hindustan petroleum corporation limited -...

TURN-KEY PROJECT OF PUTTING UP 2 NOS. BULK LPG STORAGE

AND HANDLING FACILITIES AT

M/s VIKAS WSP, SRI GANGANAGAR, RAJASTHAN

HINDUSTAN PETROLEUM CORPORATION LIMITED

(A Government of India Enterprises)

8, Shoorji Vallabhdas Marg,

Mumbai-400 001. INDIA.

HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI

TENDER FOR PUTTING UP 2 NOS. BULK LPG STORAGE AND

HANDLING FACILITIES AT

M/s VIKAS WSP, SRI GANGANAGAR, RAJASTHAN

UNPRICED BID

INDEX SR.NO. DESCRIPTION PAGE NO. 1. INTRODUCTION

2. INSTRUCTIONS TO BIDDERS 3. GENERAL TERMS AND CONDITIONS

4. SPECIAL CONDITIONS OF CONTRACT

5. SAFETY DISTANCES

6. SPECIFICATION FOR BULK LPG STORAGE AND HANDLING FACILITY AT

CONSUMER PREMISES 7. TECHNICAL SPECIFICATIONS FOR UNDERGROUND STORAGE TANKS

8. TANKER UNLOADING EQUIPMENT SPECIFICATIOS

9. CIVIL WORKS 10. MAINTENANCE AND SPARES 11. TRAINING

12. HANDING OVER REPORTS

13. BILL OF QUANTITIES 14. DRAWINGS TENDERER HAVE TO SIGN AND STAMP ALL PAGES OF THIS TENDER

DOCUMENT AS CONFIRMATION OF THEIR ACCEPTANCE.

1. INTRODUCTION �

�� !�!�"#�$��%��&��'��#()��

*(��$��+��$�,��-�( ��)�� .�/��0��

�

�

�� *'��(��+��

��

�� !�� "�� # $%� �� &�� '�� (��

�� )� *�)�+�,-*-�./�" ��0 �1 ��2�� /34�

�� !3��"��&�� $�,��-�( ��)�� .�/��0��

�

5%�"�$��#�3�� 6�� 4��*�03�/�

� � �� )� *�)+�,-*-�./�/34�� *�

�� )� � *� ,-*-� ./� � ��

�� /34� ��$� ��$� �� /34� �� 1�� *��

�� 6 �� $�� *�

"�7�89��0(//�(338'7��(��0'9��3(9�:�'7�3��'87�(4�7�:�(5874��0��(3398"��/'��

4'"�7� '7� �0'�� 7��9� �8�25�7�*� ��83�� 8�� 0'9�� 3(9�:� '7�3��'87� '�� ('/��

��/8#�'7��87��97��'87��8��0'��7��9��8�25�7�*�3(:5�7��8��0'9��3(9�:�

'7�3��'87�(4�7�:��0(//��5(��:�"7�89*�

�

1��.��2��#2�1�32�4��

$�,��-�(�#��

567897:�'��$�0��

��)�� ;;<==� ��

.�/��0��

�

��4�� 0�)��>�� ?��@#()��/��

� � � ��4�=��6��8;:=7<��>��A 0��

�

�

�

�(.6B'1#3�3�1�32��.3�.31��

�� 6 � �� )�7 *� !��&�)� ;� ,-*-./�� 1 ��2�� /34�� !��

��&�� "�$��#�3��4��9�6��*��

�

�1. �� <��!582&�� 6 ��

��8�� 3��53"��,-=,!��&*��

�� *�

�)*� �� <��

�� %��

�� >?��*�� ,?�

�� ,@� $�%�*� �� >� �� *� 3�� >� �� 5 �� %�

2�� /34�� "��3 6�� 8��!��

�� A�3�� $&��

'�� /34�� ,?�5�� 6 *�� !�8�&�� 3��'�� !�3'�&�

�� 6 �� *��

�

�B*� �� +��<�� 6 � ��9*�C>��$��

� ��!# $�8��&�� &�/34�� &��%�

� �� &�� /34��

�� +�� !3��8&�� /34� � �� $� ��$� ��

��%�� /34�� /34�"�� 1��

��(�� /34�� $�� 3�2�8�� *�

�@*� �� 9*�,??�/�$��

B� �� *� ��

�� *��

��*��

��0��C��0��'�(.3��53��

��

2. INSTRUCTIONS TO BIDDERS

SCOPE

This document specifies the scope of works to be undertaken to construct bulk LPG storage and handling facilities at Plants of M/s Vikas WSP at Sri Ganganagar .

The works to be undertaken shall be carried out in accordance with this specification, the scope of works & specifications for the installation of consumer facilities, the accompanying drawings / specifications / requirements , all the applicable Standards and codes mentioned herein, all relevant Indian Government Regulatory and Statutory requirements including that of CCOE, Nagpur, India and any other regulations needed for setting up Bulk LPG consumer facilies.

The Contractor shall supply all Labour, Equipment and Materials and consumables necessary to complete the works specified including Supervision by responsible person having knowledge on Civil , Mechanical and Electrical work connected with LPG installations. PLEASE NOTE THAT WORK IS TO BE CARRIED OUT IN EXISTING FACTORIES AND HENCE ALL SAFETY PRECAUTIONS ARE TO BE FOLLOWED. ALSO, WORKING OF FACTORIES SHOULD NOT BE AFFECTED BY THE CONTRACTOR WHILE EXECUTING THE JOB. DEFINITIONS HPCL - Hindustan Petroleum Corporation Limited. CONTRACTOR - Suitably qualified, experienced and Certified Contractor, experienced in LPG installation and Competent to carry out the works specified. It is essential that they have carried out the Similar jobs in other countries and have Experiences to interact with the local authorities. 3. REFERRED DRAWINGS & DOCUMENTS

List of drawings: Contractor to follow the schedule given below for the drawings / documents ( Minimum Requirement ): DRAWINGS GIVEN IN THE TENDER DOCUMENT ARE INDICATIVE DRAWINGS AND ARE TO BE READ IN CONJUNCTION WITH TENDER SPECIFICATIONS AND THE WORK TO BE CARRIED OUT ACCORDINGLY. IN CASE OF DISCREPANCY BETWEEN SPECIFICATIONS & INDICATIVE DRAWING, MORE STRINGENT DETAILS OF THE TWO TO BE FOLLOWED. (A) DRAWINGS ATTACHED ALONG WITH THE TENDER DOCUMENT – CONTRACTOR TO RETURN THE SAME AFTER SIGNING AND STAMPING THEM AS CONFIRMATION OF THEIR ACCEPTANCE. ( Please note that, even if the contractor attaches drawings of the system offered by them, in the bid, still the drawings / specifications attached by HPCL are the minimum requirements and have to be complied with as the minimum requirements ).

(a) P & ID

(b) Details of underground tank installation

(A) CONTRACTOR TO ATTACH FOLLOWING DRAWINGS/ DOCUMENTS ALONG WITH THEIR

OFFER.(UNPRICED BID)

(a) Details of the equipment offered – namely LPG pump, vaporizer etc. – Make and Model No along with CCOE

approval and technical brochures.

(b) Design Calculations of the Underground LPG Tank.

(c) Underground LPG Tank details , Make and details of the Gauging Devices, Pressure Switches, safety Valves and other fittings.

(d) Pneumatic Circuit Drawing.

(e) Above Ground Fill Point Details.

(B) CONTRACTOR TO SUBMIT FOLLOWING DRAWINGS IN CASE OF AWARD OF CONTRACT AND ARE TO BE APPROVED BY HPCL BEFORE STARTING WORK.

(a) LPG Control Panel Details

(b) Details of Cathodic Protection.

(c) Emergency Shut Down System details.

(d) Piping Layout drawing. Location specific pipeline fabrication drawing describing specifications of valves, pipes, pipe fittings, flanges. Also detailing location and design of pipe supports.

(e) Location Specific Electrical Layout drawing showing cable schedule, location of various electrical panels, motors, compressor.

(f) Location of specific earthing layout drawing.

(g) Location specific hazardous area drawing.

(h) Any other drawing / documents required as per Statutory requirements.

(C) AS BUILT DRAWINGS AFTER COMPLETION OF THE FACILITIE(S). SPECIFICATIONS

A. Oil Industry Safety Directorate ( Indian) Guidelines – OISD 210 B. SMPV Rules as amended in Feb 2000. C. Any other statutory requirement for LPG consumer installations. 4. SCOPE OF SUPPLY AND EXTENT OF WORKS

The turnkey job consists of various equipment and their spares for 2 years service. General list of various equipment / spares is given below ( later in the tender ) which is the minimum required and this may not be a complete list. Any additional works/equipment if required to meet the statutory requirement is also to be a part of contract, which has to be provided with out any additional cost to HPCL. It is the responsibility of the contractor to complete the job to the entire satisfaction of HPCL.

SUPPLY ITEMS 1) 2 nos. 19.9 KL Underground tank with Protective Coating at each location. Each tank shall have

Tank Gauging devices and other fittings as per SMPV Rules specified by CCOE , India. The LPG tank will have two openings one of 350 mm size to provide all instrumentation fittings and second opening of 600 mm size. The openings shall be in the form of Manhole cover.

2) Remote fill point. 3) Cathodic Protection – Sacrificial Anode Type. 4) LPG Piping Work above ground up to Fill point including supply of pipes ( Seamless Grade SA

333 Gr 6), and for evacuation upto vapouriser and downstream upto battery limit. All piping flange joints shall be provided with 40 mm wide and 3 mm thick copper jumpers. The pipe line shall be given the color code and the flow direction to indicate the LPG liquid and vapour and the flow direction.

5) Electric cables including laying in the trench. 6) Two No Earth Pit with earthing connections to Pipelines, LPG unloading pump motor etc. The

Unloading pumps and compressors and motors shall be provided with double earthing. Two nos. flexible earthing cable of sufficient length with crocodile clip at the end for connecting it to the Bulk LPG Tanker reporting for unloading. The earthing strips shall be arranged as per the earthing grid layout drawing enclosed.

7) Control panel & Emergency Shutdown Switch(ESD) system with electrical & pneumatic components.

8) 1 No Air Compressor of adequate capacity for operation of ROV`s and ESD. 9) One Nos 50 KG and 3 Nos 10 KG BIS Marked DCP Fire Extinguishers. 10) Hoses for unloading tanker – Hose conforming to BS:4089 for both Liquid Line and Vapour

Line along with Acme Nozzle at the one end and Flange at the other end of the Hose. The length of the Hoses shall be 3 meters.

11) Supply and installation of filter on LPG Unloading line. 12) Do`s and Dont`s Board and Operating instructions Boards in two languages giving details of

various operations like dispensing, unloading tanker etc. The lettering shall be on poly vinly sheet pasted on Poly Urethane Foam ( PUF ) board. The size of the board shall be 45 cms by 60 cms for operating instructions and 30 cms by 30 cms for Do`s and Dont`s. The size of the letters shall be 2.5 cm`s. The total no. of boards in two languages shall be 4 nos. for operating instructions and 2 nos. for Do`s and Dont`s.

13) vendor to display ( properly painted ) as built P&ID on a designated wall in size not less than 1.5 m by 1.5 m. in addition to this a framed P&ID and pneumatic circuit diagram of adequate size to be displayed in the control panel room / sales room.

14) Any other items needed for your system / statutory requirement.

THIRD PARTY INSPECTION OF ALL THE IMPORTED / INDIAN EQUIPMENTS AT THE MANUFACTURERS PREMISES HAVE TO BE CARRIED OUT AND COPY SUBMITTED ALONG WITH THE SUPPLY. PLEASE NOTE THAT TRAINING IS AN IMPORTANT PART OF THE PROJECT. PROPER TRAINING IS TO BE GIVEN ON THE NEW FACILITY TO THE CONSUMERS’ PERSONNEL / OPERATING STAFF. PLEASE SUBMIT TRAINING MODULE ALONG WITH UN PRICED BID WHICH WILL BE FOLLOWED FOR IMPARTING PROPER TRAINING.

TANKER UNLOADING STATION

1. Unloading Pump of 200 Liters per Minute Capacity for Unloading Bulk LPG Tanker. 2. 1 No. LPG compressor Corken Model 291 or equivalent model of Blackmer 2. Unloading Metering System – Mass Flow Type. 3. LPG Piping Work for setting up the tanker unloading station. 4. Civil Works for tanker unloading station . 5. Electrical Works / LPG Control Panel to include the tanker unloading station equipments in it.

EVACUATION FACILITY� �

1 Evacuation facility comprising of 2 nos. vaporizers each of 250 kgs/hr capacity with a canopy and with all accessories as per technical specifications and pressure regulating system for ensuring that the consumer receives LPG vapour at 2 kgs/sqcm at the battery limit.

2 1 no. 8m x 4m size LPG pump / vaporizer open shed with RCC footings, columns, flooring, RCC equipment foundations and structural steel roof structure with AC sheeting including ridge pieces, corner pieces etc.

3 Process piping consisting of supply, inspection, fabrication, welding, testing and painting and commissioning of all below mentioned materials / equipment:

� Seamless pipes for liquid / vapour / vent lines, including suitable blinds, bends, tees, couplings � Weld neck raised face flanges of 300 # rating , � Fire Safe Ball valves of 300 # rating for bullets, pumps, compressors, vaporizers, � Remote Operated Ball Valves of 300 # rating for bullets isolation, � Y-type strainers of 300 # rating , � Check Valves of 300 # rating � SS 316 Spiral Wound Asbestos filled Metallic SS gaskets, � Studs and Nuts

for all piping between LPG Tank Truck unloading bay, pumps, compressors, vaporizers up to battery limits.

HYDRANT/ SPRINKLER FACILITY In each facility, the following facilities are to be provided: 1. Main hydrant line of 150nb (6”) dia. ERW pipe with one isolation valve 2. One no. double headed hydrant point with 2 nos. Hoses and nozzles placed in a hose box and one no. of

water monitor. One 4”150# Gate or butterfly isolation valve is to be provided beneath each hydrant/monitor .

3. Sprinkler system of 20.4 LPM/sq.m. spray density in LPG Pump/ vaporizer shed. 4. Sprinkler system to cover tank truck during unloading with spray density of 10.4 LPM/sq.m. of tank

surface area and suitable spray to cool tyres and driver cabin. 5. The above sprinklers to be automatically actuated with a break glass. If the glass is broken , it should

automatically open a 4” 150# Pneumatically operated ball valve thus operating the sprinkler system in both areas, and provide a signal for starting of Fire Engine.

Note :Supply and erection of Fire engine and suction/discharge piping , construction of water tanks , fire pump shed are not in scope of PO. The job shall be carried out by our Client M/s Vikas WSP. CIVIL WORKS FOR U/G TANKS – (a) Dismantling of RCC/CC/Asphalted areas and disposal of debris, as required. (b) Excavation in all types of soil up to a maximum depth of 5 metres and disposal of excavated earth out

side the Retail Outlet as per the stipulations of the local municipal authorities. Dewatering of the sub soil water, if encountered is in the parties scope.

(c) Foundation for the bullet with minimum requirement of providing M 20 RCC ( 1:1 1/2 : 3 ) base of thickness as per drawing for resting the bullet. The quantity and the quality of the cement, sand and aggregates shall be as per IS Codes.

(d) Supply/fixing of Hold down Nuts/bolts for properly anchoring the bullet. (e) Back filling with sieved sand as per IS 383. (f) Providing 60 mm thick Cement Concrete Paver Blocks flooring with proper slope. This is to be provided

inside the rigid fencing covering full area up to the tank farm area. (g) Good quality Pebbles of Off White color in tank farm area. (h) Product Pipeline shall be laid above ground with RCC pedestals/ structural supports duly grouted.

Cables to be laid in trenches or underground in GI pipes (i) Retaining/Support wall constructed over the base slab all around the tanks in Brick Work in CM 1 :5 to

prevent water seepage in the tank farm area with CC Coping all along the length/width of the wall. (j) Any other work required for completing the construction of LPG consumer facility.

PLEASE NOTE THAT AS PER CHIEF CONTROLER OF EXPLOSIVES REQUIREMENTS, THE ADEQUACY OF THE RCC FOUNDATION OF THE TANK HAS TO BE CERTIFIED BY ANY APPROVED THIRD PARTY INSPECTION AGENCY. THIS CERTIFICATION SHOULD FORM PART OF THE RULE 33 TO BE SUBMITTED TO HPCL.

PARTY TO ALSO SUBMIT DESIGN CALCULATIONS APPROVED BY TPI OF THE ADEQUACY OF THE ANCHOR BOLT ( DIA ETC). P & I DIAGRAM IS TO BE DISPLAYED IN THE TANK FARM AREA AND THE ELECTRICAL CIRCUIT DIAGRAM AND PNEUMATIC CIRCUIT DRAWING IS TO BE DISPLAYED NEAR THE MAIN PANEL.. SITE SPECIFIC AS BUILT DRAWINGS HAVE TO BE MINIMUM ON A3 SIZE. All instrumentation fittings used in hazardous area must have CMRS and CCOE approval wherever required. All Electric and instrumentation fittings shall be either flame proof or intrinsically safe and duly approved by CCOE. Contractor to take required Municipal Corporation approval for excavation and dumping of surplus earth. Job Includes Tools, tackle equipment, manpower & supervision for actual carrying out the job in its totality. The following tasks are to be carried out by the contractor.

4.1 Excavate the area as specified. The contractor shall ensure that stability of the excavation is maintained

at all times. This may require the use of shoring and / or shuttering where ever necessary. Consideration must be given to stabilizing adjacent motor spirit tank if necessary. Provide lockable 2m high fence around tank excavation if the excavation is left open overnight. Self Glowing Signages to be displayed near the pits for safety at nights.

4.2 Prepare site for construction of other ancillary structures and services. 4.3 Co-ordinate the installation and commissioning of the Cathodic protection system ensuring that the

underground tank and all buried pipe work to be adequately protected against corrosion immediately after installation.

4.4 Restore all underground services that were disrupted during construction. 4.5 Install all electrical equipment and systems. 4.6 Install all mechanical equipment, including pneumatic system. 4.7 To Provide 2 Nos , BIS marked 75 Kg DCP Fire Extinguishers and 3 Nos 10 kg DCP Fire Extinguishers

as per attached specifications. 4.8 Pressure test and purge the installation. 4.9 Commission the installation including the verification of proper operation of all equipment (especially the

emergency shutdown system. 4.10 Paint all new structures. 4.11 Reinstate landscaping and forecourt disturbed by the installation of piping and other services to original

condition.

The contractors shall provide 3 Sets of Work as executed / AS Built Drawing with tracings upon completion along with all relevant documentation.

5.0 DEVELOPMENT APPROVALS Contractor to assist Vikas WSP/ HPCL in obtaining all statutory approvals and permits by providing all the required drawings and be present during technical discussions with Statutory Authorities. 1. C.C.O.E. approvals 2. Local Municipal Approvals 3. Pollution control/Environment approvals 4. Fire brigade approvals for fire fighting requirements or equivalent approving authorities. However, it is the exclusive responsibility of the Contractor for the following approvals : 1. Contractor to submit CCOE approval of the LPG unloading Pump, vaporizer and all

Flame Proof Fittings offered by the contractor along with the unpriced Technical Bids. 2. Calibration Chart of the underground LPG bullet duly approved by TPIA. 3. Approval, if required, from the local Municipal Corporation for excavation and dumping

of surplus earth. 6.0 QUALITY ASSURANCE PLAN Contractor to submit Quality Assurance Plan immediately after placement of PO before starting the wok. The Quality Assurance Plan has to be first approved by HPCL before starting the work. QAP shall include details of the work and the details of the stage wise inspection by HPCL for the following stages. The details given below is the minimum requirement and Party has to develop its own QAP as per the requirements of the system offered by them. ( Tentative QAP is attached ). PARTY HAD TO GET ALL IMPORTED MATERIAL INSPECTED BY THE THIRD PARTY INSPECTION AGENCY AT THE MANUFACTURER PREMISES BEFORE DESPATCH OF THE MATERIAL. MATERIAL / EQUIPMENT WILL BE ACCEPTED ONLY ON SUBMISSION OF THIRD PARTY INSPECTION REPORT. Party has to carry out Testing of all Civil Engg materials in line with QAP of the Civil Works attached, through any approved test laboratory and the test reports to be submitted along with the running bills. The minimum requirements are given below however, all testing has to be carried out as per the QAP. (i) Sand – Particle Size distribution as per IS 386 & IS 2386. (ii) Coarse Aggregate – Particle size distribution as per IS 386 & IS 2386. (iii) Cement – Manufacturers Test Certificate as per IS 8112 –1976 & IS 4031. (iv) Steel Reinforcement – Manufacturers Test Certificate as per IS 1139. (v) Cement Concrete - Crushing Strength on 150 x 150 mm cubes as per IS 456 –2000.

7.0 SUPERVISION / INSPECTION OF THE WORK

The work will be carried out either under direct supervision of HPCL and any of the Third Party Inspection Agencies appointed by the Vendor ( paid by Vendor ) . Such Third Party Inspection Agency / Consultant will carry out all the works including approval of the drawings / checking of the test reports / QAP / supervision of the Site / certification of the quantities in totality. The contractor may have to at times coordinate with such party ( TPIA / Consultant). However, the Scope of Work for the contractor shall be strictly as given in the Tender Document. The Stage wise inspection by TPIA during fabrication of the bullet is in the contractor`s scope. Approved Third party agencies are BVIS / IRS/ Bax Counsel /DNV / ICS .

8.0 SAFETY The contractor shall comply with all local occupational health and safety regulatory requirements, HPCL Safety Regulations and the other requirements if any. Contractor to obtain necessary permissions for

site works on day to day basis from HPCL’s authorized representative. The contractors supervisor shall be trained in all safety regulations and should stringently monitor compliance to safety norms.

Note: Sub contracting not allowed without approvals from HPCL.

4. SPECIAL TERMS OF THE CONTRACT

COMPLETION PERIOD : The Completion Period shall be THREE MONTHS - 3 Months from the date of LOI/PO or from the date of advise to start work by HPCL, or from the date of handing over of the encumbrance free Site whichever is later. The work shall commence with in 7 days from the date of LOI or from the date of advise to start the work , or from the date of handing over of the encumbrance free Site whichever is later. The issuance of the Rule 33 ( in presence of HPCL or HPCL appointed TPI) of the Site shall be treated as the date of completion of the work. The completion period shall be applicable for each facility separately. DELAYED DELIVERY CLAUSE : For delay in completion beyond the schedule delivery period, penalty shall be applicable as per enclosed General Terms and Conditions. For calculating the delivery period for application of delayed delivery clause, each site will be considered separately. TERMS OF PAYMENT : The Payment Terms shall be as given below : ( to be read in conjunction with Clause No 7.0 of the GTC ) (A) FOR SUPPLY , ERECTION , COMMISSIONING of EQUIPMENT (I) 70 % Payment shall be made on receipt of material at Site against respective items. (II) 20% on erection of the equipments, testing and pre commissioning. (III) 10% on handing over of the Site after making handing over report ( as per format given in the tender

document), submission of final documents, instruction manuals, operating manuals, training to HPCL personnel on entire system and complying with all the observations of the Site Acceptance Committee.

(B) FOR ERECTION OF EQUIPMENTS/PIPING AND COMMISSIONING (APPLICABLE WHERE

ERECTION AND COMMISISONING IS SEPARATE FROM SUPPLY OF ITEM)

(I) 90% on completion of erection of equipments, testing & pre commissioning. (II) 10% on handing over of the Site after making handing over report ( as per format given in the tender


(C) FOR CIVIL WORKS.

(I) 90% as per progress of the work and submission of the test reports along with the bills. (II) 10% on handing over of the Site after making handing over report ( as per format given in the tender


10 % payment shall be deducted as Retention Money against each Running Bills and the same will be released against Performance Bank Guarantee of equivalent amount. The period of Retention Money or Performance Bank Guarantee shall be 1 year from the actual date of completion.

( To be read together in conjunction with GTC) PARTY TO NOTE THAT NO MOBILISATION ADVANCE SHALL BE PAID BY HPCL. DEFECT LIABILITY PERIOD : 1 YEARS - The Defect Liability Period shall be 1 ( One) Year from the date of handing over after commissioning of the Bulk LPG consumer facility. The defect Liability Period shall be applicable for each facility separately. ( To be read together in conjunction with Clause 11 of the GTC )

WATER AND POWER : Water and Power required for the Work shall be arranged by the contractor at their own cost. LABOUR : Labour Camp shall not be permitted inside the Site premises. The responsibility of Safety and Security of the Materials and Equipment brought and installed by the Vendor at Site (till they are handed over to HPCL) will remain with the Contractor and any claim of whatsoever nature due to loss or otherwise will not be entertained.

5. SAFETY DISTANCES AS PER SMPV RULES

1. Bulk LPG storage facilities : 1.1 Layout of Facilities: Storage vessels between each other and from boundary line of the Factory shall

observe the separation distances as in Tables A. and B.

TABLE A

Minimum safety distances for Liquified Flamable Gases

Ref : Static & Mobile Pressure Vessels (Unfired) Rules, 1981

Sl. No.

Water Capacity (in Litres) Minimum distance from line of adjoining property OR group of

buildings not associated with storage and operation

Minimum distance between vessels

Above groound vessel

Under ground OR above ground

vessel covered with earth (mound)

Above groound vessel

Under ground OR above

ground vessel covered with

earth (mound) 1 Not above 2,000 5 metres 3 metres 1 metre 1 metre 2 Above 2,000 but not above 7,500 10 metres 3 metres 1 metre 1 metre

3 Above 7,500 but not above 10,000 10 metres 5 metres 1 metre 1 metre

4 Above 10,000 but not above 20,000 15 metres 7.5 metres 1.5 metres 1 metre

NOTES: (1) The distances specified above are required to be measured from the nearest point on

the periphery of the vessel.

TABLE B

Minimum Safety Distances (in metres) between facilities associated with storage and dispensing of Liquefied Petroleum Gas (LPG) in LPG dispensing station as automotive fuel to motor vehicles

Ref : Static & Mobile Pressure Vessels (Unfired) Rules, 1981 LPG storage vessel Fill point of LPG

storage vessel and Centre of LPG Tank-truck unloading hard

stand

LPG Dispenser Property line

Petroleum service station licensed in Form XII of Petroleum Rules, 1976

Fill point of

petroleum tanks

Vent pipe of

petroleum tanks

Petroleum class A/B

dispensing pump

9 (above ground / mounded vessels exceeding 7500 litres capacity).

9 (above ground / mounded vessels NOT exceeding 20,000 litres capacity OR under ground vessels).

6 (above ground / mounded vessels NOT exceeding 7500 litres capacity).

15 (above ground vessels exceeding 20,000 litres capacity).

LPG storage vessel

Refer Table A

3 (under ground vessels).

Refer Table A

9 9 9

Fill point of LPG storage vessel and Centre of LPG Tank-truck unloading hard stand

9 (above ground / mounded vessels exceeding 7500 litres capacity).

--- 6 9 6 6 6

6 (above ground / mounded vessels NOT exceeding 7500 litres capacity).

3 (under ground vessels).

Property line Refer Table A 9 6 --- 3 4 6

2.2 Fencing : The area where vessels pumping equipment, loading and unloading facilities are

provided shall be enclosed by a fence at least 2 meters high along the perimeter of the safety zone. Every fence shall have at least two means of exit and the gates of such exits shall open outwards and shall not be self locking.

SPECIFICATIONS

6. SPECIFICATION FOR BULK LPG STORAGE AND HANDLING FACILITY AT CONSUMERS’

PREMISES 1.0 STANDARDS

The design and construction of Bulk LPG consumer facility will be based on:

.

(A) SMPV Rules (B) OISD Standards (C) BIS 15000 – 2001 - Multi Port Valve Assembly

( D) Local requirement if any will supersede the above.

2.0 STATUTORY REQUIREMENTS

All Equipments, wherever required shall have the approval of CHIEF CONTROLLER OF EXPLOSIVES, NAGPUR, INDIA. All relevant statutory requirements shall be met including design to all codes, and design approvals from all Dangerous Goods Authorities. Documentation shall be provided to show evidence of compliance with Dangerous Goods requirements.

3.0 GENERAL FEATURES

The following features are general in nature and apply to all tanks, valves and pipe work wherever possible. Non compliance with these features must be nominated if not exempted elsewhere. These features shall take precedence over the drawings but not the specific sections below. - All fittings, valves and pipe work above 20 mm dia shall be flanged 300# ANSI B16.5 RF with

Steel Spiral Wound gaskets except those required as insulating joints. - All studs and nut shall be supplied zinc plated and material specifications shall be as per ASTM

A 193 Gr.B7 for Studs & ASTM A 194 Gr.2H for Nuts. Nut & Bolts shall not be used.

- All pipe work shall comply with SMPV Rules of CCOE , Nagpur, India. All metallic liquified piping shall be rated for propane as per ASME B- 31.3 with a minimum design pressure of 32.00 kg/ sqcm with a factor of safety of four. The materials of pipes shall be low carbon or alloy steel conforming to American standard ASTM-SA-333, grade 6 or API-5L. The pipeline shall be tested at one and half times of the design pressure, if hydrotested or ten percent in excess of design pressure if pneumatically tested.

- All ball valves shall be suitable for LPG operations constructed as per manufacturing standard

API 6D and shall be Fire Safe as per API 607 / BS 6755 (Part II). CONTRACTOR TO SUBMIT TEST CERTIFICATE OF TPIA CERTIFYING THE VALVES ARE MANUFACTURED AS PER API 6D AND FIRE SAFE.

4.0 FILL POINT FEATURES

The following features described are to be incorporated into the design and manufacture of the LP Gas Fill points used in LPG Bulk Installations. The manufacturer is to supply in the tender package manufacturing drawings to confirm compliance with all requirements

4.1 Above Ground Fill Point.

Aboveground fill point shall be designed to ensure it can be installed 300 to 600 mm above ground level. Aboveground fill point shall include :

- Liquid fill pipe work and vapour recovery pipe ( SA 333 Gr. 6)

- Emergency stop button.

- Remote Operated Valves on both Liquid and Vapour Line.

- Excess Flow Valves.

- Pressure Gauge.

- Strainer.

- Remote Display Unit of the Level Indicator of the Tank.

- All Structural Steel Woks

5.0 TANK FEATURES

The following features described are to be incorporated into the design and manufacture of the LP Gas Tanks. The manufacturer is to supply in the tender package manufacturing drawings to confirm compliance with all requirements

Tank to have two openings for piping connections / various fittings. The first fitting shall be of 350 NB dia and shall contain all the instrumentation fittings. The second opening shall be of 600 NB dia for all piping nozzles. The fittings shall be in the form of Manhole cover.

Tanks shall be supplied with stud pads for all fittings above 20 mm in diametre in order to utilize flanged ball valves as secondary protection due to superior joint safety in relation to threaded couplings. This excludes the safety relief valve but no other valves or fitting. The stud pads shall contain internal NPT threads in order to insert internal primary valves ( excess flow or non return ) fitted from outside of the tank.

5.1 Underground Tanks

In addition to specific details on drawings all underground LPG tanks shall have the following features: 5.1.1 deleted

5.2.2 Pipe Work

- All fittings on the Man Hole Cover (350 NB & 600 NB ) shall have valves and pipe work above 20mm dia shall be flanged 300# ANSI with Steel Spiral Wound gaskets except those required as insulating joints. The drain line shall be provided with 2 nos. be 40 NB ball valve with blind flange.

- Provision in the Pipe manifold is to be provided to evacuate the product of the U/G tank in case

of Off Spec product or Emergency by pumping the product back in the tanker through Fill Point.

- All fittings on LPG lines be Forged fittings. Mitred fittings shall not be allowed in LPG lines.

- All fittings of 40 mm and below shall be socket welded.

- If a small size tapping is to be taken from a large dia pipe e.g for taking tapping for pressure gauges, for vent line for SRV`s, PRV etc, the same shall be done using a half coupling of specifications mentioned below :

- Specifications of fittings shall be as follows :

- For sizes above 40 mm – CS Forged fittings, Butt Welded conforming to Material SA 420 GR.

WPL 6 suitable for low temperature. These fittings shall be compatible to the corresponding pipe material.

- For Sizes 40 mm and below : CS Forged fittings, Socket Welded conforming to Material SA 350

LF 2 of Rating 3000. These fittings shall be compatible to the corresponding pipe material. - All pipe work shall be schedule 80 for pipes up to 50 NB The vent pipe shall be of schedule 40

with 300# ANSI flange.

- All pipe work leaving the tank is to be fitted with insulating flange kits. Additional insulating kits are required between the liquid withdrawal actuated valve and the bypass valve. Provide 25 x 25 x 5 lugs with 6mm hole welded to pipes penetrating the pit wall for connection to anodes for cathodic protection system for the pipe work.

- The Product Pipeline is to be provided above ground on structural steel supports suitably

grouted .

SPECIFICATIONS

FOR

LPG TANK

7. TECHNICAL SPECIFICATIONS FOR UNDERGROUND LPG STORAGE TANK Scope of work, Specifications Terms and Conditions are detailed below: I. Scope of Work: a) Preparation of detailed Design Calculations including Man Hole Cover Thickness, Bullet Hold

Fasts details and Fabrication drawings which are to be approved by HPCL and Third Party Inspection Agency and Chief Controller of Explosives, Nagpur, prior to fabrication.

b) Procurement and supply of all materials like Steel Plates, various fittings like Nozzles, Flanges

etc., as required for the fabrication of Pressure Vessel in accordance with the approved specifications as per ASME Code and HPCL requirements.

c) Fabrication of entire LPG Storage Pressure Vessel. d) Dye penetration Test on root run of all Welded Joints, 100% Radiography, 100% Stress

Relieving, Hydrotesting or the Vessel at appropriate stages as per ASME code. e) Inspection / Certification by Third Party Inspection Agency approved by Chief Controller of

Explosives viz., M/s. Lloyds Register / Bureau Veritas / Bax Counsel / PDIL, covering approval of Design, Drawings, Material, Fabrication, Testing of Pressure Vessels, Fittings and Complete Vessel.

The scope includes appointment of Third Party Inspection Agency as well as payment for all their services / inspection / certification charges by the Contractor.

f) Erecting the Pressure Vessels. i) Contractor will be required to furnish Six sets of final Fabrication drawings and Design calculations

duly stamped by Third Party Inspection Agency and one set of reproducible tracings of Fabrication drawings and Design calculations to HPCL for their records.

Contractor will also furnish original copy of Certificates of Control issued by Third Party

Inspection Agency and all other Test Certificates to HPCL. j) Cleaning inside of Pressure Vessel. k) External surface coating of the Pressure Vessels after Sand Blasting the surface as per

attached specifications. Any touch up painting required after erection of Pressure vessels at site will also be carried out by the Contractor at no extra cost.

Contractor shall Supply and Install following fittings. These are the minimum requirement. However, Contractor is required to give details of all the fittings required for their system. 1. One No. Magnetic Float Type Gauge ( Rochester Gauge) with local display and one no. Slip

Tube guage. 2. One No. High Level Alarm Switch

3. 2 Nos. Safety Valves on each Pressure Vessel. Each Safety Valve to be provided through independent nozzle. To be supported by pipe or angle structure for bending against wind pressure.

4. Temperature Gauge 5. Water drain off Nozzle to be provided on the manhole cover. The water drain off pipe should be

of ¾ `` and should project just few mm above the tank bottom. The water drain pipe on top of the bullet shall be provided with two ball valves.

CONTRACTOR TO GIVE MAKE AND DETAILS OF THESE FITTINGS ALONG WITH THEIR UNPRICED BID. l) Preparation and submission of calibration charts. These charts should be approved by the Third

Party Inspection Agency. II. Design Parameters / Material Specifications :

1. Volumetric Water Capacity : 19.9 Cum. 2. Storage Capacity of LPG : VTS 3. Density of LPG : 0.52 4. Design Code : ASME Sec VIII Div. 2 5. Design pressure : 14.5 kg/cm2 Gauge at Top 6. Design Temperature : -46°C to +55°C 7. Hydraulic test pressure : As per code. 8. Radiography : 100% 9. Corrosion Allowance : 1.5 mm 10. Stress Relieving : 100% required for the

entire pressure vessel.

11. Joint Effeciency : 1 12. Inside Diameter of Pressure : VTS Vessel. 13. Length of Pressure Vessel : VTS 14. Dished Ends : Torrispherical

Note:

(i) Contractor should advise the Shell & Dish end thickness and also Man Hole Cover thickness with Design calculations in their Unpriced Bid.

(ii) All Openings will be of Flanged type with Nozzle Construction. Mateirial of specifications:

1. Shell, Dished Ends, Wear Plates : SA 537 Class I / ASTM Manhole SA- 516 Grade 70

( Impact tested for low temperature applications)

2. Nozzles : SA 333 Gr. 6 3. Flanges/ Manhole Cover : SA 350 Gr. LF2 – ASA 300

Weld neck raised face dimensions as per ANSI 16.5

4. Couplings : SA 350 Gr. LF2 6000 lbs 5. Bolts/Nuts : SA 320 Gr. L7 or SA 194 Gr.4 / Gr. 7 6. Gaskets : SA 304 / 316 Spiral Wound Asbestos filled. (iii) Nozzles :

Following Nozzles shall be provided by the Contractor on each Pressure Vessel in addition to 2 nos. of Manhole with Cover one of 350 mm dia and another of 600 mm dia. The details of the Nozzle given below are indicative and Contractor to specify the details. All Nozzles should be provided with SA 350 Gr. LF2, 300 lbs. RF blind flanges. 1. Nozzle for Liquid receipt : 1 No.

2. Nozzle for Vapour Receipt/ return : 1 No 3. Nozzle for Liquid outlet : 1 No

4. Nozzle for Pressure Equilisation : 1 No

5. Nozzle for Magnetic Float Type Level Gauge: 1 No. 6. Nozzle for Magneto Restrictive Type

Level Gauge : 1 No. 7. Nozzle for High Level : 1 No.

8. Nozzle for Water drain line : 1No 9. Temperature Gauge : 1 No ( in a Thermowell) 10. Two Nozzles for Safety Valves : 2 Nos

The Vessel shall have a Name Plate with following details : a) Manufacturer’s name and identification marks. b) The standard or code to which the vessel is constructed. c) Official stamp of the Inspector. d) Design Pressure in Kg/ sqcm. e) Date of initial hydrostatic test. f) Hydrostatic test pressure in Kg/sqcm. g) Water capacity in litres. h) Gas Capcity i) Name of the gas.

Scope of Third Party inspection:- i) Approval of fabrication drawings/design calculation. ii) Identification of raw material w.r.t. Test certificates iii) Verification of welding procedures and of validity of welders performance

Ceertificate. iv) Stage inspection during fabrication. v) Inspection of components at Contractor’s works. vi) Checking of forming of plates, edge preparation and mock assemblies. vii) Approval of all weld set ups and back chipping. viii) Examination of radiographs and supervision of repairs where necessary. ix) Attendance to other non-destructive test and such hardness measurements, D.P. check, magnetic flux

tests and ultrasonic tests where specified. x) Inspection of assembly xi) Final dimensional checks xii) Attendance of hydraulic and pneumatic tests xiii) Inspection of cleaning and painting xiv) Approval of stress relieving. xv) Issue of certificate of control

xvi) Issue of Inspection reports. xvii) Any other items of Inspection not covered above but required as per Inspection Agency / Design Code /

Statutory requirements / Safety requirements / Static and Mobile Pressure Vessels (Unfired) Rules, 1981 shall also form part of this scope of work and the same shall also be covered in the quoted rates.

Approval from CCOE :

Before taking up fabrication of Pressure Vessel at their works, the Contractor will be required to obtain approval of Chief Controller of Explosives, Nagpur on the design calculations and Fabrication drawings of the Pressure Vessel. Contractor shall furnish a copy of such approval to HPCL for records. All documents of stage wise inspection of the tanks will have to be submitted to HPCL. THE FOUNDATION BOLTS HAVE TO BE CASTED ALONG WITH CASTING OF RCC RAFT USING TEMPLATE, ANTICORROSIVE PAINT HAS TO BE ONLY SIGMA MAKE . CORRECT THICKNESS OF THE ANTICORROSIVE PAINT HAS TO BE CERTIFIED BY THE TPI WHO CARRIES OUT STAGE WISE INSPECTION OF THE BULLET AND IS IN YOUR SCOPE. SURFACE COATING AND CATHODIC PROTECTION OF UNDERGROUND LPG TANK AND LPG PIPING. 1.SURFACE COATING : For Underground LPG Tank. Surface Preparation : Blast Clean all Steel to Sa 2.5 using copper slag or equivalent. Surface profile should be 40-70 µ after blasting. Clean all blasted surface areas using dry compressed air and following paint scheme shall be applied. Paint Scheme : Sigma Cover Primer ( 7413) 1 x 50 µ Sigma TCN 300 Brown shade ( 7472 ) 1 x 200 µ Sigma TCN 300 Black Shade ( 7472 ) 1 x 200 µ ------------- TOTAL DFT 450 µµµµ 1. CATHODIC PROTECTION : Sacrificial Anode type Cathodic Protection system with a minimum life of 15 years shall be provided. The Cathodic Protection shall be complimentary to the protective surface coating on the LPG Tank and the sacrificial anode shall be either a Zinc or Magnesium anode.. The minimum requirement of the system shall be : • Pre Packed Sacrificial Anodes. • Reference Electrode. • Monitoring Panel with Test Points. • Cabling The Cathodic Protection shall be as per for applicable standards : NACE CODE – RP0285 -95

Indian Electricity Rules 1956 BS Standard – 7361 Cathodic Protection Criteria shall be : A negative ( cathodic ) potential of at least 850 mV with the cathodic protection system. The potential is measured with respect to a saturated copper / copper sulphate reference electrode containing the electrolyte. A minimum polarisiation shift of (- ) 100mV of cathodic polarization The underground piping , if any,shall be provided with PYKOTE Tape to protect it. Names of the brands /Party, to whom the jobs will be out sourced shall be furnished in tender as well as prior approval to be taken before excavation of the job. CATHODIC PROTECTION SYSTEM / SURFACE COATING SHALL BE APPROVED BY HPCL OR THIRD PARTY INSPECTION AGENCY PRIOR TO APPLICATION. PARTY TO SUBMIT QAP FOR CATHODIC PROTECTION / SURFACE COATING WHICH SHALL BE APPROVED BY HPCL / TPIA. THE CATHODIC PROTECTION SYSTEM APPLICATION AT THE SITE SHALL BE CARRIED OUT BY THE TRAINED ENGINEERS OF THE CP SYSTEM SUPPLIER ONLY. RULE 33 SHALL CONTAIN CERTIFICATION THAT CP SYSTEM HAD BEEN DONE PROPERLY. PLEASE GIVE THE DETAILS OF THE MAKE OF INSULATION GASKET AND AT WHICH JOINTS IT WILL BE USED. INSULATION GASKET SHALL ALSO BE USED FOR THE FOUNDATION BOLT OF THE BULLETS TO ISOLATE THEM FROM THE TANK AND THUS TO HAVE BETTER CATHODIC PROTECTION.

SPECIFICATIONS

OF

TANKER UNLOADING EQUIPMENTS

8. TANKER UNLOADING EQUIPMENT SPECIFICATIONS

��%�3�1#��(�3�3�1�32��2.��1�"��.'�"��1��3�)�('?(��

5�$�� 89.�7�2�(�

�� (��C��$��

5 �� D�<)???�

�� 3 ��%/34�

�� ,)�5B%��

73�0�� 7'/�

3�� E??��

0�� ,)?��

�� 1�� >?�+�>?�7��

?1�.31#�2��2��.'��32��

��0��9 � ��3�� (�>BE��' ��

�� 4��' ��

��9 � � ��

��

"�� 3��

9��"��

�� 9 ��

�� 5��

�� E??��

?2�2.�4�

��

��'��

�� '��),@=%,-E-�� 4��4 ��''�

(��

5 � �9�� >�03�

5 � �935� ,@@?�

� �� <�5 �� 0 �1 ��

'�� F�G��

�� '3�E>�

5�$�� 4��%��6��%��

��1��3�)�('?(��"3��*��0�(��+�

�#�� .3(�32�� 3D� .1�3�)� B�E�

,� 3��H� $��2�(I� ��*� �� ,�

�� 5 � ��J��

��3�� J�� 87%8��

��

)� ��"�� >?�7�� B??�K� B�

B� 3��4��H?<B??��I� B%=G�7�� B???�K� )�

@� 7��"�� B%=G�7�� B???�K� )�

>� 383�(�� "�� ,%@G�7�� B???�K� )�

E� �� >?�7�� B??�K� ,�

C� /�� '�� >?�7�� B??�K� ,�

=� 79"� �� >?�7�� B??�K� ,�

-� ��<3��"�� >?�7�� B??�K� ,�

,?� �� 9��

,,�8�� %�/ ��

� �� 9��

,)� �/3%�+3�3�� 9��

,B� �� 9��

,@�� 0��/��

�� 9��

� � � � �

�� (�� (��

�

�

��%�3�1#��(�3�3�1�32��2.�#()�(.��'.�.)'#1�3�)��E��?�

�

� 5�$�� "(7(D�%�89�(3398"��A2'"(/�7��

� '��3�� ?<)?�$�%��*�

� 8��3�� )�$�%��

� �� 9�� )??�$�%��L�@??�$�%�*�

� ��1�� (��

� (2��8�"�� B??�K�� 1�*�

� 3��4�� E???�K�� 1��

� 383� �� E???�K�� 1��

��

��%�3�1#��(�3�3�1�32��2.��1�"��.'�"�'�#21�3�)��2?(.��2.��

� 5�$��89.�7��

� 5 ��)-,�

� ��/34��

� 7 *� ��

� 7 *� ��)�7 *�

� 3�� =)>��)>*@�5B%�*��

� ��)??��%��

� ��=)>��+��

� 5�+��)B*,� ��

� ��(��

� �� "��7 �<�

� ��$��"� ��4��

� (�� 3�� 5 � �

�� .� �$� ��3��4��

�� 4��

�

��2� 1�� &�� .�� F�

B��

,� ��"�� @?�7�� =??� ,�

)� ��"��I� )>�7�� =??� )�

B� 3��4��H�?<B??��I� B%=G�7�� E???� )�

@� 7��"�� B%=G�7�� E???� )�

>� 383�(�� "�� B%@G�7�� E???� )�

E� @�#��"��'�� )>�7�� =??� ,�

�

� ?2�2.��

��

� ��

� ��'��

� �� '��),@=%,-E-�� 4��4 ��''�(��

��

� 5 � �9��C*>�03�!�89�(��9�A2'9��&�

� 5 � ��,@@?��

� � �� L�5 ��0 �1 ��

� '�� F�G��

� �� '3�E>��

�� 87�98/��

�

� #��#()��(�� 4� ��G��

� �#(�9��(�(��0��2�� 4� ��G��

� ��0��0�� 4� ��G��

� ��%��0��C��0�� 4� ��G��

��%�3�1#��(�3�3�1�32��2.�#()�$1(2.3D.��

��

�

,*��5 ��4(�89��)>?�L�/�%�(7'/�)*��0��#��

B*��5��#��

@*��

��

��3)��.3�.31� $��#�� 23#�9�#()�

�

� �� 5�� '��)=)>��B� � �/34�(�5��B,*@�

8��3�� (�� E<=�.�%��)�!�&�

8�� B?��L�=?�� B?��L�=?��

��3�� >�$�%�� ,@*>�.�%��)�!�&�

�� ,??�� ,??��

��3�� #��L�C*>�$�%�� ,-�.�%��)�!�&�

��

>* (�� +�� 7��9��

�E*��)>?�.�%�*�

�C*��1��/34��"��

�=*�� (�(�B??�K��-*��3 ��@,>�"��B�3��

,?*�� B?@�

�

�2�� 2��.2#�� ?1"� .1�)� �3D� ?2�� E(� B�E�

�*� �/��9'�(/�0�(��9��

��89�� <<<� ,>�.#�

<<<� <<<� <<<�

*� �87�98/�

3(7�/�

39853�� <<<� <<<� <<<� M�/3�%��;3� ,�

�*� 39��29��

�#'��0�

�#'�D�9� ?<,E�

.4%�5)!�&�

NG� ��%�� M�/3�%��;3� ,�

�*� �8/�78'��"(/"��

("�87� <<<<� >?�7�� 9(�� M�/3�%��;3� ,�

�*� 39��29��

9�/'��"(/"��

43� ))>�3�'� E�7�� 9(�� 383�8��:3�� ,�

�*� 39��29��

'7�'�(�89�

4/2�.� ?�LB??�3�'� ,?�7�� 9(�� 829��7�

�:3��

,�

�*� #(��9�/�"�/�'7�'�(�89�

43� ?�L�BE?�� ,>�7�� 4/(��:3�� ,�

�*� ��53*��7�89� 43� ?<,)?��4*�� OG� ��

�

�0�958��(�� ,�

�9�A2'9��J��'�*��#��'��

��''*��9��

M��/3�L�� '��),@=*��5�$��*��(�� *��

HOSES FOR UNLOADING TANKER HOSE SIZES 50 NB FOR LIQUID LINE 40 NB FOR VAPOUR LINE TYPE Conforming to BS:4089 LENGTH OF HOSE 3 METERS COUPLING AT HOSE ENDS ACME THREADED SUITABLE FOR THE TANK TRUCK AND FLANGED FOR FILL POINT END. MATERIAL HOSE MATERIAL SUITABLE FOR LPG APPLICATION. FLARE LINE A FLARE LINE IS TO BE PROVIDED AT THE UNLOADING POINT FOR FLARING OF THE CONTENTS OF THE UNLOADING HOSE. INSTALLATION SKID FOR MOUNTING THE UNLOADING PUMP : REQUIRED CANOPY FOR THE UNLOADING PUMP : REQUIRED ELECTRICAL WORKS /LPG CONTROL PANEL : REQUIRED LPG PIPING: REQUIRED CIVIL WORKS FOR INSTALLING THE UNLOADING STATION : REQUIRED TRIPPING THROUGH ESD : REQUIRED TRIPPPING IN CASE OF HIGH LEVEL IN THE BULLET: REQUIRED SELECTION OF THE TANK IN WHICH THE PRODUCT IS TO BE UNLOADED AND FROM WHICH THE LIQUID IS TO BE WITHDRAWN HAS TO BE SELECTED THROUGH A SELECTOR SWITCH AT THE UNLOADING POINT

BULK LPG CONTROL PANEL Functions of Bulk LPG Control Panel To provide an interface between the tank monitoring system ,and above ground unloading pump such that : (a) The LPG tank cannot be filled above a pre- selected level ( with suitable alarms ) and tripping of the above

ground unloading pump. To control the Emergency Shut Down System. To control the tank selection for unloading of LPG and withdrawal of LPG. The minimum requirement in LPG Control Panel shall be : 1. Receive Signal from LPG Pump and Vapouriser for Over Load, High bearing temperature , low

differential pressure on starting of LPG Pump etcc. 2. Receive signal from Liquid LPG level Monitor to Cut Off Fill point ROV in case of High Level. 3. Receive Signal from the Emergency Stops for total shutdown. 4. Receive signal from air pressure switch and shutdown the LPG System in case the feedback of

compressed air from ROV actuators is below the set limits of pressure. 5. PLC to consolidate signals from the LPG Pump and convey it to the Control Circuit. 6. Supply Power to Level Monitoring System. 7. Display Emergency shutdown system indication in the Sales Room. 8. Power the Master Air Solenoid Valve controlling compressed Air Supply to all ROV`s. 9. Various Protection devices on the Main incomer. 10. Ammeter, Voltmeter to be provided on the panel. 11. Display of the liquid LPG Content in the tank.

The Circuit diagram of the Control Panel shall be approved by HPCL or Third Party Inspection Agency The Panel shall comply with all the requirements of Indian Electricity Rules, 1956 and shall have IP –54 protection. All other Electrical Panels shall be ISI approved.

Vendor to display framed Circuit diagram in the control Panel room. CABLING LAYING OF CABLES: Entry of cables from underground trenches, to the control room shall be through pipe sleeves. Necessary precautions shall be taken to make entry point fully watertight by properly sealing the pipe sleeves.

Adequate length of cables shall be pulled inside control panels, terminal boxes, etc. so as to permit neat termination of each core.

While laying cables parallel to buildings or utility pipelines, drainage, etc. minimum clearance shall not be less than 1000 mm.

At the turning & tee off point of the cable trench, suitable chamfering shall be done in accordance with bending radius of the cable.

The cables on walls / other structures shall be through a cable tray with MS clamps of required sizes to hold the cable firmly to structure/tray.

All entries shall be sealed with sealing compound. Cables shall be neatly laid, with no crossing over of cables.

TERMINATION. OF CABLES : Termination of cables shall comprise of stripping of cable, glanding with compressed type glands, crimping of lugs on conductors and fixing the lugs on the terminals. Conductors of control cables shall be crimped with pin type or ring type lug. Power cables shall be provided with single hole lugs. Crimping Tool to be used shall be ratchet type and correct dies for each size of cable shall be used. Hammering of lugs shall not be permitted. TESTING OF CABLES : Insulation Resistance Test for low voltage control wiring and cables operating at a voltage below 250 V shall be carried out with 500 V megger. Insulation Resistance Test for medium voltage wiring and cables working at a 415 volt shall be carried out with a 1000V megger. CABLE PROTECTION PIPE : The Contractor shall provide GI pipes of required sizes for protecting the cables while emerging out of the floor or ground. CABLE RACKS/TRAYS: Racks and other supporting steel shall be painted with 2 coats of red oxide primer and two coats of enamel paint. For trays below 300 width, hot dip galvanised, perforated trays from 14 gauge sheet steel shall be used.

MAKE OF THE EQUIPMENTS

1. UNLOADING PUMP – CORKEN 2. LPG COMPRESSOR – CORKEN OR BLACKMER

3. MASS FLOW METER – EMERSION, ENDRESS & HOUSER

4. SAFETY FITTINGS ( SRV, NRV, TRV, EFCV etc) – REGO,MGM, FISHER MAKE. 5. REMOTE OPERATEDVALVES – AUDCO, VIRGO, MICRO FINISH, FLOWCHEM .

6. HIGH LEVEL ALARM – SBEM, CHEMTROL

7. MAGNETIC FLOAT TYPE – ROCHESTER GAUGE

8. MAGENTO RESTRICTIVE TYPE LEVEL INDICATOR – VEEDER ROOT, SBEM.

9. CATHODIC PROTECTION – RAYCHEM.

10. TEMPERATURE GAUGE – THERMAX, H.GURU, GOA INSTRUMENT

11. PRESSURE GAUGE – FEIBG, H GURU, GLUCK

12. AIR COMPRESSOR – INGERSOLL RAND, ELGI

PARTY TO SUBMIT MAKE AND MODEL NO. OFFERED BY THEM FOR THE ABOVE EQUIPMENMTS / FITTINGS

PARTY TO SUBMIT THE DETAILS OF MAKE AND MODEL NO. OF OTHER EQUIPMENTS / FITTINGS IN THEIR OFFER. ALL FITTINGS HAVE TO BE CCOE APPROVED ONLY.

SPECIFICATIONS

FOR

CIVIL WORKS

9. SPECIFICATIONS FOR CIVIL WORKS

1.0

EARTHWORK

Excavation shall be carried out for all types of soils including boulders, soft & hard rock. Back-filling around pit, trenches, etc., shall be carried out using suitable excavated material. Excess excavated material shall be disposed off from HPCL premises.

1.1 APPLICABLE STANDARDS / CODES :

The following Indian Standards / Codes, unless otherwise specified herein, shall be applicable. In

all cases, the latest revision of the Standards / Codes, shall be referred to :- IS – 783 Code of Practice for laying of concrete pipe. IS – 1200 Method of Measurement of Building Works. IS – 3764 Safety code for excavation work. All other codes, as referred to in the above codes, will also be applicable to the works.

1.2 The excavation shall be carried out to correct lines and levels. This shall also include, where required, proper shoring to maintain excavations and also the furnishing, erecting and maintaining of substantial barricades around excavated areas and warning lamps to ensure safety at night.

1.3 All excavation work shall be carried out in all types of soils, disintegrated rock, boulders, weathered rock, etc., manually or by mechanical equipment.

1.4 All excavation shall be kept free of water. Grading in the vicinity of excavation shall be controlled to prevent surface water running into excavated areas. When there is a continuous inflow of water and quantum of water to be handled is considered.

1.5 All back-fill material shall be subject to the approval of the HPCL representative. If any

material is rejected by him, the CONTRACTOR shall remove the same forthwith from the

site within 24 hours at no extra cost to HPCL. Surplus fill material shall be disposed off, as

directed, after the back-fill work is complete.

No earthfill shall commence until drains have been properly laid and function well.

1.6 Only selected excavated materials shall be used as backfill from the outside of the pit. Fill material shall be free from clods, silt, salts, sulphates, organic or other foreign material. All clods of earth shall be removed.

1.7 Back-filling within pit shall be carried out with local sand as per specifications . The sand /murum used shall be clean, medium grained and free from impurities.

2.0 SPECIFICATIONS FOR FILLING AROUND TANK IN PIT

The sand bed shall be laid to the falls & to the levels and full depth as shown on the drawings and the bed for the tanks shall be excavated out of the fully compacted bed using a template formed to the exact shape and size of the tanks.

2.1 The sand surround tank shall be material in compliance with clause 3.1 laid around the tanks during filling operation to a 300 mm minimum thickness and shall be hand compacted into position.

2.2 Filling material between tank surrounds shall be sand in compliance with clause 3.1 laid in maximum 200 mm layers, or other suitable material.

2.3 Compaction shall be sufficient to avoid significant settlement of the sand filling surface but shall be such as not to impose undue stresses on the tanks.

2.4 The sand filling shall be placed equally, in maximum 200 mm layers (uncompacted depth), on each side of the tanks so as to avoid any lateral displacement/rotation of the tanks during compaction.

3.0 MATERIAL SPECIFICATION

3.1 The sand for the tank bed, tank surround and filling between tanks shall consist of material complying with the following specification :- a) Good quality clean, non-aggressive sand with a maximum organic Material Content of 3% by

weight.

b) A maximum particle size of 4 mm grading zone IV as per IS:383. An alternative material may be proposed for the general mound fill (other than the sand bed and tank surround) but this has to be agreed by the HPCL/TPIA.

3.2 The stone layer to the top shall consist of clean, well graded stone free from all organic material, sulphates, or any other deleterious material.

4.0 CEMENT CONCRETE AND ALLIED WORKS:

General requirements for concrete to be used on jobs using on-site production facilities

including requirements in regard to the quality, handling, storage of ingredients,

proportioning, batching, mixing & testing of concrete, and also requirements in regard to

the quality, storage, bending and placement of reinforcement. This also covers the

transportation of concrete from the mixer to the place of final deposit and the placing,

curing, protecting, repairing and finishing of concrete.

4.1 APPLICLABLE CODES AND SPECIFICATIONS:

The following specification, standards and codes shall form part of this specification. All standards, tentative specifications, codes of practice, referred to herein, shall be the latest editions, including all applicable official amendments and revisions. In case of discrepancy, if any, between this specification and those referred hereunder, the more stringent shall govern. Decision of the HPCL representative shall be final in this regard

APPLICABLE I.S. SPECIFICATIONS AND CODES OF PRACTICE IS. : 269 - Specification for Ordinary, and Low Heat Portland Cement.

IS. : 383- Specification for coarse and fine aggregates from Natural source for concrete. IS : 456 - Code of practice for plain and reinforced concrete. IS : 516 - Method of test of strength of concrete. IS : 1786 - Specification for cold twisted Steel bars for concrete Reinforcement. IS : 2386 - Method of test for aggregates for concrete. (parts I to VIII) IS : 3696 - Safety code for scaffolds and ladders. (parts I & II). IS : 8112 - High strength ordinary Portland Cement 43 grade. IS : 12269 - - do - 53 grade. IS : 1077 - Specification for common burnt clay bricks

4.2 The quality of materials & method and control of manufacture and transportation of all concrete work irrespective of mix, whether reinforced or otherwise, and shall conform to the applicable clauses of this specification. The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard type Portland Cement, clean sand natural coarse aggregate, clean water, and admixtures, if specially called for on drawings and/or in the specifications.

4.3 The Minimum cement content for each grade of concrete shall be as shown below:-

Grade of concrete Minimum cement content /Cu.M. of finished concrete

M – 20 340 Kg. M – 25 360 Kg.

4.4 Before any concrete is placed, the entire placing programme consisting of equipment, layout,

proposed procedures and methods shall be submitted to HPCL for approval and no concrete shall be placed until HPCL representative approval has been received in writing. Equipment for conveying concrete shall be of such size and design as to ensure a practically continuous flow of concrete during depositing without segregation of materials, considering the size of the job and placement location.

4.5 Concrete shall, in all cases, be placed from as near as practicable position directly in its final position, and shall not be re-handled or caused to flow in a manner which will cause segregation, loss of materials, displacement of reinforcement, shuttering or embedded inserts, or impair its strength.

4.6 Concrete shall be compacted during placing, with approved vibrating equipment until the concrete has been consolidated to the maximum practicable density, is free of pockets of coarse aggregates and fits tightly against all form surfaces, reinforcement and embedded fixtures.

4.7 FORMWORK : The formwork shall consist of shores, bracings, sides of beams and columns, bottom of slabs,

etc. including ties, anchors, hangers, inserts, etc. complete which shall be properly designed and planned for the work. False work shall be so constructed that vertical adjustments can be made to compensate to take up any settlements. Wedges shall be used at the top or bottom of timber props, but not at both ends, to facilitate vertical adjustment or dismantling of the formwork.

4.8 Reinforcement bars, to be arranged by CONTRACTOR and shall be either plain round mild steel bars Grade I as per IS: 432 (part I) or hot rolled mild street and medium tensile steel deformed bars as per IS: 1139 or cold twisted steel bars as per IS: 1786, as shown and specified on the drawings. Substitution of reinforcement will not be permitted except upon written approval from HPCL representative. The reinforcement shall not be kept in direct contact with the ground but stacked on top of an arrangement of timber sleepers or the like. Laps and splices for reinforcement shall be provided strictly as shown on the drawings. Reinforcement shall be accurately binded with 16 gauge soft annealed wire and maintained in the correct position shown in the drawings by the use of blocks, spacers and chairs as per I.S. 2502 to prevent displacement during placing. Clear concrete cover for reinforcement shall be maintained as stated on drawings.

5.0 BRICKS :

Bricks used in works shall conform to the relevant Indian Standards. They shall be sound, hard, homogenous in texture, well burnt in kiln without being vitrified, table moulded, deep red, cherry or copper coloured, of regular shape & size shall have sharp & square edges and parallel faces. The bricks shall be free from pores, chips, flaws or humps of any kind. Bricks containing unground particles and/or which absorb water more than 15% of their weight when soaked in water for twenty-four hours shall be rejected. Overburnt or under-burnt shall be liable to rejection. The bricks shall give a clear ringing sound when struck and shall have a minimum crushing strength of 55 Kg/sq.cm., unless otherwise noted on drawings, the classes and quality requirements or bricks shall be as laid down in IS : 1077.

5.1 For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry condition. Water shall then be added and mixing continued to give a uniform mix of required consistency. The mortar shall be thoroughly mixed and the same shall be used within 25 minutes of mixing. Mortar left unused beyond the above specified period shall not be used in work and shall be rejected.

5.2 All bricks shall be thoroughly soaked in clean water for at least one hour immediately before being laid. The cement mortar for brick masonry work shall be as specified in the respective item of work. For laying bricks a layer of mortar shall be spread over the full width of the length of the lower course.

6.0 PLASTER: All joints in masonry shall be racked to a depth of 12 mm. with a hooked tool, made out for the purpose when the mortar is still green and in any case within 48 hours of its laying. The surface to be rendered shall be washed with fresh clean water, free from all dirt , loose material , grease, etc., and thoroughly wetted for 6 hours before plastering work is commenced. Concrete surface to be rendered will be however be kept dry. The wall shall not be to wet but only damp at the time of plastering. The damping shall be uniform to get uniform bond between the plaster and the wall.

The proportion of the mortar shall be as specified under the respective items of work. Cement and sand shall be mixed thoroughly in dry condition and then just enough water added to obtain a workable consistency. The quality of water, sand and cement shall be as per I:S standards. The mortar thus mixed shall be used immediately and in no case shall the mortar be allowed to stand for more than 25 minutes after mixing with water. Curing of plaster shall be started as soon as the plaster has hardened enough so as not to be damaged. The decision as to when the plaster has hardened, will be given by the HPCL representative. Curing shall be done continuously by applying water in fine spray and shall be carried out for at least 7 days. 7.0 AGGREGATES: a) "Aggregate" in general designates both fine and coarse inert materials used in the

manufacture of concrete. b) "Fine Aggregates" are aggregates most of which pass through 4.75 mm IS sieve. c) "Coarse aggregates" are aggregate most of which retain on 4.75 mm IS sieve. 7.2.2 All fine and coarse aggregate proposed for use in the work shall subject to HPCL/ TPIA

approval and after specific materials have been accepted, the source of supply of such materials, shall not be changed without prior approval of HPCL.

7.2.3 Aggregates shall, except as noted above, consist of natural sands, crushed stone and gravel from a source known to produce satisfactory aggregate for concrete and shall be chemically inert, strong, hard, durable against weathering, of limited porosity and free from deleterious materials that may cause corrosion of the reinforcement or may impair the strength and/or durability of concrete. The grading of aggregates shall be such as to produce a dense concrete of specified strength & consistency that will work readily into position without segregation and shall be based on test on concrete as specified later in this group.

7.2.4 SAMPLING AND TESTING:

Samples of the aggregates for determination of suitability shall be taken under the supervision of ENGINEER and delivered to the laboratory well in advance of the scheduled placing of concrete. Records of tests which have been made on proposed aggregates and on concrete made from this source of aggregate shall be furnished to ENGINEER in advance of the work for use in determining the aggregate suitability. The costs of all such tests, sampling, etc. shall be borne by CONTRACTOR.

7.2.5 STORAGE OF AGGREGATES:

All coarse and fine aggregate shall be stacked separately in stock piles in the material yard near the work site to avoid intermixing of different aggregates. Contamination with foreign materials and earth during storage and while heaping the materials shall be avoided. The aggregates must be of specified quality not only at the time of receiving at site but more so at the time of loading into the mixer. Rakers shall be used for lifting the coarse aggregates from stock piles. Coarse aggregates shall be piled in layers not exceeding 1.20 metres in height to prevent coning or segregation. Each layer shall cover the entire area of the stock pile before succeeding layers and started. Aggregates that have become segregated shall be rejected. Rejected material after remixing may be accepted, if subsequent tests demonstrate conformity with required gradation.

7.2.6 SPECIAL GRAVITY:

Aggregates having a specify below 2.6 (saturated surface dry basis) shall not be used without special permission of ENGINEER.

8.0 FINE AGGREGATES:

Fine aggregate, except as noted above, shall consist of natural or crushed sand conforming to IS: 383. The sand shall be clean, sharp, hard, strong and durable and shall be free from dust, vegetable substances, adherent coatings, clay, alkali, organic matter, mica, salt, or other deleterious substances which can be injurious to the setting qualities/strength/durability of concrete.

8.1 MACHINE MADE SAND:

Machine made sand will be acceptable, provided the constituent rock gravel composition shall be sound, hard, dense, inorganic, uncoated and durable against weathering.

8.2 SCREENING AND WASHING:

Sand shall be prepared for use by such screening or washing or both, as necessary, to remove all objectionable foreign matters while separating the sand grains to the required size fracation.

8.3 FOREIGN MATERIAL LIMITATIONS:

The percentage of deleterious substances in sand delivered to the mixer shall not exceed the following:

Percent by Weight Uncrushed Crushed

i) Material finer than 75 micron I.S. sieve 3.00 15.00 ii) Shale 1.00 - iii) Coal and lignite 1.00 1.00 iv) Clay lumps 1.00 1.00 v) Total of all above substances including items (i) to (iv) for uncrushed sand and items (iii) & (iv) for crushed sand. 5.00 2.00

8.4 GRADATION:

Unless otherwise directed or approved, the grading of sand shall be within the limits indicated hereunder:-

PERCENTAGE PASSING FOR I.S. Sieve Grading Grading Grading Grading Designation Zone-I Zone-II Zone-III Zone-IV 10.00 mm 100 100 100 100 4.75 mm 90-100 90-100 90-100 95-100 2.36 mm 60- 95 75-100 85-100 95-100

1.18 mm 30- 70 55- 90 75-100 90-100 600 micron 15- 34 35- 59 60- 79 80-100 300 micron 5- 20 8-30 12- 40 15- 50 150 micron 0- 10 0- 10 0-10 0- 15 Where the grading falls outside the limits of any particular grading zone of sieves, other than 600 micron I.S. sieves, by total amount not exceeding 5 %, it shall be regarded as falling within that grading zone. This tolerance shall not be applied to percentage passing the 600 micron I.S. Sieves or to percentage passing any other sieve size on the coarser limit of Grading Zone I or conforming to Grading Zone IV shall be used. Sand used for preparing concrete shall belong to Grading Zone-II. 8.5 FINENESS MODULUS:

The sand shall have a fineness modulus of not less than 2.2 nor more than 3.2. The fineness modulus is determined by adding the cumulative percentages retained on the following I.S. Sieve (4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron and 150 micron) and dividing the sum by 100.

8.6 COARSE AGGREGATES:

Coarse aggregates for concrete, except as noted above, shall conform IS: 383. This shall consist of natural or crushed stone & gravel and shall be cleanand free from elongated, flaky or laminated pieces, adhering coatings, clay lumps, coal residue, clinkers, slag, alkali,mica, organic matter or other deleterious matter.

8.7 SCREENING AND WASHING:

Natural gravel and crushed rock shall be screenedand/or washed for the removal of dust coating, if so demanded by ENGINEER.

8.8 GRADING:

The pieces shall be angular in shape and shall have granular or crystalline surfaces. Friable, flaky and laminate pieces, mica and shale, if present, shall be only in such quantities that will not, in the opinion of ENGINEER, affect adversely the strength and/or durability of concrete. The maximum size of coarse aggregates shall be specified on relevant drawings. The maximum size of coarse aggregates shall in no case be greater than 1/4 of the minimum thickness of the member, provided that the concrete can be placed without difficulty so as to surround all reinforcement thoroughly and fill the corners of the form. Plums above 150 mm and upto any reasonable size can be used in plain mass concrete work of large dimensions upto a maximum limit of 20% by volume of concrete when specifically approved by ENGINEER. For heavily reinforced concrete members, the nominal maximum size of the aggregates shall be 5 mm less than the minimum clear distance between the reinforcing main bars, or 5 mm less than the minimum cover to the reinforcement, whichever is smaller. The amount of fine particles occurring in the free state or as loose adherent shall not exceed 1% when determined by laboratory sedimentation tests as per IS: 2386. After 24 hours immersion in water, previously dried sampled shall not have gained more than 10% its oven dry weight in air, as determined by I.S. 2386.

8.9 FOREIGN MATERIAL LIMITATIONS:

The percentages of deleterious substances in the aggregate delivered to the mixer shall not exceed the following:

Percentage by weight Uncrushed Crushed

i) Material finer than 75 micron 3.00 3.00 I.S. sieve

ii) Coal and lignite 1.00 1.00

iii) Clay lumps 1.00 1.00

iv) Soft fragments 3.00 -

v) Total of all the above substances 5.00 5.00

9.0 9.1 9.2 9.3 9.4

INTERLOCKING PAVER BLOCKS The paver blocks shall have the following properties:

Crushing Strength : 35 MPa (Minimum) tested as per BS:6717. Water absorption : 3% maximum tested as per BS:1881. Abrasion resistance : As per IS:2386. Thickness : 60 mm.

All paver blocks shall be factory made using machine. All moulds and machines shall be open for inspection of TPIA/HPCL. The handmade paver blocks shall not be accepted.

The subbase shall be prepared to the required grade, level and

camber. It Shall be cleaned of all dust, dirt, and other extraneous

matter. Any ruts, soft Yielding places or any pot holes shall be

corrected by filling with good earth and well Compacted.

The sand shall be spread uniformly and evenly upon the prepared base in required quantities. It shall be spread in such a manner that after compacting the consolidated thickness will be 50 mm. However, the sand laid for bedding should be uncompacted and surface vibrator shall be used after the pavers are laid. The paver blocks shall be laid on the sand cushion and shall be

Closely Interlocked. All design patterns as instructed by HPCL

representative with One or more different colours shall be

followed.

The pavers used near the kerbing shall be machine cut by hydraulic splitter to Retain the perpendicular edges. The jointing sand shall be spread over the pavers to ensure that the same is Deposited

uniformly in the joints. The finished job shall be vibrated by means of Surface vibrator so

that all the blocks are properly interlocked. Then the excess Sand on the paver blocks

surface coming out due to vibration shall be removed by brooming.

GROUP-4 : SUPPLY FABRICATION AND ERECTION OF STRUCTURAL STEEL

1.0 SCOPE :

This section covers the general requirements for supply of steel material, where specified, fabrication and delivery at site of structural and miscellaneous steelwork.

2.0 APPLICABLE CODES AND SPECIFICATIONS :

a) MATERIALS :

1. IS : 808 - Rolled Steel Beam, Channel and Angle Sections.

2. IS : 814 - Specifications for Covered Electrodes for Metal Arc Welding for Structural Steel.

3. IS : 823 - Code of Procedure for manual metal arc welding of mild steel.

4. IS : 919 - Recommendations for limits & fits for engineering (part I & II).

5. IS : 1161 - Specifications for Steel Tubes for structural purpose.

6. IS : 1363 - Haxagon Head Bolts.

7. IS : 1367 - Technical supply conditions for threaded steel fasteners.

8. IS : 1369 - Dimension for screw thread run outs & undercuts.

9. IS : 1852 - Rolling and cutting tolerances for hot-rolled steel products.

10. IS : 2062 - Structure Steel (Standard Quality)

11 IS : 2074 - Ready Mixed Paint, Red Oxide Zinc Chromate And Priming.

12 IS : 4353 - Recommendations for submerged arc welding of mild steel and alloy steels.

b) CODES OF PRACTICE :

1 IS : 800 - Code of Practice for Construction in Steel.

2 IS : 8060 - Code of Practice for use of tubes in general building

construction.

3 IS : 816 - Code of Practice for use of Metal Arc Welding for General Construction in Mild Steel.

3.0 STEEL SUPPLIED BY THE CONTRACTOR : The CONTRACTOR shall furnish to the ENGINEER duplicate copies of all mill orders covering the

material ordered by him for this project and the test reports received from the Mills for the ENGINEER’s check and information. If mill tests reports are not available for any steel materials the same shall be got tested by the CONTRACTOR to the ENGINEER’S satisfaction to demonstrate conformity with the relevant specification. Unidentified stock material may be used, only with the prior permission from the ENGINEER in writing, for short sections at locations specifically selected by the ENGINEER and also for connections where, in the opinion of the ENGINEER, the quality of such materials would not adversely affect the strength and / or durability of the structure. The ENGINEER may also permit use of such materials for other works, if adequate random samples taken out and tested demonstrate conformity with specification and requirement for the work for which these materials are proposed to be carried out.

4.0 SUBSTITUTIONS : Wherever the CONTRACTOR, in order to accommodate his / others materials in stock, desires to substitute structural steel or plates for the sizes shown on drawings, such substitutions shall be made only after authorization in writing is given by the ENGINEER. The ENGINEER may also direct the substitution to be made, when he considers that such substitutions are necessary.

5.0 FABRICATION :

5.1 GENERAL : All workmanship and finish shall conform to IS : 800 . All materials shall be finished straight as per the tolerance limits as specified. All holes and edges shall be free of burrs. Shearing and chipping shall be neatly and accurately carried out and all portions of work exposed to view shall be neatly and accurately done and finished. Material in the shops shall be kept clean and shall be protected from damage.

5.2 CONNECTIONS : Shop connections shall be effected either by welding, or bolting, as specified on the drawings. Bolts shall be in accordance with specifications.

5.3 STRAIGHTENING : Rolled material, before being worked, shall be straightened. If straightening or flattening is necessary, it shall be done by methods that will not injure the material. Heating and/or forging shall not be permitted for straightening.

5.4 CUTTING : Cutting may be carried out by shearing, cropping or machine flame cutting, if permitted by the ENGINEER. All re-entrant corners shall be shaped notch free to a radius of at least 12 mm. Sheared or cropped edges shall be dressed to a neat workman like finish and shall be free from distortion and burrs. The kerf on machine flame cut edges shall be removed.

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. Edge planning of sheared, cropped or gas cut edges is not intended, unless the sheared, cropped or gas cut edges are such as to warrant it, or is specifically called for.

5.5 WELDING : Electrodes for shielded-arc manual welds shall comply with the requirements of IS : 814 and shall be of approved make. The electrodes for manual arc welding shall be suitable for use in the position and type of work, as laid down in the above specifications and type of work, and as recommended by the manufacturers. Electrode classification group 1 or 2 as given in IS : 814 shall be used for welding steel conforming to IS : 2062. All welds shall be made by only welders and welding operators who have been properly trained and are qualified by tests and to perform the type of work required as prescribed in the relevant applicable standards. All welds shall be free from defects like blow holes, slag inclusions, lack of penetration, undercutting, cracks, etc. All welds shall be cleaned of slag or flux and show uniform sections, smoothness of weld metal, feather edges without overlap and freedom from porosity.

5.6 TOLERANCES : The dimensional and weight tolerance for rolled shapes shall be in accordance with IS : 1852. The acceptable limits for straightness (slope and camber) for rolled or fabricated members are :- Struts and columns – L/1000 or 10 mm whichever is smaller For all other members not primarily L/500 or 15 mm whichever is in compression such as purlins, girds, smaller bracings and the web members of trusses and latticed girders. Where ‘L’ is the length of finished member, as the ENGINEER may specify.

5.7 DIMENSIONS, WORKMANSHIP & CLEANLINESS : Members shall be inspected at all stages of fabrication and assembly to verify that dimensions, tolerances, alignment, surface finish and painting are in accordance with the requirements shown on the approved shop drawing.

5.8 HANDRAILS : Handrails shall be provided on open sides of platform, stairways and landings as shown on drawings. Handrails shall be of standard weight mild steel pipe of flush welded construction, ground smooth, provided with double rail, top rail about 1 metre above platform level and pipe posts spaced as shown on drawings. Smooth uniform curves and bends shall be provided at stair return and also wherever required / specified. Posts connected to curb plates shall have a neat closure at the a bottom and 6 mm. Thick plate neatly welded to posts for attachments to curb plate. All necessary fittings including inner dowels at splices, brackets, bolts, bends, flanges and chains, where required shall be furnished by the CONTRACTOR. Open ends of all the pipe posts shall be plugged and welded. A minimum radius of

3 times the pipe diameter shall be provided at all points of direction changes in the handrail. The rate quoted for handrails shall be as per running metre of completed hand railing including posts, fitting, etc. It shall be clearly understood that individual lengths of runners, posts, etc. will not be measured for purposes of payment.

6.0 ERRORS : Any error in shop work which prevents proper assembling and fitting up of parts in the field by moderate use of drift pins or moderate amount of reaming will be classified by the ENGINEER as defective workmanship. All charges incurred by the ENGINEER either directly or indirectly because of the poor workmanship will be deducted from the amount due to the CONTRACTOR before payments made. The amount of such deduction will consist of the sum total of the costs of labour direct or indirect, material, plant, transportation, equipment rental and overhead expenses. In case the ENGINEER choose to reject the material because of poor workmanship, the cost of all handling and returning the material to the CONTRACTOR, if he so desires, shall entirely be to Contractor’s account. All the replacement materials shall conform to the same specification as for the original materials, & shall be supplied free and in all such cases, the cost of handling, transport and delivery to site shall be borne by the CONTRACTOR.

7.0 PAINTING : All fabricated steel material, except those galvanized, shall receive protective paint coating. The surface of steelwork to be painted shall be thoroughly cleaned of all loose mill scale, rust, grease, dirt and other foreign matter by hand tool cleaning, power tool cleaning or flame cleaning as specified and as directed. In power brushing, sufficient care shall be exercised not to burnish mill scale to a slick finish to which paint may not adhere properly. The paint treatment specified shall be applied either by brushing or spraying on the thoroughly cleaned and dry surface. Airless spraying shall be done if so specified. Surfaces inaccessible after assembly shall receive an additional coat of the specified paint prior to assembly. Paint shall be stirred frequently to keep the pigment in suspension. All paint delivered to the fabrication shop shall be ready mixed in original sealed containers as packed by the paint manufacturers and no thinners shall be permitted. No painting shall be done in frosty/foggy weather or when the humidity is high enough to cause condensation on the surface to be painted. Paint shall not be applied when the temperature of the surface to be painted is 45 deg. or higher.

CONSTRUCTION METHODOLOGY

1. Dismantle existing asphalt, WBM, P.C.C., R.C.C., brickwork etc., as required, to suit site condition.

Dispose of debris outside premises. Stack salvageable material at designated location and hand over this material to HPCL.

2. Excavate the pit using stable side slopes and de-water the pit, as required. It will be ensured that sound

strata is reached. Excavated pit will be barricaded. Provide shoring/strutting, if required, to prevent collapsing of earth from sides.

3. Specified thickness of soling shall be laid including filling the interstices with smaller stone after de-

watering, if required. Compact soling manually. 4. Lay P.C.C. ensuring that there is no moisture, nor water present in the pit. 5. On this P.C.C. layer, place top and bottom layers of the reinforcement bars and fix side formwork for the

raft slab. Anchor bolts shall then be fixed using template by aligning, leveling and ensuring required projection from the raft slab top. Cast raft slab R.C.C. of thickness as shown on construction drawing. Concrete shall be machine mixed & vibrated. Ensure that the pit is de-watered of subsoil water until the final setting of concrete. The foundation bolts have to be casted at the time of casting RCC raft using template

6. Curing shall be carried out for a min. period of 10 days. 7. Brick work in pit walls for full height shall be taken up as per drawing and kept wet for a period of at least

7 days. 8. Cement plaster shall be applied to the brick wall surfaces as shown in the drawing. The plastered

surface shall be maintained continuously wet until sand filling work is taken up (ref. para (9) below). 9. Sand filling work shall then be taken up. Sand filling work shall be carried out in two phases. Sand filling

in phase I will be carried out leaving the top surface formed in the profile of the tank bottom. Sand laying work shall be carried out in compacted layers of 20 cm.

10. On successful completion of the necessary tests and after the acceptance of the tank, sand filling in

phase II shall be commenced. Sand shall be laid in the compacted layers of 200mm and each layer compacted using mechanical tempers.

11. Finishing of top surface of the pit & adjacent area shall be carried out as per drawings. 12. The area in the vicinity of the pit shall be cleaned and cleared of any debris & left over construction

materials and the same shall be handed over to HPCL. CONSTRUCTION METHODOLOGY FOR CASTING OF RCC SLAB (a) ACTIVITES: As per approved drgs. 1) Reinforcement shall be bent as per the drawing and shall be secured properly with binding wires. Sufficient nos. of steel chairs of 12 mm dia tor steel of adequate length & height should be provided such that top & bottom cover to reinforcement is ensured.

2) Bolts are to cast integral with the concrete. prior to start of concrete pour bolts shall be placed in the raft .These 04 nos. of bolts shall be secured properly with the use of 02 nos. steel templates. Templates shall be made of steel angles should be provided on the top of the raft & at a height of 1.0 mts above the raft on the bolts. The layout made on the templates shall match the one available on the vessel. Additional reinforcement bars of 8mm / 10mm dia. , 500mm length should be provided in all the four directions around the bolt for all the 04 nos. of the bolts below the top reinforcement mesh. All the four bolts verticality should be ensured prior & during the concrete pour. 3) The dimensions of the raft shall be checked and should comfirm the drawing requirements. A minimum of 250mm length of bolts should be embeded inside concrete. 4) The level mark for 300mm should be given on the formwork & also ensure that 50mm cover is available to the top reinforcement mesh. 5) Adequate nos. of the cover blocks shall be provided below & side face of the raft. 6) It is to be ensured that all the water is removed from inside the raft prior to start of concrete. The concrete mix should be controlled by use of wooden / steel boxes of adequate size and concrete shall be mechanical machine mix only. 7) A minimum of 7 days curing shall be carried out for the concrete poured in the raft. (b) Equipments / tools & tackles. 1) Minimum of 06 nos. of 150mm X 150mm cube shall be made available. 2) Electrical / Petrol vibrator with at least 02. nos. of 60mm dia needle to be used for the vibration / compaction of concrete. 3) Atleast 03 nos. of boxes should be made for carrying out the volumetric batching of the sand , 10mm & 20mm aggregate. 4) 10/7 mechanical mixer.

DEWATERING 1. DESCRIPTION:

The contractor shall properly dispose of all water entering the excavation or other parts of the work, whether the water be surface or ground water.

2. EQUIPMENT:

The contractor shall furnish, install and operate pumps, points, pipes, appliances and pumps/equipment of sufficient capacity and quantity and so located as to keep all excavations and accesses free from water while work is in progress.

3. DEWATERING METHODS:

Dewatering shall be installed and operated prior to any excavation activity and shall continue throughout the time of work in that area until all construction has been installed, inspected, completed and approved by the HPCL. Any interruption, equipment failure or any other malfunction of the dewatering process that causes the uncompleted construction to be flooded, shall be reason to reject that work entirely. Dewatering equipment shall be manned and operated in a safe and protected condition at all times.

No construction of any type shall be placed upon or against saturated material. Backfill over new construction shall be clean, dry and in suitable condition to obtain proper compaction. Any extra excavation required is to be included and a part of the item. No concrete or masonry footings, foundations, or floors shall be laid in water, nor shall water be allowed to rise over them until the concrete or mortar has set at least 24hours. Water shall not be allowed to rise unequally against walls for period of 14days.

4. DRAINAGE OF EXCAVATIONS:

Excavations shall be kept free from water by the provision of sumps, trenches, sheeting or shoring cofferdams and pumping as necessary… Irrespective of the source of water, all excavations shall be kept dry by mean of approved dewatering methods during the entire excavation process and subsequent phases of the work in accordance with good and prudent engineering practices and proper construction procedures as approved by the HPCL. The dry condition shall be maintained continuously under all conditions and at all times until the work components placed in the excavation are able tom understand the effects of water, or until backfilling and its compaction has been completed. NOTE: For the purposes of this clause, the term “dry” shall not mean to preclude the presence

of dampness contained in the earth as distinct from free water being present, provided that any earth or “muck” cannot enter or contaminate the various components of the works.

If at any time the drainage is not being carried out to the HPCL’s satisfaction, the Contractor shall, at his expense, on the HPCL’s instruction, provide such additional protective measures as are necessary to prevent further deterioration of the work, and shall repair any damaged work. The dewatering method and disposal arrangements shall not cause any damage to or have any detrimental effect on adjacent structures, services or adjoining land. All damage caused by the disposal of water shall be made good at the Contractor’s expense.

Incase the rate of water inflow is quite substantial; contractor may use rich concrete mix for PCC/mud mat to compensate for the washing of the cement due to flow of water. However during the pouring of structural concrete, contractor shall ensure all the water is adequately pumped out no amount water is available at the place of pour.

TYPICAL SCHEMATIC LAYOUT OF DEWATERING.

QUALITY ASSURANCE PLAN

SLOPE

AS

PER

DR

AW

ING

PUMP

AS PER DRAWING

APPROX. 300mm

PEA GRAVEL

SPECIFICATIONS

FOR

MECHANICAL AND PIPING WORKS

��%�3�1#��(�3�3�1�32��2.��1?#��(3(��

,*�� '�� J��3��

)*�� 5�� J�� (��5�(�,?E�4��

�

B*�� J�(7�'��BE*,?��

@*�� J�� !>?�� &��

� � � � ��3�� !@?�� &�

�>*�� /�� J��9�� ><C�5�

�

E*�� 1�� J�>?��<�,>?��!��@?�(��5�(�,?E�4*�&�

� � � � ��@?�� !��=?�(��5�(�,?E�4*��&�

�

C*�� 1��J�

�

�*7 *� 7�� 0��2/�� 82��9��'(� �#(//��0'�.7�� #�'40��

��!��&� ��!��&��!��&� �� !$�%�&��

,� )??� � @?� ),-*,� � � =*,=� � � )=*>>�

)*� ,>?� � @?� ,E=*B�� C*,,�� ,=*-C��

B*� ,??� � @?� ,,@*B� � � E*?)� � � ,E*?C�

@*� =?� � @?� ==*-� � � >*@-� � � ,,*)-�

>*� >?� � @?� E?*B� � � B*-,� � � >*@@�E*� @?� � =?� @=*B� � � >*?=� � � >*@,�

C*� B)� � =?� @)*)� � � @*=)� � � @*@C�

=*� )>� � =?� BB*@� � � @*>>� � � B*)@�

-*� )?� � =?� )E*C� � � B*-,� � � )*)?�

,?*� ,>� � =?� ),*B� � � B*CB� � � ,*E)�

�

7�� 0��(��3��J��

�� 9�� 5��P�� J�

�

,* "�� J�,??Q �

)* �� $� � J�,??Q �B* ��9�� J�8�� 1��

@* ��(�� J�8�� 1��

>* ��%�� J�8�� 1��

�� 2�4��

(�� *��3'��

�� $�� 3'�� *��!�� 0��(��3��1��4�

� �

8�� 3��'�� (��J!��&��'/�!��&�9'��!��&��"��!��&�//8:��!�&�'9��!��&�3�'/�

��%�3�1#��(�3�3�1�32��2.�.-�(3(��

,*� '�� J� 5��<��9#�3��

)*� � �� J� '��,)B-�!3��'&�0��%��

� � � � � '��B>=-�B*� �� J� '��,)B-%'��B>=-��

� ��

@*� �� J� ��

>*� /�� J� ��9�� @<C�5�E*� ��1��

� 9�� J� �

�

� <<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<�� 7 ��1�� '�� $��%��

� !7��&� � � � � ��

� <<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<�

� � �� )>?�� '��B>=-� � ��C��

� )??�� '��B>=-� � ��E*B>��

� ,>?�� '��,)B-�!��'&� ��0��

� ,??�� '��,)B-�!��'&� ��0�� =?�� '��,)B-�!��'&� ��0��

� �E>�� '��,)B-�!��'&� ��0��

� �>?�� '��,)B-�!��'&� ��0��

� �@?�� '��,)B-�!��'&� ��0�� B)�� '��,)B-�!��'&� ��0��

� �)>�� '��,)B-�!��'&� ��0��

� �)?�� '��,)B-�!��'&� ��0��

� �,>�� '��,)B-�!��'&� ��0��

:�� %3.��(1.�E�3��(��32�4��

�� P�� J�

�

1. "�� J�,??Q �

2. �� $� � J�,??Q �

3. ��9�� J�8�� 1��

4. ��(�� J�8�� 1��

5. ��%�� J�8�� 1��

6. 0�� J�,?Q � ��

7. 9�� 5��

�2�4��

(�� *��3'�� $�� 3'�� *�

� � �

=*��(�� 3�� '�� J��'/��9'��"��//8:��

'9��3�'/� ��

�

��%�3�1#��(�3�3�1�32��2.�#()�(3(3�)�-2."��

,* (��/34�3��# $�� 4��(�,?E�4*��=?�� >?��7�*�� @?*�

�

�� 1��/��0��C��>��0�H=�� >��<�� 0��,��/��0��0��C��0��0��>��0��#()��G��C��0��>��

�

B* (�� $�� @?��7�� B??K�� (7�'� ,E*>� �� # �� $�� +��

��6 ��*��

�

@* (�� /34�� *�5�� /34��*�

�>* (�� @?�� $��*�

�

E* (�� $��$�� $��*��

C* '��1�� $�� *�*�� $�� 9"R��39"��

� �� J�

�=* �� J�

�

� � ��1�� @?��L�� #�� 5��(�

@)?�49*�#3/�E�� *��

�� *��

�

� � � ��1�� @?� �� J� �� $�� #��

5�� (� B>?� /�� )� �� 9�� B???*� �� *��

�

-* (�� 1�� (��5�(�,-B�4*�C�� (��5�(�,-@�4*)0�� 7��*��

�

,?* (�� $�� 53"�9�� 8��7��'��*�(�� (�5��<�B,*B�� B)*??�$�%�

�� *�� (��(��5<�(<BBB��E� �(3'<>/*��

��

��+�� *��

�

,,* (�� %�� /34� �� (3'�E�� (3'�E?C�%��EC>>�!3��

''&*� �87�9(��89� �8� �2�5'�� 9�'�'�(�� 8�� 3'(� ��9�'�:'74� �0�� "(/��

(9��5(72�(��29��(��3�9�(3'�E��(7��'9��(��*��

�

�

�

�

��13#��%�3�1#��(�3�3�1�32��2.�(3(#3��#1E3�)�-2."��

,*? ��83�J��

,*, (�� $� � ��

�� *� � 0 ��

��<��<� ��%��

�� %�� $�

�� +�� $� �� %�� *��

��

,*) (�� P� ��

� �� +�� $�� $*�

�

�� $�� J�

�� 3��!�� /34��9#�� &�� #79��

�� B??� K!� � /34� �� &�� < �� ,>?K�� 0��

� ��*��

�� %�8��%��

�� +�� 6 ��

�

� /�� $��

�

� �� <� ��<� ��

� ��

(7�'��B,*B�� J�� 3�� 9��3��*�

��(3'�,,?@�� J�� F�� #��3��

�� 9��*G�� (�5��'87�';��J�� #��A�� *�

'�J�=)B�� J�� 3 �� 5��5��(��#��

�

� 0�� <��

� �� /34�3��

�

� 3��

��=� ��13#��(�3�3�1�32��2.��15.3�1�32��-#�3�)��

)*,� (�� -?�� *�3��

�� *� '��

� �� P�� *�

�� *�� <��<��*�5��

�� +��

�� $�� $��

�� *� � '��

�� *�

�

)*)� �� *� �� *� � (�� *��

�� *� � (��

��

� �� *��

)*B� �8/�9(7��J��

�

� '��

�� *��

� (��

��

��S�B��!�S�,%=G&*��

� (�� S� ,%@�

��*�

�� 5�� ,*>��!,%,EG&*�

�

� (��

�� )*>��!,%B)G�� &� ��*�

�

� �� +�� *�

��

)*@� 39�3(9(�'87�8��3'3��(7��8�0�9��'��'74�J�

�

� 3� �� *�� *�

�

� �� 6 ��

�� *�

�

� (��

�� *��

� � ��

��*�

�� 3�� 6��

��+�� 1��$��*�

�

� ��$��*�*� ��,)*>��!,%)G&��,=��!B%@G&�� *�

�

� 2�� 6 �� *�

��

� 3�� $�� E� �� !,%@G&� ��

�� +��,*>��!,%,EG&*�

�� 3��$��E��!,%@G&��

��+��)>Q � ��$��*�

�

� #��

��$��

� �� *�

�)*>� #�/�'74J�

�

)*>*,� #��J<��

�

� 7 �� <��*�2��

(3'<,,?@*� (�� %��

��

�� $�� $�� *�

�

)*>*) #��3 ��J<�

�� #�� 5��5��(��

� 6�� <��<��%��*�

�

� (�� <��<�� *� � � ��

�� $��6 ��

��

��<��<��*��

)*>*B� 9 ��3�J�<��

�

� 9 �� 3�� *��1�� B*)>��!,?��#4&*��

#��

�� *�2��

�� 1 ��+�� *��

� �� +�� *��

0�� 6 �� *��

�� +��?*=�� ?*)��$��*� �� +�� B=�� ,>?� ��

��*��

�

� #�� <�� P�� *� ��

�� *� ��

� �� $��

�� $*��

�

� �� $��

�� *�� 1�� +��B*)>��*��

)*>*@� T ��J�<�

�

� #�� 6 ��!� ��&� �� <�� 6 ��*��

�� *�#��P�

�� 6 ��6��

�� *��

)*>*>� '�� J<�

�

8��P� ��%�� 8�� $�� *�� $�� *��

� �� *�

�

(�� 6 �� 6�� +�� *��

�� 6 �� ,?Q �� +�� *�

�

"��+�� ,??Q � ��6 ��

�� +�� $��$�� *�

�

9�� +�� 6 �� <��<

��*�� ,?�Q � ��/34�/�� *��0 �� 6 �� +�� ,??� T �� ,?Q �

�� *� � �� >� 6 ��

�� P�6 �� 6 ��

� �� ,??�6 �� 1�*��

)*>*E 9�� '�� J�

�

� ��+�� J��

� 9�� +�� (3'�� ,,?@%(��5<�<-@*��

�� +��

�� (��5<�<,@)�� (7�'� �B,*B� ��$�� $� �� *� � ��

�� <�� *� � 0�� $��

��

�� 6 *��

� �� +��

��

�� *� � �� P� ��P��

��

�� *�

��

�� 8��%� ��*�

�

� (��6 �� 6�� 3��!,??�Q&*��

� 9�� +�� 6 �� <��<�

��*�� ,?�Q � ��/34�/�� *��

�)*>*C� A�� #��3 ��J�<��

�

� 8�� $�� *� #��

�� (3'� ,,?@%(�5�� ';� � '�J� =)B*� � ��

�� *� ��)� ,%)��

�� *� � �� 6�� U��

��$� ��$��*�� <��<�� *��

�� (3'<

,,?@*� '��

�� 6 *��

� #�� 3 �� 6 �

�� *� ��

� �� <��<�� $��

�� *� �� *� '��

�� $�� +��

�+�� "� � �� 2� � �� *� ��

�� *��'��

� �� *�

�

)*>*=� ��7�'/'74�8��#�/��J<��

� (�� $��

� �� <��<�� *��

�� 6 �� 6 *�7 �� *�

�

)*>*- #�/�'74�398��29�J�<��

�� -?�

�� !�+�� &��

�� @>��*�

�� #��

�� *��

�� +��

��*��

)*>*,?��J<�

�

�� *3*� �� 9�� %��

��*�� <�+�� *��

�� *�

�)*>*,,��#�/�'74��87�25(�/��J�

�

� ��5��J�<��

�'��

�� J�

�

� 3��J��

'�<,)B-%'�<B>=-�L��9#�0��!2��/��&�

(�,?E��4*��!/34�/��&�

�� J��

�

(<)B@�4��#3��*#*�<��/34��2��/��

(<,?>��*# ��#�� /34��2��/��

� 5'��9��J�

�

� � �� 1�� *�7 �5�� /34��*�

�

� ��J�

�

�89��L�(<,?>�,>?K%B??K��(7�'��,E*>*��

� ��5��J�

�

�� J��

?�� -��(��?��

�.��

�(��I1� =8�)��5+�� 8= =�� := 7��

�I3�6;<7!9�I3�6 �;!�� 8= =�� 8= ;�

�

��I1� =<�� 8= =�� := 7�I3�4�=8�� 8= =�� 8= ;�

�

� �� $��$��(��8��$ ��(��0*� �0 ��

� �� *��

�� #��9 �� J�

�

� ��

� �� *��5��P�� *�

�

� (�� 0�� *��

�� )??� L� )>?� �� 6 *�

�

� �� +��

�� *��

� �� (��8��$ ��0��(��0 ��$�� J�

�

� ��

�� *�

�

� 8�� <��<�� *�

�

� ��

�� 1�� *�

�

� �� *��

�� *��

��

�� *� � ��

� ��+�� *�� +�� *�

�

)*E� '�� 3�<�� 3��J<��

�

� 3�� $�� $��

�� *�

�

� �� *��

� (�� +�� 6��

�� *��

�� %��$��

��*�� $�� <

��<��*�

�)*C��3 �� J�<�

�

� #��+�� $��

�� *��

�

� �� $��

�� *��

�

� #��+��

�� *��

)*= ��9��'�8�7��J��

� �� $�� $��

��+�� *��(��$��

�� *�

�� (��

��*��2�� $��

� �� 6��*�

�� /34��6 ��

�� J�

�

� ��2��J��(�,-B��4��C�� 72��J��(�,-@��4��)0��

�

� 4�$�� (��!3��?=,� ��&��$��

�� ,>?K�� B��$�� *��

�

� 4�$�� 5��!��&�4�$�� /34�� *��

��

��

�� *��

�� #�� $��6 ��$��

�� $�� $�� *��

�� $�� ,%@��,%)� ��

� �� *��

� (�� +�� )�� +��

��B�� 6�� *��

�� (�� V �� *� 5��

�� *�

�� 1��

�� <�� !3*'*� �� *'*&��*�� *� �0 �� *�

�

)*-�� 5��3�� 3��J<��

�(�� 6 ��

�� !��$&� ��6 �� 6��

�� *�� *�

�)*,?� �� 4��(�� J�<�

�

� ��1��>?�7��

��+�� W �>�� *�,�� *�� @?��

7��

�� <��<��%��*�

�#��

�� +�� 8��*�

�� R2P� ��

� �� *� �#�� *�

�

)*,,� �/�(7'74��/2�0'74��J�

�)*,,*,�� %��3��J<�

�

� (��

��!�� 8��&� �� *��

� (�� *��

�� $��

�� *� � (��

�� *�

�

� (�� <��*� �� *�

�

� �� $��

��%��*��

)*,,*)�3 �� "��J<��

�

(�� $�� *� � (��

�� *�

�

;�=� %E�.2��1�3��1��(.2��'.�4��

� �� *��

�

� �� $��

�� 8��%� �� *� � '�� *�

�

� /�� *��'�� $��

��*��

� (�� *� ��

�� $�� *�

�� (�� *��/��

� �� *�(�� 6 ��

�� $��*�

�� (�� +��%� ��

� �� <��<��

�� 6�� *�

��

� #��+��

��*�� *�

�� 7�� +�� $�

�� $��<��*�� $�� $<��*�

�

� "�� <

��

� �� *�

�� +��

��$�� *�

�

� �� %� �� +�� +�� 8��*�

�

� #��

�� 6 �� 8��P�� P��*��

� ��<��<��

�� <��<��%��*�

�� <��<��

�� *�

�

� (�� *�

�

� ��9��89��J<�

�9�� *��

� �� J�

�

�� *�

'�� 3��!/��7�� &*��*�

(�� 8��%� ��%9��*�

�

H�=� �#1�)�52��3�)��).2'��3�)��46��

8��/34�/�� 6 ��*��

� �� *��

4 �� C>��*�!)��0�� C�� 0� �� 0�� 3�� ;=H;� ��G�� 3��&*�

�

<�=� (13��3�)� ��

(��!� ��9#��&��

�(�)*>��'��?>>-??��

�� J��

� !�&��X�� J�4��(�)*>��

�

<� � (.3?.�(13��3�)4��

�3'/2;�@�0��D��9��3�� 94�9� ��$�� (�'(7�%�7�98/(��%�

�'45(��

�7 *� �� J�,��

3��$��!��&� J�C>��

�

<�� ?3��21�3�)�4��

� �3'/2;�@�5'8�� 94�9� ��$�� (�'(7�%�7�98/(��%��'45(��

�

� 7 *� �� J�,�� 3��$��!��&� J�C>��

�

<�;� �3�3�%�(13��4��

�� $�� !�

��94�9%(�'(7%7�98/(�%�'45(�&�

�

� 7 *� �� J�)�� 3��$��!��&� J�)?��

�

��%�3�1#��(�3�3�1�32��2.�?�%1�3�1#�B'3(?��.��32��,*?�� 4�7�9(/�

��

�� *� � �� $��

��

�� *� � �� 6�� $�� $��

�� $�� $�� *� � ��

� $�� +�� $��

�� < �� *��

)*?� ��83��8��#89.��

�

�� $� ��

��*��0�� $��

�� $��

�� *�� $� �� %��

� � �� P�� % ��

$��%�� <��<��*�

�� $��

�� $��*��

�� *�

�

B*?�� 9��'"'74�0(7�/'74�8��A2'35�7��

�

B*,� (��

�� P� �� $�� +��

�� *� � ��

��

��

�� *��

�

B*)� � � � � � #�� % +�� %� +�� $��

� � �� 6�� <��<��*� � (�� $��

�� *�

�

B*B� '��

�� $��

�+�� *��

� �� *��

�

@*?��39��(2�'87��8��(.�7��:��87�9(��89�

�

@*,� �� $�� %� ��

�� *��

� �� %�� P�� !��

�� &� �� %��

�� %� ��P� �� !� � �� 8��

��&*��'��

�� %��% �� *�

�

@*)� ��+�� $�� $��

�� *��

�� $��

�� $� ��

�� $��+�� *��

@*B� 8��

�� *�

�@*@��(�� $�� *� ��

��$�� *�

�

@*>� (�� $�� $�� *�

�

>*?��9��'87�8��A2'35�7��

��>*,�� $�� $� ��

��

��

��*��(�� $��*�� $�� *� � ��1��*��

4��$�� *��8��

��

� �� *�� $�� *��5�� $��$��

�� %�

� ��P� ��*� � ��

�� *��

>*)�� $�� 11�� %��$��

� �� *� � (��

�� %� �� $� �� *�

�

>*B� 9�� 6 �� >�5��+��

�� %� ��P� ��*��0 ��

�� *�

�

>*@� �� +�� 1��$��*��

� ��

� �� $*��

�>*>� (�� 6 �� *� ��

� ��*�

�

>*E� �� $� �� P��

�� *� � ��

�� $��

�� %� ��P��*��

>*C� #��

�� %��

�� %� ��P��*��

>*=� (��$�� 1��

�� $��

�� V ��*��

>*-� 8��

�� *� �/��

�� +�� *� � /�� *� � #��

�� *��

�� $*��

��+�� +�� *��

� �� )@��

� �� *�

�>*,?� �� +��

��%�� *��

�� *� �0�� +��

�� *��

>*,,� (�� *�

�� *�

�>*,)� �� +�� *�

�

E*?��(��5�/:��/�"�/'74��(/'475�7��

�E*,�� $� �$�� *� �(��

�� *�� *� ��

�� <�� P%��P%�� %� ��

��P�� *��

E*)� �� +�� *�

�

E*B� 5�� <�� <��<��*� � ��

�� 6��$��

� �� *�

�E*@�� <��$�� <��<

�� *�

�

E*>� �� *�0 ��

�� *� � �� $� �� $��

��

�� <��<�� *� � � � � � � ��

��

�� *� � (��

�� <��<��*�(�� 5��

��4��*�� *��

E*E� (��

� �� <��<��%5��*� � (��

�� *� � �� $��

�� *�

�

C*?�� 0��A2'35�7��'��/(��'�'��(��8//8#��J��

!(&� ��$��$��*�

�

!�&� �� $�� *��

C*,� �� *��

�

C*,*,� � � � '��

�

!��&�� *�

!��&��3�� *�!��&� �� $��!� ��

� �� *�

!��&�� +�� $��*�

!��&�� *�

�

C*,*)��#��

�� +�� *�� $�� !��

��$��&��!��$��&��

� �� 1��

��*��

C*,*B� �� *��

�� *� � '��

� �� ,%)?�� $�� $�� $��

�� *� � 8�� $� ��

�� *�� $��$��

�� *� �� *�

�

C*,*@��3� � � � �� $� ��

��<��<��P��%�� J��

��!��&��#��

��*�

��!��&��#�� *��!��&��#�� *�

��!��&��#��*�� *�

�

� �� 11�� *�� *�

�

�(�� <��<��

�� *�

�

C*)� �� 9 ��<�!L�� *&�J��

��C*)*,�� (�� <�

�

!��&��3�� *�

!��&��5 � � ��*�!��&��3��*��

��

� �� *��

� �� $�� *��

� �� *� � (��

� �� *�

�� *� � � ��

�� Y�P��

� �� *� ��

�� $�� $�� *��(��

�� $��

�� <��<��*�

�C*)*)��/��

�� *�

�

C*)*B� � � �� *�

�

C*)*@�� #��6��

��6�� *��

C*)*>� ��

�� *�#��

�� %�� *�

�

C*)*E�� (��

� �� *��

C*)*C� (�� $��*� � (��

�� 6��*�

�C*)*=� 9��

� �� *�

�

C*)*-� (�� *�

�

C*)*,?��

�� *�

�

C*B�� 9'(/�927��J�

��

C*B*,� (�� 6�� *�� C)�� *� � 3� � � � �� 6��

��$�� <��<��

��<��<��Y�P�� *�

�� $��

�� *� � �� +��

�� <��<��

�� +�� +�� *� � �� *�� 6��

�� *�

�

�� *��

�� *��9��

��

��<��<�� *��

=*?�� /'��8��A2'35�7��8��9��

�

=*,�� 9��*�� *�

�

-*?�� 5 '��//(7�82��/�

�(�� $��

��

�� *� ��

� �� +�� *�

�

,?*?�� 4982�'74�

�,?*,� � � �4 �� $��

��

�� J�

��!(&��7 �<��$��4 ��!�&��8��4 ��*��

�

��(*��7 �<��$��4 ��

�� 7 �<��$�� J<�

� 8��!,&��3�� 3 ��

� 8��!,&��3��

� 8��!,&��3�� <��<�� 6�� $��+�� *�

�

7 �<��$�� <�

�� (��$*�

� (�� 1 ��*�

� 9 ��3�� *�

��*��8��4 ��

�

8�� !,&�� 3 �� !)&��

�� 6�� $��+�� *��

��8�� J�

�

��&��(�� $*��&��(�� *�

��

��

�� *� �� +�� $�� 6�� $��

��+��

�� *�

��

��*�� *��(��

� �$�� *��2��

�� *��

,,*?�� 3/(��5�7��

��

�&�� (�� *��

&��

!�� +��,J)>&*�

��&�� (�� $��

��>��*�

�

�&�� $�� <� � ��$�� *�

�

��%�3�1#��(�3�3�1�32��2.��3.��3)%�3�)�B'3(?��

��

,*?� '�'�5(9.��(7��38��:3��#(��9�587'�89�C>�55��'D��

�

'�'�� 5�$��3 �� #��5 �� C>��1��

,??� �� 7�� 6 �� $�� 11�� *� � ��

� �� 5 *��*�� %� �� 6 ��

�� $�� <� �� 11��

�� 1 �� BE?� ��*� �� =?�

��@>�� *��

�� )>=?�'�� C�.�%��)�� 1 �� E?�� B?��*��

�� '�'��$�� '�J=@@)*� (�� '��

3�� '�� (�� !�3'(&� ��

� �� 03�/�� *�

�

�

��=� �3.�%E�.1��(2��4��

0�� *�� ,??�

�� *� �#�� =?�� *� ��

�� ,??��7��89�� (7�'��,E*>�,>?�' ��,-?��3��*�� =?��*��89��

� �� (7�'��,E*>�,>?�' ��,>?��3��*� � '��

�� '�J>)-?� �� L� (� �� '�'� � 5�$� � ��

� �� *�� $��*�� '�-?B*��

� �� E??��*��

�� @>?�� *��

� �� ,>?�� *� � ��

�� $�� '�J,)B-*��

�� ,>� $�%��)� � � ��$� � � �� 6 �� $*� � ��

0�� 9�� $��*��4'�7�� *�(�� '��

�� 3��'�� (��!�3'(&� ��

�� 03�/�� *�

��;�=� �3.��3)%�3�)�%2��

�

EB��+�,>��*�� 6��$�� 1�� '�JEBE%,-==��<

(� ��$� �� B>*C� .�*� ��

�� '�J�-?B��$�� *��

�� '�'�5�$��*�(�� '�� 3��'�� (��!�3'(&� ��

� �� 03�/�� *�

��

�H�=� �.(��3.�%2'��52J��

�� 4��0 �� +��1�J�C>?��+�E??��+�)>?��!B?G�+�)@G�� +*&��

� �� 9�� 3��!�93&�� ?)�7 *� ��,>��0 �� 11��*�� +��

�� $��*��3 �� $�� $��

�� +*��

�� *�� +�� *�� +�� *��

�� $�� *�(�� '��

�� 3�� '�� (�� !�3'(&� ��

�� 03�/�� *��

�

<�=� K��2DD#��

T�� 11�� EB��

�� ,E��*��7 11�� @>?�

'��C�.�%��)��'�J-?B�'�'�5�$*�(�� '��

��3��'�� (��!�3'(&� �� 03�/�� *�

�

8�=� �2)��2DD#��

� �� 11�� EB��

�� '�J->)�

�� '�J-?B*�(�� '��

3�� '�� (�� !�3'(&� �� 03�/�� *�

�

�:�=� =�")��(��3.�J�3�)'3�%.�*3�3�?1."+��

� #�� '�'� 5�$<),C,� !/��&� � �� 8)� �(9�9'�4�� !)??�

��&� � �� '�'� 5�$<@-@C� !/��&� �� '�'� 5�$<@B?=�

!/��&*��

� �3��'�'�(�'87��J�

�

� ��1�� !��&�� C>��*�� /�� B>��*�

� �� *�

� 0 �� 11��

(��3��*�� (��

'�J,)C,��*�

� �� +�� 9��

�� '�)=)>*� � ,?Q � �� 6 ��>?Q �Z�Z�6 �� *��

� '�� $��'�J),C,�!��&��

�� *�

� 5��Y�� :��

� 5��

� 3��8��7 *��*�

� '�� *�� $��*��

��

� ��3 �� $�� +��*�

�(��+�� '�� 3��'�� (��!�3'(&� �� 03�/��

��*�

�

7�=� :<�")��(��3.�J�3�)'3�%.�*3�3�?1."+��

� 5�� E��$�5*�*��!�*A*�3�� '�J)=)>&��

�� *� ��+�� '�J,?E>=<,-=B*��

�+�� *� � 7 �� *� � �� +��

��*�

�

� �� ?>�� >?�.�%��)*�

�

� �� )>��

�� 11�� '�'�

�� *�

�

� (�� 9�� "�� '�J,?E>=�!/��&�� *�

�

� 3��>?��*�� ?�� @)�.�%��)� � � ��

� �� *��

� ��+��

� ��1�� *�

�� '�'� 5�$�� 8)� �� )� .�*� ��

�� +��

'�'��$��"��*�

�� 3 �� '�'� 5�$� '�J@B?=� !/��&*� � �� $��

��+� �� /�� *� � ��

�� $�� $��$��

�� $�� )@�� *�

�

� 3�� !�� +��&� ��

�� *�� (��'�<)=)>�� 11��7 �

�� *�

�

� (��'�J)=)>�9�� !,?Q �� >?Q � �� Z�Z� �T ��&�<� �7 �� *�

�

� ��+�� B?�.�%��)�� $��

��*��

� '�� $�� '�J,?E>=� !��&� ��

�� *�

� 5��Y�� :��

� 5��

� 3��8��7 *��*�

� '�� *�

� �� $��*��

� ��3 �� $�� +��*�

�

!�=� H�<�"��2��3.�J�3�)'3�%.�*3�3�?1."+�4��

�8)��@*>� �.�*��+��

��+�� !��&� (�� '�'�5�$�!�� '�J)=C=&��

�� '�'� ��$�� $��*� � ��

�� 8)�4�*� �(��

�� '�J)=C=� �� '�� $��

��'�J)=C=�!��&�� J��

� 5��Y��

� :��

� 5�� 3��8��7 *��*�

� '�� *�

�

�!�=� �.E��%?3�1#�(2-�.��2.��3.��3)%�3�)�*3�3�?1."+�4��

��3 ��

�� $�� $��*�� $��+��

/��*�� $��

��$��$�� $�� )@��

�� *��

�� 3 �� '�J@B?=<,-=)� ��

�� '�'�5�$*�

� =�= #3��2��1((.2$��?1"��

7�#�(4��"'5(/��'9��/(4��"'T(:��'9��0��'9��398��D�7'�0�

�

MAINTENANCE

AND

SPARE PARTS

10. MAINTENANCE AND SPARE PARTS

It will be the total responsibility of the contractor to maintain the Bulk LPG consumer facility including testing of the safety fittings and equipments for a period of TWO YEARS ( 2 Years ) after commissioning. The job includes all consumables and manpower. The spares will be supplied by HPCL from the spares quoted by the contractor and purchased for the two year trouble free operations. Any other spares ( like replacement of submersible pump etc.) required over and above that quoted and purchased by HPCL will be supplied free of cost by the contractor The Scope of the work will be as per the details given below. Please note the Scope of Work for maintenance is only indicative and it will be the total responsibility of the contractor for the maintenance of the facility by visiting the same atleast once three months. This is over and above any emergency calls. A report of such monthly inspections during 2 years maintenance period shall be submitted to the concerned Sr.Regional Manager of the LPG regional office, Jodhpur with a copy to the Client (Factory Owner) . No additional payment on this account shall be made to the contractor. In case of breakdown of any equipments of the Fcaility, the Contractor shall make suitable arrangements to ensure that the same is promptly attended to and in any case not later than 24 hours of being reported either by Vikas WSP or HPCL . NON COMPLIANCE OF THE SAME WOULD ATTARACT A PENALTY OF Rs 5000/- FOR EACH DEFAULT. No payment will be made for maintaining and carrying out testing of the safety fittings & equipments of the Facility including replacement cost of any part with in two years maintenance period and cost if any, has to be built in the quotation for the same. Contractor to submit the list of the spare parts ( as recommended by the vendor for LPG Pump / Vaporizer / all other imported equipments ) required for two years trouble free operation. Contractor shall quote for all spares required for trouble free operations of the Facility for 2 years as any spares / part not quoted will have to be supplied free of cost by the contractor. The list of spare parts attached in the tender document is the mandatory minimum requirement which the contractor has to quote / supply. Contractor to add to this list and quote, if he feels that any additional spares are required for two years trouble free operations. Please note that any spares not quoted by the contractor and required for two years trouble free operation will have to be supplied / replaced by the contractor free of cost. Refresher course of training every six months during the two years period shall be part of the two years trouble free maintenance to be provided by the contractor.

MAINTENANCE OF BULK LPG FACILITY The brief Scope of Work is as given below : SCOPE OF WORK : i. Party to draw up a detailed schedule for quarterly and annual maintenance of the facility in consultation

with HPCL and as per the details given here under and follow it strictly. This will based on the equipment manufacturer recommendation of the preventive maintenance requirements and established mandatory / recommendatory standards.

ii. Corrective action shall be taken as identified during the inspection and proper records shall be

maintained. iii. If for the purpose of Maintenance any equipment or its component is to be removed or disassembled

which is under pressure, is hazardous and shall not be undertaken unless the system is depressurised, gas freed and certified.

iv. The Maintenance is to be carried out after obtaining Work Permit from Factory owner of M/s Vikas WSP

and such shall be undertaken with full knowledge and approval by authorised person. v. Equipment appurtenances, protection devices associated with the dispensing unit as incorporated in the

design and approved by CCE shall be tested, maintained, repaired and replaced as recommended by the original manufacturer from time to time.

vi. Checklist shall cover conformity with the design intention, operating and maintenance procedures,

preventive measure & protection systems and safety practices. vii. Party has to arrange for all tools & tackles of his own for carrying out maintenance work. viii. Contractor to draw up the requirements of spares to be kept as inventory for emergency purposes in

consultation with HPCL immediately after award of the job. ix. Records of all checks / tests done of the facility shall be maintained at the Factory with second copy

marked to Sr. Regional Manager – Jodhpur LPG Regional Office. x. HPCL will not provide for transportation, travelling or for any other expenditure incurred by the party

assigned for this work. Rates quoted shall be inclusive of all the above expenses. xi. Party to give the details of the Engineer, technician and helper – their educational qualifications, past

experience along with the UNPRICED BID. xii. The Party shall not sublet the work.

(I) STATUTORY REQUIREMENTS TESTING OF RELIEF/PROTECTION SYSTEM. A schedule for testing of Relief valves and Protection System of various equipment shall be as under :

Equipment/Facility Frequency Agency

Safety Relief valve Once in a year Competent person. CCOE

approved TPIA and issuance of certificate in Form – 18.

Earth Pits Once in 6 months By Licensed Electrical Contractor Thermal/Hydrostatic relief valve Once in a year Competent person Excess Flaw Check Valve Once in a year Competent person except for

Excess Flow Valve fitted on the LPG tank inlet.

High Level Alarm of storage vessel. Once in 6 months Competent/ Authorized person. Remote Operated Valves Once in 6 months Competent/ Authorized person. LPG Pump Once in 6 months Competent/ Authorized person. Emergency Push Button Trips Once in 4 month Competent / Authorized person. Cathodic Protection System Once in a year Authorized person.

LPG hoses –bulk LPG Unloading hoses. Once in 4 months Authorized person. Fire Extinguishers Once in 6 months Authorized person.

(II) TANK GAUGING SYSTEM Sensors have definite life spans and have tendency to drift significantly with time. (i) Test each sensor on a quarterly basis. (ii) Recalibrate all sensors and inputs once a quarter. Non Schedule (i) Readjust whenever the drift exceeds 5% of the full scale. (V) GENERAL DESCRIPTION OF THE MAINTENANCE WORK 1. Checking Control Panel – checking of the circuit, cleaning of the contactors etc. 2. Visual checking of the LPG Piping both above ground and in trenches. 3. Checking Level Monitoring System and Alarms. 4. Pneumatic Circuit Air Line to be checked for any kinks / leaks etc. 5. Functioning of the ROV`s and lubricating of the actuators. 6. Leak test for all manual valves 7. Strainer to be cleaned on Remote Fill Point every 3 months. 8. Functioning of the Emergency Shut Down System and shutting of the system from ESD. 9. Condition of the Electrical Cables. 10. Checking the condition of the Pressure Relief Valve, Temperature Relief Valves provided on the LPG tank

and piping. 11. Calibration of the Pressure Gauges & Temperature Gauges.

12. Calibration of the Differential Pressure Switch. 13. Calibration of all sensors of the gauging system.

LIST OF RECOMMENDED SPARES

CONTRACTOR TO FURNISH THE LIST

The list of spare parts attached in the tender document is the mandatory minimum requirement for

one site which the contractor has to quote / supply. Contractor to add to this list and quote, if

he feels that any additional spares are required for two years trouble free operations.

Please note that any spares not quoted by the contractor and required for two years trouble

free operation will have to be supplied / replaced by the contractor free of cost.

SR. NO. DESCRIPTION QTY

a) SPARES FOR ELECTRICAL ITEMS

b) SPARES FOR PNEUMATIC ITEMS

c) SPARES FOR UNLOADING PUMP

d) SPARES FOR LPG COMPRESSOR

e) SPARES FOR VAPORISER

CONTRACTOR TO ATTACH SEPARATE LIST WITH PART NUMBERS AND QUANTITY FOR

EACH EQUIPMENT.

11. TRAINING

The objective of training is to provide good understanding of all the facets of LPG handling activities including operations, procedures, maintenance and hazards of LPG and the risks associated with its handling. Training shall ensure that the jobs are performed in accordance with the laid down procedures and practices. Training shall be imparted to the staff attached with the factory at the time of induction, which is to be followed up by periodic refresher courses every 6 months during the 2 year maintenance of the Facility. The initial training ( support for operating the equipments correctly ) at the Facility shall be minimum for two days after commissioning ( Gas – In ) The training program shall inter alia cover following aspects :

a) Hazardous characteristic of LPG. b) Familiarisation with operational procedures & practices. c) Commissioning of new facilities and equipment. d) Hands on experience on operation of equipment. e) Routine maintenance activities of the facilities. f) Knowledge of emergency and manual shut down systems. g) Immediate and effective isolation of any LPG leak. h) Accounting of product. i) Safety regulations and accident prevention. j) Fire fighting facilities, methods of fire fighting and its upkeep. k) Evacuation and safe egress of the tank truck in an emergency. l) Housekeeping m) Safety in transportation of LPG. n) First aid. o) Emergency plan/drills.

i. Appropriate training techniques shall be adopted which will include :

a) Classroom training b) Hands on/practical training c) Demonstration d) Case Studies e) Training aids

ii. Proper records for the training and refresher courses shall be maintained and submitted to

HPCL.

12. HANDING OVER REPORT

HANDING OVER REPORT The Bulk LPG storage facility at M/s Vikas WSP, Sri Ganganagar, Rajasthan is handed over to M/s Hindustan Petroleum Corporation Ltd. on date after issue of Final Safety Certificate by ' Competent Person'. LPG was unloaded in the tank after HPCL completed necessary formalities at their end. The details of Handing over / taking over is as per following attachments:- 1. Attachment 1: List of material installed 2. Attachment 2: Manufacturing Test Certificates handed over 3. Attachment 3: Pre-commissioning check-list 4. Attachment 4: Site-test certificates handed over 5. Attachment 5 :Check of functioning / Operability 6. Attachment 6: Spare-parts handed over 7. Attachment 7: CCOE approval letters

ATTACHMENT-1

LIST OF EQUIPMENTS AND FITTINGS INSTALLED AT SITE ITEM SIZE/TYPE QTY Underground Tank 19.9 KL Catholic Protection system Remote Operated valves 50 nb Remote Operated valves 25 nb Manual valve 50nb Manual valve 25 nb Non- Return valve Strainer Thermal Relief valves Safety Relief valves Pressure gauge Temperature gauge Magneto Restrictive Type Level Gauge with Remote Indicator

Magnetic Float Type Gauge with local display High Level and Low level Alarm Switch Emergency Stop Buttons Air compressor LP Gas Control panel ACME Adapters Set of Spare parts

ATTACHMENT -2

LIST OF MANUFACTURER'S TEST CERTIFICATES

ITEM MAKE SR.No/

IDENTIFICATION MARK INSPECTED BY M.T.

C./TPI Cert. No

TANK

AIR COMPRESSOR

PRVs 3/4 "

EFCV 1- 1/2" EFCV 2" EFCV 1" SORF FLANGES 1" SORF FLANGES 2" SEAMLESS PIPE 50NB

SEAMLESS PIPE 25NB

LEVEL INDICATOR

MAGNETO RESTRICTIVE GAUGE

ROCHESTER LEVEL GAUGE

300# Ball valve 50mm

300# Ball valves 50mm

800# ball valves 20mm

800# ball valves 20mm

PR. GAUGE

PR. GAUGE

PR. GAUGE

TEMP.GAUGE

Emergency Stop Switch

Pr. Transmitter

Needle Valve 300# 2" NRV 300# Strainer 50mm

FITTINGS

90 DEG ELBOWS 50MM

90 DEG ELBOWS 25MM

EQUAL TEE 50MM EQUAL TEE 25MM

STUDS AND NUTS M-20 M-18 M-12 M-10

ATTACHMENT- 3

SITE TEST REPORTS HANDED OVER

(A) HYDRO & PNEUMATIC TEST REPRTS

(I) HYDROTESTING

ITEM/SECTION TESTED

ON TEST PR. Kg/Sqcm

WITNESSED BY

Contractor HPCL TPIA TANK

PIPE SECTION 50MM PUMP TO VAPORISER 50MM FILL POINT TO TANK 50 MM RETURN LINE FROM VAPOURISER

25MM VAPOUR BALANCING LINE

(II) PNEUMATIC TESTING

TANK

PIPE SECTION 50MM PUMP TO VAPORISER 50MM FILL POINT TO TANK

(B) CATHODIC PROTECTION COMMISSIONING REPORT:

Report of the party doing Cathodic Protection to be attached.

(C) EARTHING-PIT TESTING REPORT

EARTHPIT No RESISTANCE MEASURED (Ohm)

CERTIFICATION BY LICENSED ELECTRICAL PERSON

1

2

ATTACHMENT : 5

CHECK OF FUNCTIONING / OPERABILITY

EQUIPMENT DT. TESTED PERFORMANCE CHECKED / APPROVED BY

REMARKS / VALUES RECORDED

CONTRACTOR HPCL TPIA

(i) MAGNETO RESTRICTIVE GAUGE

(ii) MAGNETIC FLOT TYPE GAUGE

(iii) PRESSURE TRANSMITTER

(iv) EMERGENCY STOP PUSH-BUTTON

(v) ROVs (a) 50nb ROV on line to Vaporiser

(b) 50nb ROV at Fill point (c) 25nb ROV on vapour balancing line

(vi) LP GAS CONTROL PANEL

(vii) UNLOADING PUMP

(viii) FLOW METER (ix) AIR COMPRESSOR

(x) EARTH-PIT

(xi) C.P. SYSTEM

(xii) LPG COMPRESSOR

(xii) OTHER

ATTACHMENT-5

LIST OF SPARE-PARTS HANDED OVER

SR. No

ITEM QTY SIGNATURE OF HPCL OFFICER

1. PRESSURE GAUGE 0 TO 25 BAR 2. SEALING WASHER FOR PRESSURE

GAUGE

3. SOLENOID VALVE 4. INDICATOR LAMP 5. PUSH BUTTON 6. GASKET KIT FOR PISTON METER 7. LCD DISPLAY WITH BACK LIGHT 8. POWER SUPPLY FOR DOUBLE

HOSE CONTROLLER

9. DOUBLE MECHANICAL SEAL FOR ABOVE GROUND PUMP.

1 NO.

PARTY TO ADD ON THIS LIST AS PER THE REQUIREMENT OF THE SYSTEM FOR TROUBLE FREE OPERATIONS FOR ELECTRICAL SYSTEM, PNEUMATIC SYSTEM

ATTACHMENT- 7

CCOE APPROVAL LETTERS

1. CCOE APPROVAL LETTER FOR LPG VAPORISER 2. CCOE APPROVAL LETTER FOR TANK. 3. CCOE APPROVAL LETTER FOR UNLOADING PUMP 4. CCOE APPROVAL LETTER FOR LPG COMPRESSOR

hindustan petroleum corporation limited -...

Documents