipments and other tools/tackles in a sequential manner and ensure that plant installation is carried out in a mechanized manner to the extent possible and its mechanical completion is achieved within targeted time schedule.

Contractor shall ensure deployment of the following construction equipment as a minimum as per requirement to the maximum extent –

i Cranes of different capacities ii. Tractor trailers of different capacities iii. Grinding machines v Portable Alloy Analyzers with print out facility

vi X-ray and Radiography sources vii Stress Relieving Equipments with Recording facility x. Welding machines xi. DG sets xii. Electrical and Instrumentation equipments/measuring devices etc. xiv. Bevel Cutting Machines

xv. Test Pumps





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xvi. Compressors xvii. Gas and Mechanical cutting devices xviii. Various inspection / measuring devices

In order to minimize fabrication at site, all (major) fabricated equipment like Columns/Towers, Vessels shall be transported preferably in single piece due to limitation of space at site. Deviation to this shall be specified at the bidding stage itself. Contractor shall carry out the route survey for transportation of 'Over Dimensioned Consignments' including waterways from source of manufacture/supply to site well in advance of placement of order to ensure unhindered transportation of the same to construction site. Contractor shall arrange Cranes of suitable capacities to match with the erection requirements and inform the source and NPCIL of the same.

Crane movement roads are to be clearly identified and marked on the plot plan before planning of such movement. Construction of hard stands for positioning of crane in the fabrication yard and at erection site/locations including approach roads to the hard stands from the plant roads shall be Contractor’s responsibility. The hard stands shall be suitable for the crane loads (self load + equipment load) to facilitate erection works and to be tested for any settlement.

For the purpose of Equipment Erection, the Contractor shall deploy a Rigging team headed by a Rigging Foreman/Engineer reporting to concerned Area Engineer. Area Engineer should be well conversant with various erection techniques and shall be responsible for preparing erection schemes in accordance with the approved procedures and based on crane manuals and suiting to plant layout. Area Engineer shall have to foresee various other construction activities in the surroundings areas while planning erection schemes including safety aspects of man and machinery also.

Contractor shall prepare erection schedule in line with the overall project schedule of the Plant in phased manner with erection schemes of various equipments, vessels and submit to NPCIL for approval, Monitoring and control of erection schedule and erection activities shall be carried out by the contractor as per the approved construction procedures.

For efficient working and maintenance of construction aids, Contractor shall establish and maintain crane yard / workshop equipped with regular maintenance facilities for various construction aids for carrying out routine field maintenance during performance of the contract. Temporary approach road and hard stands, wherever required for the movement of the Cranes and other vehicles for equipment erection and transportation of material shall be properly planned and made by the C o n t r a c t o r . Weekly/fortnightly maintenance shall be planned in such a way that the same does not hamper the erection schedule.

During performances of the work, Contractor must ensure that structures, materials and equipments are adequately braced with Guys, Struts or any other means as deemed fit& approved by NPCIL. Such means shall be supplied and installed by the Contractors as required till the erection works is satisfactorily completed. Such guys, shoring, bracing, strutting, planking supports etc. shall not interfere with the work of other agencies and shall not damage or cause distortion to works executed by other agencies. All lifting tools, tackles and cranes shall be tested periodically by statutory/ competent authorities for their load carrying capacity. Such relevant valid/test certificates shall be submitted to NPCIL for review before actual use of the tools, tackles and cranes.





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Contractor shall submit the construction equipment deployment schedule. Contractor shall ensure the timely augmentation of the men, equipments and machinery depending upon the exigencies of the work to meet the overall project schedule and as per instructions of NPCIL.

14.0 CONSTRUCTION MANPOWER

Contractor is required to organize and mobilize construction staff/ manpower in a sequential manner to ensure that the work is carried out in accordance with the construction schedule. Mobilization of construction staff should be such that the progress achieved in phased manner should match with the overall Project Schedule.

For this purpose, the Contractor shall clearly indicate in his construction methodology whether work shall be done departmentally or by engaging sub-contractor or the combination of both. Contractor shall prepare detailed methodology for the work to be carried out departmentally as well as through sub-contractors clearly, defining the scope and responsibility of Contractor and his sub-contractors. Approval of NPCIL shall be obtained for engaging the sub contractors.

The works of all sub-contractors shall be managed by the construction staff of the main Contractor who shall perform the duties of construction management and shall administer, coordinate, and inspect the works of the sub-contractor(s) and be responsible for the Quality and timely completion of respective works. Contractor shall establish the pre-requisites for successful completion of sub-contractor (s) work. However, deploying the sub-contractor (s), as approved by NPCIL for any discipline, does not absolve the Contractor of his total responsibility under the subject contract.

Contractor must note that in case of any sub-contractors' failure to execute the works as per standards/specifications/drawings and/or negligence & disobedience in carrying out any order or instruction of NPCIL, the same shall be viewed very seriously and any action as deemed fit in accordance with provision(s) of the contract shall be taken by NPCIL.

Contractor must submit the construction manpower deployment schedule along with the bid. Daily construction manpower deployment report shall also be submitted by the Contractor to NPCIL on approved format. Any additional manpower of any category required to be deployed during the actual execution of the work to meet the Project time schedule and as instructed by NPCIL, shall be mobilized by the Contractor within a reasonable time. Mobilization of such additional manpower by the Contractor shall not entitle him for any additional compensation at all.

All construction supervision, coordination and management activities shall be carried out by the Contractor in accordance with the construction procedures approved by NPCIL. Contractor shall prepare construction schedules based on the Overall Project Schedule of the PLANT and submit the same to NPCIL for approval. Monitoring and control of the construction activities shall be carried out as per the approved construction schedule & procedures.

During the execution of works at site, if the Contractor engages sub-contractor (s) for execution of works at site as per approval obtained from NPCIL in line with contract





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provision(s) and in the event sub-contractor complains in writing to the NPCIL with regard to the non-payment of their dues from the Contractor for the works executed by them (excluding final payments and payments due after termination of sub-contractors' services by the main Contractor), NPCIL reserves the right to make such payment to the sub- contractors directly based on approved measurements with due notice to the Contractor. NPCIL shall release such payments to sub-contractor at the cost and risk of the Contractor in order to ensure smooth execution of work at site. All such payments made by NPCIL to the sub-contractor(s) shall be deducted from the running account bills or any other payments due to the Contractor.

The above provisions shall also be applicable in case of construction materials procured at site by the Contractor from the suppliers.

15.0 INTERFACE WITH OTHER CONTRACTORS

Contractor shall ensure that his interface with other Contractors is smooth and cordial. In case of any dispute, NPCIL decision shall be binding.

NPCIL may arrange weekly/fortnightly/monthly interface meetings. The Contractor shall depute concerned personnel to attend these meetings.

Generally, the following interfaces may be present:

Contractor shall allow movement of persons/ material/ equipment/ vehicles

belonging to other Contractors or NPCIL through the roads constructed by him.

Contractor shall coordinate with ‘neighbouring’ contractors for maintaining elevations/ levels of various interconnecting services.

Contractor shall not dump his earth, scrap or any material in other Contractors’ area.

He shall cooperate with NPCIL in maintaining good housekeeping throughout the complex.

Contractor shall ensure proper drainage and no water logging in his area/other

areas.

If requested by the NPCIL, Contractor shall allow testing of materials of other

Contractors in his laboratory, in case of emergency.

Contractor shall clearly define in the interface meeting with other contractors their erection / construction interface at their Battery limits.

16.0 COLOUR CODING OF PIPING MATERIAL

Colour coding of the pipe lines and equipments already available for KKNPP 1 &2 shall be

used for painting and identification.





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17.0 SECURITY REQUIREMENTS

For security procedures, Clause 13. 6 of the GCC and clause of SCC shall be followed. The

security procedures introduced at site from time to time shall be followed by the contractor

without failure.

18 .0 APPROVAL OF ERECTION TESTING & COMMISSIONING PROCEDURES

The CONTRACTOR shall submit to NPCIL for approval within a reasonable period a programme of works which proposes to carry out like erection, testing and commissioning activities. The programme shall also indicate the time by which the CONTRACTOR requires NPCIL to have obtained any consents, approvals, etc necessary for the purpose of the works if any. The submission to and approval by NPCIL of such programme shall not relieve the CONTRACTOR of any of his duties or responsibilities under the contract. Detailed procedure for carrying out handling of equipment and erection, WPS, PQR & WQR, ND examinations, calibration of instruments, testing and commissioning, trial operation, performance testing & handing over for all systems, structures and equipment shall be submitted by CONTRACTOR for NPCIL’s approval prior to start of these activities, in a format and contents to be approved by NPCIL. Detailed procedure for carrying out erection, testing and commissioning, trial operation, performance testing & handing over for all systems, structures and equipment as applicable shall be submitted by CONTRACTOR as per the system description and scope document.

After submission to and approval by NPCIL of such programme the CONTRACTOR shall adhere to the order of procedure and method stated therein unless he obtains the written permission of NPCIL to vary such method or order.

If at any time it should appear to NPCIL that the actual progress of the works does not conform to the programme, the CONTRACTOR shall produce, at the written request of NPCIL, a revised programme showing modifications to the approved programme necessary to ensure completion of the works within the time for completion.

The CONTRACTOR shall submit well in advance, his scheme for movement / lifting / handling of heavy equipment / components also indicating the tools, tackles and equipment he proposes to employ for the same, for approval by NPCIL prior to actual undertaking of such work. This is essential as such activities may call for measures such as additional reinforcements to avoid overloading of structures.

The CONTRACTOR shall submit a detailed write-up on performance test procedure along with sample calculations for NPCIL’s approval and the same shall be finalised prior to actual performance testing.

19.0 LAYOUT AND MEASUREMENT

All the works shall be performed to the lines, grades and elevations indicated on the

drawings. CONTRACTOR shall set out the works and shall be responsible for the true and perfect setting out of the same and also for the correctness of the positions, levels, dimensions and alignment of all parts thereof.





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Basic horizontal and vertical control points will be established and marked by NPCIL at site at suitable points. These points shall be used as datum for the works under the contract.

The CONTRACTOR shall inform NPCIL well in advance of the times and places at which he wishes to do work in the area allotted to him, so that suitable datum points may be established and checked by NPCIL to enable the CONTRACTOR to proceed with his works.

If at any time any error shall appear during the progress of any part of the work, CONTRACTOR shall, at his own expense, rectify such error, if called upon to do so, to the satisfaction of NPCIL.

CONTRACTOR shall maintain base lines and bench marks adjacent to various sections of work. In case of their unnecessary destruction by him or any of his employees, these shall be re-established by CONTRACTOR at his own expense.

The CONTRACTOR shall level and adjust the plant on its foundations preparatory to grouting and shall furnish all packing and shims required for the adjustment.

The CONTRACTOR shall check the electrical and mechanical connections to plant supplied under the contract before such plant is commissioned and shall be responsible for the correctness of such connections in accordance with the contract drawings and specifications.

MEASUREMENT OF WORK

NPCIL may, from time to time, intimate CONTRACTOR that he requires the works to be measured and CONTRACTOR shall attend or send a quality agent to assist NPCIL or his representative in taking such measurements and calculations and to furnish all particulars as may be required by him.

Where the erection of equipment, vessels and structural steel platforms are involved, the basis of such measurements and progress evaluation shall be weights specified in the shipping documents or invoices or drawings, manufacturers document as decided by NPCIL.

Should CONTRACTOR not attend or neglect or omit to send such agents, then, the measurement taken by NPCIL shall be taken to be the correct measurements of the work.

CONTRACTOR or his agent may at the time of measurement, take such notes of measurements as he may require.

The measurements so taken and certified correct by NPCIL shall be the basis for the

progress payment to the CONTRACTOR. Where the breakup of contract value on unit basis is difficult to arrive at NPCIL and CONTRACTOR shall work out at the commencement of the CONTRACT, the weightages or the cost of breakups to arrive at a mutually agreeable basis for computation of this progress estimates.

As per clause of General Conditions of Contract, regarding the terms of payment for erection and commissioning, a portion of the payment will be given on pro-rata basis against satisfactory completion of identified milestone.





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20.0 Access Roads & Temporary Buildings

The CONTRACTOR shall make the necessary temporary access roads, footways, guards as may be necessary by reason of his work, for the protection and accommodation of foot passengers or other traffic of the site personnel/ NPCIL’s personnel. CONTRACTOR shall at all times provide sufficient temporary barriers, notice boards and lights to protect and warn the public and post necessary watchman to guard the site and equipment. He shall take all precautions necessary and shall be responsible for the safety of the work to be performed by him. CONTRACTOR shall observe and display ‘SAFETY FIRST’ signs and shall have proper safety and fire protection equipment. CONTRACTOR shall construct necessary temporary buildings viz., warehouses, tool sheds, fabrication shops, enclosures, etc. for storing his equipment, tools and tackles, etc. at the site and at the place allotted by NPCIL. The responsibility and cost of erecting such buildings shall be borne by the CONTRACTOR including the cost of removing such structure after the completion of the work. The CONTRACTOR shall obtain NPCIL’s approval prior to their removal in the event NPCIL may wish to retain any for his own purpose. Adequate lighting such as flood lights, hand lights and area lighting and near all the storages, handling, fabrication, pre-assembly at erection sites for properly carrying out the work and for safety and security shall be provided by the CONTRACTOR at his own cost. His work area shall be adequately lighted during night time also. In any case, CONTRACTOR shall be liable for all damages and consequence arising out of his negligence in this regard. The CONTRACTOR shall obtain approval of NPCIL to lighting scheme prior to its installation.

21.0 NOTICES

NOTICE OF DEFECTS During the guarantee period, if any defect shall appear or damage occur due to the defective materials, workmanship or on design by contractor or from any act or omission of the CONTRACTOR, NPCIL shall forthwith inform the CONTRACTOR thereof stating in writing the nature of the defect or damage. The CONTRACTOR shall remedy all defects/damages or replacements or renewals to the satisfaction of NPCIL.

NOTICE FOR DELIVERY The CONTRACTOR shall give to NPCIL advance notice in writing of the delivery date. NOTICE OF TESTS The CONTRACTOR shall give to NPCIL advance notice in writing of the date after which he will be ready to make the Tests on completion. Unless otherwise agreed the tests shall take place within 10 days after the said date or days as NPCIL shall notify the CONTRACTOR in writing.





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NOTICE TO CONTRACTOR All notices, written orders etc. to be given to the CONTRACTOR by NPCIL under any of the provisions of the contract shall without limitations be conclusively deemed to have been received by the CONTRACTOR if delivered or mailed to the CONTRACTOR at the CONTRACTOR’s address mentioned in the work order or to the CONTRACTOR’s last known place of business or residence or to his Resident Engineer. NOTICE TO NPCIL Any notice to be given to NPCIL under the terms of the contract shall be served by sending the same by post, or leaving the same at the addresses nominated by NPCIL.

NOTICE ON CHANGE OF ADDRESS Either party to the contract may change its nominated address by prior written notice to the others.

22.0 PATTERNS, SAMPLES AND MODELS

All drawings, specifications, patterns, models and prototypes furnished to the contractor by

the Engineer are intended to be complementary and to provide for and comprise everything

necessary for the completion of work/supply and are the property of the Engineer. These

are not to be used for any works or purpose other than those for which these have been

provided and shall be returned to the Engineer immediately on completion of work/supply in

good condition.