hindustan petroleum corporation limited -...

CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS AT PARADEEP

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HINDUSTAN PETROLEUM CORPORATION LIMITED

ENGINEERING & PROJECTS

GRESHAM ASSURANCE HOUSE, 2ND

FLOOR,

A-1595(3) 1-A, SIR P M ROAD, FORT

MUMBAI-400 001

TENDER DOCUMENT

FOR

CONSTRUCTION OF

PETROLEUM OIL STORAGE TANKS

AT

PARADEEP POL TERMINAL

PARADEEP

ORISSA


Page 1 of 3

INDEX

Sr.

No.

DESCRIPTION PAGES

FROM TO

1

TENDER COVER PAGE

1

1

2

INDEX

1

3

3

PROJECT DESCRIPTION, SCOPE OF WORK & SCHEDULE OF

QUANTITIES

1 34

4 UNPRICED BID 1 5

5

TIME SCHEDULE

1

2

6

SPECIAL CONDITIONS OF CONTRACT

1

24

7

TENDER TECHNICAL SPECIFICATIONS

7.1 TECHNICAL SPECIFICATION

7.1-A GENERAL SCOPE OF WORK FOR TANKS 1 27

7.1-B TECHNICAL SPECIFICATION FOR FLOATING ROOF TANK 1 32

7.1-C TECHNICAL SPECIFICATION FOR FIXED CONE ROOF TANK 1 22

7.1-D STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING 1 10

7.1-E STANDARD INSPECTION TEST PLAN FOR TANK FABRICATION 1 7

7.1-F STANDARD SPECIFICATION FOR FIRE PROTECTION SYSTEM FOR

FLOATING ROOF TANKS

1 15

7.1-G STANDARD INSPECTION TEST PLAN FOR PIPELINE JOBS 1 4

7.1-H TECHNICAL SPECIFICATIONS FOR CONCRETE AND REINFORCEMENT

WORKS

1 15

7.1-I SPECIFICATION OF MECHANICAL SHOE SEAL & SECONDARY SEALS 1 5

7.1-J SPECIFICATION OF GAUGE POLE SLEEVE 1 2

7.1-K SPECIFICATION FOR FLEXIBLE PIPE 1 3


Page 2 of 3

7.1-

K.1

SPECIFICATION FOR STAINLESS STEEL ARMOURED HOSE 1 3

7.1-L TECHNICAL SPECIFICATION FOR PIPES 1 4

7.1-M SPECIFICATION FOR STRUCTURAL STEEL WORKS 1 58

7.1-N STANDARD SPECIFICATION FOR WELDING OF PIPELINES 1 31

7.1-O STANDARD SPECIFICATION FOR WELDING 1 8

7.2 QC FORMATS

7.2-A ANNULAR PLATE COAL TAR EPOXY PAINTING REPORT 1 1

7.2-B ANNULAR PLATE PAINTING REPORT 1 1

7.2-C API NAME PLATE 1 1

7.2-D BLASTING PAINTING REPORT 1 1

7.2-E BOTTOM PLATE SOIL SIDE BLASTING PAINTING REPORT 1 1

7.2-F CALIBRATION CHART 1 12

7.2-G FABRICATION REPORT 1 1

7.2-H FITUP INSPECTION REPORT 1 2

7.2-I IMIR 1 1

7.2-J Paint Consumption Statement 1 1

7.2-K Post welding Inspection reading for shell 1 1

7.2-L Pre welding Inspection reading for shell 1 1

7.2-M WELD VISUAL REPORT 1 1

7.2-N FABRICATION-1 1 1

7.2-O FABRICATION-2 1 1

7.2-P FABRICATION-3 1 1

7.2-Q FABRICATION-4 1 1

7.2-R fabrication document 1 1

7.2-S Grit Blasting 1 1

7.2-T Painting DFT 1 1

7.2-U PAINTING 1 1

7.2-V QAP FORMAT 1 1

7.2-W WPS FORMAT 1 31

7.3 Job Procedures

7.3.0 JOB PROCEDURES INDEX FOR TANKAGE JOB 1 2

7.3.1. PROCEDURE FOR FABRICATION AND ERECTION OF TANKAGE BY

JACKING UP METHOD

1 15

7.3.2. RADIOGRAPHY EXAMINATION PROCEDURE 1 15

7.3.3. PROCEDURE FOR VACUUM BOX TEST 1 3

7.3.4. PROCEDURE FOR LIQUID PENETRANT EXAMINATION 1 3

7.3.5. PROCEDURE FOR OIL CHALK TEST 1 2

7.3.6. PROCEDURE FOR PNEUMATIC TEST 1 3

7.3.7. HYDRO TEST 1 3

7.3.8. PROCEDURE FOR SURFACE PREPARATION AND PAINTING 1 5

7.3.9. PROCEDURE FOR ANTI CORROSIVE LAYER 1 2


Page 3 of 3

7.3.10. INSPECTION TEST PLAN FOR TANK FABRICATION 1 6

7.3.11. WELD DETAILS 1 1

7.3.12. RCC 1 7

7.3.13 POST WELD HEAT TREATMENT 1 4

7.3.14 FLOATATION & PUNCTURE TEST 1 4

7.3.15 QAP DOCUMENT DETAILS 1 8

7.3.16 TYPICAL QAP FOR TANK FABRICATION 1 5

8

TENDER DRAWINGS 39 nos

9

SAFETY, HEALTH & ENVIRONMENT(SHE) POLICY

1 8

10

PARADEEP TERMINAL LAYOUT

1

1


Page 1 of 34

PROJECT DESCRIPTION,

SCOPE OF WORK&

SCHEDULE OF QUANTITIES


Page 2 of 34

PROJECT DESCRIPTION/ SITE INFORMATION

Hindustan Petroleum Corporation Limited proposes to Augument storage capacities as a part

of revamping facilities of the Terminal at Paradeep, Orissa and has decided to invite eligible

parties to take-up the project as per the detailed job schedule enclosed. This tender

envisages Fabrication, erection, welding, testing, painting and calibration of above ground

Petroleum Oil storage tanks on the existing Pile Foundation. Details of Tanks to be

constructed are as under:

S. No. Size of Tank Product Capacity No. of

Tanks

Type

1 30.0M Dia x 10.0M Ht

HSD 6716 KL 2 Cone Roof

Vertical

2 28.0M Dia x 10.0M Ht

MS 5000 KL 2 Floating Roof

Vertical

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

obtain for himself and on his own responsibility all information that may be necessary for

preparing of the bid and entering into the contract. The cost of visiting the sites shall be at

bidder’s own expenses. No extra claim on account of non-familiarity of site conditions shall

be entertained during execution of works.

The prospective bidders are requested to thoroughly read and comprehend the various

sections of this tender document and visit the sites before quoting for the tender and offer

their most competitive rates for the job.

The site addresses is as below:

Hindustan Petroleum Corporation Ltd

Paradeep Terminal

Opposite Paradeep Railway Station,

Paradeep- 754145

Orissa

Ph : (06722) 229225/ 229226


Page 3 of 34

SCOPE OF WORK

Scope of the job involves but not limited to the following:

1. Design, Construction and testing of above ground steel storage tanks.

IMPORTANT NOTES

1. Entire Cement concrete job need to be carried out thru Ready mix concrete only. The scope of

mix design is included in the scope of bidder and the same to be vetted by reputed

engineering institute like IIT, Kharagpur or any other reputed Engineering Institutes/

Consultant duly approved by HPCL. Party has to submit vetted design calculations to EIC and

obtain approval of the same before commencement of the job. RMC plants shall be of repute

like ACC, L&T etc. Alternatively, party can also set up a batching plant at the site and make

design mix as per provision including vetting by the reputed engineering institute like IIT,

Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL.

Party has to submit vetted design calculations to EIC and obtain approval of the HPCL before

commencement of the job.The batching plant need to be certified by third party for

robustness of performance and equipments associated with it.

2. Design of storage tank is also in the scope of the bidder. Tank design along with all

components shall be vetted by IIT, Kharagpur or any reputed institute/consultant as approved

by HPCL. However, the design data sheet is to be approved by HPCL prior to commencement

of design process and subsequent vetting by IIT Kharagpur or any reputed institute/

consultant. Party has to submit vetted design calculations to EIC and obtain approval of the

HPCL before commencement of the job.Rate to include the same in respective items and No

separate payment shall be made to the party on this account.

3. Scope also includes shifting of all types of materials including scrap materials, if any lying at

the constructional area to the designated place inside the depot premises at no extra cost. Job

also includes site clearing from any debris, vegetation, bushes and trees, etc and make the site

free for construction at no extra cost.

4. Any cables / piping encountered during excavation and other construction activities, the same

shall be separated using Sand Bed and Tiles or to be re-routed, if necessary as directed by the

Engineer in charge at no extra cost to HPCL.

5. The complete requirements shall be executed comprehensively with single point

responsibility. The prospective bidders are requested to thoroughly read and comprehend the

various sections of this tender document and visit the sites before quoting for the tender.

6. If any deviation is found during execution between the specification and the drawings, it is to be

explicitly noted that the specification will hold good and supersede the drawings.

7. The bidder is required to peruse carefully all parts of tender documents and drawings and if any

difference / inconsistency is noticed, he shall bring it to attention of HPCL before submission of


Page 4 of 34

tender and shall get the clarification(s) required. Failure to do so will not entitle the successful

bidder for any extra claims on account of such discrepancies/inconsistencies.

8. All jobs shall be executed as per technical specifications, relevant codal provisions, sound

engineering practices and as directed by EIC.

Drawings required to be submitted by the Party:

1. Preparation of all detailed and working drawing for storage tanks and obtaining approval of

HPCL/ TPI/ Consultant.

2. Submission of 4 copies of all the above drawings (As built) shall be submitted along with CD

containing soft copy in AutoCAD latest version after job completion.

The prospective bidders are requested to thoroughly read and comprehend the various sections of this

tender document and visit the sites before quoting for the tender.

SITE INFORMATION

The job needs to be carried out in the working Terminal premises. Works to be commenced only after

having obtained necessary work permit on a daily basis & all safety precautions to be taken by the

party for carrying out the above jobs as directed by Engineer In Charge/ Terminal Manager.The party

will also have to arrange for all necessary safety and fire fightingequipments like fire extinguishers,

foam trolley, localised fire screen etc at no extra cost. The party will have to abide by all instructions

and directions by Engineer In Charge/ Terminal Manager while working inside the premises.

All conditions of work permit to be followed religiously by the party. The explosive meter readings and

check for presence of flammable vapour shall be checked by contractor’s supervisor along with HPCL’s

representative before undertaking hot work. Full time supervisor to be provided at work spot and job

shall be carried out only after complying with all safety norms of the depot. A full Time Qualified

Engineer who is technically competent and having sufficient Site experience to be available at site for

supervising and carrying out all the Jobs as per the Scope.

All the safety precautions including supplying & providing localised fire screens etc shall be arranged by

the Contractors as per the directions of Engineer in charge at no extra cost to HPCL. The contractor has

to take necessary precaution for the safe transportation of the material. Before quoting for the said job

the contractor is required to visit the site and make himself acquainted with the scope of the job and

quote accordingly.

The tenderers are required to go through the tender document thoroughly and carefully and offer their

most competitive rates for the job. All sets of this tender document are to be read in conjunction with

each other and accordingly quote in the priced bid.

In case of any clarifications contractor may contact Shri B. S. GOPALA KRISHNA, Senior Manager-E&P,

Engg& Projects Dept., Gresham Assurance House, 2ND

Floor, A-1595 (3), 1-A, Sir P M Road, 132, Shahid B

Singh Road, Fort, Mumbai- 400 001 on 022-22608507 regarding any queries. Party may also contact

ShriR. C. Panna, Senior Manager on 06722-229225 or 09437573955regarding any queries.


Page 5 of 34

SITE VISIT

1. The bidder is advised to visit and examine the site of works at all locations and their surrounding

and obtain for himself on his own responsibility all information that may be necessary for preparing

of the bid and entering into the contract. The cost of visiting the sites shall be at bidder’s own

expenses. No extra claim on account of non-familiarity of site conditions shall be entertained during

execution of works.

2.The bidder and any of his personnel or agents will be granted permission by the Owner to enter

upon his premises and lands for the purpose of such inspection, but only upon the explicit condition

that the bidder, his personnel or agents will release and indemnify the Owner and his personnel and

agents from and against all liability in respect thereof and will be responsible for personnel injury

(whether fatal or otherwise), loss of or damage and expenses incurred as a result hereof.

The prospective bidders are requested to thoroughly read and comprehend the various sections of this

tender document and visit the sites before quoting for the tender.


Page 6 of 34

SCHEDULE

OF

QUANTITIES


Page 7 of 34

IMPORTANT NOTES TO SCHEDULE OF QUANTITIES

1. These notes to be read in conjunction with the schedule of quantities and is integral part

of the same.

2. Scope of Work , Supply of Material, Technical Specifications, QAP, ITP( Inspection Test

Plan) Requirement of relevant Codes , SCC( Special Conditions to Contract), GTC (General

Terms & Conditions) , Schedule of Rates ,Statutory Rules & Guide Lines as applicable,

Minimum Equipment / Machineries Deployment and any other requirement to complete

the Job / Work as per this Tender Document shall be deemed to be included in SOR items.

3. For all Items preparation of Design and Construction Drawing as per relevant code &

Tech. Specifications of this Tender & vetting after review by HPCL through Third Party

approved by HPCL, Quality Control , Inspection & Job procedure, Project Scheduling &

Monitoring Document as per SCC , Submission of all these documents to HPCL for

approval deemed to be included in quoted rates.

4. Design of storage tank is also in the scope of the bidder. Tank design along with all

components shall be vetted by IIT, Kharagpur or any reputed institute/consultant as

approved by HPCL. However, the design data sheet is to be approved by HPCL prior to

commencement of design process and subsequent vetting by IIT Kharagpur or any reputed

institute/ consultant. Party has to submit vetted design calculations to EIC and obtain

approval of the HPCL before commencement of the job. Rate to include the same in

respective items and No separate payment shall be made to the party on this account.

5. The Water and Electrical power required for constructional activity shall be in the Scope of

Contractor & shall be deemed to be included in SOR Items.

6. All the Testing and Third Party Charges for Items as per tender documents elicited in

various sections shall be borne by contractor and deemed to be included in quoted rates.

7. All Tools & Tackles, Equipments, and items brought to site by contractor will be permitted

to be taken out only after completion of work & fulfillment of necessary formalities.

8. Rate for all items to include deployment of qualified Quality Control & Safety Engineer at

site from the date of LOI till completion of job as per PO. QC Engineer & Safety Engineer

deployed as per above will report to HPCL site-in-charge on daily basis for complying all

the QC/safety jobs mentioned in the PO.

9. The Drawings/QAP/ITP /Job procedures attached along with tender document are for

guidance/ tender purpose only. The successful bidder to submit the above for HPCL

approval as per the job requirements during the execution of the job.


Page 8 of 34

ITEM

NO

DESCRIPTION OF ITEM UNIT QTY

CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS 1.0 Excavation up to 2.0 meter Cubic

Meters

250

Staking out, marking the outline for excavation, excavation in any type of soil

including soft rock (except hard rock) for general site grading and tank pad

foundations/Ring beams/Foundations of underground tank etc. either by

machinery or manually up to 2.0m below NGL including removal of stumps and

roots to full extent, removal of all vegetation including bushes and grass,

dewatering, taking spot levels @ 5 m C/C in grid pattern, leveling, dressing and

rolling the excavated surface, loading, transportation of surplus earth to an

unobjectionable place inside the site premises, spreading, leveling, compaction

etc as per instructions of the engineer in charge. The job to be executed as per

attached technical specifications, job procedures etc complete and as directed by

EIC.

2.0 Murrum Filling Cubic

Meters

2000

Supplying and filling murrum of approved quality with PI of 7-17(Medium

plastic)containing not more than 20% cohesive fines namely clay, 20mm and

down size grading and Max. dry density of material not less than 1.80 gms/cc,

including excavation at borrow pits outside site premises, payment of all

royalties, taxes, etc to Statutory Authority for operating the borrow pit, loading at

borrow pit end, transportation from borrow pit to HPCL project site, removing

debris, organic matter, etc spreading in layers not exceeding 200mm loose depth,

watering, compaction with Vibratory Roller to obtain 95% of standard proctor

maximum laboratory dry density and finishing to slopes and grades as per

drawings all complete as per specifications and instructions of HPCL Engineer-in-

Charge. Rate shall be applicable for all depths below NGL and upto 3m above

NGL. The job to be executed as per attached technical specifications, job

procedures etc complete and as directed by EIC.

3.0 Rubble Soling Cubic

meters

75


Page 9 of 34

Providing and laying 230mm thick or specified thickness dry trap rubble stone

(granite/basalt)soling at all depths including hand packing, filling the interstices

with chips, spalls and binding with grit and selected murrum, watering,

compaction by hand ramming & rolling with 1 MT hand roller etc complete as per

attached job procedures, technical specification and as per direction of EIC.

4.0 Plain Cement Concrete 1:2:4 Cubic

Meters

50

Providing and laying Plain Cement Concrete of nominal volumetric mix 1:2:4(1

Cement; 2 Sand: 4Crushed stone aggregates) with 40mm and down size graded

aggregates for bed block for foundations& any other work as per HPCL

requirement including any required shuttering, machine mixing, tamping,

ramming, curing, etc all complete as per Specifications,Drawings, job procedures

etc and instructions of HPCL Engineer-in-Charge.

5.0 RCC M 20 - Tank Apron Cubic

Meters

135

Designing of mix, Providing, mixing and placing in position M20 mix concrete with

20 mm and down size well graded crushed aggregate including fixing form work,

compacting and curing etc complete as per specifications but excluding the cost

of supply and placing in position steel reinforcement which will be paid under

separateitem. Mobile weigh batcher or Ready Mix Concrete shall be adopted.

Mix Design shall be for Normal exposure. .Concrete ingredients shall conform to

IS 456- 2000. Rate also to include necessary Polythene sheets of approved quality

to be placed before laying the concrete. The job to be executed as per attached

technical specifications, job procedures etc complete and as directed by EIC.

6.0 RCC M 20 - Ring Beam for above ground tanks Cubic

meters

75

Designing of Mix, Providing and laying Reinforced Cement Concrete of M-20

Grade with 20mm and down size graded crushed stone aggregates for RCC Toe

beam around Morrum tank pads, supply of all required materials like cement,

stone aggregates, water, sand, labour, equipments, carrying out vibrating,

tamping, finishing, curing, testing all complete as per specifications including

shuttering required to hold the RCC in place all complete. Quoted rates to exclude

the cost of supplying and providing Reinforcement Steel. Mobile weigh batcher or


Page 10 of 34

Ready Mix Concrete shall be adopted. Mix Design shall be for Normal exposure.

NOTE: Rate also to include necessary brickwork in CM 1:5 required for shuttering

on the inside face of the plinth beam to match the slope and thickness of the tank

apron. The job to be executed as per attached technical specifications, job

procedures etc complete and as directed by EIC.

7.0 REINFORCEMENT STEEL Metric

ton

12.5

Supply, fabrication and laying in position steel reinforcement conforming to

IS:1786 at all depths including cutting, cold bending, tying and placing in position

the rods, with necessary 18 SWG black annealed binding wire including cost of

binding wire and any other incidental charges etc., complete as per standard

specification. Laps, chairs and spacer bars shall not be considered for

measurement and payment. The job to be executed as per attached technical

specifications, job procedures etc complete and as directed by EIC.

8.0 ANTI CORROSIVE LAYER Square

meters

3000

Providing and laying 100mm thick (compacted thickness) anti-corrosive layer

under the tank bottom mixed using sand mixes with 80/100 grade bitumen (8% to

10% by volume) including supplying all materials, transportation, machine mixing,

laying, tamping, rolling with 10 MT roller and finishing to required slope including

all labour required to complete the job as per specifications and instruction of

Engineer In Charge.

FABRICATION, ERECTION & WELDING – BOTTOM, SHELL, PONTOON

ROOF/DECK ETC. FOR A/G TANKS (PLATES SUPPLIED BY HPCL).

SCHEDULE OF TANKS

(1) HSD TANKS - 30.0MDia x 10.0 M Ht- Self-supporting Fixed cone roof – 2 No.

(2) MS TANKS - 28.0 M Dia x 10.0 MHt – External Floating Roof – 2 No.

Plate work for above scheduled Tanks(For Annular bottom and sketch, shell

and roof/deck plates): Taking over and Transportation of Free issue Plates


Page 11 of 34

from HPCL Storage yard to Work site/ Contractor's fabrication yard,

preparation of fabrication drawings and obtain HPCL approval, fabrication

and erection of Shell plates by Jacking-up method, Bottom Sketch and

annular plates with backing strip, plate fabricated wind girders, bearing

plates for Pipe supports, pads for structural bracings/ supports provided to

wind girders, datum plates, shell manhole necks, bolting and cover flanges

for Shell manholes, reinforcing pads for shell manholes, Nozzle reinforcing

pads, pads for all Shell appurtenances and attachments ,sprinkler deflector

plates, fabrication and installation of all items as per drawings, provision of

Hydraulic jacks, supply and fabrication of cleats and wedges and clamps,

supply of all materials as per Scope of work of supply, welding and other

consumables, bolts, nuts and gaskets, labour, equipment, machinery, tools,

tackles, etc to complete the work in all respects as per approved drawings,

tech specifications, job procedures, QAP/ITP, Codes, standards, Scope of

work complete and instructions of HPCL Engineer-in-Charge .After

completion of work, the Contractor has to carry out reconciliation of free

Issue steel plates, returning Surplus Full Plates/Off cuts/ Accountable scrap to

HPCL storage yard.Rate to include radiographic inspection of weld jointsas

detailed in SECTION 8 OF API 650. Job to include copper slag blasting of

required profile to the underside of bottom/ sketch/ annular plates (soil

side) along with 2 coats of High Build Coal Tar Epoxy of min DFT 100 micron

per coat and one primer coat of inorganic zinc silicate of minimum 65

micron (Total DFT 265mm minimum).

The Tank design along with all components shall be vetted by IIT, Kharagpur

or any reputed institute/consultant as approved by HPCL.However, the

design data sheet is to be approved by HPCL prior to commencement of

design process and subsequent vetting by the bidder.

All the Testing/Design/Third party inspection/vetting requirements as per

attached technical specifications/job procedures shall be included in the

quoted rate. No separate payment will be made for the same.

9.0 Annular/Sketch plates of the tanks with 8 mm to 12 mm thick plates

including bearing plates.

Metric

Ton

310

10.0 Shell strakes of thickness varying from 6 mm to 22 mm including extension

plates.

Metric

Ton

400

11.0 Roof plates including foam dam plates including design of floating roof. Metric

ton

250


Page 12 of 34

NOTE : (for Item Nos9 to11)

1) For fabrication details reference shall be made to technical specifications/

applicable codes and standards.

2) Quantity of steel given is approximate. Payment shall be made for actual

quantities of plates laid/ erected duly certified by the Engineer at site. The

payment and reconciliation will be made on theoretical weight only

3) MS plates in sizes available will be supplied to the contractor at site and

contractor shall prepare fabrication drawings for approval, prior to

commencement of fabrication work.

4) Design and drawing for entire fabrication and welding sequence to be

submitted to HPCL for approval and design to be approved by HPCL before

commencement of fabrication.

5) Method of inventory and recovery of steel plates issued by HPCL shall be

as per relevant clause of SPECIAL TERMS AND CONDITIONS attached.

6) Fabrication work of Tanks shall be carried out by Jacking up Method only.

7) Vendor to note that for welding of tanks, the following electrodes only

should be used. E-6013 of brands like ESAB or approved equivalent for

plate thk less than 12 mm.

E-7018 of brands like ESAB/D&H or approved equivalent for plate thk equal

to and more than 12 mm and for shell to annual plate joint from inside

and outside.

8)Scope of the job includes carrying out radiography of shell joints using

gamma ray as detailed in API650 & Appendix A / technical specs.

9) Rate for the above plate work items should be offered after thoroughly

comprehending all the sections of the bid document.

10) The underside of all floating roofs and fixed roof shall be seal welded

and the rate to include the same.

Important Note:- If the Gamma ray source needs to be kept inside the

location on a continuous basis, all precautions as stipulated by BARC needs

to be strictly followed and approval shall be obtained from them before

keeping the source inside the location.

STRUCTURAL STEEL WORK USING STRUCTURAL STEEL SUPPLIED BY

CONTRACTOR.REFERENCE SHALL BE MADE TO THE SPECIAL TERMS AND

CONDITIONS FOR SCOPE OF SUPPLY AND OTHER DETAILED SPECIFICATIONS

OF MATERIAL.

(For item nos. 12 to 20)


Page 13 of 34

STRUCTURAL/PLATE WORK

Structural/ Plate work: Supply, fabrication, erection, inspection and testing of

steel structures as per approved drawings and designs such as rolled

sections, gratings and flats for curb angles, spiral stairways, landings, top

platform, earthing connections cleats, wind girder supports & pad plates,

stiffeners/ gussets for wind girder, deflector plate for wind girders, stiffeners/

catwalks for interconnecting tanks, supply of all materials, consumables,

labour, equipments/ machinery, tools & tackles required to complete the

work as per drawings, Scope of work, technical specifications, job

procedures, QAP/ITP complete and instructions of HPCL Engineer-in-Charge.

Rate to include supply, fabrication, erection & welding, straightening, cutting

to required length supply and fixing all nuts and bolts washers wherever

required for following items. Separate measurements will not be taken for

nuts, bolts, washers etc for payment purpose.

All structural designs shall be vetted by IIT, Kharagpur or any reputed

institute/consultant as approved by HPCL.However, the design data sheet is

to be approved by HPCL prior to commencement of design process and

subsequent vetting by the bidder.

All the Testing/Design/Third party inspection/vetting requirements as per


quoted rate. No separate payment will be made for the same.

12.0 Supply, fabrication, welding and erection of all floating roof structural, rim

and frame angles, pontoon stiffening rafters, curb angles, cleats, support

structural for sprinkler system and foam system, and all angles, gusset

plates, wind girders etc complete as per specifications.

Metric

Ton

30

13.0 Supply, fabrication, welding and erection of all self-supporting fixed cone roof

structural trusses, rafters, cleats, gussets etc complete as per attached

technical specifications, drawings, job procedures, QAP/ITP and as directed

by EIC.

Job also to include copper slag blasting of the structural members followed

by one coat of 65 micron inorganic zinc silicate primer. The primer shall be

followed with one coat of 100 micron HBMIO followed by two coats of

each of 40 micron polyurethane paint of approved make and shade.

Metric

Ton

40

14.0 Structural steel for the hand rail of the stringer type spiral stairway, landing Metric 6


Page 14 of 34

platforms and roof top railing like angles, flats and connecting cleat angles.

Note:- Hand rails will be pipe hand rails and will be paid though separate

item.

The stairway step gratings, landing platform gratings, MS square rods will be

paid through a separate item.

Ton

15.0 Structural steel for ladder, track, rollers, axle and connecting flat of the self-

leveling steps made out of MS gratings only Rate to include supply and

bracing of brass strip over wheels of rolling ladder in floating roof tanks.

Note: Hand rails will be pipe hand rails and will be paid though separate

item. The stairway step gratings will be paid through a separate item.

Metric

Ton

6

16.0 Supply, fabrication, welding and erection of pipe hand rails for the staircase

made out of 40 mm diaSch 80 seamless pipe conforming to ASTM A106.

Metric

Ton

3

17.0 MS square bars of 20 mm size for stairway and ladder as per attached

drawings and technical specifications and as directed by EIC.

Metric

Ton

2

MS GRATINGS

Supply, fabrication, welding and erection of the following size MS gratings

with MS flat in honey comb pattern as shown in the drawing. The Gratings

shall be fabricated out of 25x6 MS flats(Outer frame, Straight flats) and 25x 3

MS Bent flats. Rate includes grit blasting thoroughly to S.A 2.5 of Swedish

Ivonsk Standard SIS 055900-Latest edition and applying one coat (DFT 65

microns) of inorganic zinc silicate (Zinc anode 304) primer of Berger or

approved equivalent. (For items 56 to 58) followed by 100 micron HBMIO.

18.0 800 x 250 mm size gratings for all stairways with honeycomb pattern. Square

meter

65

19.0 800 x 1000 mm size grating for the top and mid landing platforms with honey

comb pattern.

Square

meter

55

20.0 800 x 200 mm size gratings for all rolling ladder stairways with honeycomb

pattern.

Square

meter

25

TANK APPURTENANCES

REFERENCE SHALL BE MADE TO THE SPECIAL TERMS AND CONDITIONS FOR

SCOPE OF SUPPLY AND OTHER DETAILED SPECIFICATIONS OF MATERIAL.


Page 15 of 34

All appurtenances to be fabricated in line with requirements of API 650.

SHELL APPURTENANCES(For items 21 to 24)

Appurtenances: Preparation of Drawings and obtaining approval from HPCL,

Supply, Fabrication, installation, welding, inspection and testing required for

the following nozzles( Reinforcing pads covered under plate work) including

supply of pipes, Nozzle flanges and Blind/ companion/ matching flanges

wherever required as per approved drawings and standards along with

gaskets and bolting, conducting air pressure test for Reinforcing pads, supply

of all required materials, consumables and labour to complete the work as

per attached drawings, technical specifications, standards, codes, Scope of

work and as per instructions of HPCL engineer. Nozzle neck lengths shall be

as per drawings/ data sheets/specs.

21.0 SHELL MANHOLES

600 mm nominal dia shell manhole with neck ring, manhole cover plate with

handle, bolting flange, MS reinforcement pad plate,3 mm thk oil permeate

gasket, stud bolts and nuts. Only plates for reinforcement pad will be

supplied by HPCL. Quoted rates are deemed to include supply and fabrication

of neck ring, testing including radiography, bolting flange, cover plate, gasket,

stud bolts and nuts.

Each 8

SHELL NOZZLE

Shell nozzles of the following sizes with reinforcement pad plate, using

seamless pipes conforming to ASTM A 106 Grade XS, for nozzle sizes upto

and including 300mm. The nozzle sizes above 300 mm shall be fabricated

form MS plate of IS 2062: grade A/B of thickness as per the provision laid

down in API- 650. The nozzle shall be with ASA class 150 forged steel slip on

flanges with holes drilled as per ANSI-B-16.5 inside as well as outside, 350

mm dia x 600 mm length semi circular anti splash trough inside the tank, 2

mm thk oil permeate gasket, stud bolts, flanges including fixing of HPCL

supplied valve complete as per specifications. Only plates for reinforcement

pad will be supplied by HPCL. Quoted rates are deemed to include supply and

fabrication of nozzle, trough, slip-on flanges, gasket and stud bolts and nuts.

The job shall also include DP testing of the root and radiography of the seam

joint in case of nozzle being fabricated from plates.

22.0 450 mm DIA using MS plate conforming to IS 2062 Gr.A/B Each 8

23.0 250mm DIA using seamless pipes conforming to ASTM A 106 Grade XS Each 4

24.0 WATER DRAW OFF NOZZLE Each 16


Page 16 of 34

Water draw off nozzles of 80 mm dia with reinforcement pad plate,

seamless pipe of A 106 XS Grade, ASA class 150 forged steel slip on flanges

with holes drilled as per ANSI-B-16.5 inside as well as outside, 2 mm thk oil

permeate gasket, stud bolts, flanges including fixing of HPCL supplied valves

(2 Nos) with blind flange with a spool piece in between of approx.200 mm

length. The rate shall include supply, fabrication, erection, welding and

testing of the above including flanges and pipe. Only plates for reinforcement

pad will be supplied by HPCL. Job also to include supply and provision of bend

inside the tank with anti-vortex plate at the tip as per attached drawings,

technical specifications etc and as directed by EIC.

25.0 SUPPLY & FIXING FOAM POURER & MAKER WITH NOZZLES

Foam pourer nozzles of 150 mm dia with reinforcement pad plate, seamless

pipe, ASA class 150 slip on flanges with holes as per ANSI-B 16.5, foam

deflector, gasket, nuts, bolts, washers, flanges including fixing of foam maker

&foam pourer for floating roof and fixed cone roof as per design/tech

specifications/standards/codes complete. Job also includes supplying and

fixing of approved foam maker & pourers as per technical specs attached at

required elevation with gasket, stud bolts, etc complete. All the

Testing/Design/Third party inspection/vetting requirements as per attached

technical specifications/job procedures shall be included in the quoted rate.

No separate payment will be made for the same. The job to be executed as

per attached technical specifications, job procedures etc complete and as

directed by EIC.

Each 16

26.0 PRESSURE TRANSMITTER NOZZLE Each 4

Pressure transmitter nozzles of 80 mm dia with reinforcement pad plate,

seamless pipe of A 106 XS Grade, ASA class 150 forged steel slip on flanges

with holes drilled as per ANSI-B-16.5, gasket, stud bolts, flanges including

fixing of HPCL supplied valve with blind flange. Only plates for reinforcement

pad will be supplied by HPCL. The job to be executed as per attached

technical specifications, job procedures etc complete and as directed by EIC

FLOATING ROOF APPURTENANCES

Supply fabrication erection and welding of the following roof appurtenances.

Rate to include supply, fabrication and welding of the neck rings, MS

ERW/Seamless pipes, bolting flanges, MS plate slip on flanges, manhole

covers with handle, all gaskets ,stud bolts and fabrication and welding of all


Page 17 of 34

reinforcement pad plates as per drawing complete as per specifications. For

all roof appurtenances only plates for reinforcement pad will be supplied by

HPCL. All the Testing/Design/Third party inspection/vetting requirements as

per attached technical specifications/job procedures shall be included in the

quoted rate. No separate payment will be made for the same.The job to be

executed as per attached technical specifications, job procedures etc

complete and as directed by EIC (For items 27 to 43 )

27.0 DECK THROUGH MANHOLES-600mm NB

600 mm NB deck through manhole with 6 mm sleeve, manhole cover, bolting

flange, reinforcement pad plate and cat ladder with ISA 65 x 65 x 8 and 25

mm plain rods @ 250 c-c. Structural steel work for cat ladders will be paid

separately under item no 17. The job to be executed as per attached

technical specifications, job procedures, drawings etc complete and as

directed by EIC

Each 2

28.0 DECK THROUGH MANHOLES- 750mm NB

750 mm NB deck through manhole with 6 mm sleeve, manhole cover, bolting

flange, reinforcement pad plate and cat ladder with ISA 65 x 65 x 8 and 25

mm plain rods @ 250 c-c. Structural steel work for cat ladders will be paid

separately under item no 17. The job to be executed as per attached

technical specifications, job procedures, drawings etc complete and as

directed by EIC.

Each 2

29.0 GAUGEWELL SLEEVE FOR AUTOLEVEL GAUGE AND MANUAL GAUGE PIPE.

Fabrication and erection of 500 NB and 1.5 mt long MS ERW sleeve

(fabrication) of thickness 6 mm for auto level gauge float. Rate to include

welding the pipe to the pontoon bottom and top plates with reinforcement

plates, welding suitable flange (to be supplied by the party) conforming to

ASA class 150 and holes drilled as per ANSI-B-16.5, fabrication ,welding and

fixing of cover plate with necessary sockets for gauge float string/ guides

including necessary stud bolts and gaskets. Job also to include supply and

fixing of 20mm thick brass flange and 20mm thick neoprene sheet to suit the

above. The job to be executed as per attached technical specifications, job

procedures, drawings etc complete and as directed by EIC

EACH 4


Page 18 of 34

30.0 PONTOON MANHOLES

500 mm nominal diameter manholes with cover plates and handles. Suitable

Neoprene rubber beading / lining of 5/6 mm shall be provided on the neck of

pontoon manhole with proper fixing arrangement to prevent any sparking.

Manhole cover shall be provided with proper locking/venting arrangement.

The job to be executed as per attached technical specifications, job


Each 56

31.0 AUTO BLEEDER VENT

Supply, fabrication, erection of 300 mm dia pipe conforming to ASTM A 105

Gr.BSch 40 for auto bleeder vent as per drawing. All materials including

brazing of pipes is in the scope of vendor. The job to be executed as per

attached technical specifications, job procedures, drawings etc complete and

as directed by EIC

Each 4

32.0 RIM VENT

Supply, fabrication, erection of 150 mm nominal dia rim vent, including fixing

of vendor supplied Aluminium pressure vacuum (PV) vent as per attached

specs and approved makes. Rate to include supply, fabrication, erection of

pipe, flanges and PV vent.

Each 4

33.0 EMERGENCY DRAIN

Supply, fabrication, erection of 150 mm nominal dia emergency drain with

water trough and water seal with Sch 40 seamless pipe all accessories

complete as per approved drawings.

Each 2

CENTRAL ARTICULATED ROOF DRAIN ASSEMBLY

Roof Drain: Design, sizing, Preparation of drawings, submission of design

calculations and obtaining HPCL approval, supply, fabrication and erection of

primary Roof Drain Flexible (make) roof drain system made from unbonded

flexible pipe conforming to API17j of make Co flexip or MESA or HPCL

approved equivalent as detailed specification attached (Annexure II) with

Cast steel Non-return Valve including Supply, fabrication and installation of

suitable Shell nozzle for Roof Drain ,Supply, fabrication and welding for inlet

piping from Roof Drain sump to Inlet side of Selected system and Outlet

piping from Outlet side of Selected system to shell nozzle with required


Page 19 of 34

shoes, guides and guards, if any as per Manufacturer's instructions; Supply,

fabrication and erection of Roof drain Extension piping along with cast steel

Gate valve, supports and foundation for Roof drain extension, etc, Testing

and completing the work in all respects as per specifications, drawings and

instructions of HPCL Engineer-in-Charge, providing Performance Guarantee

for the entire System for 3 years from the date of Commissioning. The drain

shall be so designed that the entire rain water (125 mm/hr – to be

considered for design of roof drain) is immediately drained off. Bolts

used inside the tank should be of stainless steel.(for item 34)

Complete layout of Primary Roof Drain shall be provided by the supplier and

installed by the Contractor. Contractor shall supply all required materials.

34.0 28 M DIA X 10.0 Mt HT TANK – External Floating Roof

EACH 2

FLOATING ROOF LEGS

35.0 100 mm NB (actual length to be as per site conditions) seamless pipes of

schedule 40 thickness for sleeves of legs.

Meters 100

36.0 80 mm NB( actual length to be as per site conditions)seamless pipes of

schedule 80 thickness for leg supports with holes drilled as specified in the

drawing for two operating levels one at 1.8 mt and the other at 1.2 mt

respectively and MS rod and cotter pin of specified size.

Meters 180

NOTE: (Note: for items 35 & 36)

1. Reference shall be made to specifications for materials in contractor’s

scope of supply for scope of supply and details of specifications of pipes.

2. The 80 mm dia leg support shall have 36mm dia sleeve at locations where

holes are drilled.

3. Bearing plate under each pipe supports (legs) shall be welded around.

4. 100 mm Sleeve shall be brass brazed at the top and bottom for length. of

50 mm measured along the pipe.

5. The leg pins shall be stainless steel and 32 mm in diameter.

6. The rates to include supply and fixing of neoprene between sleeve and leg


Page 20 of 34

supports as per details provided in attached drawing.

37.0 COMBINED STILL WELL PIPES 400 MM NB

Supply, fabrication, erection and welding of the 400 mm NB gauge well using

seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness with

holes drilled as per drawing. Rate to include supply, fabrication and welding

of the neck rings, seamless pipes, bolting flanges, supplying and fixing of all

gaskets ,stud bolts and fabrication and connecting the well pipes with party

supplied Al gauge hatches complete along with welding of 600 x 600 x 8 mm

datum plate as per specifications. Rate also to include providing and fixing

guide pole cover/housing of approved design and make to minimize

evaporation of MS/HSD and other volatile organic compound (VOC).

Necessary structural supports shall be paid vide item no 12. Job to be

executed as per attached technical specifications, job procedures, drawings

etc complete and as directed by EIC

Note: One no. 200 mm NB & one no. 80mm NB pipes shall be placed inside

400mm NB pipes erected against this item. However, the same shall be paid

separately against item nos. 39&40 respectively. Party shall quote only for

400 mm NB Combined still well pipes.

Meters 26

38.0 GUAGE WELL PIPES 300 MM NB


seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness with

holes drilled as per drawing. Rate to include supply, fabrication and welding

of the neck rings, seamless pipes, bolting flanges, supplying and fixing of all

gaskets ,stud bolts and fabrication and connecting the well pipes with party

supplied Al gauge hatches complete along with welding of 600 x 600 x 8 mm

datum plate as per specifications. Rate also to include providing and fixing

guide pole cover/housing of approved design and make to minimize

evaporation of MS/HSD and other volatile organic compound (VOC).

Necessary structural supports shall be paid vide item no 13.0. Job to be

executed as per attached technical specifications, job procedures, drawings

etc complete and as directed by EIC.

Meters 26



Meters 26


Page 21 of 34

seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness

with holes drilled as per drawing. Rate to include supply, fabrication and

welding of the neck rings, seamless pipes, bolting flanges, supplying and

fixing of all gaskets ,stud bolts and fabrication and connecting the well

pipes complete along with welding of 600 x 600 x 8 mm datum plate as

per specifications. Necessary structural supports shall be paid vide item

no 12.0. Job to be executed as per attached technical specifications, job


Note: 200 mm NB pipes shall be placed inside 400mm NB pipes erected

against this item for floating roof tank.

40.0 AVERAGE TEMP. SENSOR PIPE. Meters 26

Supply, fabrication, erection and welding of the slotted pipes (80 mm NB x

5.5 mm thick) conforming to IS: 1978 YST 210 grade inside manual gauge well

pipe of floating roof tanks and standalone arrangement in cone roof tanks for

installation of average temp. sensor. Rate to include supply, fabrication and

welding of the neck rings, MS ERW pipes, bolting flanges, fixing arrangements

if any, supplying and fixing of all gaskets stud bolts and fabrication as per

technical specifications and instructions of the engineer in charge.

Note: The above 80mm NB pipes shall be placed inside 400mm NB pipes

erected against this item for floating roof tank.

41.0 SHUNT SPRINGS

Providing and fixing suitable stainless steel flats of size 300mm x 50 mm x

3.15mm at the bottom of the pontoon @ 2.5 m c/c around the periphery.

Rate to include supply of SS bolts, nuts, washers etc complete as per attached

drawings, technical specifications complete and as directed by EIC.

EACH 75

42.0 ROOF STOPPER: supply , fabrication/welding of roof stoppers made

out of 100 mm NB pipe sch 40 of length 75mm brazed on outside the

surface of the pipe and as per details provided in the std drawing for

roof stopper for floating roof tanks

EACH 10

MECHANICAL SHOE SEAL

Primary Mechanical Shoe Seal with Secondary seal: Design, Preparation of


Page 22 of 34

all drawings and obtaining HPCL approval. Supply of all materials and

installation of primary mechanical shoe seal using SS metallic shoe of dept

1.2mm (for sliding contact along with primary seal fabric) and rim mounted

Secondary Seal along with all fixtures, inspection and testing of all materials

and sealing device namely Pusher Mechanism of SS 304 grade, Hanger, dip

curtain of PTFE, SS shunt, shoe, Secondary seal. Providing Two Year

performance Guarantee for the Primary and Secondary seals from the date of

commissioning all complete as per specifications, standards and instructions

of HPCL Engineer-in-Charge. Contractor shall furnish the name of the supplier

and Model quoted in the tender along with relevant catalogues in Unpriced

Bid.

43.0 28 M DIA TANK Each 2

Design, Supply, fabrication, erection, welding of circulation vents as per

attached drawings, technical specifications and as directed by EIC etc

complete.

FIXED CONE ROOF APPURTENANCES(item No: 44 to 47)

Supply fabrication erection and welding of the following roof appurtenances.

Rate to include supply, fabrication and welding of the neck rings, MS ERW

pipes, bolting flanges, MS plate slip on flanges, manhole covers with handle,

all gaskets ,stud bolts and fabrication and welding of all reinforcement pad

plates as per drawing complete as per specifications. For all roof

appurtenances only plates for reinforcement pad will be supplied by HPCL. All

the Testing/Design/Third party inspection/vetting requirements as per


quoted rate. No separate payment will be made for the same. The job to be

executed as per attached technical specifications, job procedures etc

complete and as directed by EIC

44.0 ROOF MANHOLES – Fixed Cone Roof Each 4

600 mm nominal dia roof manhole with neck ring, manhole cover plate with

handle, bolting flange, MS reinforcement pad plate and suitable dia stud

bolts etc complete.

45.0 ROOF NOZZLES (VENT) with PRV – Fixed Cone Roof Each 4


Page 23 of 34

Supply and fixing of 200 mm dia. Roof nozzles With PRV as per attached

specifications with reinforcement pad plate, MS ERW pipe of suitable

thickness,180 degree forged steel bend of sch 40, ASA class 150 slip on

flanges with holes drilled as per ANSI-B-16.5, stud bolts, washers etc

complete. Rate to include fixing of vendor supplied Aluminium pressure

relief valve.



seamless pipes conforming to ASTM A 106 Gr B of schedule 40 thickness

with holes drilled as per drawing. Rate to include supply, fabrication and

welding of the neck rings, seamless pipes, bolting flanges, supplying and

fixing of all gaskets ,stud bolts and fabrication and connecting the well

pipes with party supplied Al gauge hatches complete along with welding

of 600 x 600 x 8 mm datum plate as per specifications. Necessary

structural supports shall be paid vide item no 13.0.Job to be executed as

per attached technical specifications, job procedures, drawings etc


Meters 52

47.0 AVERAGE TEMP. SENSOR PIPE. Meters 26

Supply, fabrication, erection and welding of the slotted pipes (80 mm NB x

5.5 mm thick) conforming to IS: 1978 YST 210 grade. Rate to include supply,

fabrication and welding of the neck rings, MS ERW pipes, bolting flanges,

screwable cap, fixing arrangements if any, supplying and fixing of all gaskets

stud bolts and fabrication as per technical specifications and instructions of

the engineer in charge.

TESTING OF TANKS:( for items 48 to 53)

Conducting tests such as Vacuum box test, Dye penetration test, Pneumatic

test, diesel chalk test and hydro test as outlined in API 650 and the job to be

executedas per attached technical specifications, job procedures etc

complete and as directed by EIC.

BOTTOM TESTING. (Note: For items 48 & 49)

Testing of the welding joints of the tank bottom with vacuum box method up

to a vacuum of 5 psi (absolute). Rate to include arrangement of all equipment

like glass box, compressor rubber tubes, torch lights and mud packing

complete as per attached technical specifications, job procedures


Page 24 of 34

etccomplete and as directed by EIC.

48.0 30.0 M Dia x 10.0 M HtSelf-supporting Fixed cone roof Tank

EACH

2

49.0 28.0 M Dia x 10.0 M Ht External Floating roof Tank

EACH

2

SHELL TESTING (Note: For item nos50&51)

Hydrostatic testing of tank shell by filling water upto curb angle including

supply and filling water. Rate to include supply and filling of water up to max.

liquid level, observing for weld joint leaks or plate leaks if any, hammering

the joints as per the directions of Engineer-in-charge, decanting water after

successful completion of testing, cleaning the bottom, shell and roof and

drying it completely etc. as per attached technical specifications, job

procedures etc complete and as directed by EIC specifications including diesel

chalk test for the shell to bottom joint prior to hydrotest.

50.0 30.0 M Dia x 10.0 M Ht Self-supporting Fixed cone roof Tank

EACH

2


EACH

2

NOTE: In case of any leaks observed during any of the above tests contractor

shall decant the water up to 300 mm below the leak, repair the leak and

again test the tank by filling the water to the satisfaction of the Engineer-in-

charge. Contractor shall repeat the process till all the leaks are rectified.

ROOF TESTING (Note: For items 52&53)

Testing of the welding joints of the long & short seam of cone roof and

pontoons of Floating roof & deck of IFR with pneumatic pressure method.

The rate to include arrangement of all the equipments, accessories etc and as

per technical specifications, job procedures etc complete and including

diesel chalk test/vacuum box test where ever necessary for pontoons and as

directed by EIC complete.

52.0 30.0 M Dia x 10.0 M HtSelf-supporting Fixed cone roof Tank

EACH 2


Page 25 of 34


EACH

2

TANK CALIBRATION

CALIBRATION OF TANK BOTTOM(Note: For Item Nos 54 & 55)

Physical calibration of the following dia tank bottom by calibrated flow meter

up to the datum plate. Rate to include arrangement of equipment necessary

pumping water, taking readings as per technical specifications, job

procedures etc complete and as directed by EICand presenting the same etc.

complete including certification by proper statutory authorities.


EACH

2


EACH

2

CALIBRATION OF TANK SHELL(Note: For item Nos 56 & 57)

Calibration of tank shell using strapping tape when the tank is full with water.

Rate to include supply and erection of necessary scaffolding, platforms,

taking readings at top, middle and bottom of each shell strake after applying

sufficient pull by spring balance and presenting results as per technical

specifications, job procedures etc complete and as directed by EIC including

certification by proper statutory authorities.


EACH

2


EACH

2

(Note: For item nos 54 to 57)

1) The calibrated strapping tape (100 Rmt) shall be supplied by Contractor.

2) Contractor shall carry out both bottoms by flow meter up to crown and

shell calibration in the presence of the representatives of W&M and HPCL.

The calibration charts shall be prepared by contractor and get the same

certified by W&M. The contractor shall make all necessary arrangements for


Page 26 of 34

the visit of representatives from W&M. All statutory fees and any other

expenses in this regard shall be borne by the contractor. Rate quoted in the

above 4 items shall include certification by W&M. Certificates to be handed

over to HPCL.

MISCELLANEOUS ITEMS (ITEM NOS 58 to 61)

58.0 PRESSURE RELIEF LINE Meters 250

Supply, fabrication and fixing of 25 mm dia MS heavy duty Sch 80 thickness

seamless pipeline from receipt/delivery line up to the top most

shell/roof/nozzle of the fixed roof tank and shell manhole/Nozzle/free drop

pipe at top in the floating roof tank. Rate to include supply and fixing of

necessary MS forged slip on flanges, tees, elbows, U clamps and supply and

fixing of ISA 50 x 50 x 6 angles for supports (of required nos) per tank to the

shell. Job to be executed as per technical specifications, drawings, job

procedures etc complete and as directed by EIC (MS angles will be paid

separately in the structural steel item )

59.0 GATE VALVE 25MM DIA

Supply and fixing of 25 mm dia forged steel gate valves class 1500 with

flanged ends of approved make. Job to be executed as per technical

specifications, drawings, job procedures etc complete and as directed by EIC.

Each 40

60.0 NON RETURN VALVE 25 MM DIA

Supply and fixing of 25 mm dia forged steel horizontal non-return valve class

1500 with flanged ends of approved make. Job to be executed as per

technical specifications, drawings, job procedures etc complete and as

directed by EIC.

Each 18

61.0 THERMAL SAFETY VALVE Each 18

Supply ,fixing of thermal safety valve for a differential pressure of range 6.5-

7.5 kg/cm2 as per attached technical specifications, drawings and as directed

by EIC complete. The TSV shall be designed for back pressure of max 1.5

kg/cm2. The Make of the TSV shall be “Tyco” or equivalent as approved by

HPCL. The design calculations for selection for a particular tanks regarding set

pressure shall be submitted by the vendor and the same shall be approved by

HPCL before procurement.


Page 27 of 34

TANK EARTHING

EARTHING PITS

Providing and constructing plate electrode type earthing pits conforming to

IS- 3043 latest edition as per drawing enclosed, with all GI parts. Rate to

include supply of all material necessary for earthing pit, supply and welding

MS earthing boss to the tank shell at 500 mm above the bottom plate and

connecting the boss with pit and pipe electrode by 50 x 6 mm thk MS

galvanised strip. Rate also to include carrying out megger testing of pits and

issuing test certificate from licensed electrical contractor. Job to be executed

as per technical specifications, drawings, job procedures etc complete and as

directed by EIC. The size of manhole cover for earthing pits with GI plate

shall be 600 x 600 mm & minimum weight of cover with frame shall be 42 kg.

62.0 Earth Pits with GI Plates using 600 x 600 x 6.3mm GI plates Each 20

63.0 50x6mm GI FLAT

Supply and fabrication of 50 x 6mm GI flats strips required for earthing. The

strips shall be bolted with brass nuts on one side of equipment and other

with the electrode. The pieces of flat in between the ends shall be welded

and coated with one coat of bitumen.

Running

Meter

1000

64.0 COPPER CABLE

Supply and fixing of 25 sq. mm braided copper cables between rolling ladder

and track & rolling ladder and platform at the top. Rate to include supply and

fixing of Copper lugs, bolts etc. complete. Job to be executed as per technical

specifications, drawings, job procedures etc complete and as directed by EIC

Meters 40

65.0 CHAIN BARRIER

Supply fabrication and fixing of 12 mm dia 750 mm long barriers at a height

of 1.0 M and 0.5 M each at the entrance of staircase platforms of tanks along

with 6 mm dia MS hooks openable type as detailed in the drawing.Job to be

executed as per technical specifications, drawings, job procedures etc

complete and as directed by EIC.

Each 10

SPRINKLER /FOAM SYSTEM(Note: For items 66 to 70)


Page 28 of 34

Design, supply, fabrication, erection and testing of following size pipes for

sprinkler system conforming to IS 1239/3589 as per attached specs in the

specified curvature and installing with necessary GI ‘U’ clamps supplied by

the party on the periphery of floating roof tanks on angle support welded on

the shell of the tanks. Job includes supply, fabrication, welding of necessary

half couplings to MS pipe for fixing m sprinkler nozzles, fabrication and

welding of angle supports (shall be paid separately under the item no. 20).

The curved pipe to have flange joints every 6 m for ease of removal and

replacement at a later date. Supplying and fixing necessary flanges, gaskets,

stud bolts as per HPCL specs attached to this tender are in the scope of the

vendor. Rate to include all the Testing/Design/Third party

inspection/vetting requirements as per attached technical

specifications/job procedures shall be included in the quoted rate. No

separate payment will be made for the same.Job to be executed as per

technical specifications, drawings, job procedures etc complete and as

directed by EIC.

66.0 75 mm dia Meters 400


Design, supply, fabrication, erection and testing of following size pipes for

sprinkler/foam system conforming to IS 1239/3589 as per attached specs for

the vertical tap-off / connection for sprinkler lines / foam makers including

installing necessary ‘U’ clamps/ stopper rods on the periphery of floating roof

tanks and on support angles (shall be paid separately under the item no. 55)

welded on the shell of the tanks. Battery limit flange also to be supplied and

welded by the party. (Note: For items 68 & 69)



70.0 SPRINKLER NOZZLES

Design, supply and installation of water sprinkler nozzles as per attached

specs on the above installed water sprinkler line.

EACH 500

Note:- For the items 66 to 70, party to submit the design from a reputed fire

fighting equipment manufacturer/ consultant for sprinkler / foam line

sizing and selection of numbers & K value of the sprinkler nozzles provided


Page 29 of 34

at each level, based on tender specs ,TPI vetted, for HPCL approval before

proceeding with the procurement activities.

EXTERNAL PAINTING OF TANKS

71.0 COPPER SLAG BLASTING :

Preparation of surfaces of tank shell, roof / deck and roof top railings,

staircases, landing platforms, shell, roof/deck appurtenances, nozzles, tank

body valves, walkway cum wind girder & its railing, stiffener rings/sprinkler/

foam lines, roof top railings, staircases, landing platforms, stiffener rings/

wind girders, wind girder cum walkway and its railings, Gauge Well & Foam

pourer platforms, structural supports/ brackets/ ribs, curb angles, bottom

plate projections, spiral staircases including steps from walkway to Guage

Well Pipes for Floating roof tanks, Rolling ladder including track for FR tanks,

expansion, sprinkler & foam pipelines etc of all the tanks on the tank etc. by

copper slag blasting with approved quality copper slag, thoroughly to S.A 2.5

of Swedish Ivonsk Standard SIS 055900- 1967 to bare metal to ensure

thorough cleaning of surfaces to receive paints as per specifications. Rate to

include for providing and fixing DOUBLE PIPE scaffolding with working

platforms, inspection ladders/steps/walkways etc in an approved/safe

manner and cleaning of Tank Farm area after shot blasting is completed. Job

to be executed as per technical specifications, drawings, job procedures etc


Note: Contractor to arrange and keep at site relevant Swedish photographic

standards, calibrated profile gauges, calibrated digital Elco meter for

inspection by HPCL Site In charge failing which permission to proceed with

the work will not be granted. Please refer the Special terms & Conditions of

the contract also.

Square

Meters

14000

72.0 PRIMING COAT-EXTERNAL

Supply and application of one coat 65 micron DFT zinc anode 304 primer of

Berger or approved equivalent by HPCL, to shell, roof, roof top railings,

staircase, landing platforms, all shell/roof /deck appurtenances, nozzles and

tank body valves, stiffener / wind girder, stiffener rings/ wind girders, wind

girder cum walkway and its railings, Gauge Well & Foam Pourer platforms,

structural supports/ brackets/ ribs, curb angles, bottom plate projections,

spiral staircases including steps from walkway to Gauge Well Pipes for

Floating roof tanks, Rolling ladder including track for FR tanks, expansion,

sprinkler & foam pipelines etc of all the tanks. Rate to include wastages,

Square

Meters

11000


Page 30 of 34

mixing the paint properly as per manufacturer's specifications, applying with

air less spray gun till 65 micron DFT of paint thickness is obtained, testing for

thickness, providing pipe DOUBLE scaffolding etc. complete. Job to be

executed as per technical specifications, drawings, job procedures etc


73.0 INTERMEDIATE COAT

Supply and painting One coat of 100 micron of Epilux 155 HB MIO of Berger

or approved Make to shell and roof including all appurtenances, roof top

railings, staircase, landing platforms, all shell/roof /deck appurtenances,

nozzles and tank body valves, stiffener / wind girder cum walkway and its

railings, gauge well & Foam pourer platforms, structural supports/ brackets/

ribs, curb angles, bottom plate projections, spiral staircases including steps

from walkway to Guage Well Pipes for Floating roof tanks, rolling ladder

including tracks for FR tanks, expansion, sprinkler & foam pipelines etc. Rate

to include wastages, mixing as per manufacture's specifications, providing

necessary DOUBLE pipe scaffolding, testing for thickness etc complete and

applying with air less spray gun till 100 micron DFT of paint thickness is

obtained, testing for thickness , providing pipe scaffolding etc. complete.

Job to be executed as per technical specifications, drawings, job

procedures etc complete and as directed by EIC

Note: - Payment for item no 71 to 73 will be made on actual surface area of

tank shell and roof measured only once. No separate measurement will be

taken for nozzles, shell/deck/roof appurtenance, tank body valves, roof top

railings, staircases, landing platforms, stiffener rings/ wind girders, wind

girder cum walkway and its railings, gauge well & Foam pourer platforms,

structural supports/ brackets/ ribs, curb angles, bottom plate projections,

spiral staircases including steps from walkway to Gauge Well Pipes for

Floating roof tanks, Rolling ladder including track for FR tanks, expansion,

sprinkler & foam pipelines etc of all the tanks for payment purposes.

However, floor area of walkway cum wind girders / stiffener rings will be

measured for payment purpose and will be paid through this item only.

Square

Meters

11000

74.0 FINISH COAT -EXTERNAL

Supply and painting with Bergerthane Enamel or approved equivalent as

approved by HPCL, in not less than two coats to shell and roof of approved

shade including all appurtenances nozzles and tank body valves, Gauge well

& Foam pourer platforms, structural supports/ brackets/ ribs, curb angles,

Square

Meters

11000


Page 31 of 34

bottom plate projections, expansion, sprinkler & foam pipelines with

appropriate colour shade etc. Rate to include wastages, mixing as per

manufacturers specifications, providing necessary pipe scaffolding, applying

in two or more coats to achieve 80 micron DFT (40 micron in each coat) ,

using conventional spray/air less spray gun till the required DFT of paint

thickness is obtained, testing for thickness , providing pipe scaffolding etc.

complete.

Painting shall be applied to tank shell, roof, deck, shell and roof

appurtenances, nozzles and tank body valves etc.

Note: - Payment for this item will be made on actual surface area of tank

shell and roof measured only once. Also, floor area of walkway cum wind

girders catwalk will be measured for payment purpose and will be paid

through this item only. No separate measurement will be taken for nozzles,

shell/deck / roof appurtenance, tank body valves. Stiffener rings/ wind

girders, gauge well & Foam pourer platforms, structural supports/

brackets/ ribs, curb angles, bottom plate projections, expansion, sprinkler

& foam pipelines etc of all the tanks for payment purposes. However roof

top railings, walkway cum wind girder railing, staircases, landing platforms,

etc will be paid through separate items.

INTERNAL PAINTING

75.0 PRIMING COAT -INTERNAL

Supply and application of one coat 65 micron DFT zinc anode 304 primer of

Berger or approved equivalent make to total bottom, shell and under side of

the deck. Rate to include wastages, mixing the paint properly as per

manufacturer's specifications, applying with air less spray gun till 65 micron

DFT of paint thickness is obtained, testing for thickness , providing pipe

scaffolding etc. complete.

Square

Meters

3500

76.0 FINISH COAT-INTERNAL

Supply and application of two coats 100 micron DFT each Epilux 78 HB TL of

Berger or approved equivalent make to total bottom, shell and underside of

floating roof deck. Rate to include wastages, mixing the paint properly as per

manufacturer's specifications, applying with air less spray gun till 200 micron

DFT of paint thickness is obtained, testing for thickness , providing pipe

scaffolding etc. Complete.

Square

Meters

3500


Page 32 of 34

Note: - Payment for this item will be made on actual surface area of tank

shell and roof measured only once.

PU PAINTING OF WALK WAY CUM WIND GIRDER RAILING OF FLOATING

ROOF TANKS AND ROOF TOP RAILINGS OF FIXED CONE ROOF TANKS :

Supply and painting with Bergethane enamel or approved equivalent and

approved shade by HPCL, of approved shade, mixing as per manufacture's

specifications, providing necessary pipe scaffolding, applying in two or more

coats to achieve 60 micron DFT , testing for thickness etc complete. Painting

shall be applied to roof top railings , walk ways cum wind girders, including

vertical posts, mid and bottom flats, angle support etc. and other exposed

steel structure on the following above ground tanks.

77.0 30.0 M Dia x 10.0 M Ht Self-supporting Fixed cone roof Tank EACH

2

78.0 28.0 M Dia x 10.0 M Ht External Floating/Open roof Tank

EACH

2

PU PAINTING( STAIRWAY) :

Supply and painting with Bergerthane enamel or approved equivalent by

HPCL, of approved shade, mixing as per manufacture's specifications,

applying in two or more coats with conventional spray / air less spray gun to

achieve 60 micron DFT , testing for thickness etc complete. Painting shall be

applied to stairway including all landing platforms, roof top platforms, all

gratings, flats, square rods, vertical posts and other exposed steel structure

on the following above ground tanks including providing necessary pipe

scaffolding etc complete.


EACH

2

80.0 28.0 M Dia x 10.0 M Ht External Floating roof/open roof Tank

EACH

2

PU PAINTING OF ROLLING LADDER


Page 33 of 34

Supply and painting with Bergerthane enamel or approved equivalent by

HPCL, mixing as per manufacture's specifications, applying in two or more

coats to achieve 60 micron DFT, testing for thickness etc complete. Painting

shall be applied to rolling ladder of MS tank including all gratings, flats,

square rods, vertical posts and other exposed steel structure on the following

above ground tanks including providing necessary pipe scaffolding etc

complete.


EACH

2

82.0 HEADINGS

Supply and painting of Corporations name in HINDI / ENGLISH in 600 mm size

letters in the middle of the top shell of the tank as directed by EIC in Black

enamel paint.

EACH 4

83.0 LETTERING

Supply and painting the following on the second shell of the tanks in black

enamel paint.

Tank number : 230 mm ht

Name of product : 150 mm ht

Tank capacity : 80 mm ht

Size of tank : 80 mm ht

Safe filling height : 80 mm ht

Date painted : 80 mm ht

Date Commissioned.: 80 mm ht

Date of Calibration : 80 mm ht

Date of Hydro testing : 80 mm ht

Due Date of Cleaning : 80 mm ht

If any additional details are required to be painted, the same shall be painted

at no extra cost.

EACH 4

84.0 LOGO

Supply and painting the logo sign of the 2.4 M x 3.0 M size for the above

ground tanks on the top or penultimate shell or as directed by Engineer-In-

Charge. Rate to include for supply of required shade of enamel paints of

approved make, supply and erection of pipe scaffolding and painting the logo

EACH 4


Page 34 of 34

as per standard drawing complete. Logo should be painted as per required

colour code.

85.0 COPPER SLAG BLASTING AND PRIMER COAT INSIDE PONTOONS EACH 56

Preparation of internal surfaces of the floating roof pontoons by Cu slag

blasting (during fabrication itself) thoroughly to S.A 2.5 of Swedish Ivonsk

Standard SIS 055900-Latest edition to bare metal and applying with one coat

(DFT-60microns) of Zinc Anode 304 primer of Berger or approved equivalent

followed by 100 micron HBMIO as per attached technical specifications, job

procedures complete and as directed by EIC.


Page 1 of 5

UNPRICED BID


Page 2 of 5

SR.

NO DESCRIPTION UNIT QUANTITY

1 Excavation up to 2.0 meter Cubic Meters 250

2 Murrum Filling Cubic Meters 2000

3 Rubble Soling Cubic meters 75

4 Plain Cement Concrete 1:2:4 Cubic Meters 50

5 RCC M 20 Tank Apron Cubic Meters 135

6 RCC M 20 Ring Beam Cubic Meters 75

7 REINFORCEMENT STEEL Metric ton 12.5

8 ANTI CORROSIVE LAYER Square meters 3000

9

F & L BOTTOM PLATES Underside painting

incl. Metric Ton 310

10 F& L SHELL PLATES Metric Ton 400

11 F & L ROOF/DECK PLATE Metric ton 250

12 S & I ROOF STRUTURALS- FR Metric Ton 30

13

S & I ROOF STRUTURALS- CR-

Blasting/painting incl. Metric Ton 40

14 S& I HAND RAILS- Structurals Metric Ton 6

15 S& I ROLLING LADDER Metric Ton 6

16 S& I HAND RAILS- Pipes Metric Ton 3

17 S & I MS SQUARE BAR Metric Ton 2

18 S&I MS GRATNG 800 x 250 MM Square meter 65

19 S& I MS GRATNG 800 x 1000 MM Square meter 55

20 S&I MS GRATING 800 X 200 MM Square meter 25

21 SHELL MANHOLES Each 8

22 SHELL NOZZLE 450mm Each 8

23 SHELL NOZZLE 250mm Each 4


Page 3 of 5

24 WATER DRAW OFF NOZZLE Each 16

25 S& I FOAM POURER/MAKER Each 16

26 PRESSURE TRANSMITTER NOZZLE Each 4

27 DECK THROUGH MANHOLES-600mm NB Each 2

28 DECK THROUGH MANHOLES- 750mm NB Each 2

29 GAUGEWELL SLEEVE EACH 4

30 PONTOON MANHOLES Each 56

31 AUTO BLEEDER VENT Each 4

32 RIM VENT Each 4

33 EMERGENCY DRAIN Each 2

34 CENTRAL ROOF DRAIN ASSEMBLY EACH 2

35 S&I 100 MM NB (SCH 40) SLEEVE Meters 100

36 S & I 80 MM NB(SCH 80) LEGS Meters 180

37 COMBINED STILL WELL PIPES 400 MM NB Meters 26

38 GUAGE WELL PIPES 300 MM NB Meters 26

39 GUAGE WELL PIPES 200 MM NB Meters 26

40 AVERAGE TEMP. SENSOR PIPE. Meters 26

41 SHUNT SPRINGS EACH 75

42 ROOF STOPPER EACH 10

43

MECH SEAL WITH SECONDARY SEAL-28 M

DIA TANK Each 2

44 ROOF MANHOLE-CR Each 4

45 ROOF NOZZLE WITH PRV-CR Each 4

46 GAUGE WELL PIPES 200MM –CR Meters 52

47 TEMP. SENSOR PIPE- CR Meters 26

48 BOTTOM TESTING 30.0M Diax10.0M Ht Each 2


Page 4 of 5

CR TANK

49

BOTTOM TESTING 28.0MDiax10.0M Ht FR

TANK Each 2

50

SHELL TESTING 30.0M Diax10.0M Ht CR

TANK Each 2

51

SHELL TESTING 28.0MDiax10.0MHt FR

TANK Each 2

52

ROOF TESTING 30.0M Diax10.0M Ht CR

TANK Each 2

53

ROOF TESTING 28.0MDiax10.0M Ht FR

TANK Each 2

54

BOTTOM CALIBRATION 30.0M Diax10.0M

Ht CR TANK Each 2

55

BOTTOM CALIBRATION 28.0MDiax10.0M

Ht FR TANK Each 2

56

SHELL CALIBRATION 30.0M Diax10.0M Ht

CR TANK Each 2

57

SHELL CALIBRATION 28.0MDiax10.0M Ht

FR TANK Each 2

58 PRESSURE RELIEF LINE Meters 250

59 25 MM DIA GATE VALVE Each 40

60 NON RETURN VALVE 25 MM DIA Each 18

61 THERMAL SAFETY VALVES Each 18

62 EARTHING PITS Each 20

63 50x6 mm GI Flat Each 1000

64 COPPER CABLE Meters 40

65 CHAIN BARRIER Each 10

66 S&L 75MM DIA CIRC SPRNKLR Meters 400

67 S&L 100 MM DIA CIRC SPRNKLR Meters 800

68 S& L 150 MM DIA VERT. HEADR Meters 120


Page 5 of 5

69 S& L 100 MM DIA VERT. HEADR Meters 200

70 S& F SPRINKLER NOZZLES EACH 500

71 COPPER SLAG BLASTING Square Meters 14000

72 PRIMING COAT-EXTERNAL Square Meters 11000

73 INTERMEDIATE COAT Square Meters 11000

74 FINISH COAT –EXTERNAL Square Meters 11000

75 PRIMING COAT -INTERNAL Square Meters 3500

76 FINISH COAT-INTERNAL Square Meters 3500

77 PU PAINT OF ROOF RAILING 30 M DIA Each 2

78 PU PAINT OF WG & RAILING 28 M DIA Each 2

79 PU PAINT-STR.WAY 30 M DIA CR TANK Each 2

80 PU PAINT-STR.WAY 28 M DIA FR TANK Each 2

81 PU PAINT OF ROLLING LADDER Each 2

82 HEADINGS Each 4

83 LETTERING Each 4

84 LOGO Each 4

85 PAINTING OF PONTOONS Each 56


Page 1 of 2

TIME SCHEDULE


Page 2 of 2

TIME SCHEDULE

DESCRIPTION OF WORK:

CONSTRUCTION OF PETROLEUM OIL STORAGE TANKS AT

PARADEEP POL TERMINAL, ORISSA

PART COMPLETION PERIOD

A CONSTRUCTION OF PRODUCT STORAGE TANKS 6 MONTHS

(FROM THE DATE OF HANDING OVER OF THE SITE)

LOCATION: PARADEEPPOL TERMINAL

PARADEEP

ORISSA

NOTE:

1) Time for completion shall be reckoned from the date of issue of Fax/ Letter of

Intent/Purchase Order by HPCL.

2) Time for completion shall include the time required for mobilization, design,

QAP, fabrication, erection, Testing, calibration, handing over, demobilization,

carrying out the works as per requirements of Contract Document and

instructions of HPCL Engineer-in-Charge.


Page 1 of 24

SPECIAL CONDITIONS

OF

CONTRACT


Page 2 of 24

1.0 GENERAL

1.1 Special Conditions of Contract (SCC) shall be read in conjunction with the

General Conditions of Contract (GCC) also referred to as General Terms &

Conditions of Works Contract, Schedule of Quantities, specifications of

work, drawings and any other document forming part of this Contract

wherever the context so requires.

1.2 Notwithstanding the sub-division of the document into these separate

sections and volumes, every part of each shall be deemed to be

supplementary of every other part and shall be read with and into the

Contract so far as it may be practicable to do so.

1.3 Where any portion of the GCC is repugnant to or at variance with any

provisions of the Special Conditions of Contract, then unless a different

intention appears, the provision(s) of the Special Conditions of Contract

shall be deemed to override the provision(s) of GCC only to the extent

that such repugnancy or variations in the Special Conditions of Contract

are not possible of being reconciled with the provisions of GCC.

1.4 Wherever it is stated in this Bidding Document that such and such a

supply is to be affected or such and such a work is to be carried out, it

shall be understood that the same shall be affected and /or carried out by

the Contractor at his own cost, unless a different intention is specifically

and expressly stated herein or otherwise explicit from the context.

Contract Price shall be deemed to have included such cost.

1.5 The materials, design & workmanship shall satisfy the applicable relevant

Indian Standards, the job specifications contained herein & codes referred

to. Where the job specifications stipulate requirements in addition to those

contained in the standard codes and specifications, these additional

requirements shall also be satisfied. In the absence of any Standard /

Specifications / Codes of practice for detailed specifications covering any

part of the work covered in this bidding document, the instructions /

directions of Engineer-in-Charge will be binding upon the Contractor.


Page 3 of 24

1.6 In case of contradiction between relevant Indian standards, GCC, Special

Conditions of Contract, Specifications, Drawings and Schedule of Rates, the

following shall prevail in order of precedence.

i) Detailed Purchase Order along with Statement of Agreed Variations, if any,

and its enclosures .

ii) Fax of Intent (FOI)/Letter of Intent(LOI)

iii) Schedule of Quantities AND Technical specifications

iv) Special Conditions of Contract

v) Drawings/data sheets/job procedures

vi) Instructions to Bidders

vii) General Conditions of Contract

viii) Relevant Indian Standards.

1.7 SAFETY, FIRE FIGHTING AND SPECIFIC REQUIREMENTS OF HPCL

1.7.1 Contractor shall provide adequate number of standard lengths of IS Stamped Fire

hoses, IS Stamped DCP Fire extinguishers, fire buckets with sand and nozzles.

These items can be taken back by the Contractor after completion of work. Sand

shall also be maintained dry by the Contractor with fresh supply, whenever

required. Work permit may not be issued by HPCL in the absence of above items.

1.7.2 Safety Helmets shall be provided to all the employees of Contractor including

that of his labour contractors.

1.7.3 Safety Belts and Harnesses shall be provided by the Contractor in adequate

number for the workers working at heights.

1.7.4 Proper earthing shall be provided for all equipments and generators.

2.0 THE WORK

2.1 Scope of Work & Scope of Supply

2.1.1 The scope of work and Scope of Supply covered in this Contract

will be as described in Scope of work provided in the Instructions


Page 4 of 24

to bidders, Schedule of Quantities, Technical Specifications,

Drawings, etc.

2.2 Time Schedule

The Completion period for Construction of Petroleum Oil storage tanks on existing

pile foundation shall be 6(SIX) Months from the date of handing over the site.

2.2.1 Time is the essence of this Contract. The period of completion given includes

the time required for mobilization as well as testing, rectifications, if any,

retesting, demobilization and completion in all respects to the satisfaction

of the Engineer-in-Charge.

2.2.2 A joint program of execution of work will be prepared by the Engineer-in-

Charge and Contractor. This program will take into account the time of

completion period of the Contract.

2.2.3 Monthly execution program will be drawn up by the Engineer-in-Charge

jointly with the Contractor based on availability of materials, work fronts

and the joint program of execution as referred to above. The Contractor

shall scrupulously adhere to the Targets / Program by deploying adequate

personnel, Construction Equipment, Tools and Tackles and also by Timely

Supply of required materials coming within his scope of supply as per

Contract. In all matters concerning the extent of target set out in the

monthly program and the degree of achievement, the decision of the

Engineer-in-Charge will be final and binding upon the Contractor.

2.2.4 Contractor shall give every day category-wise labour and equipment

deployment report along with the progress of work done on previous day

in the proforma prescribed by the Engineer-in-Charge.

2.3 Measurement of Works

2.3.1 Mode of measurement will be as specified in Specifications or SOR.

2.4 Payment Terms

2.4.1 Payment will be released within 15 days of submission of duly certified Running

Account Bills at Disbursement section at Mumbai after deduction of


Page 5 of 24

WCST(Works Contract Sales Tax) or VAT whichever is applicable, IT(Income Tax)

and any other statutory deduction as applicable from time to time, Any

MRR(Materials Received Report- An internal document forwarded by HPCL Site –

in-Charge/ Engineer to Disbursement Section along with Contractor’s Bill and

duly certified measurement sheets for release of payment) Deductions, LD, etc.

In case of Final Bill, Payment will be released within 45 days of submission of

duly certified Final Bill along with all requisite documents, drawings, etc.

Payment break up for various items covered in SOR/PRICED BID is as indicated as

Appendix 1 to SCC. No further alteration is permitted in approved payment

break up.

2.5 Temporary Works

2.5.1 All temporary works, enabling works, including dewatering of surface and

subsoil water, preparation and maintenance of temporary drains at the

work site, preparation and maintenance of approaches to working areas,

adequate lighting, wherever required, for execution of the work, shall be

the responsibility of the Contractor and all costs towards the same shall be

deemed to have been included in the quoted prices.

2.6 Quality Assurance

2.6.1 Detailed quality assurance programme to be followed for the execution of

Contract under various divisions of works will be mutually discussed and

agreed to.

2.6.2 The Contractor shall establish, document and maintain an effective

quality assurance system as outlined in the specifications and various codes

and standards.

2.6.4 The Owner/Consultant or their representative shall reserve the right to

inspect/witness, review any or all stages of work at shop/site as deemed

necessary for quality assurance and / or timely completion of the work.

2.6.5 In case Contractor fails to follow the instructions of Engineer-in-Charge

with respect to above clauses, next payment due to him shall not be

released unless and until he complies with the instructions to the full

satisfaction of Engineer-in-Charge


Page 6 of 24

2.7 Leads

2.7.1 For the various works, in case of contradiction, leads mentioned in the

Schedule of Quantities shall prevail over those indicated in the Technical

specifications.

3.0 ROYALTY, INCOME TAX, SERVICE TAX AND PRICES

3.1 Royalty

3.1.1 All royalties etc., as may be required for any Borrow Areas, including right

of way etc., to be arranged by Contractor shall be deemed to have been

included in the quoted prices.

3.1.2 Contractor’s quoted rates should include the royalty on different applicable

items as per the prevailing State Government rates. In case, Owner is able

to obtain the exemption of royalty from the State Government the

Contractor shall pass on the same to Owner for all the items involving

royalty. Any increase in prevailing rate of royalty shall be borne by the

Contractor at no extra cost to the Owner.

3.2 Income Tax

3.2.1 Income Tax at the prevailing rate as applicable from time to time shall be deducted

from Contractor’s Bills as per Income Tax Act and quoted rates shall be inclusive

of this. Owner will issue the TDS (Tax Deduction at Source) Certificate.

3.3 Firm Prices

3.3.1 The contract price shall remain firm and fixed till the completion of work in

all respects and no escalation in prices on any account shall be admissible

to the Contractor except for statutory variations as per General Terms and

Conditions (GTC).


Page 7 of 24

4 PROVIDENT FUND,LABOUR, LABOUR LAWS AND SITE REQUIREMENTS

4.1 Provident Fund

4.1.1 The Contractor shall strictly comply with the provisions of Employees

Provident Fund Act and register himself with Regional Provident Fund

Commissioner (RPFC) before commencing work. The Contractor shall deposit

Employees and Employers contributions to the RPFC every month. The

Contractor shall furnish along with each Running bill, the challan / receipt

for the payment made to the RPFC for the preceding month. The

Contractor shall furnish the code number allotted by the RPFC Authority to

the Engineer-in-Charge before commencing the work.

4.1.2 In case the RPFC challan / receipt, as above, is not furnished, Owner shall

deduct 16% (sixteen percent) of the payable amount from Contractor’s

running bill and retain the same as a deposit. Such retained amounts shall

be refunded to Contractor on production of RPFC Challan / receipt for the

period covered by the related running bill.

4.2 Labour License

4.2.1 Before starting of work, Contractor shall obtain a license from concerned

authorities under the Contract Labour (Abolition and Regulation) Act 1970,

and furnish copy of the same to Owner.

4.3 Labour Relations

4.3.1 In case of labour unrest/labour dispute arising out of non-implementation

of any law, the responsibility shall solely lie with the Contractor and they

shall remove/resolve the same satisfactorily at his cost and risk.

4.3.2 The Contractor shall at all times take all reasonable precautions to prevent

any unlawful, riotous or disorderly conduct by or amongst his staff and

labour and to preserve peace and protection of persons and property in

the neighbourhoods of the Works against such conduct.


Page 8 of 24

4.4 Employment of Local Labour

4.4.1 The Contractor shall ensure that local labour skilled and / or unskilled, to

the extent available shall be employed in this work. In case of non –

availability of suitable labour in any category out of the above persons,

labour from outside may be employed.

4.4.2 The Contractor shall not recruit personnel of any category from among

those who are already employed by other agencies working at site but

shall make maximum use of local labour available.

4.5 Site Cleaning

4.5.1 The Contractor shall clean and keep clean the work site from time to time

to the satisfaction of the Engineer-in-Charge for easy access to work site

and to ensure safe passage, movement and working.

4.5.2 The Contractor shall dispose off the unserviceable materials, debris etc., to

the earmarked area within the premises or any other location outside the

premises as decided by the Engineer-in-Charge. No extra payment shall be paid

on this account.

4.5.3 Review/Approval of Drawings, Design and other documents submitted by

Contractor

4.5.3.1 HPCL/consultant will normally require and utilize a maximum time frame of seven

(07) working days from the date of Receipt for Review/Approval of Drawings,

Design and other documents submitted by Contractor. Upon Review of the

submitted documents, HPCL may give their comments and ask for redesign/

resubmission after necessary rectifications/ modifications and the time frame of

7 working days will be applicable for same.

4.6 Protection of Existing Facilities

4.6.1 Contractor shall obtain all clearance (work permit) from the Owner, as may

be required from time to time, prior to start of work. Work without

permit shall not be carried out within the existing premises.


Page 9 of 24

4.6.2 Contractor shall obtain plans and full details of all existing and planned

facilities/services/utilities from the Owner and shall follow these plans

closely at all times during the performance of work. Contractor shall be

responsible for location and protection of all facilities/utilities and

structures at his own cost.

4.6.3 Despite all precautions, should any damage to any structure / utility etc. occur,

the Contractor shall contact the Owner / authority concerned and

Contractor shall forthwith carry out repair at his expenses under the

direction and to the satisfaction of Engineer-in-Charge and the

Owner/concerned authority.

4.6.4 Contractor shall take all precautions to ensure that no damage is caused

to the existing facilities etc., during construction. Existing

structures/facilities/utilities damaged / disturbed during construction shall be

repaired and restored to their original condition by Contractor after

completion of construction to the complete satisfaction of Owner.

4.7 Work Front

4.7.1 The work involved under this Contract may include such works as

have to be taken up and completed after other agencies have completed

their jobs. The Contractor will be required and bound to take up as and

when the fronts are available for the same and no claim of any sort

whatsoever shall be admissible to the Contractor on this account. Only

extension of time limit shall be admissible, if the availabilities of work

fronts to the Contractor are delayed due to any reason not attributable to

the Contractor and the same is clearly recorded.

4.8 Site Facilities

4.8.1 The Contractor shall arrange for the following facilities at site, for workmen

deployed/engaged by him / his sub-contractor, at his own cost:

i) Arrangement for First Aid.

ii) Arrangement for clean & potable drinking water.

iii) A crèche where 10 or more women workers are having children below

the age of 6 years.

iv) Any other facility/utility as may be required under the Contract as per the

existing legislation/regulations.


Page 10 of 24

4.9 Contractor’s Site Office and Stores

4.9.1 Owner shall provide land only for contractor’s site office and stores and

fabrication yard, if any at site. However, same shall be dismantled prior to

submission of Final Bill.

4.9.2 The Contractor shall remove all temporary buildings / facilities etc., before

leaving the site after completion of works in all respect.

4.10 Construction Power and Water

4.10.1 Owner shall not provide power and the Contractor shall be exclusively

responsible to make his own arrangements for supply of power, without

any extra cost to the Owner.

4.10.2 Water required for the works shall be arranged by the Contractor. The

contractor has to make all necessary arrangement for drawing water

including making temporary storage, pumping etc.

4.10.3 CEMENT:

Cement required for execution of the job under the entire scope of work (other

than for Ready Mix Concrete where the cement is from the RMC manufacturer

scope) contained in this tender shall be supplied at provided at site by the

contractor at his own cost. Contractor to include the cost of cement required

for execution of various items included in this tender in their quoted rates.

Cement shall be of 43 / 53 Grade OPC as specified in the technical specifications

of Ultra Tech Cement/ Gujarat Ambuja / ACC / Birla / Lafarge Makes only and

shall conform to IS relevent standards of latest edition. Contractor to produce

Invoice Copy of every batch of cement procured at site to EIC. However, HPCL’s

decision with regard to the specific brand of cement to be procured for the

execution of the work shall be final and binding on the contractor.

Cement shall be procured and brought to site atleast 15 days in advance.

Sample from every batch of cement brought to site shall be tested for standard

test as per the specification of relevant IS standards in approved Laboratory and

Test Certificate shall be submitted to EIC for verification. Only after obtaining

approval of EIC, cement shall be put into use. Manufacturer’s Batch Test

Certificates backed by Factory’s Invoice for the batch will also be acceptable for

approval of cement. Contractor shall bring cement well in advance before full


Page 11 of 24

consumption of previous lot. No claims for extension of completion period for

stoppage of work on account of non-availability of cement / delays is testing

procedures will be entertained/accepted by HPCL.

For all computation purposes, the theoretical cement consumption shall be

considered as per CPWD standards. Cement cost shall be recovered for under-

consumption at the penal rate of Rs.7000/- per MT. Empty cement bag shall be

the property of the contractor. Theoretical weight of cement in a bag will be

considered as 50 Kgs. Bags weighing upto 4% less shall be accepted by HPCL.

Any shortage in weight of any cement bag by more than 4% will be to

contractor’s account. Contractor shall maintain necessary weighing scale at site

for the purpose of random checking of the weight of cement bags by

representative of HPCL.

The contractor will be required to maintain a stock register for receipt, issuance

and daily consumption of cement at site. Cement shall be regulated on the basis

of 1st receipt to go as 1st issue. Cement not consumed within 3 months after

bringing to site shall not be used and shall be removed from site with prior

written permission of EIC.

All RA bills including the final bills will be accompanied by Cement Consumption

Statements giving the detailed working of cement used.

Contractor shall construct suitable temporary godown at site for storage of

cement under his lock and key. The contractor will be fully responsible for safe

custody of cement.

HPCL will not entertain any claims by the Contractor for theft, loss or damages to

cement. Contractor shall not remove from the site any cement bags at any time.

Permissible wastage shall be total 3% of the theoretical consumption. However,

these wastage shall be considered in excess of the theoretical quantity required

for the various items of work. No extra payment will be made towards this

wastage and the same will be in the contractor’s account. The contractor shall

be penalised for any under-consumption of cement at the rate of Rs7000/- per

MT.

4.10.4 STEEL:

Entire quantity of reinforcement / structural steel required for the project shall

be supplied and provided at site by the contractor at his own cost. Contractor

to include the cost of steel reinforcement / structural steel required to be used

against various items of this scope of work in their quoted rates. HPCL shall not

supply any reinforcement / structural steel. The contractor shall make necessary


Page 12 of 24

arrangement at his own cost for unloading, storage of steel in the open duly

fenced under locking arrangement. The reinforcement steel shall be procured

from Tata/SAIL/Vizag Steel/Jindal and will produce invoice for the same to EIC

for every batch of procurement alongwith Manufacturer’s Test Certificate.

In the case of steel reinforcement or structural steel the theoretical quantity of

steel shall be taken as the quantity required as per design or as authorised by

Architect/Consultant /HPCL’s Engineer including authorised lap lengths/chairs

etc. No further claim towards additional wastage due to lap length / full length

bars or other consideration including rolling margin will be entertained. No

payment will be made or measurement recorded for binding wires which shall

be of 18 SWG gauge and shall be provided by the contractor.

For the purpose of dealing and accounting, only linear measurements will be

taken and any difference in weight based on linear measurement and actual

weight shall be to contractor’s account. Quoted rate shall be deemed to include

the above and the wastage mentioned below. No claim whatsoever shall be

entertained on account of wastage and difference in weight as referred to

above.

All binding wires required for tying the reinforcement in position etc. will be

supplied by the contractor. Cost of this binding wire and labour will be included

in the item for binding and placing reinforcement in position.

It will be necessary that the contractor get the steel tested at his own cost at a

Govt. approved laboratory as per the testing schedule or as per the EIC’s advise,

for strength and other properties specified in IS – 1786 latest editioin before

using it in the work.

The contractor will be required to maintain a register for recording details of

steel receipt, steel utilised and balance at site.

Final bill will be accompanied by steel consumption statement.

In every case, it shall be the contractor’s responsibility to ensure the standard of

quality and the correctness of quantity of steel procured at site by him.

The permissible wastage (wastage defined as bars having less than 3 mt. Length)

shall be of 3% of theoretical consumption. Recovery for less consumption as per

theoretical consumption will be recovered at Rs.50,000/- per MT. All scrap

(scrap defined as pieces of steel bars measuring less than 3 mt. in length) shall be


Page 13 of 24

the property of the contractor. The wastage quantity shall not be considered to

be included within the theoretical quantity and no extra shall be payable on

account of wastage.

4.11 Construction

4.11.1 Rules and Regulations

4.11.2 Contractor shall observe in addition to Codes specified in respective

specification, all national and local laws, ordinances, rules and regulations

and requirements pertaining to the work and shall be responsible for extra

costs arising from violations of the same.

5.0 Procedures

5.1 Various procedures and method statements to be adopted by Contractor

during the construction as required as per the respective specifications

shall be submitted to Engineer-in-Charge in due time for approval.

5.2 Security

5.2.1 As the premises will be protected area, entry into the area shall be

restricted and may be governed by issue of photo gate passes. The

Contractor shall arrange to obtain through the Engineer-in-Charge, well in

advance, all necessary entry permits/gate passes for his staffs and labourers

and entry and exit of his men and materials shall be subject to vigorous

checking by the security staff. The Contractor shall not be eligible for any

claim or extension of time whatsoever on this account.

5.2.2 It shall be the responsibility of the contractor to safeguard all his

materials/owned from theft, damage etc. For this purpose the contractor shall

be allowed to keep his own security inside HPCL premises

5.3 Drawings and Documents

5.3.1 Drawings accompanying the Bidding Document are indicative of scope of

work and issued for bidding purpose only. Purpose of these drawings is to


Page 14 of 24

enable the bidder to make an offer in line with the requirements of the

owner.

5.3.2 The contractor as per ‘scope of work’ shall carry out preparation of detailed

and working drawings. Detailed construction layout drawings as needed

shall be prepared by contractor and got reviewed/approved by Engineer-in-

Charge/Architect before taking up the work.

5.4 Rounding off

5.4.1 All payments to and recoveries from the Contractor shall be rounded off to

the nearest rupee. Wherever the amount to be paid / recovered consists of

a fraction of a rupee (paise), the amount shall be rounded off to the next

higher rupee if the fraction consists of 50 (fifty) paise or more and if the

faction of a rupee is less than 50 (fifty) paise, the same shall be ignored.

5.5 Contractor’s Billing System

5.5.1 HPCL will provide an approved format for Measurement sheets, Bill Summary and

Bill Abstract. Contractor has to ensure that these data are updated for each

subsequent RA and Final Bill.

5.5.1 HPCL will utilize these data for processing and verification of the

Contractor’s bill.

5.6 Site Organization

5.6.1 The Contractor shall without prejudice to his overall responsibility to

execute and complete the works as per specifications and time schedule

progressively deploy adequate qualified and experienced personnel together

with skilled / unskilled manpower and augment the same as decided by

Engineer-in-Charge depending on the exigencies of work to suit the

construction schedule without any additional cost to Owner.

5.6.2 The Contractor shall provide all necessary superintendence during the

execution of the Works and as long thereafter as the Engineer-in-Charge

may consider necessary for the proper fulfilling of the Contractor’s

obligations under the Contract Such superintendence shall be given by


Page 15 of 24

sufficient persons having adequate knowledge of the operations to be

carried out (including the methods and techniques required, the hazards

likely to be encountered and methods of preventing accidents) for the

satisfactory and safe execution of the Work. The workmen deployed by

the Contractor should also possess the necessary license etc., if required

under the existing laws, rules and regulations.

5.7 Additional / Extra Works

Owner reserves the right to execute any additional works / extra works,

during the execution of work, either by themselves or by appointing any other

agency, even though such works are incidental to and necessary for the

completion of works awarded to the Contractor.

5.8 Responsibility of Contractor

5.8.1 It shall be the responsibility of the contractor to obtain the approval for

any revision and/or modifications decided by the contractor from the

Owner / Engineer-in-Charge before implementation. Also such revisions and /

or modifications if accepted / approved by the Owner / Engineer-in-Charge

shall be carried out at no extra cost to the owner. Any change required

during functional requirements or for efficient running of system, keeping

the basic parameters unchanged and which has not been indicated by the

contractor in the data / drawings furnished along with the offer shall be

carried out by the contractor at no extra cost to the owner.

5.8.2 All expenses towards mobilization at site and demobilization including

bringing in equipment, work force, materials, dismantling the equipment,

clearing the site etc. shall be deemed to be included in the prices quoted

and no separate payments on account of such expenses shall be

entertained.

5.8.3 It shall be entirely the contractor’s responsibility to provide, operate and

maintain all necessary construction equipment, steel scaffoldings and safety

gadgets, cranes and other lifting tackles, tools and appliances to perform

the work in a workman like and efficient manner and complete all the

jobs as per time schedule.

5.8.4 Preparing approaches and working area for the movement of his men and

machinery.


Page 16 of 24

5.8.5 The procurement and supply in sequences and at the appropriate time of

all materials, and consumables shall be entirely the contractor’s

responsibility and his rates for execution of work will be inclusive of

supply of all these items.

5.9 Coordination with other agencies

5.9.1 Contractor shall be responsible for proper coordination with other agencies

operating at the site of work so that work may be carried out

concurrently, without any hindrance to others. The Engineer – in – Charge

shall resolve disputes, if any, in this regard, and his decision shall be final

and binding on the Contractor.

5.10 Underground and overhead structures

5.10.1 The Contractor will familiarize himself with and obtain information and

details from the Owner in respect of all existing structures, and utilities

existing at the job site before commencing work. The Contractor shall

execute the work in such a manner that the said structures, utilities, etc.

are not disturbed or damaged, and shall indemnify and keep indemnified the

Owner from and against any destruction thereof or damages thereto.

5.11 Documents required with final bill

5.11.1 Statement of final bills – issue of No Claim/ No Due Certificate

5.11.2 The Contractor shall furnish a No-Claim/No-Due declaration indicating that there

are no balance dues to his sub-vendor/sub-contractors/labour contractors along

with the Final Bill.

5.12 Working hours

5.12.1 Depending upon the requirement, time schedule / drawing/ programme

and the target set to complete the job in time, the works may also have

to continue beyond normal working hours/night hours / holidays or during

such periods with out causing any inconvenience to the neighbours/others with

due permission from EIC, for which no extra claim shall be entertained.


Page 17 of 24

However for all such working contractor’s responsible representative shall be

available at site to receive the work permit to be issued by HPCL. With out

responsible representative of the contractor, no work shall be allowed inside the

premises.

6.0 TESTS, INSPECTION AND COMPLETION

6.1 Tests and Inspection

6.1.1 The Contractor shall carry out the various tests as enumerated in the

technical specifications of this Bidding Document and technical documents

that will be furnished to him during the performance of the work at no

extra cost to the Owner.

6.1.2 All the tests either on the field or at outside laboratories concerning the

execution of the work and supply of materials by the Contractor shall be

carried out by Contractor at his cost.

6.1.3 The work is subject to inspection at all times by the Engineer-in-Charge.

The Contractor shall carry out all instructions given during inspection and

shall ensure that the work is being carried out according to the technical

specifications of this bidding document, the technical documents that will

be furnished to him during performance of work and the relevant codes of

practice.

6.1.4 Compressed air for carrying out works ,if required shall be arranged by the

Contractor at his own cost.

6.1.5 For material supplied by Owner, Contractor shall carry out the tests, if

required by the Engineer-in-Charge, and the cost of such tests shall be

reimbursed by the Owner at actual to the Contractor on production of

documentary evidence.

6.1.6 All results of inspection and tests will be recorded in the inspection

reports, proforma of which will be approved by the Engineer-in-Charge.

These reports shall form part of the completion documents. Any work not

conforming to execution drawings, specifications or codes shall be rejected

and the Contractor shall carry out the rectifications at his own cost.


Page 18 of 24

6.2Final Inspection

After completion of all tests as per specification the whole work w ill be subject to a

final inspection to ensure that job has been completed as per requirement.

If any defect is noticed, the Contractor will be notified by the Engineer-in-

Charge and he shall make good the defects with utmost speed. If

however, the Contractor fails to attend to these defects within a

reasonable time (time period shall be fixed by the Engineer-in-Charge) then

Engineer-in-Charge may have defects rectified at Contractor’s cost.

6.3 Inspection of Supply Items

6.3.1 All inspection and tests on bought out items shall be made as required by

specifications forming part of this contract. Various stages of inspection

and testing shall be identified after receipt of Quality Assurance

Programme from the contractor / manufacturer.

6.3.2 Inspection calls shall be given for association of Owner , as per

mutually agreed programme in prescribed proforma , giving details of

equipment and attaching relevant test certificates and internal inspection

report of the contractor. All drawings, general arrangement and other

contract drawings, specifications, catalogues etc. pertaining to equipment

offered for inspection shall be got approved by Owner and copies shall be

made available to Owner before hand for undertaking inspection.

6.3.3 The contractor shall ensure full and free access to the inspection

engineer of Owner at the contractor’s or their sub-contractor’s premises at

any time during contract period to facilitate him to carry out inspection

and testing assignments.

6.3.4 The contractor / sub – contractor shall provide all instruments, tools,

necessary testing and other inspection facilities to inspection engineer of

Owner free of cost for carrying out inspection.

6.3.5 Where facilities for testing do not exist in the contractor’s / sub-

contractor’s laboratories, samples and test pieces shall be drawn by the

contractor / sub-contractor in presence of Inspection Engineer of Owner and

duly sealed by the later and sent for tests in Government approved test


Page 19 of 24

house or any other testing laboratories approved by the Inspection

Engineer at the contractor’s cost.

6.3.6 The contractor shall comply with the instructions of the Inspection

Engineer fully and with promptitude.

6.3.7 The contractor shall ensure that the equipment / assemblies /

component of the plant and equipment required to be inspected are not

assembled or dispatched before inspection.

6.3.8 The contractor shall not offer equipment for inspection in painted

conditions unless otherwise agreed in writing with the Owner .

6.3.9 The contractor shall ensure that the parts once rejected by the

inspection engineer are not used in the manufacture of the plant and

equipment. Where parts rejected by the inspection engineer have been

rectified or altered, such parts shall be segregated for separate inspection

and approval, before being used in the work.

6.3.10 On satisfactory completion of final inspection and testing, all accepted

part of the work and equipment shall be stamped suitably and inspection

certificate shall be stamped suitably and inspection certificate shall be

issued in requisite copies for all accepted items. For stage inspection and

for rejected items, only inspection memo shall be issued indicating therein

the details of observations and remarks.

6.3.11 All inspections and tests shall be made as required by the

specifications forming part of this contract. Contractor shall advise HPCL in

writing at least fifteen days in advance of the date of final inspection /

tests. Manufacturers inspection or testing certificate for equipment and

materials supplied may be considered for acceptance, at the discretion of

Engineer-in-Charge. All costs towards testing etc. shall be borne by the

contractor within their quoted rates.

6.4 Documentation

6.4.1 Completion Documents

The following documents shall also be submitted by the Contractor in

triplicate as part of completion documents :


Page 20 of 24

a) Test certificate for materials supplied by the Contractor.

b) Certified records of field tests on materials / equipment, as applicable.

c) Material appropriation statement as required.

d) Six sets of drawings showing therein the as built conditions of the

work duly approved by the Engineer-in-Charge along with one set of

reproducible on polyester film (drawings prepared by Contractor)

along with soft form of the same.

e) Other documents as mentioned in Technical Specification.

6.4.2 “AS BUILT” Drawings

Upon completion of work, the Contractor shall complete all drawings to

“As built” status (including all vendor / Sub – vendor’s drawings for

bought out items) and provide the Owner, the following :

a. One complete set of all original tracings / reproducible along with the

soft form of the same.

b. Six complete sets of prints.

7.0 OTHERS

7.1 Dispute Settlement between Govt. Dept. / PSU & PSE

7.1.1 In the event of any disputes or differences between the Contractor and the

Owner, if the Contractor is a Government department, a Government

company or an undertaking in the public sector, then such disputes or

differences shall be resolved amicably by mutual consultation or through

the good offices or empowered agencies of the Government. If such

resolution is not possible, then the unresolved disputes or differences shall

be referred to arbitration of an arbitrator to be nominated by the

Secretary. Department of legal affairs (Law Secretary) in terms of the

Office Memorandum No. 55 / 1 / 75 – CF dated 19th

December 1975 issued

by the Cabinet Secretariat (Dept. of Cabinet Affairs) as modified from time

to time. The Arbitration Conciliation Act 1996 shall not be applicable to

the arbitrator under this clause. The award of the arbitrator shall be

binding upon parties to the dispute, provided, however any party aggrieved

by such award may make a further reference for setting aside or revision


Page 21 of 24

of the award to Law Secretary whose decision shall bind the parties finally

and conclusively.

7.2 Project Scheduling and Monitoring

7.2.1 The following schedules / documents / reports shall be prepared and

submitted by the CONTRACTOR for review / approval at various stages of

the contract.

7.2.3 After placement of Purchase Order

Upon placement of Purchase Order, Contractor has to furnish a detailed bar

chart within 15 days of issue of FOI/LOI.

7.2.4 Project Review Meetings

7.2.4.1 The CONTRACTOR shall present the programme and status at various review

meetings as required.

Monthly Review Meeting

Level of Participation:Senior Officers of Owner & Contractor.

Agenda a)Progress Status/ statistics. .

b) Completion Outlook

c) Major hold ups / slippages.

d) Assistance required.

e) Critical issues.

f) Client query / approval.

Venue : Site

7.2.5 Progress Reports

I) Monthly Progress Report


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This report shall be submitted in three copies on a monthly basis

within Ten calendar days from cut-off date as agreed upon, covering

overall scenario of the work. The report shall include but not be

limited to the following :

a) Brief introduction of the work.

b) Activities executed / achievements during the month.

c) Scheduled vs actual percentage progress and progress curves for

sub-ordering, manufacturing / delivery, sub-contracting, construction

activities and overall quantum wise status of purchase orders against

scheduled.

d) Areas of concern / problems / hold ups, impact and action plans.

e) Resource deployment status.

f) Annexure giving status summary for Material Requisitions and

deliveries, sub-contracting and construction

Distribution: OWNER Two copies & One at Site.

II) Daily Report:

Daily report in duplicate as out lined in 2.2.4 of SCC and any other additional

information/data/guideline/job procedure sought by Engineer-in-Charge shall be

submitted without fail to HPCL at site by contractor.

7.3 General Environment Requirement

The contractor has to ensure efficient use of natural resources like water,

fuel oil and lubricants. The contractor should ensure proper awareness to

workers to maintain a green and clean environment inside / outside the

building premises. The contractor must collect and dispose of all the waste

and scrap materials at the designated place only as directed by Engineer – in

– Charge.

7.4 DEFECT LIABILITY PERIOD/Warranty Period

As per clause No. 5n of GTC.

7.5 Form C/D etc will not be issued by M/s HPCL


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APPENDIX -1 TO SCC

TERMS OF PAYMENTS

1.1 The basis and terms of payment without prejudice to any other mode of

recovery available to Owner, shall be as given below :

1.2 The Contractor shall be paid monthly running account bills at stages of

completion of individual item / work, based on the joint measurement, in

the following manner after deductions of necessary dues payable by

Contractor to the Owner such as Retention money, Taxes, Duties etc. in

accordance with various provisions made elsewhere in this document.

1.3 SPECIAL PAYMENT TERMS

Following payment shall be made to the contractor against the running bills

subject to the rate awarded to him and the clause regarding retention money as

per general terms and conditions.

1. Plate Work :(Item nos9 to 11)

30 % after Fabrication

25 % after erection & welding,

10% after radiography

30 % after hydro-testing

5% after Completion and acceptance by HPCL as pr SOR

2. Structural Steel Works/Grating: (Item Nos 12 to20)

50 % after supply of material at site

15 % after fabrication

20 % after erection/welding/bolting

10% after painting

5% after Completion and acceptance by HPCL as per SOR

3. Mechanical Shoe Seal (Primary) & Secondary Seal ( item no43)


25 % after installation.

5 % aftercompletion and acceptance by HPCL as per SOR


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4. Central Roof Drain – Unbonded flexible pipe( item No:34)


25 % after installation.

5 % after Completionand acceptance by HPCL as per SOR

5. For all the remaining items

95% after completion of the job

5% after completion and acceptance by HPCL as per SOR

NOTES :

1.For Each stage, necessary testing shall be completed prior to claiming the

percentage break-up as given above

2. Partial bill will be processed only after submission of duly certified copy of

proof of payment towards royalty.

3. Final bill will be processed only after submission of “No objection certificate”

from relevant statutory authorities towards payment of royalty.

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Page 1 of 27

GENERAL SCOPE OF WORK

FOR TANKS

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Page 2 of 27

1.0 SCOPE OF WORK

1.1. Contractor’s Scope of Work :

The scope of work for Contractor shall include the following but not limited to the same. The scope of work shall also include other items / works required to complete the work in all respects as per specifications, standards, drawings, IS codes/API Standards & instructions of HPCL whether specifically mentioned or not in the tender document :

i) Design, Fabrication, Erection, Welding including welding Procedure & welder

qualifications and welding all the joints in accordance to respective WPS, marking etc as per API 650 for the tanks as given in Annexure1 is completely in the Contractor’s Scope of Work.

ii) Preparation of all detailed and working drawings including plate cutting

diagrams for various components of storage tanks & getting the same reviewed and approved by HPCL prior to commencement of work. No work will commence without HPCL’s approval on drawing by Engineer in Charge.

iii) Preparation, Submission for Review and obtaining approval from HPCL for

Detailed Quality Assurance System plans/ procedures developed by contractor basis Std. Inspection & Test Plan furnished in this tender/ Scope of work/SOR/GTCC/SCC & other relevant codes. The same shall be reviewed / approved by HPCL prior to commencement of work. The required competent man power, machinery, tools, tackles, equipments, etc required to execute the work as per the Approved Quality assurance plan (QAP) shall be the responsibility of contractor. Due records will be maintained by contractor through out the work period as per instructions of Engineer-in- Charge.

Vii) Time is the essence of this contract. Monthly/weekly Execution Plans will be developed by Contractor in consultation with Engineer- in- Charge & execution of work as per these plans will be the sole responsibility of contractor. Scheduling & Monitoring of awarded work is the SOLE RESPONSIBILITY of contractor, in this regards rates quoted shall include following:

1. Kick off Meeting shall be planned by contractor within SEVEN DAYS from date of LOI.

2. Contractor shall submit DETAILED BAR CHART/RESOUCE PLAN/MICRO SCHEDULING ACTIVITY WISE giving earliest & latest date with back up calculation of Man –Power, Machinery, Consumables,, etc for HPCL’s approval for Tankage Work All the queries on matter suggested by HPCL will be complied on mutual discussion basis & Final Detailed Bar Chart will be made implemented within Fifteen days from date of LOI.

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Page 3 of 27

3. Contractor will provide his authorized nominee at site to take participation in weekly meeting & to sign the Records of Meeting.

4. Contractor will submit on daily basis Progress Report to be generated at site in E Form through E- Mail @ the address provided by HPCL giving all the details including valid reasons for delay if any vis-à-vis to commitment i.e. weekly plan /monthly plan /approved bar chart in prescribed format approved by HPCL.

5. Contractor to submit procurement plans for various item falling under their scope to supply under this tender along with Bar Chart vide point Vii 2.

iv) (A) Submission of Design calculations of TANK AS PER RESPECTIVE standards in detail for review by EIL or IIT, Kharagpur or equivalent as approved by HPCL and thereafter, approval by HPCL. The document shall be first submitted to HPCL and same shall be forwarded by HPCL to EIL or IIT or any other approved institution by HPCL. The charges for vetting of design by EIL or IIT, Kharagpur shall be borne by the Contractor. It shall be the sole responsibility of the Contractor to prove these design calculations details while conducting the Test to HPCL Engineer in toto. Contractor shall also carry out design calculations as per API 650 & other relevant codes for Shell, Bottom plates incl. annular sketch plate, wind girder, stability against wind & seismic movement, Brackets for Top Wind Girder /Plate form, Brackets for Sprinkler & Foam Pipe etc

v) Procurement & Supply of materials & consumables as indicated in contractor’s scope of supply.

vi) Loading, transportation and handling of all free issue materials from Owner’s stores to work site/ Contractor’s store and fabrication yard as applicable including supply of all necessary tools, tackles, transportation and handling equipments, etc.

vii) Stripping/Removal of vegetation for fabrication yard at Site.

viii) Welding procedure & Welder qualification :

1. Welding Procedure Specifications for all the Weld Joints to be made in field for Bottom, Shell & Roof along with all other type of joints shall be prepared by contractor as per QW-482 Suggested Format for WPS in ASME Sect.IX. (Sample Joint design QW 402 for various joint is attached in Tender Document). The same will be vetted/certified by HPCL approved Third Party like IRS, BV, TUV etc. The weld joints will be made in accordance to respective approved WPS only.

2. QW-483 i.e. Procedure Qualification records (PQR) as per ASME Sect IX to be

performed in accordance to API 650 with required lab test on test piece in supervision of HPCL Engineer & approved Third Party like IRS,BV,TUV etc. PQR document duly vetted / certified by Third Party shall be submitted to HPCL.

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Page 4 of 27

3. QW 484 ASME Sect.IX Welding Operator Performance Qualification will be

conducted in presence of HPCL Engineer and HPCL approved Third Party like IRS, BV, TUV etc.. at site. After due testing of Test Piece like radiography etc WOPQ duly certified by Third party will be submitted to HPCL for all proposed deployed welding operators.

4. Contractor shall submit proposed number of radiographs shots as per API 650

along with procedures for undertaking shots on the drawing i.e. operating with required due safety /Health/Environment precautions and Film review norms in accordance to API 650, ASME IX & respective other standards duly vetted by HPCL approved Third Party to enable HPCL to direct for Shots.

5. FILMS will be reviewed & vetted by HPCL approved Third Party. HPCL will witness the process randomly.

6. All the third party charges shall be borne by the contractor. No separate payment will be made on this account.

ix) Supply, Fabrication and erection of various shell appurtenances and

nozzles.

x) SHELL ERECTION & DISMANTLING SHALL BE STRICTLY BY JACKING UP METHOD. Required Load Calculation shall be submitted & prior HPCL’s approval shall be taken. For safety reasons test certificate for fitness of equipments & accessories shall be submitted. Min. one Jack per Three Metre circumferentially shall be provided. Plates shall be made after removal of Jacks to it’s original thickness to the best satisfaction of HPCL.The Load calculations and Test certificate for fitness of the equipments shall be vetted by approved third party agency and the charges towards the same shall be borne by the contractor.

xi) Supply, Fabrication and erection of Inlet and outlet troughs for Inlet and

Outlet nozzles.

xii) Design, Fabrication, Erection and testing of External single deck floating roof (EFR)and its components with foam dam and its accessories including pipe supports & appurtenances including welding on underside.

xiii) Design, Fabrication, Erection and testing of Fixed Cone roof tanks with self

supporting(FR) truss and its components with necessary sprinkler/foam appurtenances etc and its accessories.

xiv) Design, Fabrication, Erection and testing of Open roof tanks appurtenances

etc and its accessories.

xv) Supply, Fabrication and erection of various Roof appurtenances and nozzles.

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Page 5 of 27

xvi) Conducting Floatation test for the roof (EFR & IFR)

xvii) Procurement, Third party Inspection, supply, installation and testing of

primary roof drains of Flexible Hose Pipe type with associated rigid piping sections, if any and brass non return valve including shell nozzles for roof drain extension piping (from gate valve to storm water drain) along with gate valve, support& foundation of roof drain etc including supply of all materials. The Flexible roof drain shall be manufactured by( A) Coflexip (Flexi France) / ( B) Well stream Holding Plc U.K / (C) NKT Flexible Denmark.(D) Pivot master (E) MESA

xviii) Design and its vetting/ Review and approval by HPCL, procurement, supply,

fabrication, erection, testing, & commissioning of Sprinkler/Foam system complete in all respects, structural supports for Foam cooling system risers, etc.

xix) Design and its vetting/ review and Approval, procurement, Third party

Inspection, supply & installation of Primary shoe seal and Secondary seals floating roof tanks s with all components and accessories etc as per manufacturer’s instructions.

xx) Supply & fabrication of stairways, handrails, landing platforms, curb angle,

bracing for foam dam, structural supports for primary wind girders.

xxi) Supply, fabrication, installation and testing of various roof appurtenances for Single and Double Deck Pontoon Type for both External and internal floating roof & Fixed Cone Roof Self supported.

xxii) Supply, fabrication & erection of Gauge hatch with still well, still wells for

level transmitters, level switch & temperature instruments etc and Gauge socks.

xxiii) Supply, fabrication & erection of earth connection as per respective IS code.

Xxvi) Radiography / DP / Diesel chalk/ Vacuum box test/ any other test on various

components of tanks as per Specifications of this Tender document, requirements of API standard & instructions from Engineer-in-Charge. Additionally, all Horizontal and vertical Shell joints including extensions above the Maximum Design Liquid Level shall be Dye Penetrant Tested after Root Run and necessary repairs carried out as per HPCL’s instructions. All radiography Films shall be reviewed by a HPCL approved Third Party Inspection Agency.

xxvii) Calibration of tanks and getting approval from Weights & Measure department using contractor’s own tape,tools ,tackles etc.

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xxviii) Carrying out hydrostatic / water fill up test in accordance to OISD 129/ Standard Specifications of this Tender & keeping the records for same, pneumatic , vacuum & other test as specified in code/ specifications & as per requirements of Engineer-in-Charge using contractor’s own equipment. Fixed cone Roof leak proof test as per code/specifications.

xxix) Pontoon Leak proof test by air @ 20mm water column as directed by HPCL

& deck weld joints with Vaccum Box Methods. Floating Roof Joints like joining of Pantoon & deck which can not be tested by Vaccum Box Method shall undergo DP test for Root Run . Puncture Test or Satisfying design condition by filling the quantity of water on deck / & pantoon shall be carried out successfully to establish the design.

xxx) Accomplishment of any other item of work required to make the storage

tanks ready for commissioning and as per instruction of Engineer-in- Charge.

xxxi) Assistance to HPCL for commissioning of the tanks including supply of manpower, supervision, labour with all required tools and spares. This commissioning assistance shall extend upto 24 hrs beyond completion of first Pump-in of product in to the tanks.

xxxii) Supply of all equipment, machineries, tools, tackles etc, labour and

supervision of all works at site.

xxxiii) Clean-up job at site for all surplus material, debris, scrap, construction equipment etc as per direction of Engineer-in – charge.

xxxiii) Reconciliation of free issue steel / material and returning excess plates, off

cuts and scrap as per direction of Engineer-in – charge. xxxiv) Supply of Power required for the job shall be the responsibility of the

Contractor & will be in his scope. HPCL will not give any connection from their existing electrical system.

xxxv) Complying & meeting all the safety rules & regulations as per standards &

instructions of Engineer- in – Charge will be the sole responsibility of contractor.

xxxvi) Supply of all required materials, supplying and providing /Double scaffolding

wherever required, Carrying out Grit blasting and surface preparation, primer and finish painting.

xxxvii) Quoted rates for work to include deployment of Qualified Quality Control

Engineer/Safety Engineers at site right from starting date whose responsibility is to prepare all the Quality control/Safety records as sought in PO, relevant to work, relevant codes, and other requirements to ensure full

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compliance on quality/Safety during execution as guided by HPCL. The suggested formats for QC re cords for Civil Foundation & Tankage work attached with this section i.e scope of work.

xxxviii) The work will be performed as outlined in Standard Inspection Test Plan for

Tank Fabrication(ITP) in the tender document/ developed by contractor basis this Tender document duly approved by HPCL. This ITP can undergo revision at the sole discretion of HPCL Engineer- in – Charge to meet the on- going practical scenario at site while execution and to improve the quality of work. Job Methodology will be prepared by contractor for items as sought by HPCL for proper execution & quality of Work.

xxxix) Material handling arrangement i.e MS Plate, Sand, Sand asphalt mix

movement etc at site has to be properly & effectively designed by contractor . The same shall be got approved from HPCL prior to work commencement. The rates quoted shall be inclusive of this. HPCL will not allow to change/ amend/break any other existing facilities construced/under construction.

xl) Supply of Gauge Hatch & Leg Support Sacks, Liquid mounted Mech Shoe

Seal as per attach specifications.

xli) Contractor will have to make all necessary arrangement for water requirement for the entire job. After Hydro test & First Test water shall be disposed off by Contractor in an un-objectionable manner to HPCL , Statutory Authorities like PCB etc & it’s neighbors in unobjectionable manner at his cost & efforts. The tank shall be washed with sweet water by contractor at no extra cost to HPCL before commissioning.

SCOPE OF SUPPLY

2.1 OWNER’S SCOPE OF SUPPLY 2.1.1 Subject to the provisions mentioned elsewhere in the tender document, HPCL

will issue the following materials free of charge from Stores at Site for the Steel plates IS2062 of regular width & Length required only for the following components of the tanks:

- Bottom: Annular Ring & Sketch plates - Shell - Shell extension for stairway and foam connection - Roof Plates for Self supported Fixed Cone Roof. - Internal and External Floating Roof: Pontoon Bottom & Top, Deck plates,

Outer & Inner Rim , Doubler plates, Bulk Head & foam dam and

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appurtenances. - RF Pads & bearing plates for floating roof pipe support, pontoon manhole

neck & cover plate. - Reinforcing pads for all shell openings and manholes.

-Top wind girder including extensions for stairways and plate stiffeners as applicable.

-Secondary wind girder as per design requirements of the tank s including plate gussets/ plate stiffeners.

-Tertiary wind girders as per design requirements of the tanks including plate gussets/ plate stiffeners

2.1.3)SCRAP/ CUTTING ALLOWANCES FOR OWNER’S FREE ISSUE

MATERIALS

The plates will be issued by HPCL to the Contractor on Theoretical weight basis. At the end of the work, Reconciliation shall be also done on theoretical weight basis only.

A Tabulated statement showing the size wise plates issued and Total

consumption will be prepared as per HPCL instructions. Based on the Total consumption in MT as a sum of individual sizewise consumption for a particular site, generation of maximum 2.7% Returnable accountable scrap is allowed. The Returnable Accountable scrap includes Offcuts and plates smaller than 2400mm perimeter. Offcut plates shall be of minimum perimeter 2400 mm generated as per approved cutting Schedules. Plates smaller than 2400mm in perimeter are also classified under Returnable Accountable Scrap. On an overall basis, the generation of accountable scrap shall be limited to 2.7% of total net consumption taken as a sum of net consumption for various sizes. However, the Contractor shall make an all out effort at the time of preparation of Drawings/ BOQ to limit the generation of Returnable Accountable Scrap to a minimum preferably less than 2.7%.It will be the responsibility of the Contractor to load, transport the accountable scrap, weigh at weighbridge including payment of weighbridge charges, return to HPCL Premises, Unloading and handing over to HPCL at their Storeyard/ scrap yard as per instructions of HPCL Engineer-in-Charge. Apart from Accountable Scrap, the Contractor shall be allowed a maximum of 0.30% of Burnout Losses.

In case, the actual generation of Returnable Accountable scrap on overall basis is higher than 2.7% or burnout losses being greater than 0.30% of Overall consumption(Theoretical tonnage), then HPCL shall effect recovery @ Rs. 60,000/= per MT for excess scrap generation and/or burnout loss. It shall be therefore the sole responsibility of the Contractor to plan the cutting

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schedule to control his scrap generation within above limits.

2.2 CONTRACTOR’S SCOPE OF SUPPLY

The procurement and supply in sequence and at the appropriate time of all materials and consumables including structural steel (Plates & sections) required for completion of works as per drawings, specifications and standards except the materials specifically listed in Cl.no 2.1 above shall entirely be the contractor’s responsibility. The items to be supplied by the contractor are in general but not limited to following:

A) All steel plates required for the components other than those listed in

Cl.2.1.1.

B) All consumables such as electrodes, filler wires, acetylene, grease, oil, gases, electricity etc.

C) All structural steel sections wherever required for curb angles, Top wind

girders Supports/stiffeners/ extensions for stairways, Top wind girder bracings, Secondary wind girders, supports for Fire water Cooling Spray Headers/ risers, supports for Foam system risers, spiral stairways, landings , platforms, handrails, bracing for foam dam, Inlet and Outlet Nozzle Troughs, Gratings(which may be fabricated by the Contractor at a workshop/ factory outside HPCL premises), stiffeners for Shell extension and supports for top platform, trusses for Roof ,INSULATION STUBS & RING ANGLES ETC.

D) All pontoon stiffeners for floating roof.

E) Rolling Ladder, internal ladders, hand rail for stairways, ladders,

platforms, etc.

F) All seamless pipes for nozzle necks 200mm NB and below, internal pipes, Nozzle necks for openings more than 200mm,Materials for Inlet/ Outlet Nozzle troughs, floating roof supports, bleeder vents, emergency drain, extension piping for roof drain, etc.

G) All pipe fittings, valves, flanges, matching flanges and blind covers wherever specified for all nozzles, stainless steel wire mesh for emergency

drain, brass items and brazing for Auto bleeder vents/legs

H)Repeatable lay pattern Flexible Hose Pipe type primary roof drain after Third Party Inspection with associated rigid piping sections, if any adequately supported on Bottom/ from deck underside, necessary shoes/ guards, etc as per Manufacturer’s instructions including brass non return valve, gate valve, extension piping. The Flexible roof drain shall be manufactured by ( A) Coflexip (Flexi France) / ( B) Well stream Holding Plc U.K / (C) NKT Flexible Denmark.

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I) Bolts, nuts and gaskets for roof & shell manholes, nozzles with blind cover/ matching flange, bolts & nuts for roof structure and other structural works.

J) Seals (Primary & Secondary) and weather protector, wherever applicable of approved make, guide rollers, roof stoppers, earthing cable, shunts etc. Seals shall be supplied after Third Party Inspection only.

L) Gauge Hatch with cover. Gauge Pipe/ Leg Support Sleeves. M) Pipes, fittings, flanges and bolts and nuts and spray Nozzles and orifice

plates and structural supports for Piping for Fixed water Cooling spray system.

N) Pipes, fittings, flanges, orifice plates, Foam makers/ Pourers and deflectors on point of spray on shell and structural supports for Piping for Foam system

O) GI Deflector plates including supporting arrangement required for cooling

system.

P) Internal Bolts & Gaskets. Q) Strapping tapes & accessories for calibration.

R) Radiographic Films & Consumables for NDT.

S) Earth connections, support cleats for pipes, structures & cables.

T) Any Blind flanges, valves, nipples, plugs, bolts, nuts, gaskets, etc required for

conducting hydrostatic testing and any other test required by HPCL. U) All primer materials and painting materials, scaffolding, Ferrous Grit and

related equipment for Painting. V) Aluminum/Brass plate for still well. W) Water required for the entire job including hydrotest

Note:

While every effort has been made to list all the supply items, it shall be the sole responsibility of the Contractor to review the list and seek clarifications, if any at the time of Unpriced Bid itself. HPCL undertakes to provide only Free Issue Steel plates for Fabrication and all the other items shall be supplied by the Contractor only. No claims/ disputes by the Bidder/ Contractor shall be entertained by HPCL at a later date.

3.0 DOCUMENTS / FABRICATION DRAWING DETAILS

The Contractor shall submit the detail fabrication drawings/ documents in the

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following sequence:

1. Drawing Index

2. General arrangement drawing of tank showing design data, basic dimensions, thickness, nozzle & internal parts.

3. Bottom and annular ring layout.

4. Shell plate layout showing location of nozzles & their distances from weld

seams.

5. Nozzle orientation on shell.

6. Details of wind girders.

7. Spiral stairway, ladder and platform.

8. Plate layout of Pontoon top & Bottom, Roof Deck, inner &outer rim , bulk heads for floating roof, floating roof support details, details of appurtenances on floating roof , detail along with design calculation.

9. Any other design calculations as per contract. 10. Orientation and details of nozzles on tank roof.

11. Details of shell & roof nozzles.

12. Details of tank internals like still wells, roof stoppers etc.

13. Details of Foam & Cooling System along with supporting calculations.

13. Details of Rim Seals (Primary & Primary/Secondary)

14. Details of Roof Drains (Primary & Emergency) along with design

calculations.

15. Plate cutting diagram for Free Issue Plates along with indicating anticipated the oritical scrap i.e. Burn oil losses & Accountable losses.

16. Material test certificate for items supplied by contractor.

17. Welding procedures & welders qualification reports

18. Radiography test reports.

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19. Final Inspection certificate and Hydrostatic test report.

20. Calibration Charts

21. Self Support Roof 22. As - Built drawing showing details as listed in Sr. No 1 to 15 & 21 above in

HARD/ SOFT COPIES including one set of tracing of all drawings

4.0 MANDATORY SPARES

OVER AND ABOVE THE QUANTITY CONSUMED IN TESTING AND /OR INSTALLED AFTER TESTING, CONTRACTOR SHALL SUPPLY FOLLOWING SPARES, WHICH SHALL BE HANDED OVER TO OWNER:

A. 10% FASTENERS WITH MINIMUM OF 2 NO.S. B. 2 SETS OF GASKETS FOR EACH SHELL AND ROOF NOZZLE

REQUIRED FOR BLIND FLANGE/ COVER/ MATCHING FLANGE AND FOR SHELL/ ROOF NOZZLE FLANGES INCLUDING MANHOLES.

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SPECIFICATIONS

FOR

MATERIALS

IN

CONTRACTOR’S SCOPE

OF

SUPPLY

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SPECIFICATIONS FOR MATERIALS IN CONTRACTOR’S SCOPE OF

SUPPLY

1.0 SCOPE:

This specification covers the material specification requirements for the materials to be supplied by the Contractor. All the materials covered in this specification shall be sourced from reputed manufacturers/ vendors with API Monogram License / ISI Mark License.

2.0 VENDORS: In cases where ISI / API/ASTM mark may not be available on the materials, Contractor shall obtain HPCL approval for the subject vendor on a case-to-case basis. For rolled structural sections, materials must be sourced from SAIL, RINL, VIZAG Steel or TISCO. LSAW/ Seamless pipes must be sourced from Surya Roshni, SAWPIPES, Welspun, Maharashtra Seamless, Jindal, SAIL, Indian seamless or Man Industries or any other reputed foreign vendor approved by HPCL.

3.0 TESTING:

Contractor has to provide Batchwise Manufacturer Test/Guarantee Certificates and the Heat No.s or Batch No.s shall be clearly identified on the materials along with ISI/API markings, as applicable. All the Manufacturer test Certificates shall be as per relevant Codes/ standards. Any material rejected by HPCL shall be forthwith removed from Site. Additionally, HPCL may also select samples of materials in accordance with relevant codes/ standards for testing at HPCL approved laboratory such as National Testing Laboratory or any other reputed lab. Contractor shall arrange for testing the same at his own cost. The frequency of such testing shall be as per relevant Codes/ standards.

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4.0 LIST OF ITEMS IN CONTRACTOR’S SCOPE OF SUPPLY WITH

SPECIFICATIONS: SL.NO. ITEM DESCRIPTION MATERIAL SPECIFICATIONS 1 COMBINED

STILL WELL for GAUGE WELL TEMP. ELEMENT LEVEL TRANSMITTER

Pipes 406.4 MM/ 12.7 MM WT/123.3 KG/M WITH 219.1MM/SCH.40 & 88.9 MM/7.6 MMWT/15.24 KG/M & 300 MM/SCH.40

API 5L GR. A, B OR X 42 (LSAW) ASTM A 106GR.B(SEAMLESS) SEAMLESS ASTM A-106 GR.B SEAMLESS ASTM A 106 GR.B

2 PLATE FABRICATION

PLATES IS: 2062 GR. A OR B

3 STRUCTURALS incldg. GRATINGS

SECTIONS IS: 2062 GR.A

4 NOZZLE NECKS 300 NB AND BELOW- XS SCHEDULE

SEAMLESS ASTM A-106 GR.B

5

NOZZLE NECKS ABOVE 300MM NB 14MM THK

IS: 2062 GR.A

6 NOZZLE FLANGES(EXCEPT MANWAY)

ASTM A 105 SORF 150#

7 MANWAY NECK AND FLANGES

IS: 2062 GR.A

8 BOLTING FOR NOZZLES

IS: 1367 CL. 4.6/4.0

9 BOLTING FOR STRUCTURE

IS: 1363

10 PIPE FITTINGS ASTM A 234 WPB 11 HANDRAILS PIPES IS: 1239 MEDIUM

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12

GASKETS(CAF)

SHEET

CHAMPION OIL & WATER

13 PONTOON & DECK PIPE SUPPORTS

80 NB S80/7.6TK 100 NB S 40/6 TK 32 NB S40/3.6TK

ASTM A-53/ IS:1978 ASTM A-53/ IS:1978 ASTM A-53/IS:1978

14 ROOF DRAIN EXTENSION/RIM VENT

PIPE VALVE

ASTM A 53 GR.B SCH 40 GATE VALVE 150#(API 600, RF, A 216 GR. WCB, 13% CR.TRIM)

15 COOLING WATER SYSTEM PIPING

2 IN TO 6 IN 8 IN TO 16 IN SORF, SWRF AND BLRF FITTINGS CAPS SPRAY NOZZLE

IS: 1239 HVY BLACK IS:3589 GR.410 ASTM A 105 SW:ASTM A 105 BW: ASTM A 234 GR. WPB ASTM A 105 CU. ALLOY GR. LTB-2, CHROMIUM PLATED

16 FOAM SYSTEM PIPING

SAME AS COOLING SYSTEM PIPING

SAME AS COOLING SYSTEM PIPING(SPRAY NOZZLES NOT APPLICABLE)

4.0 For items not listed above such as bushes, split pins, neoprene bushes, etc, for

which Manufacturer Test certificates may not be available, HPCL may approve for incorporation in works based on visual inspection.

5.0 Shoe seal /SS leg pins to be included

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ANNEXURES

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TECHNICALSPECIFICATIONS

FOR

FLOATING ROOF TANK (EXTERNAL & INTERNAL)

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CONTENTS

1.0 SCOPE

2.0 REFERENCE

3.0 SELECTION OF MATERIALS

4.0 DRAWINGS AND DOCUMENTS

5.0 FABRICATION AND ERECTION

6.0 APPURTENANCES

7.0 INSPECTION AND TESTING

8.0 CALIBRATION

9.0 PAINTING

10.0 TOLERANCES

11.0 IDENTIFICATION,PACKING & TRANSPORTATION

12.0 GUARANTEE 13.0 INTERNAL FLOATING ROOF

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STANDARD SPECIFICATIONS FOR FABRICATION,

ERECTION AND TESTING OF ABOVE GROUND STORAGE FLOATING ROOF TANKS

1.0 SCOPE 1.1 This specification covers the minimum requirements for

design, selection of materials, fabrication, erection, inspection, testing, fitting of other attachments and appurtenances, cleaning, calibration and painting of A/G FLOATING ROOF FOR PETROLEUM PRODUCTS storage tanks and is intended to supplement the minimum requirements of the applicable codes.

1.2 Engineering drawings shall take precedence over

specifications/standards. 1.3 The Review/ approval of design by HPCL shall not absolve

Contractor from the responsibility of successful performance of Floating Roof(External/Internal). It shall be the sole responsibility of the Contractor to ensure successful performance of Floating Roof design.

2.0 REFERENCE 2.1 Design Codes The following codes in their latest edition shall form the

basis for design, fabrication, inspection, testing and acceptance of storage tanks :

API Standard 650 : Welded steel tanks for oil

(Latest edition) storage

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IS : 875 (Part 3) : Code of practice for design loads, wind loads(other than earthquake) For building and structures. IS: 1893 : Criteria for earthquake resistant

design of Structures. API : 2000 : Venting atmospheric and low pressure storage tanks. IS : 2007 : Method for calibration of Vertical Oil Storage tanks. IS : 2008 : Method for computation of capacity tables for Vertical Oil Storage tanks API : RP 2003 : Protection against ignitions arising out of static, lightning and . stray currents

ASME Sect IX : Welding

OISD-129 : Inspection of storage tanks.

OISD-117 : Fire Protection facilities for Petroleum depots and Terminals.

OISD-118 : Layouts for Oil & Gas installations.

OISD-105 : Work permit system.

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2.2 Materials Codes Material to be used shall conform to:

Indian Standard Specifications or ASTM standards as applicable.

2.3 Regulations

National laws and regulations together with local bye-laws for the country or state wherever the tanks are to be erected must be compiled with.

3.0 SELECTION OF MATERIALS 3.1 All materials shall be as per applicable Codes. 3.2 Manhole necks, nozzle necks 250 mm NB and above may

be fabricated from same plate material as used for shell. 3.3 Plate material used for ring flanges shall have a minimum

UTS of 4200 Kg./cm2 . For Flange thickness over 38 mm, plate material shall be boiler quality, fine-grained, killed, and normalised and impact tested as per the requirements of API Standard 650.

3.4 All clips and attachments shall be fabricated from carbon

steel plates of weldable quality. 3.5 Gaskets for manholes fitted with blind flanges shall conform

to IS: 2712. 3.0 mm thickness. All the nozzles shall be fitted with spiral wound gasket with CS outer ring & SS inner ring (API 601) up to24” dia.

3.6 Bolts and nuts for all nozzles fitted with blind flanges shall

conform to IS: 1367, ASTM A-307 Gr. B, A-193 Gr. B-7, or

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A-194 Gr. 2H. Bolts and nuts for all structures shall conform to IS: 1363.

3.7 Floating roof pipe supports and pipe sleeves shall be of

carbon steel conforming to ASTM A-53 /IS: 1978. 3.8 Following classifications of electrodes are recommended for

welding. However, minimum requirements of applicable codes and appendices should be adhered to:

a] Low hydrogen electrodes namely, E-7018 shall

be used for all manual metal-arc welds of shall courses having a thickness of 12mm or more and for attachment of shell courses to bottom or annular plates.E-7018 will be used for any weld joint(butt/fillet) having one plate thickness equivalent or more than 12mm

b] High cellulose/rutile type electrodes namely, E-

6013 as per the AWS classification SFA 5.1 is acceptable for all other welding.

ESAB, ADVANI OERLIKON & D&H SECHERON make electrodes will only be permitted to be used in the works. Based on above, fabricator shall furnish samples of welding electrodes to Engineer-in-Charge for approval.

4.0 DRAWINGS AND DOCUMENTS 4.1 All individual tank data sheets shall have

dimensional/design as well as material specification. Final drawing with revisions, if any, shall be issued after award of contract/purchase order.

4.2 Contractor shall prepare all design calculations in

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accordance to API 650 with product density 0.86 for shell, Bottom & FR and fabrication drawings based on the drawings/ written instructions issued on award of contract/purchase order and shall include the following:

1. Drawing index and Schedule of Submission. 2. Design calculation for Bottom, Shell ands floating roof

for HPCL review. 3. GA drawing covering all details shown in HPCL data

sheets like list of appurtenances, lists of standards and specifications, materials of construction, Tank design data, General Notes including details of test to be conducted on tank, specification and brand-name of welding electrodes to be used etc.

4. Plate layout, details of welding as per approved WPS for

each weld joint and bill of material for bottom sketch and annular plates.

5. Development details of welding as per approved WPS

for each weld joint and Bill of Materials for shell including shell extensions showing location of nozzles and stairway on developed shell.

6. Plate layout, details of welding as per approved WPS for

each weld joint and Bill of Material for Floating Roof. 8. Details of spiral stairway and extension stairway to still

well platform/ LT platform, landings and handrails with bill of materials.

9. Details of wind girders with Bill of Material.

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10. Details of rolling ladder and track and Earthing connections with Bill of Material for floating roof tanks.

11. Details of Roof Supporting Structure and Buoys with Bill

of Material for Floating roof tanks. 12. Details of shell nozzles and Inlet/ Outlet Troughs and

shell earthing cleats with Bill of Material. 13. Details of Primary Foam seal and Secondary Seal and

details of earthing shunts for F.R. Tanks. 14. Details of Floating Roof appurtenances, roof stopper

and leg supports for Floating Roof including Bill of Materials for FR Tanks.

15. Orientation of floating roof appurtenances, leg supports,

plate joints, rolling ladder track etc. for FR Tanks. 16. Details of primary roof drain and Drain sump for F.R.

tanks including Bill of Material. 17. Details of still-wells, Gauge hatch and Bill of Material. 18. Details of mounting of Rim vents. 19. Details of Emergency Roof Drains. 20. Details of Foam Cooling System along with Foam

makers and orifice plates. 21. Details of Fixed water spray cooling System along with

deflector plates along with structural supports mounted atop secondary and tertiary wind girders and spray nozzles and orifice plates.

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22. Details of Roof opening for Automation level/

temperature gauge. 22. Plate cutting diagrams for all free issue material. 23. Plate reconciliation statement for free issue material. In case the contractor intends to make some

modification for accommodating his fabrication facilities or available materials, the same shall be submitted to HPCL for approval with supplementary design calculations. The approved modifications shall be incorporated in fabrication drawing and submitted to HPCL for approval.

4.4 Requisite number (as per the Time schedule of this

Work/Tender document) of prints of detailed fabrication drawings prepared by contractor shall be sent to HPCL for approval and one copy shall be returned to the contractor after comments/approval. No fabrication / erection shall be carried out without approved drawings.

5.0 FABRICATION AND ERECTION 5.1 Plates a] Plates edges shall preferably be sheared or machine

cut as per code. All machined parts shall be suitably protected before assembly.

b] Pug/Gas cut plates shall be grounded to the

satisfaction of the Engineer- in-Charge. c] All formed plates shall be match marked with paint on

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the concave side with numbers as shown on erection drawings.

5.2 Structural steel and Roof a] Structural steel fabrication shall be carried out to the

required shapes for making the structure. b] A pre-assembly of a sufficient part of roof structure may

be called for by the Engineer-in-Charge to assess the correct workmanship.

5.3 Bottom

a) Prior to bottom plate laying, foundation ( Murrum/Sand pad) shall be checked for unevenness/elevation difference which shall not be more than +/-3mm in any 3 meter of circumference and +/- 13mm in total circumference.

b) The clear extension of annular plate shall be 80mm from the outer surface of the first shell.

c) The annular plate will be 10mm thick and the bottom/sketch plate shall be 8 mm

d)Bottom slope shall be 1in 100 for Cone up or cone down tanks or as shown in the respective tank drawings.

e] Overlaps shall be properly cleaned with steel wire

brush before welding. f] Single pass welds are not permitted.

g] Arrange the laps to shade the water towards the Bottom

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drain Nozzle/ shell. h] Annular plates shall be assembled by butt welding with

backing strips and the sketch plates shall be lap welded to the Annular plates.

i] Three plates lap joints shall be suitably joggled to a length of 150 mm minimum to facilitate welding. Joggling shall be to the satisfaction of Engineer-in-Charge.

j] Contractor shall provide a Welding sequence which

shall be adopted so as to give minimum shrinkage and distortion and it shall be indicated on fabrication drawings. The contractor shall submit the methodology which shall describe the welding sequence along with stiffeners or any other special methodology to keep distortion to minimum.This shall be approved by Engineer-in-Charge.

k] Bearing plate under each leg support for floating roof

tanks shall be centered and welded to the bottom plate by a continuous fillet weld of size equivalent to bottom plate thickness. Plates shall be 600 mm round or square and 10 mm thick (minimum).

l) The backing strip provided underneath of annular plate shall be 10mm thick 150mm wide throughout the length of the butt joint.

m) The annular butt joint will be subjected to 50% Radiography as per API 650.

n) The bottom/sketch/annular plates shall be painted underneath & top along with Copper slag blasting as per the painting specification provided in the tender document.

o) All the fillet/butt welds shall be performed by the approved welder having approved WPQR only duly vetted by TPI and EIC.

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5.4 Shell a) Shell erection shall be carried out by Jack – up method

only. Calculations for deployment of number of jacks and their placement/ location shall be submitted by the Contractor for HPCL’s approval. The deployed jacks along with accessories like hydraulic tubes, power pack, end connections, traverse corrugations on the stem shall have necessary certification /vetting by TPI for safety reasons. The operating /maintenance procedure for the jacks shall be submitted for HPCL for approval along with TPI vetting. The proposed Lube oil usage shall be strictly as per manufacturers recommendation and the same shall be vetted by the TPI for no. of changes, storing and usage etc.

b) All vertical and horizontal shell joints shall be full

penetration and full fusion welds using any one of the edge preparations permitted by the Code API 650/ASME Section IX. Single side butt welds are not permitted. The Single “V” edge preparation(60+/- 1 degree) shall be made for all the vertical butt welds of shell plates thickness 8mm.The Double “V” edge preparation (60 +/- 1 degree)shall be made for all the vertical butt welds of shell plates thickness more than 10mm. the Horizontal welds up to 10mm thick shall have single “v” edge preparation(45+/- 1 degree) and Double “v” edge preparation(45+/- 1 degree) shall be made for all the thickness of shell plates more than 12mm.

c] Top curb angle shall be lap or butt welded to the top

course with flange turned outside. Whenever Curb angle is provided as a lap on the shell it shall a clear over

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hang of 25mm from the top of the shell. The thickness of curb angle shall in no case shall be less than 8mm.

d) The height of any shell shall not be less than 1000mm

and it is to be ensured while jacking up that approved drawing is followed in toto.

e) The height of Extension plate shall be at least 1000mm

and shall have a clear fillet weld on the Curb angle of minimum size 8mm.

f) The stiffening ring provide as walkway shall not have a

clear width less than 710mm and shall be located 1100mm below the Curb angle.

g] Drain holes of 20 mm diameter suitably staggered shall

be provided on the horizontal plates of the stiffening ring (wind girder).

h] Hand railing shall be provided all around when stiffening

ring is used as walkway for floating roof rank. i] Curb angle and stiffening ring butt joints shall stagger by

300mm minimum with the vertical shell plate welds. j] Vertical joints should preferably be offset by at least

1000mm. k] First shell course plates shall be so arranged that the

vertical joints clear the annular ring welds or sketch plates welds by at least 300 mm. Vertical joints of the shell courses shall also clear the nozzle attachment welds or reinforcement pad welds as per code and applicable appendices.

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l) The shell to bottom joints are performed as fillet welds for the annular plate thickness less than 12mm. The bottom edge preparation for the first shell plate more than 12mm thick annular plate shall be a Double”V” as per clause no: 5.1.5.7/fig: 5-3.c of API 650 11th edition

m] Holes shall not be made in shell plates for erection

purpose. n] Shell plate alignment shall be within the limits specified

in code API 650. HPCL has achieved the vertical alignment/plumb per 15

meter height in the range of 15mm, thus the expected plumbness is in the range of 15mm+/- 20%

o] For floating roof tanks, internal diameter shall be

maintained in all shell courses. p) The erection cleats for jacks or any other purpose shall

be removed properly and the same need to be refilled with electrode of 7018 and grinded to make good the surface irregularities’ to the satisfaction of EIC

p] After completion, the inside surface of floating roof tanks

walls shall be ground to remove any roughness liable to impair the seal.

5.5 Floating Roof 5.5.1 Overview a] Floating Roof of tanks less than or equal to 12Min dia

and more than 60M in dia shall be of double deck type construction. Tanks having dia greater than 12M but less than or equal to 60 shall be of Single deck annular

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pontoon type construction with or with out buoys. b] When floating roof is in the highest position, tank shall

be capable of holding its design capacity. c] Floating roof shall be designed by Contractor

considering design data given on each drawing / tender. Roof shall be designed to eliminate the presence of any air vapor mixture under the deck.

d] The floating roof shall be provided with at least one

manhole of 750 NB. This manhole shall be provided with a ladder for stepping down to bottom when the roof is in the lowest position. For tanks greater than 8 m dia. Additional manhole of 600 NB shall be provided. These manholes shall have suitable clearance from tanks internals.

e] On the bottom side of deck, where flexure can be

anticipated adjacent to girders supports or other relatively rigid members, full fillet welds not less than 150mm long on 250mm centers shall be used on any plate laps that occur within 300 mm of any such members. Additionally, the remaining lengths of all lap seams shall be stitch welded for 50 mm lengths @ 400mm c/c.

f] Contractor shall design the parameters of the floating

roof such that when floating in product (of specific gravity 0.70) the maximum submergence shall be within 95% of the rim height under conditions as listed below:

(i) For single deck annular pontoon type external

floating roofs for the following conditions:

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- The submergence of outer rim when 254 mm rain water is accumulated on the roof with primary Roof Drain inoperative.

- The submergence of inner and outer rim

near the punctured compartments when deck and two adjacent pontoon compartments are punctured.

(ii) For Double Deck Floating Roof Tanks The submergence of outer rim near the punctured

compartments when any two adjacent compartment are punctured.

g] Contractors shall carry out buoyancy (including

tilting) calculations for the floating roof for all the conditions of (f) mentioned above, when it is floating on test water, Calculated value shall be compared with actual submergence measured during floatation test. The provisions of Clause C.3.4.2 of API 650 shall also be satisfied.

h) Top decks of double deck & of Pontoon section shall have minimum slope of 1 in 64.

5.5.2 Contractor shall submit design calculations for external

floating roofs for sufficient buoyancy to keep the roof afloat and with primary roof drains inoperative for the following conditions

(a) For single deck annular pontoon type external

floating roofs considering - The submergence of outer rim when 254

mm rain water is accumulated on the roof with primary Roof Drains inoperative.

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- The submergence of inner and outer rim near the punctured compartments when deck and two adjacent pontoon compartments are punctured with No water or live load.

b) Design of leg supports, bleeder vent, emergency

drain and primary drains.

b) Design of pontoons and Deflection of deck and structural integrity of floating roof for annular pontoon type floating roofs when centre deck is loaded by its design rain water or when the centre deck and two adjacent pontoons are punctured. The provisions of Clause C.3.4.2 of API 650 shall also be satisfied.

5.5.3 a) Deck shall have level surface with permanent

slope towards the drain sump to avoid stagnation of rain water.

b) Each compartment of the floating roof shall be

provided with a 500 NB manhole with cover. c) Each buoy, if provided, shall have 150 NB

inspection opening with cover and bolting.

c) Central deck and pontoon shall be suitably stiffened, if required, and calculation for the structural integrity of the floating roof shall be submitted to HPCL for approval.

5.5.4 Seal Details of Liquid Mounted Mechanical Shoe seal and

Secondary seal in G.I construction shall be as per the specification annexure attached in this tender.

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5.5.5 Floating Roof Supports a) Support shall be adjustable to two position

1) The lower position (minimum 1200 mm)

shall permit the roof to go as low as possible without interference with any internal accessories and roof seal mechanism.

2) The upper position (for cleaning) shall provide a clearance of 1800mm between the pontoon / deck edges and bottom.

b) The number of leg supports shall be determined & designed to ensure that while resting they do not deform the tank bottom and roof; the effective length of the pipe support should be taken as 1.5 times of actual length of the pipe support in clean-out position.

c) Pipe sleeves shall project sufficiently above the

roof to take care of flooded condition of roof and extend sufficiently below the roof to prevent escape of vapour (minimum 200 mm).The pipe sleeves shall be brazed for a length of 50mm at the top and bottom of the sleeve and the cotter pin shall be of stainless steel as shown in the drawings.

d) Pipe support length shall be readjusted after

hydraulic testing of tank so as to take care of the initial settlement of the tank bottom.

e) The maximum spacing between the leg support shall be 5 ( Five) metre.

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5.5.6 Rolling ladder and track shall be provided as per HPCL Standard Drawings enclosed in this Document.

5.5.7 Roof Drains

a) Roof Drains of Repeatable lay pattern shall be provided by the Contractor as per Manufacturer recommendations with internal supports and shoes/ Guards, Connecting piping duly supported from Roof drain sump to inlet of system and Connecting piping from outlet side of system to Roof Drain Nozzle on shell, if any; Swing check Non return valve with CI body and brass/bronze valve and seat shall be provided for the primary drain for single deck floating roofs. Detailed specifications are provided in annexure-Specification for flexible pipe for Tank Roof Drain system for floating Roof tanks.

b) The slope of deck leading to primary roof drain

sump shall be planned for complete water drainage equivalent to maximum recorded rainfall per hour for given site without allowing any accumulation of water, the deck being at the lowest operating level.

c) Emergency drain shall be provided to take care of

primary roof drain failure. This drain shall be equipped with water seal sump inside the roof to prevent back flow of the stored product. It should start functioning after accumulation of around 200mm of rain fall on deck.

d) The minimum thickness of drain pipe shall be

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Sch. 40.

5.5.8 Vents

a) Roof shall be provided with automatic bleeder vents designed to open before the roof reaches its lowest positions and to close when the roof rises above this point. Also same operation should follow in the clean-out position.

5.5.9 Gauge Well/Anti-rotational Device

Gauge hatch size shall be as indicated in the drawing and it shall have a quick opening cover. Gauge hatch shall be spark proof type. Gauge well pipe and Pipe for Level Transmitter/ TE shall be located on either side of Rolling Ladder. This shall also act as anti-rotational device. No additional anti-rotational device is suggested.

5.5.10 Earthing of Floating Roof

a) Copper cables shall be provided between ladder and track and also between ladder and shell. Two such independent connections should exist in parallel.

b) Adequate number of earthing shunts shall be

provided for the seal.

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6.0 APPURTENANCES 6.1 Nozzles & Accessories

a) All appurtenances and accessories as shown in

the respective tank drawings shall be supplied by the Contractor.

b) Manhole and nozzles with blind flanges shall be

provided with gaskets and boltings.

c) Nozzle and manholes may be shop assembled.

d) Flange faces shall be varnished and protected by wooden discs using at least three bolts.

e) All nozzles and accessories shall be prefabricated

and attached to the shell plate. The prefabricated assembly shall be stress relieved prior to installation, wherever required as per code and applicable appendices.

6.2 Stairways, Roof Access and Handrailing.

Each tank shall be provided with stairway and roof access. Handrailing if not indicated otherwise on tank drawings shall be provided all around.

6.3 Settling Marker :

Marker shall be provided on the shell, 500mm from the bottom to check tank settlement. Size shall be 50x50x5mm angle and 100mm long. The distance between setting market is approximately 5 meter.(minimum 4 numbers).

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Shell settlement measurement shall be made after tank

erection, prior to hydro testing and during water filling. While taking measurement on settling markers, rim space

(distance between shell and outer rim) shall also be measured at location corresponding to settling markers for floating roof tanks.

Bottom internal measurements shall be made after hydro

testing; such measurement shall be made at all pipe support location. Additional measurements shall be made in annular plate region at 5 meter intervals around the tank shell.


Inspection shall be co-ordinated by Engineer-in-Charge at all stages.

7.1 Inspection

a) All tanks shall be offered for inspection at all stages as desired by Engineer-in-Charge.

b) HPCL’S representatives shall have free access to

the entire contractor’s as well as to worksite.

c) The contractor shall provided all facilities, such as access ladder, lighting, tools and tackles, instruments etc. and personnel to inspectors, for proper execution of their inspection.

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d) All the inspection shall be carried out in

accordance with the relevant codes and requirements of drawings and specifications.

d) Approval of the HPCL’S Engineer-in-Charge shall

in no way relieve the contractor of his responsibilities for proper execution of work.

7.1.2 Welding Procedure a) No weld joint will be performed by welder without

having approved WPQR and WPS for the particular joint.

b) Welding procedure specification(WPS)- QW-482 ASME Section-IX: WPS for all the joints will be written by the party incorporating all the requirements like joints/groove design, pre/post weld treatments, filler metal details like 6013/7018,No.of weld layers including no.of beads per layer with electrode class& dia/current/volt/traverse speed/other remarks etc. All the WPS will be vetted by HPCL approve TPI agency prior to approval of EIC.

c) The performance qualification record (PQR) QW-483 ASME Section-IX: PQR will be carried out for establishing the mechanical properties and all other requisite variables. It shall be done for 6013 & 7018 separately for Horizontal & Vertical on test coupon thickness recommended by ASME Section IX for work to be undertaken. Required destructive test will be undertaken as per ASME section IX. The entire PQR process will be done

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under the supervision of third party. d) The Welder performance qualification record

(WPQR) QW-484 ASME Section-IX: WPQR will be performed under the supervision of HPCL approved third party and approval vetting will be granted by TPI for successful welders I prescribed format recommended by ASME Section-IX. During this process TPI will also vet the various accessories like Welding rectifier, regulator, holder; cable etc and the record will be maintained for the same. The records shall be used as benchmarking for QC.

c) No welding shall be undertaken without approval of the welding procedure and welder qualification test by the Engineer-in-charge.

Note: as a sample WPS/WPQR/PQR used at other HPCL sites are attached.

7.1.3 Radiography and Inspection of Welds

a) All welds shall be inspected and tested as per

Section 6.1 of API 650, eleventh/latest edition and this specification.

b) All long seams of fabricated nozzles shall be fully

radiographed.

c) Weld areas/shots to be radiographed shall be designated by the Engineer-in-charge. No. of shots will be as per API 650 as per clause 8.1.2 of eleventh edition.

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d) Radiographs shall be taken as soon as welding of

the Joint is completed. If repairs are required, these shall be carried out before starting other welds. New radiography examination of such repairs shall also be carried out by the Contractor at his own cost. The no. and location of radiograph along with welder identification shall be properly maintained by the contractor as per figure 8.1 of API 650 of Clause 8.1 ,11th edition.

d) Radiograph film length shall be 250 mm min. except if the weld is less than 250 mm long. In such cases, film length shall be full length of weld.

f) Radiographic film shall be of approved quality KODAK/approved make by HPCL/TPI.

g) Welds examined by radiography shall be judged acceptable or unacceptable by standards of paragraph UW-51(b) in section VIII of the ASME code (attached)

h) The radiography films and reports shall be reviewed and approved by a HPCL approved Third Party Agency. The quoted rates are deemed to include same. The evaluator (TPI person) shall have a Level-II/III of certification of ASNT-SNT-TC-IA. The film shall have a proper identification marks vide point no:d above along with TPI certification.

7.1.4 Liquid penetrant examination: Wherever specified in drawing/code, liquid penetrant

examination shall be carried out as per specifications and codes. Additionally, all Horizontal and vertical Shell joints including extensions above the Maximum Design Liquid

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Level shall be Dye Penetrant Tested after Root Run and necessary repairs carried out.

It is to be noted that the entire weld joints which are non accessible to any type of regular tests like vacuum box, Hydro test, Pneumatic test shall undergo DP test for root run mandatorily.

The bottom to shell joint root run shall undergo Kerosene-chalk test prior to DP test from both inside to outside and vice versa mandatorily.

7.2 Testing

All equipment required for testing shall be supplied by the contractor. Opening other than those used for hydrostatic test or any

other test shall be closed by plugs and blind flanges supplied by the contractors.

7.2.1 Bottom test

a) A detailed description of the proposed test method shall be first submitted for approval to the Engineer-in-Charge.

b) Vacuum box testing shall be carried out for

detection of leaks in the bottom s per clause no: 8.6 API 650 11th edition. All the fillet joints of bottom/Annular/Sketch shall undergo vacuum box test at 35 Kpa(3.5 PSI) for 10 minutes prior to shell erection/fixing leg bearing plate for support for various appurtenances like leg, Gaugewell etc..,

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c) The weld joints under the shell periphery shall be

Vacuum box tested (i.e. annular butt joint) as above(7.2.b) before erection and welding of first shell course.

e) Contractor shall test the tank bottom for the entire

weld length in the presence of the Engineer-in-Charge and test reports shall be issued accordingly.

f) The root run of all joints of central sum shall undergo DP test in presence of EIC.The central Sump in Cone down type of Tanks shall be hydro tested at a pressure of 10.5 Kg/cm2 for 4 hour duration.

7.2.2 Shell Test

a) Bottom to shell joints shall be tested as follows: i) Inner fillet weld shall be inspected and tested

prior to welding the outside fillet weld. Leak test shall be performed with penetrating oil after removal of slag. Oil shall be removed before, welding the outer fillet.

ii) Examination for inner fillet to detect cracks shall

be performed using either the liquid penetrant method or DP test.

b) All welded lugs and brackets used for erection

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purpose shall be carefully removed from inside and outside surface of the tank to the satisfaction of the Engineer-in-Charge.

c) The shell joints above the Design Liquid level and

not subjected to Hydro test shall be radiographed in accordance with API and all such joints shall be Dye penetrant tested for entire length after Root run.

d) Contractor shall perform the hydrostatic test in the

presence of Engineer-in-Charge on each tank after complete erection. Any defects observed during the test shall be repaired by the contractor. No Hot work shall be permitted after Hydrotest.

e) Filling of the tank may be restricted by HPCL

Engineer-in-Charge for preloading of foundation and hydrostatic test may be extended over a period of 4 weeks or more to ensure proper settlement of the tanks.

f) The filling height, for floating roof tanks shall be

restricted to maximum height so that weather shield does not go beyond curb angle while carrying out the hydrostatic testing /filling up water. The steps shall be as follows:

1) On completion of tank and after cleaning, the

tank shall be filled with water as follows, unless otherwise specified in the tender documents.

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Filling shall be in 4 stages- 25%, 50%, 75% and 100%. After each stage a load stabilization period shall be observed:

- 24 hrs between each stage for tanks with a capacity equal or more than 10,000 cu.m.

- 12 hrs between each stage for tanks with a capacity under 10,000 cu.m.

Filling rate shall not exceed 5 metres per day. g) When the tank is full all the weld joints shall be

hammered by the Contractor in the presence of Engineer-in-Charge. In case of any defect it shall be repaired and retested by the Contractor as per instructions of Engineer-in-charge.

h) Tank shall be emptied at a maximum water level variation rate of 5 metres per day or as per instructions of Engineer-in-Charge.

i) All weld repairs shall be done with water level minimum 300 mm below the joint being repaired.

7.2.3 Floating roof testing

Floating roof test shall be as recommended in API Standard 650 Appendix C or Appendix H and also as given below :

a) During floatation test of roof, contractor shall carry

out the proof test as follows on each size of the tank selected by Engineer-in-Charge.

i) For annular pontoon type external floating roofs, with primary drains closed, water equivalent to 10” of rainfall over the tank area shall be poured

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on the deck and in the stabilized state submergence of outer rim shall not exceed 65% of its height at any point.

ii) For annular pontoon type external as well as internal floating roofs the condition of deck and two adjacent pontoon compartments punctured shall be simulated and the submergence of inner rim and outer rim at the punctured pontoon shall be compared with the calculated value.

iii) Failing to meet the above requirements contractor shall rectify the floating roof and test at his cost till the above requirements are satisfied.

b) All compartment including buoys shall be tested for liquid tightness.

c) Sealing devices shall be installed after floatation

test.

7.2.5 Nozzle Reinforcing Plates Nozzle reinforcing plates shall be pneumatically tested at

1.05 kg/cm2g with soap solution. This test shall be carried out before filling the tank for hydrostatic testing.

7.2.6 Primary Drains

Drain pipes in floating roof tank shall be pressure tested with water at 4 kg/cm2g. During the floatation test, the roof drain valve shall be kept open and observed for leakage of the tank contents into pipe drain.

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8.0 CALIBRATION

Strapping and Calibration of all tanks shall be done in accordance with IS:2007 & 2008 (Latest editions) and certified/stamped and signed by Inspector of weights and measures department.

9.0 PAINTING

For details of primer and painting, Painting specification shall be referred to.

10.0 TOLERANCE 10.1 Shell

For tanks to have acceptable appearance and to permit proper functioning of floating roof, they shall have tolerances strictly as specified in applicable codes/tender document whichever is stringent.

10.2 Floating Roof Tolerance Tolerance allowed on the annular clearance between shell

and floating Roof shall be compatible with the requirement specified by seal manufacturer. This shall be maximum 50 mm radially.

11.0 IDENTIFICATION, PACKING AND TRANSPORTATION 11.1 Identification

Each plate and structural member shall be clearly marked with the specification number, drawing number and assembly number.

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11.2 Packing and Transportation a. All plates shall be transported in tractor or trailer and shall

not be dragged. b. All rolled shell plates shall be packed properly to retain the

shape and shall be handled carefully to avoid damage during transit.

c. Contractor shall be responsible for transportation of material fabricated in his workshop or worksite.

12.0 GUARANTEE Guarantee, if not covered by the General Conditions of contract, shall be as following:

12.1 The entire Work shall be guaranteed in accordance with conditions given in the “General terms and Conditions of Contract” and “Special Conditions of Contract”.

12.2 Any part of tank found detective within 12 months from the date of Completion of work as per Completion Certificate and not having been subjected to faulty operations or incorrect service conditions shall be promptly replaced/repaired and reassembled by the contractor at his own cost, failing which owner has the right to get the same replaced/repaired by others and charge the cost incurred to the contractor.

13.0 INTERNAL FLOATING ROOF Internal floating roofs shall be designed, fabricated, erected ,welded ,inspected, tested commissioned complete in all respects per API 650,Appendix –H (latest edition)and HPCL,s EIC’s approved drawings and procedures.

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�TECHNICAL SPECIFICATIONS

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SELF SUPPORTED

FIXED CONE ROOF TANK

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Page 2 of 22

CONTENTS

1.0 SCOPE

2.0 REFERENCE

3.0 SELECTION OF MATERIALS

4.0 DRAWINGS AND DOCUMENTS

5.0 FABRICATION AND ERECTION

6.0 APPURTENANCES


8.0 CALIBRATION

9.0 PAINTING

10.0 TOLERANCES

11. IDENTIFICATION, PACKING AND TRANSPORTATION

12.0 GUARANTEE

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STANDARD SPECIFICATIONS FOR FABRICATION,

ERECTION AND TESTING OF ABOVE GROUND STORAGE SELF SUPPORTING CONE ROOF TANKS WITH CONE

DOWN BOTTOM & SUMP 1.0 SCOPE 1.1 This specification covers the minimum requirements for

design, selection of materials, fabrication, erection, inspection, testing, fitting of other attachments and appurtenances, cleaning, calibration and painting of A/G SELF SUPPORTING FIXED CONE ROOF TANKS storage and is intended to supplement the minimum requirements of the applicable codes.

1.2 Engineering drawings shall take precedence over

specifications/standards. 1.3 The Review/ approval of design by HPCL shall not

absolve Contractor from the responsibility of successful performance of Self Supporting Cone Roof. It shall be the sole responsibility of the Contractor to ensure successful performance of Roof design.

1.4 The tanks shall be designed as per API 650 strictly. The

design calculation in the scope of contract includes Bottom Plate(Annular/Sketch), Shell, Wind girders if any, Top Kerb Angle, Roof Plates, Self Supporting Trusses(Main Beam) and Rafters ,Check for overturning of tank under wind load, seismic design etc for HPCL’s approval prior to drawing preparation .

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2.0 REFERENCE 2.1 Design Codes The following codes in their latest edition shall form the

basis for design, fabrication, inspection, testing and acceptance of storage tanks :

API Standard 650 : Welded steel tanks for oil

(Latest edition) storage IS : 875 (Part 3) : Code of practice for design loads

Wind loads (other than earthquake) for building and structures.

IS : 1893 : Criteria for earthquake resistant

design of Structures. API : 2000 : Venting atmospheric and low pressure storage tanks. IS : 2007 : Method for calibration of Vertical Oil Storage tanks. IS : 2008 : Method for computation of capacity tables for Vertical Oil storage tanks API : RP 2003 : Protection against ignitions arising

out of static, lightning and stray currents.

OISD-129 : Inspection of storage tanks.

OISD-11 : Fire Protection facilities for Petroleum Depots and Terminals

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OISD-118 : Layouts for Oil & Gas installations. OISD-105 : Work permit system.

2.2 Materials Codes Material to be used shall conform to: Steel plates confirming to IS 2062. Indian Standard Specifications or ASTM standards as Applicable 2.3 Regulations

Central laws and regulations together with local bye-laws for the location wherever the tanks are to be erected must be compiled with.

3.0 SELECTION OF MATERIALS 3.1 All materials shall be as per applicable Codes. 3.2 Manhole necks, nozzle necks 250 mm NB and above may

be fabricated from same plate material as used for shell. 3.3 Plate material used for ring flanges shall have a minimum

UTS of 4200 Kg./cm2 . For Flange thickness over 38 mm, plate material shall be boiler quality, fine-grained, killed, normalised and impact tested as per the requirements of API Standard 650.

3.4 All clips and attachments shall be fabricated from carbon

steel plates of weldable quality. 3.5 Gaskets for manholes fitted with blind flanges shall

conform to IS: 2712.Thickness of gasket shall be 3.0 mm. Champion OIL Service gaskets may be used.

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3.6 Bolts and nuts for all nozzles fitted with blind flanges shall conform to IS: 1367, ASTM A-307 Gr. B, A-193 Gr. B-7, or A-194 Gr. 2H. Bolts and nuts for all structurals shall conform to IS: 1363.

3.7 Following classifications of electrodes are recommended

for welding. However, minimum requirements of applicable codes and appendices should be adhered to:

a] Low hydrogen electrodes namely, E-7018 shall be used for all manual metal-arc welds of shall courses having a thickness of 12mm or more and for attachment of shell courses to bottom or annular plates.

b] High cellulose/rutile type electrodes namely, E-

6013 as per the AWS classification SFA 5.1 is acceptable for all other welding.

ESAB and ADVANI OERLIKON make electrodes will only be permitted to be used in the works. Based on above, fabricator shall furnish samples of welding electrodes to Engineer-in-Charge for approval.

4.0 DRAWINGS AND DOCUMENTS 4.1 All individual tank data sheets shall have

dimensional/design as well as material specification. Final drawing with revisions, if any, shall be issued after award of contract/purchase order.

Contractor shall submit the detailed design calculation for

self supporting Cone roof (C.R.) to HPCL for vetting and review of design and approval by HPCL.

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4.2 Contractor shall prepare all design calculations and

fabrication drawings based on the drawings issued on award of contract/purchase order and shall include the following:

1. Drawing index and Schedule of Submission. 2. Design calculation for Self supporting Cone roof for

HPCL review & approval. 3. GA drawing covering all details shown in HPCL data

sheets like list of appurtenances, lists of standards and specifications, materials of construction, Tank design data, General Notes including details of test to be conducted on tank, specification and brand-name of welding electrodes to be used etc.

4. Plate layout, details of welding and bill of material for

bottom sketch & annular plates, Central sump and arrangement of supports for the pipes dipping in to the sump. The Bottom shall be Cone down type with a Sump of approx. capacity 200 litres at the centre.

5. Development details of welding and Bill of Materials

for shell including shell extensions showing location of all the Shell appurtenances including Manholes, nozzles, inlet trough and stairway on developed shell through a Nozzle orientation drawing.

6. 2 No. Water draw off Nozzle & 1 No. Fast Flush

Nozzle are provided with pipes that extend up to the Sump and dip in to the sump. This arrangement is to be shown on drawing.

7. Plate layout, details of welding and Bill of Material for

Cone Roof Layout.

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8. Details of spiral stairway and extension stairway to

Top platform, landings and handrails with bill of materials.

9. Details of wind girders with Bill of Material. 10. Details of Earthing connections for Shell with Bill of

Material. 11. Details of Roof Supporting Structure with Bill of

Material. 12. Details of shell nozzles and Inlet Troughs with Bill of

Material. 13. Details of Roof appurtenances including Roof

manholes, vents, Temperature transmitter Nozzles, Temperature hatch, Gauge well & Dip Pipe, Gauge Hatch along with respective Bill of Materials.

14. Nozzle Orientation of roof appurtenances, plate joints,

Stairway, etc. 15. Details of mounting of Roof vents. 16. Details of Foam Cooling System, supports for the

Foam intake pipes, Foam intake pipes along with Foam makers and orifice plates.

17. Details of Pressure relief lines & pressure transmitter

nozzles. 18. Plate cutting diagrams for all free issue material. 19. Plate reconciliation statement for free issue material.

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20. Details of all datum plates. In case the contractor intends to make some

modification for accommodating his fabrication facilities or available materials, the same shall be submitted to HPCL for approval with supplementary design calculations. The approved modifications shall be incorporated in fabrication drawing and submitted to HPCL for approval.

4.3 Requisite number (as per the Time schedule of this

Work/Tender document) of prints of detailed fabrication drawings prepared by contractor shall be sent to HPCL for approval and one copy shall be returned to the contractor after comments/approval. No fabrication / erection shall be carried out without approved drawings.

5.0 FABRICATION AND ERECTION 5.1 Plates a] Plates edges shall preferably be sheared or machine

cut as per code. All machined parts shall be suitably protected before assembly.

b] Gas cut plates shall be grounded to the satisfaction

of the Engineer-in-Charge. c] All formed plates shall be match marked with paint on

the concave side with numbers as shown on erection drawings.

5.2 Structural steel and Roof a] Structural steel fabrication shall be carried out to the

required shapes for making the structure.

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b] A pre-assembly of a sufficient part of roof structure

may be called for by the Engineer-in-Charge to assess the correct workmanship.

5.3 Bottom a] Bottom slope shall be as indicated in the respective

tank drawings. The Bottom shall be Cone Down type with a central sump of approx. 200 litres capacity.

b] Overlaps shall be properly cleaned with steel wire

brush before welding. c] Single pass welds are not permitted.

d] Arrange the laps to shade the water towards the Central Sump. Pipes from Water draw off nozzle and Fast Flush Nozzle on shell shall dip into the sump. Suitable supports from the bottom shall be provided for these pipes.

e] Annular plates shall be assembled by butt welding with

backing strips and the sketch plates shall be lap welded to the Annular & Sketch plates.

f] Three plates lap joints shall be suitably joggled to a

length of 150 mm minimum to facilitate welding. Joggling shall be to the satisfaction of Engineer-in-Charge.

g] Contractor shall provide a Welding sequence which

shall be adopted so as to give minimum shrinkage and distortion and it shall be indicated on fabrication drawings. This shall be approved by Engineer-in-Charge.

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h] Bearing plates & Datum plates shall be fabricated as per standard drawings and positioned as per AFC Drawings.

5.4 Shell a) Shell erection shall be carried out by Jack – up

method only. Calculations for deployment of number of jacks and their placement/ location shall be submitted by the Contractor for HPCL’s approval.

b) All vertical and horizontal shell joints shall be full

penetration and full fusion welds using any one of the edge preparations permitted by the Code. Single side butt welds are not permitted.

c] Top curb angle shall be lap or butt welded to the top

course with flange turned outside. d] Drain holes of 20 mm diameter suitably staggered

shall be provided on the horizontal plates of the stiffening ring (wind girder).

e] Hand railing shall be provided all around when

stiffening ring is used as walkway for floating roof rank. f] Curb angle and stiffening ring joints shall not coincide

with the vertical shell plate welds. g] Vertical joints should preferably be offset by at least

1000mm. h] First shell course plates shall be so arranged that the

vertical joints clear the annular ring welds or sketch plates welds by at least 300 mm. Vertical joints of the shell courses shall also clear the nozzle attachment

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welds or reinforcement pad welds as per code and applicable appendices.

i] Holes shall not be made in shell plates for erection

purpose. j] Shell plate alignment shall be within the limits

specified in code and as approved by HPCL. k] For floating roof tanks, internal diameter shall be

maintained in all shell courses. l] During erection, strapping must be carried out at three

different levels for each strake as a crosscheck for plumb.

5.5 Fixed Roof a) The Roof plates shall be supported by structures as

indicated in the drawings. b) The slope of the Cone Roof shall be in accordance with API 650. c) All supporting structures shall be designed to carry the

minimum loads as specified in codes. While designing, contractor shall also consider lateral loads caused by one bay loaded and the other bay not loaded.

d) Roof shall be joined to the shell by means of continuous

fillet (5mm max) weld on the curb angle. Roof to shell joint shall be frangible type.

e) Roof plates shall not be welded to the supporting

structure. The roof plates shall rest on the structure.

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5.6 Vents Roof shall be provided with 300mm diameter goose neck type vent.

5.7 Gauge Wells

Gauge hatch size shall be as indicated in the drawing and it shall have a quick opening cover. Gauge hatch shall be spark proof type. Gauge well pipe and Telescopic Pipes for Radar Gauge/Temperature transmitter shall be located accessible to Top landing platform. Gauge well pipes shall be provided with slot holes.

6.0 APPURTENANCES 6.1 Nozzles & Accessories

a) All appurtenances and accessories as shown in

the respective tank drawings shall be supplied by the Contractor.

b) Manhole and nozzles with blind flanges shall be

provided with gaskets and boltings.

c) Nozzle and manholes may be shop assembled.

d) Flange faces shall be varnished and protected by wooden discs using at least three bolts.

e) All nozzles and accessories shall be

prefabricated and attached to the shell plate. The prefabricated assembly shall be stress

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relieved prior to installation, wherever required as per code and applicable appendices.

6.2 Stairways, Roof Access and Handrailing.

Each tank shall be provided with stairway and roof

access. Hand railing shall be provided all around.

6.3 Settling Marker :

Marker shall be provided on the shell, 500mm from the bottom to check tank settlement. Size shall be 50x50x5mm angle and 100mm long. The distance between settling marker is approximately 5 meter.(minimum 4 numbers).

Shell settlement measurement shall be made after tank

erection, prior to hydro testing and during water filling. Bottom internal measurements shall be made after

hydro testing; such measurement shall be made at all pipe support locations. Additional measurements shall be made in annular plate region at 5 meter intervals around the tank shell.


Inspection shall be carried out by HPCL Engineer-in-Charge at all stages.

7.1 Inspection

a) All tanks shall be offered for inspection at all stages as desired by Engineer-in-Charge.

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b) HPCL’S representatives shall have free access

to the entire contractor’s shops as well as to worksite.

c) The contractor shall provided all facilities, such

as access ladder, lighting, tools and tackles, instruments etc. and personnel to inspectors, for proper execution of their inspection.

d) All the inspection shall be carried out in

accordance with the relevant codes and requirements of drawings and specifications.

e) Approval of the HPCL’S Engineer-in-Charge

shall in no way relieve the contractor of his responsibilities for proper execution of work.

7.1.2 Welding Procedure

a) Welding procedure qualification shall be carried out as per Exhibits enclosed in tender and as per details in Scope of Work.

b) No welding shall be undertaken without

approval of the welding procedure and welder qualification test by the Engineer-in-charge.

7.1.3 Radiography and Inspection of Welds

a) All welds shall be inspected and tested as per

Section 6.1 of API 650 and this specification.

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b) All long seams of fabricated nozzles shall be fully radiographed.

c) Weld areas to be radiographed shall be

designated by the Engineer-in-charge.

d) Radiographs shall be taken as soon as welding of the Joint is completed. If repairs are required, these shall be carried out before starting other welds. New radiography examination of such repairs shall also be carried out by the Contractor at his own cost.

e) Radiograph film length shall be 250 mm min.

except if the weld is less than 250 mm long. In such cases, film length shall be full length of weld.

f) Radiographic film shall be of approved quality. g) The radiography films and reports shall be

reviewed and approved by a HPCL approved Third Party Agency. The quoted rates are deemed to include same.

7.1.4 Liquid penetrant examination:

Wherever specified in drawing/code, liquid penetrant examination shall be carried out as per specifications and codes.

7.2 Testing All equipment required for testing shall be supplied by the contractor.

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Openings other than those used for hydrostatic test or any other test shall be closed by plugs and blind flanges supplied by the contractors.

7.2.1 Bottom test

a) A detailed description of the proposed test method shall be first submitted for approval to the Engineer-in-Charge.

b) Vacuum box testing shall be carried out for

detection of leaks in the bottom.

c) The weld joints under the shell periphery shall be tested before erection and welding of first shell course.

d) Contractor shall test the tank bottom for the

entire weld length in the presence of the Engineer-in-Charge and test reports shall be issued accordingly.

7.2.2 Shell Test

a) Bottom to shell joints shall be tested as follows:

i) Inner filter weld shall be inspected and tested prior to welding the outside fillet weld. Leak test shall be performed with penetrating oil after removal of slag. Oil shall be removed before, welding the outer fillet.

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ii) Examination for inner fillet to detect cracks shall be performed using either the liquid penetrant method or Magnetic particle method.

b) All welded lugs and brackets used for erection

purpose shall be carefully removed from inside and outside surface of the tank to the satisfaction of the Engineer-in-Charge.

c) The shell joints upto kerb angle shall be

subjected to hydrotest.

d) Contractor shall perform the hydrostatic test in the presence of Engineer-in-Charge on each tank after complete erection. Any defects observed during the test shall be repaired by the contractor. No Hot work shall be permitted after Hydrotest.

e) Filling of the tank may be restricted by HPCL

Engineer-in-Charge for preloading of foundation and hydrostatic test may be extended over a period of 4 weeks or more to ensure proper settlement of the tanks.

f) The filling height shall be restricted to a

maximum height while carrying out the hydrostatic testing /filling up water. The steps shall be as follows:

g) On completion of tank and after cleaning,

the tank shall be filled with water as follows, unless otherwise specified in the tender documents.

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Filling shall be in 4 stages- 25%, 50%, 75% and 100%. After each stage a load stabilization period shall be observed:

- 24 hrs between each stage for tanks with a capacity equal or more than 10,000 cu.m.

- 12 hrs between each stage for tanks with a capacity under 10,000 cu.m.

Filling rate shall not exceed 5 metres per day.

d) When the tank is full all the weld joints shall be hammered by the Contractor in the presence of Engineer-in-Charge. In case of any defect it shall be repaired and retested by the Contractor as per instructions of Engineer-in-charge.

e) Tank shall be emptied at a maximum water level variation rate of 5 metres per day or as per instructions of Engineer-in-Charge.

f) All weld repairs shall be done with water level minimum 300 mm below the joint being repaired.

7.2.3 Fixed roof testing a) After filling the tank upto curb angle or max.

liquid level,all openings in the roof shall be closed and internal air pressure shall be applied equivalent to the weight of roof plates

b) Pressure testing of roof for leak detection shall be carried out as per code.

c) For vacuum test the tank shall be emptied up to 1m level from the bottom. The openings shall be closed and draining continued with care until the vacuum of 25mm water gauge or the design vacuum whichever is higher is obtained and checked by vacuum gauge. However for tanks having diameter 20m and

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above, design check for vacuum shall be made before proceeding with the test.

7.2.4 Nozzle Reinforcing Plates a) Nozzle reinforcing plates shall be pneumatically tested

at 1.05 kg/cm2g with soap solution. This test shall be carried out before filling the tank for hydrostatic testing. All the weld joints in roof shall be checked with soap suds for detection of leaks.

b) Observations will be made for leakages during Hydrostatic testing.

7.2.5 Pipes for water draw off & fast flush

Pipes for above shall be pressure tested with water at 6 kg/cm2g.

8.0 CALIBRATION

Strapping and Calibration of all tanks shall be done in accordance with IS:2007 & 2008 (Latest editions).

9.0 PAINTING

For details of primer and painting, Painting specification shall be referred to.

10.0 TOLERANCE 10.1 Shell

For tanks to have acceptable appearance and to permit proper functioning, they shall have tolerances strictly as specified in applicable codes.

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11.0 IDENTIFICATION, PACKING AND TRANSPORTATION 11.1 Identification

Each plate and structural member shall be clearly marked with the specification number, drawing number and assembly number.

11.2 Packing and Transportation

a. All plates shall be transported in tractor or trailer and shall not be dragged.

b. All rolled shell plates shall be packed properly to retain the shape and shall be handled carefully to avoid damage during transit.

c. Contractor shall be responsible for transportation of material fabricated in his workshop or worksite.

12.0 GUARANTEE

Guarantee, if not covered by the General Conditions of contract, shall be as following:

12.1 The entire Work shall be guaranteed in accordance with conditions given in the “ General terms and Conditions of Contract” and “Special Conditions of Contract”.

12.2 Any part of tank found detective within 12 months from the date of Completion of work as per Completion Certificate and not having been subjected to faulty operations or incorrect service conditions shall be promptly replaced/repaired and reassembled by the contractor at his own cost, failing which owner has the right to get the same replaced/repaired by others and charge the cost incurred to the contractor.

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13. STRUCTURAL STEEL Structural Steel sections manufactured by SAIL, RINL,

VIZAG, TISCO or JINDAL only shall be permitted to satisfactory sample testing.

14.0 INSULATED TANKS

Insulated tanks i.e. Tanks operating at elevated temperatures shall be designed, fabricated, erected ,welded ,inspected, tested commissioned complete in all respects per API 650,Appendix –M (latest edition)and HPCL,s EIC’s approved drawings and procedures.

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STANDARD

SPECIFICATION

FOR SHOP AND

FIELD PAINTING

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STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING 1.0 GENERAL 1.1 These technical specifications shall be applicable for the work covered by the

Contract. It is understood that Contractor shall complete the work in all respects with best quality materials and workmanship, best engineering practice, Manufacturer recommendations, ITP and instructions of HPCL.

1.2 All the items covered in this specification are required to be supplied by the

Contractor only. 2.0 SCOPE

Scope of work covered in this specification shall include but not limited to the following:

1. Surface preparation for all components of A/G product storage tanks covered in

this Contract. 2. Selection, procurement and application of primers, paints and other materials on

various metallic surfaces including providing all requisite scaffolding, spray equipment, compressors, applicators, brushes, etc.

3. Lettering, marking as per HPCL requirements. 3.0 CODES AND STANDARDS 3.1 REFERENCE STANDARDS IS : 5 IS : 101 ASTM STANDARDS 3.2 SURFACE PREPARATION STANDARDS SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988 THIS STANDARD CONTAINS PHOTOGRAPHS OF THE VARIOUS

STANDARDS ON FOUR DIFFERENT DEGREES OF RUSTED STEEL. MANUFACTURER’S BROCHURES AND INSTRUCTIONS WITH RESPECT TO

STORAGE, SURFACE PREPARATION, MIXING AND THINNING, APPLICATION AND CURING INTERVALS.

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4.0 EQUIPMENT All tools, brushes, rollers, spray guns, abrasive materials, sand, hand/ power tools for cleaning, scaffolding materials, air compressors, instrument for measuring humidity, profilemeter etc required for the works shall be supplied by the Contractor.

5.0 SURFACE PREPARATION, COATING APPLICATION AND DOCUMENTATION

5.1 GENERAL 5.1.1 In order to achieve the maximum durability, copper slag cleaning shall be

followed. 5.1.2 Mill scale, rust, rust scale, etc. shall be fully removed by copper slag blast cleaning

to SA 2 ½ or equivalent as per SWEDISH STANDARD: IS-05-5900-1967/ISO-8501-1-1988.

5.1.3 Copper slag Blast cleaning shall not be performed where dust can contaminate

surfaces undergoing such cleaning or in conditions where the humidity exceeds 85%.

5.1.4 The first coat of primer must be applied on dry surface immediately and in any case within 4 hrs of cleaning of surface.

5.1.5 Blasting and painting shall in general be avoided during unfavorable weather conditions.

5.2 PROCEDURE FOR SURFACE PREPARATION 5.2.1 COPPER SLAG BLAST CLEANING

SPECIFICATIONS FOR COPPER SLAG BLASTING : 1. The surface shall be cleaned of all dust and heavier layers of rust by copper slag

blasting the entire internal surface to photographic standard SIS: 055900-1967. 2. The consumption rate of copper slag is 1.6 Kg/Sqm of the blasted area. This has

to be ensured strictly. 3. All tools, equipments, base material, hand and power tools for cleaning, including

scaffolding material, copper slag blasting equipment, air compressor etc. shall be arranged by the contractor at site in sufficient quantity.

4. The compressor used shall be of size enough to produce displacement of 5.6 to

7.0 Cum/Min of air at a pressure of 7 Kg/sqcm. Standard blasting equipment, hoppers, hoses nozzles and attachments shall be used to obtain best test results and to maintain safety standards. The rate of cleaning shall be about 15 sq.mt. per hour

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at a pressure of 7 kg/sq.cm. 5. The abrasive used shall be of the physical properties as mentioned below and

shall be free from oil, loan and mud etc. 6. The blast cleaned surface shall be blasted with dry compressed air before

applying primer. This should be done even if the surface appears very clean and white in colour. The white colour may be due to deposition of silicon and reflection of light on the surface.

7. Proper earthing and bonding arrangements shall be made to prevent any damage

by sparks produced by static electricity. Bonding shall be done between tank and blast nozzles and hopper and air compressor also. The bonding conductor should not be less than 16 SWG single strand copper cable.

8. The time gap between blast cleaning and application of primer shall not be more

than THREE hours. Blast cleaning work shall, commence from top to bottom. 9. The blast cleaning operation shall be carried out keeping the nozzle at an angle of

30 degree to the vertical in order to prevent rebounding abrasive from showing down the abrasives emerging from nozzle and from under cutting the material to be removed.

A blast cleaning, the percentage of bare metal obtained shall be between 95% to 100%

of each of sq.cm. of the blasted area corresponding to photographic visual standards of SA 2 ½ of the Swedish standard referred above.

10. Arrangements for inspection of various stages of the job shall be made available

by the Contractor so that the entire copper slag blasted area is available for inspection. Any defective work noticed shall be immediately rectified and even reblasting shall be done if necessary.

Physical Properties of Copper Slag :

� Colour : Black. � Grain shape : Granulated, Angular multifaceted. � Hardness : 5 to 7 Moh’s scale. � Sp. Gravity : 3.2 to 3.7 � Bulk Density : 1.87 Kg/ltr. � Moisture Content : less than 1 %

Sieve Analysis of copper slag : Sieve Size ( mm ) Range (%) -4.0 to +3.0 2 to 4

-3 to +2.36 3 to 12

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-2.36 to + 1 40 to 55 -1 to + 0.5 15 to 30 -0.5 to + 0.212 6 to 12 -0.212 below 0.2 to 1.0

5.3 COATING PROCEDURE AND APPLICATION

5.3.1 Copper Slag blasted surface upon inspection and clearance by HPCL shall be coated with one complete application of primer as soon as practicable and in no case later than 4 hrs on the same day. Applied paint shall have the required Dry Film Thickness (DFT) after drying which shall be measured and recorded by the contractor and should be submitted to HPCL.

5.3.2 Each coat shall be in a proper state of cure or dryness before the application of succeeding coat. Manufacturer’s instructions shall be followed for intercoat interval.

5.3.3 The type of application may be Airspray or Airless spray or Brush application as per manufacturer recommendation and HPCL instructions for getting satisfactory results.

5.3.4 For each coat, the painter should know the WFT corresponding to the specified DFT and standardize the paint application technique accordingly. This has to be ensured in a qualification trial by Contractor.

5.4 SCAFFOLDING

Double pipe scaffolding shall be used and all the painters shall be provided with Safety belts for ensuring accident free working.

5.5 DOCUMENTATION

1. A written quality Plan with procedure for qualification trials and for actual work.

2. Daily progress Report with details of humidity, surface preparation, surface profile, Dry film thickness particulars of applications, number of coats applied, type of materials used, methodology-Air or Airless or Brush, progress of work vs programme.

3. Code and Batch numbers of primers and paint materials used.

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4. Type of testing equipments and their calibration.

5. Elcometer and Profilemeter readings for the various components jointly recorded with HPCL.

6. Paint consumption statement along with the Theoretical consumption requirements.

6.0 RECOMMENDED MANUFACTURERS

• ASIAN PAINTS • BERGER PAINTS • GOODLASS NEROLAC • JENSON AND NICHOLSON • SHALIMAR PAINTS • BOMBAY PAINTS

7.0 HPCL LOGO AND LETTERING

HPCL will provide their LOGO with sizing, Flow, coloring and same is to be provided to the Tanks.

HPCL will also convey to the Contractor in writing details of the lettering for product and tank details along with the desired color-coding and same has to be arranged by the Contractor.


8.1 All painting materials including primers and thinners brought to site by the Contractor for application shall be directly procured from Approved manufacturers as per specifications and shall be accompanied by Manufacturer Test Certificates.

8.2 HPCL may call for tests for the primers and paints including verification of batchwise tests for physical and chemical analysis. The Contractor shall carry out the same at his own cost and provide the results to HPCL.

8.3 The painting work shall be subjected to inspection by HPCL at all times. Stages of

inspection are as follows: 1) Surface preparation 2) Primer application 3) Each coat of paint All records of inspection shall be maintained in Registers and jointly signed by HPCL and Contractor.

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Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the satisfaction of HPCL before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, Contractor shall be fully responsible for making good any defects found during Final inspection or during the Defect Liability period. DFT shall be checked and wherever shot same shall be made up with additional coats.

8.4 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats in consultation with manufacturer.

8.5 Calibrated Digital Elcometers, surface profile gauges (calibrated Profilemeter) and any other inspection instrument required by HPCL shall be provided by the contractor at site.

8.6 The contractor shall arrange expert technical support at site by paint Manufacturer who will cross verify independently regarding surface preparation and DFT and quality and provide a report to HPCL.

9.0 PRIMERS AND FINISH COATS DESIGNATIONS

PRIMERS

P-6 : EPOXY ZINC PHOSPHATE PRIMER

FINSIH COATS/ PAINTS

F-2 : ACRYLIC POLYURETHANE FINISH

F-6 : HIGH BUILD EPOXY FINISH COATING

F-7 : HIGH BUILD COAL TAR EPOXY COATING

F-9 : INORGANIC ZINC SILICATE COATING PAINTING FOR PIPING

SL.NO. TYPE OF PIPING

SURFACE PREPARATION

PAINT SYSTEM TOTAL DFT IN MICRONS FIELD

PRIMER FINISH PAINT

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1 FIRE WATER

SA 2 1/2 1 COAT OF F-9 @ 65-75 MICRONS DFT/ COAT + 1 COAT OF P-6 @ 40 MICRONS DFT/ COAT (65+40=105)

1 COAT OF F-6 @ 100 MICRONS DFT/COAT+ 1 COAT OF F-2 @ 40 MICRONS DFT/COAT (100+40 =140)

P-6 AS STRIPE COAT (RED SHADE); F-6 (GREY) AND F-2 (FIRE RED; IS:536)

2 FOAM SA 2 1/2 1 COAT OF F-9 @ 65-75 MICRONS DFT/ COAT + 1 COAT OF P-6 @ 40 MICRONS DFT/ COAT (65+40=105)

1 COAT OF F-6 @ 100 MICRONS DFT/COAT+ 1 COAT OF F-2 @ 40 MICRONS DFT/COAT (100+40 =140)

P-6 AS STRIPE COAT (RED SHADE); F-6 (GREY) AND F-2 (GOLDEN YELLOW; IS:356)

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6 PAINTING FOR FLOATING ROOF TANKS: INTERNAL

SL.NO. COMPONENT SURFACE PREPARATION

PAINT SYSTEM TOTAL DFT IN MICRONS FIELD

PRIMER FINISH PAINT

1 Underside of Floating roof deck and pontoon bottom, product side of annular and sketch bottom plate, inside surface of shell upto 1m ht from bottom, outer surface of still well from bottom to max. Liquid level, structural steel roof ladders, ladder on still well, roof supports upto long leg ht, datum plate, inside face of all shell nozzles and trough.

SA 2 1/2 1 COAT OF F-9 @ 65-75 MICRONS DFT/ COAT

3 COAT OF F-6(AMINE CURED) @ 100 MICRONS DFT/COAT (300)

F-6 (GREY) Total=365 microns

2 Inside pontoon SA 2 1/2 1 COAT OF F-9 @ 65-75 MICRONS

2 COAT OF F-6(amine

F-6 (GREY)

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DFT/ COAT

cured) @ 80 MICRONS DFT/COAT (80x2=160)

Total=225 microns

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6. PAINTING FOR FLOATING ROOF TANKS: EXTERNAL


PAINT SYSTEM TOTAL DFT IN MICRONS

FIELD PRIMER

FINISH PAINT

1 Soil side of bottom plates

SA 2 1/2 1 COAT OF F-9 @ 65-75 MICRONS DFT/ COAT

3 COATs OF F-7 @ 100 MICRONS DFT/COAT (300)

Total=365 microns 1 coat-black shade; 2 nd coat: tanned brown and 3 rd coat: black)

2 External shell, wind girders, WG supports, Floating roof topside with associated structurals, roof supports above roof, rolling ladder, spiral stairway incldg. Gratings, chequered plates, kerb angle, foam dam, hatches, covers, pontoon top, sides and deck top

SA 2 1/2 1 COAT OF F-9 @ 65-75 MICRONS DFT/ COAT + 1 COAT OF P-6(RED) @ 40 MICRONS DFT/COAT (65+40=105)

1 COAT OF F-6(AMIDE CURED)@ 100 MICRONS DFT/COAT + 2 COATS OF F-2 @ 40MICRONS DFT/COAT (100+2 X40=180)

F-6(Grey) Total=285microns)

3 Inside surface of shell from top edge to Max. design liquid level(that is, 1.50m above Max. liquid level)




4 All still well pipes above max. liquid level




ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.

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� PAINTING FOR FIXED CONE ROOF OF INTERNAL FLOATING ROOF TANKS: EXTERNAL


PAINT SYSTEM TOTAL DFT IN MICRONS

FIELD PRIMER

FINISH PAINT

1 EXTERNAL SURFACE OF FIXED CONE ROOF OF INTERNAL FLOATING ROOF




ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.

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Page 1 of 4

STANDARD

INSPECTION

TEST PLAN

FOR

PIPELINE JOBS

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Page 2 of 4

1.0 GENERAL The enclosed ITPs shall be followed for the works to be performed by the Contractor under this Tender. The provisions indicated for stagewise inspection by HPCL are a minimum and the contractor shall develop a detailed ITP and obtain approval for the same prior to commencement of work. Contractor to carry out 100% examination of all activities.

2.0 LEGEND HP: Hold point; A point which requires inspection/ verification and acceptance by HPCL before

any further processing is permitted. The Contractor shall not process the activity/ item beyond a Hold point without written approval by HPCL.

W: Witness Point; An activity which requires witnessing by HPCL when the activity is performed. Rw: Review of Contractor’s documentation. S: Surveillance Inspection by HPCL; Monitoring or making observations to verify whether or not materials/ items or

services conform to specified requirements. Surveillance activities may include audit, inspections, witness of testing, review of quality documentation & records, etc.

WC: 100% examination by Contractor. Responsibility for execution of the inspection/testing is with the Contractor.

______________________________________________________________________

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Page 3 of 4

S.NO. ACTIVITY CONTRACTOR HPCL ________________________________________________________________________

A. PRIOR TO FABRICATION

1. Acceptance of the survey work prior to pipeline laying WC HP

2. Acceptance of the Pipe support sleepers WC HP

3. Incoming Material - Owner’s Supply WC Rw - Contractor’s supply, including check testing WC HP

4. Welding Filler Material Approval/Qualification a) Manufacturing Test Certificate/Documents WC Rw b) Testing, if any WC W

5. WPS/PQR ( For Product Piping only ) a) Procedure WC HP b) Testing i) Carbon Steel WC HP c) Approval of Final WPS/PQR WC HP Note : Party to establish WPS/PQR within 15 days from the date of LOI

6. a) Welder performance Qualification Test WC W b) Certification & Approval of welder WC HP

(For Product Piping Only) 7. Review & approval of P&ID, GAD & Isometric drawings WC HP 8. Fabrication, erection, testing procedure for job WC HP

B. FABRICATION, ERECTION, WELDING & TESTING OF PIPES

1. Blast cleaning (For Product piping only) and painting of pipes WC W

2. Pipe edge preparation, aligning over sleepers WC W

3. Erection & fitup of pipes including fittings, flanges etc., WC W 4. Sequence of welding WC S

5. Baking of electrodes WC S

6. Inter-pass cleaning WC S

7. Visual check of welding WC W

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8. DPT/RADIOGRAPHY of the joints WC HP 9. Erection of valves WC W 10. Pipe supports welding WC W 11. Hydrotesting WC HP

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TECHNICAL

SPECIFICATIONS

FOR

CONCRETE AND

REINFORCEMENT

WORKS

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1. CONCRETE AND STEEL REINFORCEMENT 1.1 GENERAL: This section describes and specifies work required for plain and reinforced cement

concrete including reinforcement and form work. Unless otherwise specified or agreed in writing by the EIC, all materials and methods used in the production, testing and handling of concrete shall comply with the latest editions or amendments of the relevant Indian Standards.

1.2 MATERIALS: All materials shall be obtained from sources approved by the EIC. The agreed source or

quality of any material shall not be changed during the course of the contract except with the approval of the EIC.

Whenever requested by the EIC, the Contractor shall provide a certificate from the

manufacturer, for each and every delivery of material, showing the source, quantity delivered and confirming that the material has been tested and conforms to the required Indian Standard.

1.3 TESTING OF CONCRETE MATERIALS : Prior to the commencement of concrete work, the contractor shall get all cement

aggregates and water tested in the laboratories approved by the EIC and shall keep the approved samples in the site office for inspection at any time of the concreting operation. The test certificates shall be submitted to EIC for review & approval before concreting. During construction also, the materials shall be sampled and tested as often as deemed necessary and also as per the “Periodicity of Testing” by the EIC. Samples shall be taken and tested in accordance with the latest revision of relevant Indian Standard Specifications and the cost thereto shall be borne by the Contractor.

1.4 CEMENT : The cement used throughout the work shall be to the approval of the EIC. A certificate

shall be obtained from the manufacturers and produced to EIC for each delivery of cement and it shall comply with the requirements of as mentioned in the “Technical Specification – Materials” . The Contractor shall store the cement in storage sheds to be provided by him for this purpose at site. The cement shall be delivered to the site in bags sealed with the manufacturer's seal and different types of cement shall be stored separately. The storage sheds with watertight walls and roof, shall be maintained in a perfectly dry and wall ventilated condition, 12" above ground level and the cement shall be stored a per instructions issued by EIC. It shall be turned over from the bottom as and when required by the EIC. Any cement which has been deteriorated caked or which has been damaged due to any reason whatsoever shall not be used. No cement shall be used for the works that has been stored at site for more than three months. Test samples of cement may be drawn from each consignment as delivered and tested by the EIC. Should the results of such test show that any samples does not comply with the specified requirement, the whole consignment from which the sample was taken, shall be rejected and forthwith removed entirely from the site and replaced with cement of satisfactory quality.

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1.5 SAND :

Sand to be used for concrete shall be well graded mixture from coarse to fine grains, complying with the requirements of IS 383 Latest edition. It shall be clean, hard and free from salt, earth, clay and other impurities. Fine sand confirming to Zone – iv shall not be used. It will comply with sieve analysis in accordance with IS 2386 Part I & II.

Unless initially clean, all sand shall be thoroughly and carefully cleaned by screening and washing in fresh and clean water. The screened and washed sand shall not contain more than 8% by volume of clay, dust and silt immediately after allowing it to settle for 3 hours in water.

Field tests shall be carried out regularly to ensure the suitability of sand. Sample loads shall be available at site for inspection of the EIC and if approved by him

all sand in the work shall be of quality at least equal thereto. In case of sand containing moisture the proportions of concrete materials shall be

adjusted to give the correct mixture. 1.6 COARSE AGGREGATE : The coarse aggregate for the reinforced concrete work shall consist of crushed gravel,

black trap, granite or other stone to the approval of the EIC and shall be free from dust confirming to IS – 383 latest edition. If considered necessary by the EIC, the aggregate shall be washed specially until an approved cleanliness is obtained. The use of laminated stone, flat or flaky material will not be permitted. The combined coarse aggregate shall in all respects be so graded as to allow 95% to 100% by weight to pass a 20mm I.S. sieve 25% to 55% by weight to pass a 5mm I.S. sieve and 0% by weight to pass a 5mm I.S. sieve. The aggregates of different sizes shall be stored in separate stacks in clean state and free from all dirt.

The coarse aggregate where absorption of water after 24 hours immersion is more than

5% by weight shall not be used. When required by the EIC the tests indicated in I.S. 383 or IS-2386 ( all parts ) shall be

got carried out by the Contractor at his cost to show the acceptability of the materials. Stowage piles of aggregate shall have good drainage, preclude inclusion of foreign

matter and preserve the gradation. 1.7 WATER : Water used for all purpose in this contract shall be free from oil, acid, vegetable matter,

salts or dirt of any kind which will have adverse effect on cement or steel in the case of reinforced concrete. Whenever called for, the Contractor shall produce test results for water being used on work. The water quality shall confirm to IS-456-2000.

1.8 ADMIXTURES:

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Admixtures or Cement containing additives (such as accelerators, retarders, water proofing agents etc.) shall not be used unless specified or otherwise directed or approved by the EICs). The Admixtures shall confirm to IS-9103 latest edition.

1.9 FORM WORK : The form work shall be designed and constructed in such a manner that all concrete

work shall be true to line, level and size, and free from honeycombing, pinholes, surface irregularities and every other defect whatsoever.

All form work shall be adequately propped, braced and framed to prevent deformation under weight and pressure of wet concrete, constructional loads, wind, vibrations and other forces. All joints in shuttering shall be close fitting to prevent the loss of cement paste or mortar from the concrete.

All form work shall be carefully cleaned and coated with an approved proprietary mould

oil before use, care being taken to keep all reinforcement away from contact with such oil. All moulds shall be free from sawdust, shavings, dirt, mud or other debris by hosing with water or oil free compressed air.

The shuttering for beams and slabs shall be erected so that the shuttering on the sides

of the beams and of the soffits of the slabs can be removed without disturbing the beam bottoms. For beams having spans greater than 6 meters and for cantilevers, the form work shall be given adequate upward camber as directed by the EIC.

Details of all temporary work (timbering, staging etc.) are to be submitted for the

approval of the EIC and the form work shall be inspected and approved by the EIC before concrete is placed within it. Notwithstanding such approval, any damage or consequences arising there from shall be the Contractor's entire responsibility.

1.10 PROPORTIONS FOR CONCRETE: The contractor shall design concrete mixes (by Ready Mix Concrete Plants ) to produce

concrete of the required strengths. The contractor must submit full designs done from RMC plants of the mixes for approval of EIC and trial mixes will be prepared by the contractor in the presence of the EIC, having workability, strength, minimum cement content and surface finish as criteria. Notwithstanding the acceptance by the EIC of any mix design and series of trial mixes, variations may be made to the proportions when considered necessary by the EIC. Such variations may be made also to normal mixes if used, but variations of this nature will not be allowed to affect the unit price of concrete.

For both Nominal as well as Design mix concrete, the quantity of cement shall be

determined by weight. Where standard bags of cement are used, their weight shall be checked at frequent intervals and any loss in weight due to leakage etc. shall be made good.

In the case of Nominal Mix concrete, aggregates shall be measured by volume, cement

by weight and mixing water in graduated cans. In the case of controlled concrete all

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aggregates and cement shall be measured by weight in approved weigh batching equipment. Mixing water shall be measured in graduated cans.

While calculating the amount of mixing water, the moisture content of the aggregates

shall be taken into account. The grades of concrete shall be in accordance with Table below the cement content of

the mixes specified shall not exceed the minimum content specified in Table by more than 20%.

READY MIX CONCRETE :

The provision in this section shall apply to all concrete grades and is to be considered as a supplementary to general provisions for Plain Cement Concrete & Reinforced Cement Concrete works.

• Ready mix concrete (RMC) may be manufactured in a central automatic weigh batching

plant and transported to the job by agitating Transit mixers. The RMC is to be sourced from reputed & approved batching plants as mentioned in the approved list of manufacturers or suppliers only. The design mix has to be submitted to HPCL before concreting and the same has to be approved by HPCL before concreting is done.

• The design mix is to be carried out as per IS-10262.

• Note : No puzzolonic material such as Fly ash, Metakaoline & rice husk ash etc shall be

used for the work.

• The standard deviation for concrete mix design will be considered as per Table 8 of IS-456-2000.

• The proportion of fine aggregates to coarse aggregates should be adjusted so as to

keep them within the specified limits as mentioned in IS-383. • The Bidders have to submit the Quality Assurance Plan of theirs as well as the RMC

plant for approval and shall strictly adhere to the same. • The admixtures used shall confirm to IS-9103.

APPLICABLE CODES AND SPECIFICATIONS; The following specifications, standards and codes are made a 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 between this specification and those referred to herein, this specification shall govern. APPLICABLE IS SPECIFICATIONS AND CODES OF PRACTICE:

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IS 269:- Specification for ordinary, rapid hardening and low heat portland cement. IS-10262: Recommended guidelines for concrete mix design. IS 8112:- Specification for high strength ordinary, portland cement. IS 1489 - Specification for portland - pozzolona cement. IS 383:- Specification for coarse and find aggregates from natural source for concrete. IS 455: - Specification for Portland Slag Cement IS 2386:- Methods of test for aggregates for concrete. (Part I to VIII) IS 516:- Method of test for strength of concrete. IS 1199:- Method of sampling and analysis of concrete. IS 3025:- Methods of sampling and test (Physical and chemical) water used in industry. IS 432:- Specification for mild steel and medium tensile steel (parts I & II) bars and hard drawn steel wire for concrete reinforcement. IS 1139:- Specification for hot rolled mild steel and medium tensile steel deformed bars for concrete reinforcement. IS 4926: Ready Mix Concrete – Code Of Practice IS 1566:- Specification for plain hard drawn steel wire fabric (Part I) for concrete reinforcement. IS 1786:- Specification for cold twisted steel bars for concrete reinforcement. IS 2645:- Specification for integral cement waterproofing compound. IS 456:- Code of practice for plain and reinforced concrete. IS 3370:- Code of practice for concrete structures for storage of liquids (Part I to IV) IS 2502:- Code of practice for bending and fixing of bars for concrete reinforcement. IS 2571:- Code of practice for laying in situ cement concrete flooring. IS 3596:- Safety code for scaffolds and ladders. (Part I & II) IS 1200:- Method of measurement of building works.

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In the event that state, city or other Government bodies have requirements, more stringent than those set forth in this specification, such requirements shall be considered part of this specification and shall supersede this specification where applicable.The quality of materials , method and control of manufacture and transportation of all concrete works irrespective of the mix , whether reinforced or otherwise, shall conform to the applicable portion of this specification.Engineer shall have the right to inspect the source/s of material/s , the layout of operations of procurement and storage of materials, the concrete batching and mixing equipment and quality control system. Such an inspection shall be arranged and approval of Engineer-In-Charge shall be obtained prior to starting of concrete work. Concrete shall be mixed by mechanical mixer only and no hand mixing shall be allowed for RCC works. GENERAL: The quality of materials and method and control of manufacture and transportation of all concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portions of this specification.Engineer shall have the right to inspect the source/s of material/s, the layout and operation of procurement and storage of materials, the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and Engineer’s approval obtained, prior to starting of concrete work. MATERIALS FOR STANDARD CONCRETE: 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 or specifications. CONSISTENCY: The consistency of the concrete shall be such that it flows sluggish during pumping of concrete into the forms and around the reinforcement without any segregation coarse aggregate from mortar. The slump tests are mandatory and shall be carried out at regular intervals so that the consistency concrete can be monitored. PLACING OF CONCRETE: Concreting shall commence only after inspection and written approval by EIC. Shuttering shall be clean and free from deposits of foreign materials and proper deshuttering agent shall be applied to the surface. Proper arrangements shall be provided for conveying the concrete the place of deposition without disturbing the reinforcement. COMPACTION: Concrete shall be compacted immediately after placing by means of mechanical vibrators. All RCC works shall be cured for a minimum period of 14 days or more as advised by EIC. INSPECTION AND RECTIFICATION OF DEFECTS:

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Immediately on removal of forms, the RCC works shall be examined by the Engg. -in-Charge /

Architects before any defects are made good.

The work that has sagged or contains honey combing to an extent detrimental to the structural

safety or architectural concept shall be rejected.

Surface defects on a minor nature may be accepted and the same shall be rectified as follows

:

a) Bulges due to movement of forms, ridges at forms, ridges at form joints shall be carefully

chipped and then rubbed with a grinding stone.

b) Honeycombed and other defective areas must be chipped out, the edges being out as

straight as possible and perpendicular to the surface. Shallow patches are first treated with

a coat of thin grout (1 cement : 1 sand) and then filled with mortar similar to that used in

concrete. Large and deep patches shall be filled up with concrete held in place by forms

and shall be reinforced.

c) Holes left by bolts shall be filled carefully with mortar. Holes extending right through the

concrete shall be filled with mortar with a pressure gun.

d) The same amount of care to cure the material in patches should be taken as with the whole

structure.

POST TREATMENT OF SURFACE :

The surface which has to receive plaster or where it has to be joined with brick masonry walls

shall be properly roughened immediately after the shuttering is removed.

ACCEPTANCE CRITERIA OF CONCRETE WORK : will be as per IS-456-2000(CL.16).

MEASUREMENT

All measurements shall be as per IS 1200

1.11 MIXING OF CONCRETE: Mixing of concrete shall continue until there is a uniform distribution of material and the

concrete is uniform in colour and consistency and for at least two minutes.

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Mixes and weigh batches shall be maintained in first class condition throughout the contract and any mixer or plant which is faulty shall not be used. The drums on all mixers shall revolve at the speed recommended by the maker. A mixer of any type which has been out of use for more than 20 minutes shall be thoroughly cleaned out before any fresh concrete is mixed. All equipment shall be maintained in a clean serviceable condition and their accuracy periodically checked.

1.12 SLUMP TEST : The Contractor shall keep at the site of the works for the EIC’s use or his representative

a standard slump test mould and shall provide facilities throughout the construction for tests to be made as and when the EIC may require.

1.13 COMPRESSIVE STRENGTH : Concrete shall confirm to IS-456-2000.(Clause.16) The Contractor shall keep on site minimum 12 no.s standard 15 cm test cube moulds

and ancillary equipment for preparing test cubes. Before the Contractor commences any concrete construction he shall make six cubes of mix concrete with the cement sand, aggregate and water which he proposes using on the contract and shall have them tested at a Laboratory approved by the EIC/EIC. Three cubes shall be tested at 7 days and three cubes at 28 days after casting and curing. In all cases the cubes shall give the minimum compressive strength. No concrete construction shall be commenced until Preliminary Tests on the six cubes referred above have been completed and results show the concrete to have the minimum compressive strength. As construction proceeds samples from fresh concrete shall be taken as per IS 1199 - 1959 and cubes shall be made, cured and tested in accordance with IS 516 1959.

Three test specimens shall be made from each sample for testing at 28 days. Additional

cubes may be required for various purposes as to determine the strength of concrete at 7 days or at the time of striking form work, or to determine the duration of curing, or to check the testing error.

The test strength of the sample shall be the average of the strength of three specimens.

The individual variation should not be more than 15 percent of the average. Any part of the work from which the cubes fail to give the required minimum

compressive strength shall be dealt with by the Contractor as directed by the EIC and at the expenses of the Contractor.

The concrete is also liable to be rejected or repaired as per the instructions of the

EIC/EIC if it is porous or honeycombed, its placing has been interrupted without providing a construction joint or the reinforcement has been disproportionately displaced. The rejected concrete has to be demolished and redone to the satisfaction of the EIC free of cost.

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The Contractor shall keep a daily record (Concrete Pour Card ) showing the date when each portion of concrete is poured in slab, beam, column etc., curing, removal of form work and test cube results at 7 days and 28 days period. They shall be sent immediately to the EIC/EIC.

1.14 TRANSPORTING, PLACING AND COMPACTING OF CONCRETE : The concrete shall be transported maintaining required workability in a manner such as

to avoid the segregation of the constituent materials, and loss of any of the ingredients. It shall be deposited as nearly as practicable in its final position to avoid re handling. It shall be placed and compacted before setting commences and should not be subsequently disturbed. Methods of pouring should be such as to preclude segregation, and to avoid displacement of reinforcement and movement of form work. Concrete Pumping needs to be arranged for conveying the concrete from transit mixers to work spot.

The concrete should be thoroughly compacted and fully worked around the

reinforcement, around embedded fixtures and into the corner of the form work without formation of honeycombing, pinholes or surface irregularities and any other defects whatsoever.

The use of mechanical vibrators having capacity of producing vibrations at a rate not

less than 5000 cycles per minute is recommended. Over vibration or vibration of very wet concrete is harmful. In addition to mechanical vibration, sufficient hand tools must be used to assure full consolidation around reinforcement and at edges and corners.

The deposition of concrete shall be carried out as continuously as possible to reduce to

minimum joints between new concrete and concrete which has set. Where construction joints are necessary they shall be formed at right angles to the axis of the member concerned by the insertion of rigid stopping off forms, against which concrete can be properly rammed or as per the advise of Structural EIC..

No unset concrete shall be brought into contact with unset concrete containing cement

of different type. Special permission and instructions shall be obtained when concrete has to be deposited under water.

Accumulation of set concrete on the reinforcement shall be avoided. Before fresh

concrete is deposited upon or against any concrete which has already hardened, the surface of hardened concrete shall be well roughened if necessary by chipping and laitance remove. The surface shall then be swept clean with wire brushes, thoroughly wetted and covered with a thin layer of cement mortar.

1.15 PROTECTION OF CONCRETE : Newly placed concrete shall be protected by approved means from rain, sun and drying

winds. Concrete placed below the ground shall be protected from falling earth during and after placing. Approved means shall be taken to protect immature concrete from damage by debris, excessive loading, vibration, abrasion, deleterious ground-water,

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mixing with earth or other materials that may impair the strength and durability of concrete.

1.16 CONSTRUCTION JOINTS : Before construction commences the Contractor shall submit to the EIC, for his

approval, sketches showing proposed positions of construction joints. Each section of concrete shall be poured continuously between construction joints.

Shuttering to all construction joints should be so made that it produces on the face of joints a suitable grooved or indented surface to act as a sheer key or bond for the subsequent concrete. Inclined joints shall not be permitted.

If the concrete has been allowed to harden excessively, the surface shall be chipped

over its whole surface to a depth of at least 3/8"and thereafter thoroughly washed. If the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet surface with wire brushes to avoid dislodgement of particles of aggregate. Before fresh concrete is added to the other site of a construction joint the surface of the old concrete will be thoroughly wetted and then covered with a thin layer of cement mortar of the same quality as that in the concrete.

No distortion or displacement of reinforcement from the positions shown on the

drawings shall be permitted at construction joints. Water stoppers shall be provided to the construction joints of terrace slabs, kitchen and

bathroom slabs, and water retaining structures where water leakage poses serious problems.

1.17 STRUCTURAL JOINTS : Expansion joints or other permanent structural joints shall be provided in the positions

and of the form described in the drawings or elsewhere. In no case shall the reinforcement, corner protecting angles or other fixed metal items, embedded or bonded into concrete run continuously through as expansion joint. The placing of concrete on either side of the expansion joint shall be done separately after an interval of atleast 7 days.

1.18 CUTTING INTO CONCRETE : No concrete shall be cut into, nor shall it be interfered with in any way, without the prior

approval in writing of the EIC. Necessary holes shall be provided as required for plumbing work and for electrical pipes etc. at the time of execution.

1.19 CURING OF CONCRETE : Exposed surfaces of concrete shall be kept continuously in a damp or wet condition for

at least seven days from the date of placing of concrete.

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Approved curing compounds may be used in lieu of moist curing with the permission of

the EIC. Such compounds shall be applied to all exposed surfaces of the concrete as soon as possible after the concrete has set.

1.20 SUPERVISION: Constant and strict supervision of all the items of the construction is necessary during

the progress of the work, including the proportioning and mixing of the concrete. Supervision is also of extreme importance to check the reinforcement and its placing before being covered.

Before any important operation, such as concreting or striking off the form work is

started, adequate notice shall be given to the EIC.

1.21 CONTRACTOR'S RATES TO INCLUDE : The rates of contractor for providing and laying cement concrete in various grades or

proportions in the Schedule of Quantities shall, apart from any other factors specified elsewhere in the tender documents, include for the following:

(a) For all factors and method of work described in these specifications. (b) For all materials, labour, tools and plants, scaffolding, etc. mixing, conveying and

placing concrete in position, ramming, vibrating, trawling, curing, providing necessary scaffolding and removing the same after the work is complete.

(c) Unless otherwise specified in the Schedule of Quantities the cost for concrete items

shall include for providing and fixing form work as described inclusive of erecting, propping to required heights, bracing, providing stays, struts, bolts, nuts and everything necessary to keep the forms rigid, smoothening the surface to receive concrete as per detailed drawing, striking and stripping form work after the concrete is cured, hacking the concrete surface required to receive plaster etc.

(d) The reinforcement in case of Reinforced Concrete work will be paid for separately

unless otherwise stated in the particular items, but rate shall include for pouring concrete and packing around reinforcement.

(e) The measurement of concrete will be as per detailed drawings, shapes and size based

on net structural sizes as per drawings i.e. exclusive of plaster. (f) Rates for concrete items shall cover for any shape of structural members like columns,

beams, facias, fins, louvers etc. and for cantilevered beams slabs etc. (g) Formation and treatment of contraction and expansion joints (where water bars like

copper strips or joint fillers like 'Shalitex' are specified, such materials shall be paid for separately.

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(h) Design of mixes where so required by specification in an approved Laboratory and on tests of materials and work required in the opinion of the EIC and described in these specifications.

(i) Fixing all inserts like pipes, plugs, forming holes etc. as described. (j) Weigh-batching using a Mechanical weigh-batcher or a batching plant or where so

specified for volumetric batching. (k) For taking out dowel bars, fan hooks etc. through shuttering. (l) In case where at the junctions of beams, columns, slabs, the composition of concrete

mix or specified strength be different for columns, beams and slabs, then in such cases only the richer concrete among those specified for in all these members shall be used at the junctions and rate quoted for columns, beams and slabs or any member entering such junctions shall allow for the same. Rate shall also cover for spill over of richer concrete in beams to natural angle of repose of wet concrete required from practical considerations, while concreting the junctions.

(m) For forming drip moulds in Chajjas, sills, etc. and where shown in the drawings or as

directed. (n) For work at all levels. 2 STEEL REINFORCEMENT : 2.1 HIGH STRENGTH DEFORMED BARS : Wherever deformed high strength reinforcement bars are specified, the contractor shall

use one of the following, accompanied by a certificate from the Manufacturer like TATA/SAIL/VIZAG only confirming to IS-1786 latest edition.

2.2 CLEANING OF REINFORCEMENT : Before steel reinforcement is placed in position, the surface of the reinforcement shall

be cleaned of rust, dust, grease and other objectionable substances. 2.3 CUTTING OF REINFORCEMENT : Before the reinforcement bars are cut, the contractor shall study the lengths of bars

required as per drawings and shall carry out cutting only to suit the sizes required as per drawings.

2.4 PLACING AND SECURING : Reinforcement bars shall be accurately placed and secured in position and firmly

supported or wedged by precast concrete blocks of suitable thickness, at sufficiently close intervals, so that they will not sag between the supports or get displaced during the placing of concrete or any other operation of the work. It is most important to maintain reinforcement in its correct position without displacement and to maintain the

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correct specified cover. Contractor shall be responsible for all costs for rectification required in case the bars are displaced out of their correct position.

2.5 BINDING WIRE : The reinforcement shall be securely bound wherever bars cross or wherever required

with 18 gauge soft annealed steel wire. 2.6 WELDING : Welding of bars shall not be carried out unless specially authorised in writing by

Structural EIC. 2.7 BENDS ETC : Bends, cranks etc. on steel reinforcement shall be carefully formed, care being taken to

keep bends out of winding. Otherwise, all rods shall be truly straight. If any bend shows signs of brittleness or cracking, the rod shall be removed immediately from the site. Minimum radius of 9 times diameter of the bar shall be used unless otherwise specified in the drawings. However, in respect of standard hooks the radius of bend shall be 2 times of diameter of bar. Heating of reinforcement of bar to facilitate bending will not be permitted. The bars shall always be bent cold.

In case of mild steel reinforcement bars of larger sizes, where cold bending is not

possible, they may be bent by heating with written permission of the Project Engineer. Bars when bent hot shall not be heated beyond cherry red colour and after bending, shall be allowed to cool slowly without quenching. The bars damaged or weakened in any way in bending shall not be used on the work. High strength deformed bars shall in no case be heated to facilitate bending or cranking.

2.8 INSPECTION OF REINFORCEMENT : No concreting shall be commenced until the Structural EIC has inspected the

reinforcement in position and until his approval has been obtained. A notice of at least 24 hours shall be given to the Project Engineer by the Contractor for

inspection of reinforcement. If in the opinion of the Project Engineer any material is not in accordance with the

specification or the reinforcement is incorrectly spaced, bent or otherwise defective, the contractor shall immediately remove such materials from the site and replace the same and rectify any other defects in accordance with the instruction of the Project Engineer to his entire satisfaction.

2.9 NET MEASUREMENTS : Reinforcement shall be placed as shown on the structural drawings and payment will be

made on the net measurements from drawings. No laps, dowels, chairs and pins in reinforcement shall be paid for. The Contractor shall allow in his quoted rate for all wastage which will not be paid for.

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2.10 RATES QUOTED FOR REINFORCEMENT SHALL IN ADDITION TO ANY FACTORS MENTIONED ELSEWHERE SHALL ALSO INCLUDE FOR :

(a) All cutting to lengths, labour in bending and cranking, forming hooked ends, handling, hoisting and everything necessary to fix reinforcement in work as per drawings.

(b) Cost of binding wire required as described. (c) Cost of PVC blocks to maintain cover and holding reinforcement in position. (d) For fabricating and fixing reinforcement in any structural member irrespective of its

location, dimensions and level. (e) Removal of rust and every other undesirable substances, using wire brush etc. as

described. (f) Stock piling of reinforcement as described. (g) Work at all levels.

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SPECIFICATION OF MECHANICAL SHOE SEAL (LIQUID MOUNTED

MECHANICAL SEAL) Mechanical Shoe Seals comprise a metallic sealing ring, which is held in permanent contact with the tank shell and extends into the product by a system of independent hanger and pusher mechanisms, and with a continuous sealing apron curtain closing the gap between the rim and the top of the “Shoe”. The product vapors are contained between the “shoe”, apron curtain and the floating roof. The design of the Mechanical Shoe Seal should be “Channel Hanger” Type with independent hanger and pusher devices. The design of the Mechanical Shoe Seal should be such that in service installation is enabled with no hot work allowed i.e. no welding or flame cutting. The Mechanical Shoe Seal should conform tightly to shell plate contours adaptable to existing rim and shell configuration, including wide variations in rim gap. The seal is characterized by a shoe-to-shoe slip joint connection, which allows for any variation in the rim space irregularities between the rim and tank shell, while containing the product vapors. It should be custom designed to suit the tank. The Channel hanger type assembly should successfully maintain a constant seal elevation even with a wide rim space. Stainless steel shoes shall have a minimum nominal thickness of 1.2 mm (18 gauges). Stainless steel shall conform to the requirements of ASTM A 240/A 240M (austenitic type only). Pusher mechanism should be SS conforming to the requirement of Stainless Steel as given above. Static Shunt to be SS conforming to the requirement of Stainless Steel as given above. All fasteners shall be Stainless Steel only. Hanger Channels assembly should be minimum 14 gauge. Seal Curtain/ Dip Curtain should be compatible with stored product, recommended 0.5mm thk PTFE. A protective mechanism should be provided to protect the vapour curtain. VENDOR / MANUFACTURER ELIGIBILTY Vendor shall have proven experience in supplying & installing the mechanical Shoe Seal in India with necessary documentary proof for having executed such jobs in the last 2 Years for a minimum dia of 30 Mtr.

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INSPECTION CRITERIA : Maximum seal gap area will be 200 cm2/m of tank diameter. Vendor should inspect the seals once in six months during guarantee / warrantee period & Vapour loss calculations meeting CPCB standards to the relevant clause using Tank 4.0 (latest version) software, incorporating local weather conditions shall be provided along with the inspection report. Scope of Third Party Inspection Seal Curtain: Testing of properties to be witnessed and verified. Other tests to be carried out at a reputed laboratory and the results shall be furnished for review / approval. GUARANTEE: 24 months from the date of installation & 30 months from the date of supply which ever is earlier.

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Specifications of Secondary Seal

Secondary seal shall be of compression plate rim mounted horizontal or vertical (preferably horizontal), made from series of metallic sheet joined together to form a ring with a non-metallic tip that slide on the inside surface of the tank shell. The joints to be bolted or sliding and to incorporate gasket at the point of overlap of the compression plate. Compression plate of the secondary sealing system should be sized to match the existing annular space between the tank shell & the floating roof. The compression plate should be clamped on the Rim flat/angle with channels duly galvanized. The compression plate to have the compression channel gasketing. It should provide “Leak tight” joint between the plates. Each seal plate should be sealed with the adjacent plate in a fashion to eliminate vapor loss. Stainless steel compression plates shall have a minimum nominal thickness of 1.2 mm (18 gauge). Stainless steel shall conform to the requirements of ASTM A 240/A 240M (austenitic type only). Static Shunt to be SS conforming to the requirement of Stainless Steel as given above. All fasteners to be galvanized for seals of galvanized construction & SS for SS construction. A protective mechanism should be provided to facilitate smooth re-entry of the secondary Seal onto the Tank Shell in the event of Tank overfilling. Secondary seal system shall be tight fitted, rim mounted, with a wiper Tip made of a polymer compatible to the stored product. The Sealing Gasket to be made of a polymer compatible to the stored product. Seal shall have very low coefficient of friction, shall not damage or score the tank shell. Metallic seal components shall have adequate corrosion protection for long life. All material used in the seal manufacturing shall be tested and certified for extended use in hydrocarbon products. It should be custom designed to suit the tank. Additionally, the secondary seal should have the following design features,

A. Safely ground lightening strike. B. Minimize seal gap and shed water to the extent possible. C. Capable in operating effectively over irregular rim gaps. D. To install from above the deck without any hot works.

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E. Seal material must be compatible with product stored. F. Non-metallic parts must resist cracking and tearing. G. Metallic components must resist corrosion. H. To be able to dismantle the secondary seal, without affecting

evaporative loss control characteristics of primary seal. I. Secondary seal shall extend from the roof to the tank shell and shall

not be attached to the primary seal. VENDOR / MANUFACTURER ELIGIBILTY Vendor shall have proven experience in supplying & installing the mechanical Shoe Seal in India with necessary documentary proof for having executed such jobs in the last 2 Years for a minimum dia of 30 Mtr. INSPECTION CRITERIA : Maximum seal gap area will be 20 cm2/m of tank diameter. Vendor should inspect the seals once in six months during guarantee / warrantee period & Vapor loss calculations meeting CPCB standards to the relevant clause using Tank 4.0 (latest version) software, incorporating local weather conditions shall be provided along with the inspection report. Scope of Third Party Inspection. Wiper Tip Material : Testing of properties to be witnessed and verified. Tests of other components to be carried out at a reputed laboratory and the results shall be furnished for review / approval. GUARANTEE : 24 months from the date of installation & 30 months from the date of supply which ever is earlier.

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Specification for Gauge Pole Sleeve / Landing Leg Sleeve The Gauge Pole Sleeve shall consist of a flexible enclosure to be installed over existing slotted gauge pole along the height of the pole and can adjust its height depending upon the height of the deck in an external floating roof tank. The Landing Leg Sleeve is a flexible enclosure to be installed over existing telescopic landing legs along the height of the pipe. This flexible enclosing device should completely enclose the slotted gauge pole and the landing leg while eliminating VOC emission pathway from inside the tank through the gauge pole slots and the landing legs. It should also seal any opening between well cover and any other openings in the gauge pole well & landing leg area. Gauge pole sleeve / Landing leg sleeve shall be self adjusting type and can be easily retrofitted on existing gauge poles & landing legs. The Gauge Pole Sleeve / Landing leg sleeve shall be provided to minimize emissions through the gauge pole slots and landing leg area. The detailed specifications of the gauge pole sleeve shall be as follows, 1. It should be custom designed to suit the pole & leg of the floating roof tank. 2. Gauge pole sleeve / Landing Leg Sleeve material shall be a minimum of 0.4 mm thickness. 3. The Sleeve material shall be non corrosive while handling petroleum hydrocarbons. 4. The Sleeve material shall withstand Rain water. 5. The Sleeve material shall be 100% compatible & corrosion free for any type of Hydrocarbons. 6. The finished sleeve material shall be free of all oils, solvents and release agents. The material should be of uniform thickness and be free from cosmetic defects. 7. The sleeve Material fabric shall not wick or become brittle during its service life. The Gauge pole sleeve material will be resistant to the effects of wind, rain, sand, UV rays & be suitable for service up to +800 C. 8. The gauge pole sleeve / landing leg sleeve should be able to be installed while the tank is in service. VENDOR / MANUFACTURER ELIGIBILTY Vendor shall have proven experience in supplying & installing the gauge pole sleeve / landing leg sleeve in India with necessary documentary proof for having executed such jobs in the last 2 Years. INSPECTION CRITERIA: Vendor should inspect the Sleeve once in six months during guarantee / warrantee period & Vapor loss calculations using Tank 4.0 (latest version) software, incorporating local weather conditions shall be provided along with the inspection report. Scope of third party inspection Gauge Pole / Landing Leg Sleeve Material: Testing of Properties to be witnessed & Verified.

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Tests of other components to be carried out at a reputed laboratory and the results shall be furnished for review / approval. GUARANTEE : 36 months from the date of installation & 42 months from the date of supply which ever is earlier.

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SPECIFICATION FOR

UNBONDED FLEXIBLE PIPE

FOR

TANK ROOF DRAIN SYSTEM

OF

FLOATING ROOF TANKS

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1.0 SCOPE

1.1 This specification covers design, manufacturer, supply, testing supervision of installation and guarantee of unbonded flexible hose pipe including connecting flanges for floating roof tank as per API-650 latest edition.

1.2 The manufacturing plant shall be API – 17J certified. Approved Manufacturer ( A) Coflexip (Flexi France) ( B) Well stream Holding Plc U.K (C) NKT Flexible Denmark

2.0 TECHNICAL SPECIFICATION

2.1 Flexible pipe shall consist of two layers, each layer unbonded to each other as

follows:

� Inner layer shall be SS type 304 Carcass.

� Outer layer shall be polyamide/thermoplastic made of Nylon 11, Rilsan brand.

� Each layer shall be un bonded as per Cl.3.46 of API17J(3rd edition, July

2008).Interchangeability of layers is not allowed. � The inner carcass should be of interlocked metallic construction as per

cl.3.12 of API17J(3rd edition, July 2008). � Flexible pipe must be 100% resistant to aromatics and petroleum

products stored in the subject tanks and should confirm to Cl.5.2.1 of API 17J. The design life of pie should be 20 years.

� Flexible pipe must provide Repetitive Lay Pattern (RLP) without any

external support or accessories like tethered assemblies, ballasting etc., during its full operational life.

� Poly amide extrusions should confirm to Cl.8.3.1.2 of API17J(3rd edition,

July 2008). � Assembled hose will not be acceptable. The bidder shall manufacturer

both layers independently as per 17J.

� Flexible pipe shall have Built-in end fittings with ASME B 165, 150# CS RF swivel flange.

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� Full length of pipe shall be in single continuous length without any intermediate joints in between the two end flanges. Vulcanization is not acceptable.

� The unbounded flexible hose should be designed in such way that the

inner SS type 304 carcass is held in tension to keep the hose in same position as it was when installed. No kinking of flexible pipe shall take place during movement (upward/downward) of the roof.

� No chemical attack, Gas penetration or ballasting and mechanical wear

shall take place with the flexible pipe.

� Flexible pipe shall not induce lateral forces on the floating roof. 2.2 Vendor shall guarantee the product for minimum 3 years after installation. 2.3 Vendor /Manufacturer of the flexible pipe must have a minimum of 3 years of

field proven reference in India for similar application in floating roof tanks. Relevant document from the customers shall be furnished along with bid.

2.4 Flexible pipe shall be inspected by Lloyds/DNV/EIL/ABS/Bureau Veritas or any

other Third Party Inspection Agency approved by HPCL and relevant certificates shall be furnished.

2.5 The manufacturer shall provide hydro test certificates for the flexible pipe duly

certified by Third Party Independent Inspection agency. 2.6 Bidder shall specify the make offered in their unpriced bid along with all

necessary literature, catalogues, etc. for above.

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1. The vendor’s scope covers design, manufacture, supply, testing, installation, hydro test, supervision of commissioning & guarantee of stainless steel armored hose as per API-650 (latest edition) including connecting flange for floating roof tank.

2. Stainless steel armored hose as per API 650 in contact with liquid stored in the tank must be 100 % resistant to aromatics.

3. Stainless steel armored hose as per API 650 must provide REPETITIVE LAY PATTERN (RLP) without any external support or accessories like tethered assemblies, ballasting, chain etc, during its full operational life.

4. Assembled hose shall not be acceptable.

5. Flexible tube shall have built in end-fittings with ASME B 16.5 #150, A105 Flange.

6. The designed working pressure rating for the flexible drain tube should be 30 PSI and the test pressure should be 60 PSI.

7. Full length of tube shall be in single continuous length without any intermediate joints in between the two end flanges

8. The stainless steel armored hose should be designed in a way that the hose shall be kept in the same position as it was when installed. No kinking of stainless steel armored hose as per API 650 shall take place during movement (upward/downward) of the roof.

9. No chemical attack, gas penetration or ballasting and mechanical wear shall take place with flexible tube

10. Stainless steel armored hose shall not induce lateral force on the floating roof.

11. Stainless steel armored hose shall be inspected by third party inspection agency LLOYDS/DNV/CEIL/BV or any other third party inspection agency approved by HPCL.

12. Relevant certificate / documents (along with each flexible line) shall be furnished along with supply

13. Third party inspection includes pressurizing the flexible hose to the test pressure (60 psi),

allow it to stabilize and maintain pressure for 4 hours & carry out a visual inspection for leaks

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14. The manufacturer shall provide hydro test certificate for the flexible hose duly certified by third party inspection agency.

15. Vendor shall confirm the adequacy of the design of stainless steel armored hose as per

API 650(its size & length) for 100% evacuation when the roof is in its lowest position during maximum rainfall intensity period

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Page 1 of 4

TECHNICAL SPECIFICATIONS

FOR

PIPES

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Page 2 of 4

TECHNICAL NOTES FOR PIPES 1.0] GENERAL 1] All pipe and their dimensions, tolerance, chemical composition and physical properties. Heat

treatment hydro test and other testing and marking shall conform to the codes and standards specified herein. In case of any deviations the same should to be highlighted.

2] Test report shall be supplied for al mandatory test as per the applicable material specifications Test report shall also be furnished for any supplementary test specified herein.

3] Material test certificates (physical properties chemical composition and Heat treatment report) shall also be furnished for the pipes supplied.

4] Steel made by acid Bessemer process shall not be acceptable. 5] All longitudinally welded pipes other than IS: 3589 should employ automatic welding only.

Vendor shall specify the type of welding technique which will be employed. 6] Pipe shall be supplied in single random length OF 4 – 7 Mtrs. 7] Seamless and LSAW pipes shall not have any circumferential seam joint in a random length. 8] Pipes with Bevel ends shall be in accordance with ANSI B-16.25 weld contours shall be as

follows. Material Wall Thickness Weld Contour Carbon Steel [Except low Temp. CS.]

Upto and incl. 22mm Fig. 2 type A

9] Specified heat treatment for CS shall be carried out after weld repairs, number of weld repairs at

same spot shall be restricted to max two by approved repair procedure. 2.0] HYDRO TEST As per relevant IS code ie. IS1978 / 3589 or 1239 3.0] MARKING AND DESPATCH 1] All pipe shall be marked in accordance with the applicable codes, standards and specifications.

In addition the PO No and item digit code will also be marked. 2] Point or ink marking shall not carry any harmful metal or metallic salts such as lead. Zinc or

copper which causes corrosive attack on heating. 3] Pipe shall be dry, clean and free from moisture, dirt and loss foreign material of any kind. 4] Pipe shall be protected from rust, corrosion and mechanical damage during transportation,

shipment and storage. 5] Rust preventive used on machined surfaces to be welded shall be easily removable with a

petroleum solvent or shall not be harmful to welding. 6] Both ends of the pipe shall be protected with the following material:

PE Plastic Cap BE Wood, Metal or Plastic cover.

End protectors to be used on BE shall be securely and tightly attached with belt or wire.

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4.0] Quality and data/ documentation requirements 1] QA plan Vendor during bidding stage shall confirm compliance to his Quality Assurance plan consisting

of relevant procedures covering various activities like design and engineering material procurement, manufacture, inspection and testing documentation dispatch to site erection and commissioning wherever applicable and maintenance of quality records in the post order stage. The vendor shall confirm the validity of their QA plans and submit only deviation/revisions if any to these plans to Sr. Manager –E&P HPCL 1 floor Hindustan Bhavan for approval within two weeks from the date of receipt of FOI/PO whichever is earlier.

2] ITP Vendor shall submit inspection and test plan for approval within 2 weeks of FOI/PO and before

commencement of manufacture to Sr. Manager –E&P and should cover bought out items from sub vendors.

3] Drawing Schedule Vendor shall submit a total index of drawings and documents required for review/records along

with the scheduled date of submission of each drawing/document within 2 weeks from date of issue of FOI PO whichever is earlier where ever required.

4] Progress report and Schedule Vendor shall submit Monthly Progress Report and update procurement engineering and

manufacturing schedule every month starting from 2 weeks from date of issue of FOI/PO whichever is earlier.

5] Waiver and deviation Vendor shall strictly comply with the PO stipulations and no deviations shall be permitted. 6] Procurement of Bought out Materials All critical materials such as casting, forging, fitting, pressure holding parts electrical and

instrument accessories etc. shall be purchased by the vendor from HPCL approved suppliers only. It would be preferable for the vendor to enlist the services of vendor having EIL approval. Vendor shall submit a list of bought out materials for HPCL approval within 2 weeks from the date of issue of FOI/PO whichever is earlier.

7] Calibration Records Vendor shall use only calibrated measuring and test instruments and maintain calibration

records. Vendor shall furnish records of calibration of measuring and test instruments including recalibration records to Third party inspection Agency on demand.

8] Inspection test status Inspection and test status of products shall be identified by using markings. Authorized stamps,

tags, route cards, inspection cards etc. during the course of manufacture to clearly indicate acceptance rejection of tests stages of inspection performed during its manufacturing cycle.

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Page 4 of 4

9] Quality records Vendor shall maintain quality records as per his procedures inspection reports & test records

copies shall be furnished to HPCL/Third Party Inspection Agency. 10] Identification and Traceability Vendor shall establish and maintain a standard written procedure for identifying the products

from applicable drawing specifications or other documents during all stages of production delivery and installation. A copy of this standard procedure shall be made available to HPCL/Third Party Inspection Agency. The Vendor shall ensure that each product which is going in the process of fabrication / manufacture / construction / erection has proper identification throughout the process including the final output.

11] Vendor document for Review and Records General

1] All documents shall be in English language and MKS system of units. 2] Review of the Vendor drawing by Third Party Inspection Agency / HPCL would be only

to review the compatibility with basic design and concepts and in no way absolve the vendor of his responsibility to comply with PO requirements applicable codes, specifications and statutory rules/regulations.

3] Submission of documents for review/records shall commence within 2 weeks from the date of issue of FOI/PO

4] Unless otherwise agreed the vendor shall submit all drawings and document sin number of copies as stipulated in the vendor data requirement from along with documents index. The documents shall be submitted in soft copies wherever specified.

11.1] Vendor shall ensure that each drawing shall contain the following information: PO No name of equipment, tag no., name of project, Client, Drawing/Document title,

Drawing No., Revision and date. The drawing document shall be checked approved and duly signed stamped by the vendor

Revisions and date. 11.2] Documents under review Category. Following review codes shall be used for review of vendor documents / drawings. Code 1 Approved Code 2 Proceed with manufacture / fabrication as per commented Document revised document required. Code 3 re submit for review as marked. 12] Final Documents Final drawings/documents consisting of Technical Data Manual is a compilation of As-Built

Certified. Drawing and data manufacturing and test records. Installation operating and maintenance instructions and each set shall include six copies.

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d) Preparation of design calculations for non-standard connections, temporary bracings etc_ for approval of purchaser. �

e) Cold straightening of section and plates, whenever they are bent and kinked. �

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3.3.5.6 Instrumental checking of correctness of initial setting out of structures and adjustment of alignment shall be carried out in sequence and at different stages as required. The final leveling and alignment shall be carried out immediately after completion of each section of a building.

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5.1.3 INSPECTION AND APPROVAL OF SURFACE

• All painting materials including primers and thinners brought to site by the Contractor for application shall be directly procured from Approved manufacturers as per specifications and shall be accompanied by Manufacturer Test Certificates.

• HPCL may call for tests for the primers and paints including verification of batch wise

tests for physical and chemical analysis. The Contractor shall carry out the same at his own cost and provide the results to HPCL.

• The painting work shall be subjected to inspection by HPCL at all times. Stages of

inspection are as follows: • Surface Preparation • Primer application • Each coat of paint

• All records of inspection shall be maintained in Registers and jointly signed by HPCL and Contractor.

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• Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the satisfaction of HPCL before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, Contractor shall be fully responsible for making good any defects found during Final inspection or during the Defect Liability period. DFT shall be checked and wherever shot same shall be made up with additional coats.

• The shades of successive coats should be slightly different in colour in order to ensure application of individual coats in consultation with manufacturer.

• Calibrated Digital Elcometers, surface profile gauges and any other inspection

instrument required by HPCL shall be provided by the contractor at site.

• The contractor shall arrange expert technical support at site by paint Manufacturer who will cross verify independently regarding surface preparation and DFT and quality and provide a report to HPCL.

5.1.4 DOCUMENTATION:

1.A written quality Plan with procedure for qualification trials and for actual work.

2.Daily progress Report with details of humidity, surface preparation, surface profile, Dry film thickness particulars of applications, number of coats applied, type of materials used, methodology-Air or Airless or Brush, progress of work vs programme.

3.Code and Batch numbers of primers and paint materials used.

4.Type of testing equipments and their calibration.

5.Elcometer readings for the various components jointly recorded with HPCL.

6.Paint consumption statement along with the Theoretical consumption requirements. �

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-(�.��6 6 ��

1 2 3 4 5 Contractor HPCL

Heat No:

DFT Reading - High Build Coal Tar Epoxy Coating @ 365 micron in finall

QC Engineer

Contractor

BOTTOM PLATE FINAL PAINT

Remarks

Surface preparation

Date:Tank No: Activity:-

P.O. No: Party: Job:Plate use Location:

Contractor.Site Incharge

H.P.C.L.

SignatureSl No Plate No


Plate No

Surface Preparation

on as per standerd S/A

2½

DFT Reading - Inorganic Zinc Silicate Coating @ 65-70 micron Signature

Contractor

ANNULAR PLATE PAINTING REPORT

Date:Tank No: Activity:- Heat No:

Surface preparation

P.O. No: Party: Job: Plate use Location:

QC EngineerContractor.

Site InchargeH.P.C.L.

RemarksSl No

TANK NO.

JOB NO. 1

CONTRACT NO.

DESIGNED BY

MANUFACTURED FOR

ITEM NO.

MANUFACTURER SERIAL NO.

INSPECTED BY HPCL YEAR OF FABRICATION

CODE/ APPENDIX

DESIGN TEMP. 65.0 Degree C

DESIGN PRESSURE Atmospheric

TEST PRESSURE Full of water

PARTIAL STRESS RELIEF NIL

DATE OF CALIBRATION DESIGN SPECIFIC GRAVITY

API 650 - Appendix C

Floating Roof/ Cone Roof Tank

NOMINAL DIAMETER

NOMINAL HEIGHT

NOMINAL CAPACITY

API NAME PLATE

Hindustan Petroleum Corporation Limited

NAME OF THE CONTRACTOR

HP LOGO

DESIGN LIQUID LEVEL


P.O. No: Party: Job: Plate use Location:

Activity:- Cu slag Blasting and PrimerHeat No:

Sl No

Surface preparation

QC EngineerContractor


Plate No

Surface Preparation on as per standerd S/A 2½ (profile meter

reading)


Remarks

ContractorGRIT BLASTING SURFACE PREPARATION SA 2½

SHELL PLATE FINAL PAINTING REPORT

Date:Tank No:


Plate No

Surface Preparation

on as per standerd S/A

2½


ContractorGRIT BLASTING SURFACE PREPARATION SA 2½

BOTTOM PLATE SOIL SIDE BLASTING & PAINTING REPORT

Date:Tank No: Activity:- Heat No:

Surface preparation

P.O. No:Party: Job: Plate use Location:

QC EngineerContractor


RemarksSl No

Owners Name : Hindustan Petroleum Corporaion Limited.

Location

Tank No. : 9

Type : Vertical Cylindrical Singal Deck Floating Roof Tank.

Avg. Internal Dia. : 21.993 Mtrs.

Actual Height : 14.55 Mtrs.

Reference Height : 16.63 Mtrs.

Capacity - Safe Filling : 4858 K L

Nominal capacity : 5000 K L

Tilt TO The Tank : 2.0 Cms.

Height of datum plate : 19.0 Cms.

Wt. of Roof : 51000 KGS.

Legs Positions L.Legs : 137.2 Cms.

H.Legs : 197.2 Cms.

Product : MS

Calibrated On : 02.02.2007.

Valid Upto : 01.02.2012.

Safe Filling Height : 12.80 Mtrs.

Notes :The level of Datum plate of the tank immediately below the Gaugewell pipe should be taken as zero depth in the calibration chart.

This calibration chart is valid upto 01.02.2012 or even earlier to the date of making any addition or alteration in the tank or change its position.

Calibration chart table is set out to show litres at the intervals of 5.0 cms .Use fraction part table for immediate dips to get accurate results.

Certified that calibration upto cone top for Bottom plate was physically done by filling water through water meter.

Page 1/12

Hindustan Petroleum Corporation Limited.

Calibration Chart

Calibration Chart Tank No. Ownres Name : Hindustan Petroleum Corporation Limited.

Dip In Volume In Dip In Volume In Dip In Volume InCms. Litres Cms. Litres Cms. Litres Cms. Litres

0 6233 250 945026 500 1894985 0.1 3805 16033 255 964027 505 1913983 0.2 760

10 33610 260 983027 510 1932981 0.3 114015 52190 265 1002027 515 1951979 0.4 152020 71191 270 1021028 520 1970977 0.5 190025 90191 275 1040028 525 1989975 0.6 228030 109187 280 1059029 530 2008973 0.7 266035 128190 285 1078029 535 2027972 0.8 304040 147198 290 1097029 540 2046971 0.9 342045 166208 295 1116030 545 2065970 1.0 3800

50 185224 300 1135030 550 2084969 1.1 418055 204242 305 1154031 555 2103968 1.2 456060 223256 310 1173031 560 2122966 1.3 494065 242266 315 1192031 565 2141965 1.4 532070 261275 320 1211032 570 2160964 1.5 570075 280281 325 1230032 575 2179963 1.6 608080 299287 330 1249032 580 2198962 1.7 646085 318291 335 1268033 585 2217960 1.8 684090 337280 340 1287033 590 2236959 1.9 722095 356257 345 1306034 595 2255958 2.0 7601

100 375231 350 1325034 600 2274957 2.1 7981105 394204 355 1344034 605 2293956 2.2 8361110 413171 360 1363035 610 2312955 2.3 8741115 432141 365 1382035 615 2331953 2.4 9121120 451111 370 1401036 620 2350952 2.5 9501125 470082 375 1420036 625 2369951 2.6 9881130 489052 380 1439034 630 2388950 2.7 10261135 508022 385 1458032 635 2407949 2.8 10641140 527010 390 1477030 640 2426947 2.9 11021145 546011 395 1496028 645 2445946 3.0 11401

150 565013 400 1515026 650 2464945 3.1 11781155 584014 405 1534024 655 2483944 3.2 12161160 603016 410 1553022 660 2502943 3.3 12541165 622017 415 1572020 665 2521941 3.4 12921170 641019 420 1591018 670 2540940 3.5 13301175 660020 425 1610016 675 2559939 3.6 13681180 679021 430 1629014 680 2578942 3.7 14061185 698021 435 1648012 685 2597946 3.8 14441190 717022 440 1667010 690 2616949 3.9 14821195 736022 445 1686008 695 2635953 4.0 15201

200 755022 450 1705005 700 2654956 4.1 15581205 774023 455 1724003 705 2673960 4.2 15961210 793023 460 1743001 710 2692963 4.3 16341215 812024 465 1761999 715 2711967 4.4 16721220 831024 470 1780997 720 2730970 4.5 17101225 850024 475 1799995 725 2749974 4.6 17481230 869025 480 1818993 730 2768977 4.7 17861235 888025 485 1837991 735 2787981 4.8 18241240 907025 490 1856989 740 2806985 4.9 18621245 926026 495 1875987 745 2825988

Pg 2/12

Fractions

Calibration Chart Tank No. Ownres Name : Hindustan Petroleum Corporation Limited.

Dip In Volume In Dip In Volume In Dip In Volume InCms. Litres Cms. Litres Cms. Litres Cms. Litres750 2844992 1000 3794992 1250 4744867 0.1 380755 2863995 1005 3813989 1255 4763865 0.2 760760 2882999 1010 3832986 1260 4782863 0.3 1140765 2902002 1015 3851983 1265 4801861 0.4 1520770 2921006 1020 3870981 1270 4820858 0.5 1900775 2940009 1025 3889978 1275 4839856 0.6 2280780 2959013 1030 3908975 1280 4858854 0.7 2660785 2978016 1035 3927972 ----- ----- 0.8 3040790 2997020 1040 3946970 0.9 3420795 3016023 1045 3965967 1.0 3800

800 3035027 1050 3984964 1.1 4180805 3054030 1055 4003961 1.2 4560810 3073034 1060 4022958 1.3 4940815 3092037 1065 4041956 1.4 5320820 3111041 1070 4060953 1.5 5700825 3130045 1075 4079950 1.6 6080830 3149046 1080 4098947 1.7 6460835 3168044 1085 4117945 1.8 6840840 3187043 1090 4136942 1.9 7220845 3206041 1095 4155939 2.0 7601

850 3225040 1100 4174936 2.1 7981855 3244038 1105 4193934 2.2 8361860 3263037 1110 4212931 2.3 8741865 3282036 1115 4231928 2.4 9121870 3301034 1120 4250925 2.5 9501875 3320033 1125 4269923 2.6 9881880 3339031 1130 4288920 2.7 10261885 3358030 1135 4307918 2.8 10641890 3377029 1140 4326916 2.9 11021895 3396027 1145 4345913 3.0 11401

900 3415026 1150 4364911 3.1 11781905 3434024 1155 4383909 3.2 12161910 3453023 1160 4402907 3.3 12541915 3472021 1165 4421905 3.4 12921920 3491020 1170 4440902 3.5 13301925 3510019 1175 4459900 3.6 13681930 3529017 1180 4478898 3.7 14061935 3548016 1185 4497896 3.8 14441940 3567014 1190 4516894 3.9 14821945 3586013 1195 4535891 4.0 15201

950 3605011 1200 4554889 4.1 15581955 3624010 1205 4573887 4.2 15961960 3643009 1210 4592885 4.3 16341965 3662007 1215 4611883 4.4 16721970 3681006 1220 4630880 4.5 17101975 3700004 1225 4649878 4.6 17481980 3719003 1230 4668876 4.7 17861985 3738000 1235 4687874 4.8 18241990 3756997 1240 4706872 4.9 18621995 3775994 1245 4725869

Pg 3/12

Fractions

Tank NO.

Shell Capacity Calculation.

1 2 3 4 5 6 7 8 9Avg.Ext.Circum. 3.1428 69.2200 69.2180 69.2010 69.1900 69.1860 69.1770 69.1620 69.1630 69.1580Thickness 14.0 14.0 12.0 10.0 8.0 8.0 6.0 6.0 6.0Thick 2 py t 0.087998 0.087998 0.075427 0.062856 0.050285 0.050285 0.037714 0.037714 0.000000V.Jts. 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012Total Dedudction 0.099998 0.099998 0.087427 0.074856 0.062285 0.062285 0.049714 0.049714 0.012000Avg.Int.Circum. 69.1200 69.1180 69.1136 69.1151 69.1237 69.1147 69.1123 69.1133 69.1460Radius 6.2856 10.99656 10.99625 10.99554 10.99579 10.99715 10.99572 10.99534 10.9955 11.0007Lit./5 Cms. 21.993 19002.06 19000.96 18998.53 18999.39 19004.10 18999.16 18997.82 18998.37 19016.36CDW 0.576 19001.49 19000.39 18997.95 18998.82 19003.53 18998.58 18997.24 18997.79 19015.78Lit / Cms. Avg. 3800.257 3800.297 3800.077 3799.590 3799.763 3800.706 3799.716 3799.449 3799.559 3803.157Shell Height 201 200 150 150 152 151 150 151 150C. Height 25.5 175.500 175.5 375.5 525.5 675.5 827.5 978.5 1128.5 1279.5 1429.5Cap.Of shell 666952 760015 569939 569964 577707 573757 569917 573733 570474

CDW Common dead wood.C. Height Commulative Height

Page 4/12


Tank No.

0 0-5 5.-10 10.-15 15.-20 20.-25 25-30 30-35 35-40 40-45 45-506233 9800 17577 16680 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487

1900 -0.236 -0.788 -0.788 4.700 1.270 3.820-1.329 1.630 3.270 -0.788 5.220 4.240

1.650 3.300 3.270 -0.788 5.2200.388 3.880 3.300 3.270 -0.788-4.429 -4.429 3.880 3.300 3.270-3.250 -3.610 -4.429 3.880 3.300

-3.610 -4.429 3.880-3.610 -4.429

-3.6106233 9800 17577 18580 19001.487 18999.922 18996.688 19003.110 19007.810 19009.600 19016.390

50-55 55-60 60-65 65-70 70-75 75-80 80-85 85-90 90-95 95-100 100-10519001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487

4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.2404.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 4.240 2.9705.220 5.220 5.220 5.220 5.220 5.220 3.133 -11.400 -20.360 -20.360 -20.360-0.788 -0.788 -0.788 -0.788 -0.788 -0.788 -0.236 -0.970 -0.970 -0.970 -0.9703.270 2.940 3.880 1.940 -4.429 -0.490 -0.970 -4.429 -4.429 -4.429 -4.4293.300 0.990 -4.429 -4.429 -3.610 -4.429 -4.429 -3.610 -3.580 -6.400 -6.4003.880 3.880 -3.610 -3.610 -3.610 -3.610 -3.610 -3.610 -3.610-4.429 -4.429-3.610 -3.610

19016.810 19014.170 19010.240 19008.300 19006.360 19005.870 19003.855 18989.558 18977.018 18974.198 18972.928

105-110 110-115 115-120 120-125 125-130 130-135 135-140 140-175 19001.4870 680-825 19003.528619001.487 19001.487 19001.487 19001.487 19001.487 19001.487 19001.487 175-180 19000.4950 825-830 19001.0550

0.424 -20.360 -20.360 -20.360 -20.360 -20.360 -8.960 180-375 19000.3870 830-975 18998.5800-20.360 -0.490 -4.429 -4.429 -4.429 -4.429 -1.950 375-380 18998.1935 975-980 18998.1795-0.970 -4.429 -6.400 -6.400 -6.400 -6.400 -2.820 380-525 18997.9521 980-1125 18997.2449-4.429 -6.400 525-530 18998.7285 1125-1130 18997.4100-6.400 530-675 18998.8160 1130-1275 18997.7947-2.890 675-680 19003.0585

18966.862 18969.808 18970.298 18970.298 18970.298 18970.298 18987.757

Page 5/12

Addition , Deduction

Tank No.

Discription

Dip Pipe 29.21 cms dia 0.27 Litres / 5 cms Comman dead wood0.54 for 2 nos.

Temp. Sensor Pipe 2 " 0.036 Litres / 5 cms comman dead wood

Manhole 60.0 x 18 0.848 4.24 Ltr / 5 cm + 45.5 to 105.5 cms.

Manhole 60.0 x 18 0.848 4.24 Ltr / 5 cm + 43.5 to 103.5 cms.

Central Roof drain pipe 0.7229 3.61 Ltr / 5 cm - 25.5 to 109 cms.36.66 legth

Central R.D.Drum 4.07 20.36 Ltr / 5 cm - 87.2 to 137.2 cms.

Pipe inlet nozzle 47.5x28 1.04458 5.22 Ltr / 5 cm + 35.5 to 83.0 cms.

Pipe inlet nozzle 29*29 0.6605 3.3 Ltr / 5 cm + 27.5 to 56.5 cms.


Trough 0.0788 0.788 Ltr / 5 cm - 23.5 to 81.5 cms.


Trough 0.0788 0.788 Ltr / 5 cm - 23.5 to 81.5 cms.

Emergency drain 2 nos 0.194 0.97 Ltr / 5 cm - 77.5 to 112.5 cms.

Leg support43 nos 4" sleeve 0.03 6.4 Ltr / 5 cm - 23.5 to 137.2 cms.

43 nos 3" legs 0.02 4.429 Ltr / 5 cm - 92.2 to 137.2 cms.

Pg 6/12


Dead Wood Calculation

Tank No.

" 0 " 6233 Litres

from 0 to 5 cms 9800 Litres

from 5 to 10 cms 17577 Litres

from 10 to 14.5cms. 18580 Litres

we will deduct 2 nos. gauge well pipe and 1 no temp sencor pipe throuout shell ht by 0.576 lit / 5 cms.

From 15 to 20 cms. 19001.487 Lit / 5 cm

From 20 to 25 cms. 19001.487 Lit / 5 cmTrough 2nos. -0.236 Lit / 1.5 cmDeduction for legs support pipe -1.329 Lit / 1.5 cm

18999.922 Lit / 5 cm

From 25 to 30 cms. 19001.487 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 12" 1.63 Lit / 2.5 cmPipe 12" 1.65 Lit /2. 5 cmPipe 0.388 Lit / 0.5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.25 Lit / 4.5 cm

18996.688 Lit / 5 cm

From 30 to 35 cms. 19001.487 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 12" 3.270 Lit / 5 cmPipe 12" 3.300 Lit / 5 cmPipe 3.880 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19003.110 Lit / 5 cm

From 35 to 40 cms. 19001.487 Lit / 5 cmPipe inlet 18" 4.700 Lit / 4.5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 12" 3.270 Lit / 5 cmPipe 12" 3.300 Lit / 5 cmPipe 3.880 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19007.810 Lit / 5 cm

Pg 7/12

Mathematical Computation


when bottom covered with water, reading at datum plate is 14.5 cm

Tank No. From 40 to 45 cms 19001.487 Lit / 5 cmAddition for manholes 1.270 Lit / 1.5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 12" 3.270 Lit / 5 cmPipe 12" 3.300 Lit / 5 cmPipe 3.880 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19009.600 Lit / 5 cm

From 45 to 50 cm 19001.487 Lit / 5 cmAddition for manholes 3.820 Lit / 4.5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 12" 3.270 Lit / 5 cmPipe 12" 3.300 Lit / 5 cmPipe 3.880 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19016.390 Lit / 5 cm

From 50 to 55 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 12" 3.270 Lit / 5 cmPipe 12" 3.300 Lit / 5 cmpipe inlet 3.880 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19016.810 Lit / 5 cm

From 55 to 60 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 0.3 cmPipe 12" 2.940 Lit / 4.5 cmPipe 12" 0.990 Lit / 1.5cmPipe 3.880 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19014.170 Lit / 5 cm

From 60 to 65 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 3.880 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19010.240 Lit / 5 cmPg 8/12


Tank No.

From 65 to 70 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmPipe 1.940 Lit / 2.5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19008.300 Lit / 5 cm

From 70 to 75 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19006.360 Lit / 5 cm

From 75 to 80 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 5.220 Lit / 5 cmTrough 2nos. -0.788 Lit / 5 cmEmergancy Drain -0.490 Lit / 2.5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19005.870 Lit / 5 cm

From 80 to 85 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmPipe inlet 18" 3.133 Lit / 3.0 cmTrough 2nos. -0.236 Lit / 1.5cmEmergancy Drain -0.970 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

19003.855 Lit / 5 cm

From 85 to 90 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmDeduction R Drum -11.400 Lit / 2.8 cmEmergancy Drain -0.970 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

18989.558 Lit / 5 cm

Pg 9/12


Tank No.

From 90 to 95 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmDeduction R Drum -20.360 Lit / 5 cmEmergancy Drain -0.970 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for sleeves -3.580 Lit / 2.8 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

18977.018 Lit / 5 cm

From 95 to 100 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmDeduction R Drum -20.360 Lit / 5 cmEmergancy Drain -0.970 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for sleeves -6.400 Lit / 3.7 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

18974.198 Lit / 5 cm

From 100 to105 cm 19001.487 Lit / 5 cmAddition for manholes 4.240 Lit / 5 cmAddition for manholes 2.970 Lit / 3.5 cmDeduction R Drum -20.360 Lit / 5 cmEmergancy Drain -0.970 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for sleeves -6.400 Lit / 5 cmDeduction for roof drain pipe -3.610 Lit / 5 cm

18972.928 Lit / 5 cm

From 105 to 110 cm 19001.487 Lit / 5 cmAddition for manholes 0.424 Lit / 0.5 cmDeduction R Drum -20.360 Lit / 5 cmEmergancy Drain -0.970 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for sleeves -6.400 Lit / 5 cmDeduction for roof drain pipe -2.890 Lit / 4 cm

18966.862 Lit / 5 cm

From 110 to 115 cm 19001.487 Lit / 5 cmDeduction R Drum -20.360 Lit / 5 cmEmergancy Drain -0.490 Lit / 2.5cmDeduction for legs support pipe -4.429 Lit / 5 cmDeduction for sleeves -6.400 Lit / 5 cm

18969.808 Lit / 5 cm

Pg 10/12


Tank No.

From 115 to 135 cm 19001.487 Lit / 5 cmDeduction R Drum -20.360 Lit / 5 cmDeduction for legs support pipe -4.429 Lit / 4 cmDeduction for sleeves -6.400 Lit / 3.8 cm

18970.298 Lit / 5 cm

From 135 to 140 cm 19001.487 Lit / 5 cmDeduction R Drum -8.960 Lit / 2.2cmDeduction for legs support pipe -1.950 Lit / 5 cmDeduction for sleeves -2.820 Lit / 2.2 cm

18987.757 Lit / 5 cm

Pg 11/12


1 For dip reading not given in the table, take the capacity shown against the nearest lower depth and add to it at every or proportionate fraction table.

2 No deduction for roof weight is to be made when the liquid is not touching the floating roof.(a) when the roof is on LOW LEGS , the off float position is 137.2 cms. depth.(b) when the roof is on HIGH LEGS, the off float position is 197.2 cms. depth.

3 (a) The fully floating position of the roof depends upon the gravity of the tank contents. The following is the method for finding the fully floating positions of the roof.

Fully flaoting position of the roof = off float position in cms+Roof weight displacement in cms. Roof weight in Kilograms 1

Roof weight displacement in cms. = --------------------------------------------- X----------------------------------------Density of stock at tank temp. in Kgs./ Ltrs. Liters / cms. for the tank.

Eg. Tank contents = MS , Tank Temperature= 32 C.Density of Stock = 0.73 kgs / ltrs. at 32 C

Displacements due to roof weight = -------------------------------= 18.38 cms.

Fully floating positions of the roof = 137.2+18.38=155.58 When roof on Low LEGS= 197.2+18.38=215.58 When roof on High LEGS

(b) When roof is fully floating, the tank volume must be corrected for roof weight displacement.

DATA :- Gauge readings = 253.7 cms Tank Temperature = 32 C. Density of stock = 0.73 Kgs / ltrs.

51000Volume of oil displacement due to roof weight = ---------------------------------- = 69863 Litres

0.73Calculations : -

Capacity for 250.0 cms .= 945026 Ltrs.Capacity for 3.0 cms.= 11401 Ltrs.Capacity for 0.7 cms.= 2660 Ltrs.Capacity for 253.7 cms.= 959087 Ltrs.Net capacity for 253.7 cms = 959087 -69863 =889224 Ltrs.

4 The roof is to be considered as partly submerged where the level is in between off float position and full float positionproportionate capacity due to roof weight is to be deducted when the roof is partly submerged.

A typical calculations would be as follows :-

DATA Gauge readings = 145.0 cms.Tank Temperature = 32 C Density of stock = 0.73 Kgs/ Ltrs.69863

Now Approximate disp. = --------------------X (145-137.2) = 29648 Litres18.38

Calculations : - Capacity for 145 cms.at tank temperature 546011 Ltrs.Total displacement due to roof weight 69863 Ltrs.Approx .displacement 29648 Ltrs.

Net volume for 145 cms at tank temperature = 546011-29648 541015 Ltrs.516363 Ltrs

5 Volume obtained when roof is partly submerged as in (4) above are not accurate . The roof should, therefore, be always kepteither fully floating or completely - Off float by pushing water at the bottom.

6 The roof should always be maintained on Low legs while the tank is in service.

Pg 12/12

Instruction of use of calibration chart for tank no.

51000

3800.257 X 0.73


REMARKSDIMENTION CHECKED

Date:

DRG NO

P.O. No: Party:

SL. NO.

ITEM NO DESCRIPTION SIZE QTY Contractor HPCL

Contractor HPCL

Tank No:

ContractorFABRICATION REPORT

QC ENGINEER SITE INCHARGE

Job:

QCR NO: DATE:

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THICKNESS FITUP DATEDESCRIPTION/LINE NO

JOINT NO TYPE OF JOINT

SIZE

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JOINT NOTYPE OF

JOINT

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SIGNATUREREMARKSTHICKNESS

UNDULATION OF ANNULAR

JOINT

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TANK NO:

DATESL NO

P.O. NO:

DATE:

INTERNAL MATERIAL INSPECTION REPORT (IMIR)

JOB : PO NO. : PARTY:

SL NOMATERIAL

DESCRIPTIONDATE OF

INSPECTIONREQUIREMENT AS PER

PO ACTUAL Contractor's

sign HPCL sign REMARKS

JOB : Paint:PO No: Colour: Contractor: Consumption / Sqm:

Date of Receipt

RGP No Batch No. Mfg Dt.Qty Recd

in LtrsCumu Qty

RecdDate of

Consmptn

Qty Consumed

in LtrPainting Location

Area of Painting in

Sqm

Cumul Consmptn

BalanceContractor

SignHPCL Sign


Paint Consumption Report

Plumb Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º

Top

Middle

Bottom

Radial Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º

Top

Middle

Bottom

DIA AT FOLLOWING

Top

Middle

Bottom

PLUMB READING

RADIUS READING in mm

DIA READING in mm

ContractorPOST WELDING INSPECTION READINGS FOR SHELL

Date:Tank No:

P.O. No: Party:

Job: Shell No:

45-225 90-270 135-3150-180

CIRCUMFERENCE READING in mm

Circumference of Shell (Averege reading) TOP MIDDLE BOTTOM

QC ENGINEER SITE INCHARGEContractor HPCL

Plumb Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º

Top

Middle

Bottom

Radial Area 0 / 360º 45º 90º 135º 180º 225º 270º 315º

Top

Middle

Bottom

DIA AT FOLLOWING

Top

Middle

Bottom

Joint No 1 2 3 4 5 6 7 8

Top

Middle

Bottom

ROOT GAP READING in mm

QC ENGINEER SITE INCHARGEContractor HPCL

Circumference of Shell (Averege reading) TOP MIDDLE BOTTOM

CIRCUMFERENCE READING in mm

Job: Shell No:

45-225 90-270 135-3150-180

ContractorPRE WELDING INSPECTION READINGS FOR SHELL

Date:Tank No:

P.O. No:Party:

PLUMB READING

RADIUS READING in mm

DIA READING in mm

PO NO:

DATE:

Contractor HPCL

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WELDER NO

DATESIGNATURE

REMARKSTYPE OF JOINT

THICKNESS WELD VISUAL

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Documentation for fabrication Date: P.O: Tank No: Party: Activity: - Job:

Sr.No Plate No Length MM

Thickness (Randomly)

MM

Remarks

Contractor

QC Engineer Site in Charge Contractor H.P.C.L




MM

Remarks

Contractor



Breadth MM


MM

Diagonal check both side. MM

Remarks

1

2

3

4

5

6

7

8

Q.C Enginee Site Incharge Contractor HPCL

Contractor





MM

Remarks

Contractor


GRIT BLASTING SURFACE PREPARATION SA 2 ½ Date: P.O: Tank No: Party: Activity: - Cu slag Blasting and primer Job: Plate Use Location: Surface Preparation:

Sr. No. Plate No.

Heat No.

L*B*T Surface preparation on as per standard S/A 2 1/2

DFT Reading – primer name @ micron

Signature Remark


CONTRACTOR


FINISH PAINT DFT READING Date: P.O: Tank No: Party: Activity: - Finish Paint Job: Plate Use Location: Surface Preparation:

Sr. No.

Plate No.

L*B*T MM

DFT Reading – High Build Epoxy Finish Coating @ 100 micron

Signature Remark


Contractor


GRIT BLASTING SURFACE PREPARATION SA 2 ½ Date: P.O: Tank No: Party: Activity: - Job: Plate Use Location: Surface Preparation:

Sr. No.

Plate No.

Heat No.

L*B*T MM

Surface preparation on as per standard S/A 2 1/2

DFT Reading – Inorganic Zinc Silicate Coating @ 65-70

micron

Signature Remark

1 2 3 4 5 Contractor

HPCL

DOC.NO.

DATE:

PAGE :

TITLE

SL.NO. ACTIVITY/ DESCRIPTION CHARACTERISTICS TO BE CHECKED TYPE / METHOD OF CHECKACTION /EXTENT OF CHECK BY

CONTRACTORTYPE AND EXTEND OF CHECK BY JACOBS

RECORDS REQD.TO BE SUBMITTED / MAINTAINED BY CONTRACTOR

TYPE OF RECORD/BASIS

A CIVIL WORK

1 Accuracy Measurement Detail Check 100 % Review records Yes Lab Reports/ Site Test

2.a Construction Materials

Sand Physical properties Physical Tests Detail Check 100 % Review records Yes Lab Test/ Site Test

Soil Usability Visual Detail Check 100 % Review records Yes Site Report

Calibration of Test / Measuring Instruments

QUALITY ASSURANCE PLAN

Soil Usability Visual Detail Check 100 % Review records Yes Site Report

Ready Mix Concrete Physical properties Physical Tests Detail Check 100 % Review records Yes Lab Test/ Site Test

Cement Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate

Aggregrates Physical properties Physical Tests Detail Check 100 % Review records Yes Lab Test/ Site Test

Bitumen Physical Properties Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate

Reinforcement Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate

Foundation Bolt Physical & Chemical Properties Review Records Detail Check 100 % Review records Yes

Coating Thickness Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate

b Construction Equipments

Excavator Workability Visual Detail Check 100 % Review records Yes Site Report

RTO Permission(If reqd.) Review Records Detail Check 100 % Review records Yes RTO Permits

Concrete Mixer Workability Visual Detail Check 100 % Review records Yes Site Report

Vibrators Workability Visual Detail Check 100 % Review records Yes Site Report

Trucks / Dumper Workability Visual Detail Check 100 % Review records Yes Site Report


c Consumables

Water Chemical Properties Chemical Tests Detail Check 100 % Review records Yes Lab Test

Physical & Chemical Properties

Mfrs Test Certificate/ Lab. Test Report

Physical & Chemical Properties

DOC.NO.

DATE:

PAGE :

TITLE





3 Survey and Layout Dimensions Measurement Detail Check 100 % Check/witness Yes Joint Record

4.a Tank Pad Foundation

Excavation Dimension Measurement Detail Check 100 % Check/witness Yes Field Books,Record of profile and final Level, Field Test Records


Hard Strata Visual Detail Check 100 % Check/witness at random Yes Site Report & Records

Sand filling Dimension Measurement Detail Check 100 % Check/witness at random Yes Site Report & Records

Consolidation Phy.test Detail Check 100 % Check/witness at random Yes Site Report

Ring Beam Dimension Detail Check 100 % Check/witness Yes Site Report

Pre-concreting Check Check list Detail Check 100 % Review records Yes Site Report

Cube CR Strength Physical Tests Detail Check 100 % Check/witness Yes Lab Test / Site Test

Bitumen carpet Dimension,Profile Measurement Detail Check 100 % Check/witness Yes Site Report

Consolidation Visual Detail Check 100 % Check/witness Yes Site Report

Apron work Dimension,Profile Detail Check 100 % Check/witness at random Yes Site Report

b Road work Dimension,Profile Detail Check 100 % Check/witness at random Yes Site Report/Joint Records

Consolidation Visual Detail Check 100 % Check/witness at random Yes Site Report/Joint Records

5 Safety Review Detail Check 100 % Yes

6 As Built Drawing Dimensions with co-ordinates Review Submit Review records DrawingsMarks up on Drawings

Measurement & Visual



records of periodic checks of tools & tackles,Lifting Machinery ,Electrical equipments etc

Close Vigliance on Day to day basisAwarness / Implement & apply as per norms

DOC.NO.

DATE:

PAGE :

TITLE





B TANK CONSTRUCTION

1 Calibration of Tests/Measuring Instruments Accuarcy Measurement Detail Check 100 % Review records Yes Lab reports/Site Tests

2a Materials

Plates and Structurals Physical,Chemical Properties Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate

Lab Test Certificate

Detail Check 100 % Review records Yes Site ReportDimensions and surface qualityMeasurements and Visual


Pipes for nozzles Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate


Detail Check 100 % Review records Yes Site Report

Flanges for nozzles Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate



Lamination free Visual,UT(If reqd.) Detail Check 100 % Review records Yes Mfrs Test Certificate

Site Report

Pipe fittings Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate



Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate


Bolts, nuts for nozzle flanges & StructuralsPhysical,chemical properties, heat treatment

Physical,chemical properties

Dimensions and surface qualityMeasurements and Visual

Physical,chemical properties, heat treatment

Dimensions and surface quality Measurement & Visual

Dimensions and surface quality Measurement & Visual

Physical,chemical properties, heat treatment

Dimensions and surface qualityMeasurement & Visual

DOC.NO.

DATE:

PAGE :

TITLE





b Equipments

DG Set Workability Visual Detail Check 100 % Review records Yes

Hydra Workability Visual Detail Check 100 % Review records Yes


Welding Rectifiers Workability Visual Detail Check 100 % Review records Yes

Grinding Machines Workability Visual Detail Check 100 % Review records Yes Site Report

Cutting Sets Workability Visual Detail Check 100 % Review records Yes Site Report

Erection Jacks Workability Lab Test/Visual Detail Check 100 % Review records Yes


Site Report,Calibration Report

Site Report,Load test

Site Report,Callibration Report /Fit Certificates

Site Report,Load test certificates

Erection Jacks Workability Lab Test/Visual Detail Check 100 % Review records Yes


Chain Pully Blocks Workability Lab Test/Visual Detail Check 100 % Review records Yes Site Report

Load Test Certificate

c Consumables

Electrodes Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate

Grinding Wheel Workability Visual Detail Check 100 % Review records Yes Site Report / MTC

Gases Workability Visual Detail Check 100 % Review records Yes Site Report

3 Fabrication Drawing Technical Requirements Review of Drawing Detail Check 100 % Review and Approve Yes

4 Detail Check 100 % Check/witness Yes Joint Report

CSF-52-301

5 Fabrication and Erection

a Bottom plates

Fabrication Detail Check 100 % Review records Yes Site Report /ED316

Annular Plate Detail Check 100 % Check/witness at random Yes Site Report /ED316

Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report /ED316

Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316

Internal flow Radiography Detail Check 100 % Review records Yes Site Report /ED328

Approved Drawings ED 318

Pre Erection Take over of foundation Dimension, Profile Consolidation Measurement / Visual

Dimension, checking diagonal & squaring

Measurement / Visual

Physical, chemical Properties

Site Report,Load test certificates

Alignment,Fitup,Root gap Cleanliness of joint



Smoothness and reinforcement of final weld

DOC.NO.

DATE:

PAGE :

TITLE





Bottom sketch plates Detail Check 100 % Check/witness Yes Site Report /ED316

Weld soundness Detail Check 100 % Check/witness Yes Site Report /ED316

Fitment, dimension Detail Check 100 % Check/witness at random Yes Site Report /ED316


Annular plate to shell plate Fitment,dimension Detail Check 100 % Check/witness at random Yes Site Report /ED316

Annular plate to Bottom sketch plate Measurement / Visual

Measurement / VisualFitment, dimension, Slope

Visual/Vacuum Box Testing

Visual/Vacuum Box Testing


Annular plate to shell plate Fitment,dimension Detail Check 100 % Check/witness at random Yes Site Report /ED316


Leak tightness LPT Detail Check 100 % Check/witness Yes Site Report /ED327

b Shell plates


Fitment of weld Joints Detail Check 100 % Check/witness at random Yes Site Report /ED316

Cleanliness of joint Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316

Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report /ED316

Free of flow Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316

Finished Butt Weld Joints Visual Detail Check 100 % Check/witness at random Yes Site Report /ED316

Internal Radiography Detail Check 100 % Review records Yes Site Report /ED328

(10% & all Tee joint)

Detail Check 100 % Check/witness Yes Site Report /ED320


Dimension,Checking diagonal & squaring


Visual/Oil-chalk Testing


Measurement / Visual Plumbness

Measurement / Plumbness

Alignment,Fitup,Root gap

Smoathness and reinforcement of final weld

Peaking,Banding, Verticality,Circularity

Root run after back gauging of Butt weld Joints

DOC.NO.

DATE:

PAGE :

TITLE





c

Fabrication Layout Detail Check 100 % Check/witness at random Yes Site Report /ED390

Fitment, Dimension Detail Check 100 % Check/witness at random Yes Site Report

Weld soundness Visual Detail Check 100 % Check/witness at random Yes Site Report /ED324

Erection Layout Detail Check 100 % Check/witness at random Yes Site Report /ED390

Roof Structure,Curb angle,Wind Girder Etc.





Fitment,dimension,slope Detail Check 100 % Check/witness at random Yes Site Report /ED390

Weld soundness Visual / Pneumatic Test Detail Check 100 % Check/witness Yes Site Report /ED390

d Roof Plates


Erection Fitment, dimension,Slope Detail Check 100 % Check/witness at random Yes Site Report /ED316

Weld soundness Visual / Air Test Detail Check 100 % Check/witness Yes Site Report /ED316

e Shell appurtenances

Fabrication Dimension Detail Check 100 % Check/witness at random Yes Site Report

Detail Check 100 % Check/witness at random Yes Site Report

Orientation Dimension Measurement Detail Check 100 % Witness Yes Site Report

Fitment of weld Joints Detail Check 100 % Witness Yes Site Report

(Nozzle to Shell)

Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report

Finished Weld joints Visual Detail Check 100 % Check/witness at random Yes Site Report

RF Pad/ Nozzle to shell Leak tightness DP Test / Air Test Detail Check 100 % Check/witness Yes Site Report

Alignment,Fitup,Root Gap Cleanliness of joint



Dimension, checking diagonal & squaring


Smoathness and reinforcement of final weld






DOC.NO.

DATE:

PAGE :

TITLE





f Roof appurtenances

Fabrication Dimension Detail Check 100 % Check/witness at random Yes Site Report

Detail Check 100 % Check/witness at random Yes Site Report

Orientation Dimension Measurement Detail Check 100 % Witness Yes Site Report






Alignment,Fitup,Root Gap



(Nozzle to Roof)

Dimension & Shape Detail Check 100 % Check/witness at random Yes Site Report

Finished Weld Joints Visual Detail Check 100 % Check/witness at random Yes Site Report

g Detail Check 100 % Witness/ Review of Film Yes Site Report

h Inspection during hydrotest Leak tightness Visual Detail Check 100 % Witness Yes Site Report

vertically Detail Check 100 % Witness Yes Site Report

Settlement Measurement Detail Check 100 % Witness Yes Site Report

i Calibration Capacity with filling height Measurement Detail Check 100 % Check/witness at random Yes Calibration Chart

5 safety Review Detail Check 100 % Yes

6 As Built Drawing Dimensions with co-ordinates Review Submit Review records Drawings

records of periodic checks of tools & tackles,Lifting Machinery ,Electrical Equipments etc

Mark up on Drawing

Measurement / Plumbness



Close Vigliance on Day to day basis


Smoothness and reinforcement of final weld

Inspection prior to release for HydrotestCompleteness,Cleanliness,Overall dimension, Plumbness,Orientation, Radiography etc

Awarness, implement and apply as per norms

Measurements / Visual Verification of Documents

DOC.NO.

DATE:

PAGE :

TITLE





C WELDING AND TESTING1 Accuracy Measurement Detail Check 100 % Review records Yes Lab Reports/Site Test

2a Base Material Correctness Review Detail Check 100 % Review records Yes Lab Reports/Site Testb Welding Equipment

Welding Rectifiers Workability Visual Detail Check 100 % Review records Yes

Grinding Machines Workability Visual Detail Check 100 % Review records Yes Site Reportc Consumables

Electrodes Review Records Detail Check 100 % Review records Yes Mfrs Test Certificate


Site Report,calibration Certificates

Physical,Chemical Properties

Calibration of Test/ Measuring Instruments

3 Submit Review records Yes Welding Procedure Spec.ASME Sec IX /ED-323

4

a Welding of Test Piece Conduct Witness Witness Yes Site Report

b NDT Internal Radiography(100%) Detail Check 100 % Review records Yes Site ReportDestructive Test Physical Test Physical Properties Witness Witness Yes Lab Test Certificate

5

Welder Test Conduct Witness Witness Yes Site Report

NDT Internal Flow Radiography(100%) Detail Check 100 % Review records Yes Site Report6 Procedurea Radiography Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure

ASME Sec Vb Dye Penetrant Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure

ASME Sec Vc Ultrasonic Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure

ASME Sec Vd Diesel Chalk Test Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure

ASME Sec Ve Vacuum Box Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure

API 650 & Sec Vf Air Test Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure

API 650 & Sec Vg Hydro Test Correctness Scrutiny Preparation & Submit Review records / Procedures Approval Yes Approved Procedure

API 650 & Sec V

Welding Procedure Qualification

Welder Performance Qualification

Ability of Welder to Perform

Establishing Correctness of welding variables

Physical,Chemical Properties

Welding Procedure Specification

DOC.NO.

DATE:

PAGE :

TITLE





D PAINTING

1 Accuarcy Measurment Detail Check 100 % Review records Yes Lab Reports/Site Test

2a Material


Calibration of Test/ Measuring Instruments

Paints & Thinner Chemical Properties Review Detail Check 100 % Review records Yes Mfrs Test certificate

b Equipments

Compressor Workability Visual Detail Check 100 % Review records Yes Site Report

Blasting Equipments Workability Visual Detail Check 100 % Review records Yes Site Report

Spray Painting Equipments Workability Visual Detail Check 100 % Review records Yes Site Report

3 Take Over of Tank for painting Completeness Visual Detail Check 100 % Check/witness at random Yes Site Report

4 Surface Visual Detail Check 100 % Witness Yes Site Report

5 Primer application- DFT Check Thickness Measurement Detail Check 100 % Witness Yes Site Report

6 Final Painting -DFT Check Thickness Measurement Detail Check 100 % Witness Yes Site Report

7 Equipment Identification Numbering Visual Detail Check 100 % Witness Yes Site Report

E MECHANICAL COMPELETION Completeness Visual Detail Check 100 % Check/witness at random Yes Site Report

F FINAL INSPECTION Detail Check 100 % Witness Yes Site Report

G DOCUMENTATION Completeness Submit Review Yes QA/QC Documents As Built Drawings. Test Reports

Overall quality, Data keeping

Surface Preparation / Grit Blasting

Completeness,Cleanliness, Overall dimension, Plumbness,Orientation, Radiography etc


Verification of Documents

WPS NO.:DATE :PQR NO.:

CLIENT :LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 1 (A)

Type : SQ BUTT

Backing : NO FIG 1 (A)

Backing Material Type / Grade : NA

WELDING PROCESS : SMAW TYPE : MANUAL

BASE METALS (QW 403)

Material Specification : IS 2062 / EQ. To IS 2062 / EQ.

Type / Grade No. : GR.B To GR.B

P. No. : 1 To 1

Group No. : 1 To 1

Thick of Coupon : 6 mm

Thickness Range : 6 mmFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 6013 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 2 Consumable Insert : NoneMake : ESAB/ADVANI/D&H

POSITION (QW 405)Position of Groove : 3G Position of Fillet : NA

3.15 mm


QW-482 - WELDING PROCEDURE SPECIFICATION(REF. SPECIFICATION : ASME SECTION IX)

AWS No. (CLASS) : UPHILLPREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String or weave Bead : String / WeavingVolts : 18 to 30 Orifice or Gas Cup Size : NAElectrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 140 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single

Travel Speed Range : SEE TABLEPeening : NA

WELDING PROCEDUREHeat Input

Class Dia Amps Range Volts Range kJ / mm

ROOT SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS SMAW E6013 3.15 90 to 130 24 to 28AFTER BACK CHIP - - -FINAL SMAW E6013 3.15 90 to 130 24 to 28APPROVAL

NAME :

SIGNATURE :

DATE :

HINDUSTAN PETROLUEM CORP. LTD

STRAIGHTSTRAIGHT

-STRAIGHT

85 to 10090 to 125

-

mm / min

90 ot 125-

Type & Pol.Filler Material Travel Speed

Pass No. Welding ProcessCurrent & Voltage


CLIENT :LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 1 (B)

Type : SQ BUTT

Backing : NO FIG 1 (B)






P. No. : 1 To 1

Group No. : 1 To 1


Thickness Range : 6 to 8 mmFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 6013 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 2 Consumable Insert : NoneMake : ESAB/ADVANI/D&H

POSITION (QW 405)Position of Groove : 2G Position of Fillet : NAAWS No. (CLASS) : -


QW-482 - WELDING PROCEDURE SPECIFICATION

3.15 / 4 mm

(REF. SPECIFICATION : ASME SECTION IX)

AWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : REVERSE Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 140 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT SMAW E6013 3.15 80 to 115 20 to 24SUB. PASS SMAW E6013 4 120 to 190 24 to 28AFTER BACK CHIP - - -SUB. PASS SMAW E6013 4 120 to 180 24 to 28FINAL SMAW E6013 4 120 to 180 24 to 28APPROVAL

NAME :

SIGNATURE :DATE :

100 ot 150

STRAIGHTSTRAIGHT 100 to 150

Travel Speed

STRAIGHT- -

Pass No. Welding ProcessCurrent & Voltage

mm / min

80 to 100

100 ot 150


Type & Pol.

-

Filler Material

STRAIGHT


CLIENT :LOCATION :


Type : SINGLE "V"







P. No. : 1 To 1

Group No. : 1 To 1




3.15 / 4 mm



AWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 140 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single





NAME :

SIGNATURE :

DATE :


- - -STRAIGHT 100 ot 150STRAIGHT 100 ot 150

STRAIGHT 80 to 100STRAIGHT 100 to 150

Pass No. Welding ProcessFiller Material Current & Voltage Travel Speed

Type & Pol. mm / min


CLIENT :LOCATION :


Type : SQ BUTT







P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)

Hindustan Petroleum Corporation LimitedMAHUL TERMINAL

3.15 mm


POSITION (QW 405)Position of Groove : 3G Position of Fillet : NAAWS No. (CLASS) : UPHILLPREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 18 to 30 Orifice or Gas Cup Size : NAElectrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 140 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS SMAW E6013 3.15 90 to 130 24 to 28AFTER BACK CHIP - - -FINAL SMAW E6013 3.15 90 to 130 24 to 28APPROVAL

NAME :

SIGNATURE :

DATE :


STRAIGHT 85 to 100

90 ot 125


STRAIGHT- - -

Travel Speed

STRAIGHT 90 to 125

Pass No. Welding ProcessFiller Material Current & Voltage


CLIENT :LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 2(B)

Type : SQ BUTT



WELDING PROCESS : SMAW TYPE : MANUALBASE METALS (QW 403) Material Specification : IS 2062 / EQ. To IS 2062 / EQ.Type / Grade No. : GR.B To GR.BP. No. : 1 To 1Group No. : 1 To 1Thick of Coupon : 5 mmThickness Range : 5 mmFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 6013 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 2 Consumable Insert : NoneMake : ESAB/ADVANI/D&H



3.15 / 4 mm


PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 140 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single





NAME :

SIGNATURE :

DATE :

Welding ProcessType & Pol. mm / min

Pass No.Current & Voltage Travel Speed

STRAIGHT 100 ot 150STRAIGHT 100 ot 150

Filler Material

STRAIGHT 80 to 100


STRAIGHT 100 to 150- - -


CLIENT :LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 3

Type : T FILLET

Backing : NO FIG 3






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)Position of Groove : - Position of Fillet : 2F

3.15 / 4 mm



Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS SMAW E7018 4 120 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :

mm / min



Type & Pol.

80 to 12090 to 150

REVERSEREVERSE

Travel Speed


CLIENT :LOCATION :

JOINT DESIGN (QW 402) SKETCH / DETAIL : 3A

Type : T FILLET

Backing : NO FIG 3






P. No. : 1 To 1

Group No. : 1 To 1






3.15 / 4 mm

Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS ROOT 2 SMAW E7018 4 120 to 190 24 to 28SUB. PASS ROOT 3 SMAW E7018 4 120 to 190 24 to 28SUB. PASS 4 TO 5 SMAW E7018 4 120 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :




REVERSE 80 to 120REVERSE 90 to 150REVERSE 90 to 150REVERSE 90 to 150


CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 4






P. No. : 1 To 1

Group No. : 1 To 1

Thick of Coupon : 8 mmThickness Range : 8 mmFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 7018 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 2 Consumable Insert : NoneMake : ESAB/ADVANI/D&H

POSITION (QW 405)Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)



3.15 / 4 mm

Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : STRAIGHT Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




INSIDEROOT SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (2) SMAW E7018 4 120 to 190 24 to 28SUB. PASS (3) SMAW E7018 4 120 to 190 24 to 28OUTSIDE1ST PASS SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (2) SMAW E7018 4 120 to 190 24 to 28FINAL (3) SMAW E7018 4 120 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :

Travel Speed

REVERSE


100 to 150REVERSE 100 to 150


REVERSE

REVERSE 90 to 15080 to 120


REVERSE 90 to 120

REVERSE 90 to 150


CLIENT :LOCATION :


Type : DOUBLE "V"

Backing : NO FIG 4






P. No. : 1 To 1

Group No. : 1 To 1

Thick of Coupon : 12 mmThickness Range : 12 to 24 mmFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 7018 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 2 Consumable Insert : NoneMake : ESAB/ADVANI/D&H

POSITION (QW 405)Position of Groove : 3G Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)

3.15 / 4 mm



Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : REVERSE Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




INSIDEROOT SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (2) SMAW E7018 4 120 to 190 24 to 28SUB. PASS (3) SMAW E7018 4 120 to 190 24 to 28BACK SIDE1ST PASS SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (2) SMAW E7018 4 120 to 190 24 to 28FINAL (3) SMAW E7018 4 120 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :


REVERSE 100 to 150REVERSE 100 to 150

REVERSE 90 to 150

REVERSE 90 to 120





CLIENT :LOCATION :


Type : SQUARE BUTT WITH BACKING STRIP & FILLET

Backing : YES FIG 5


WELDING PROCESS : SMAW TYPE : MANUALBASE METALS (QW 403) Material Specification : IS 2062 / EQ. To IS 2062 / EQ.Type / Grade No. : GR.B To GR.BP. No. : 1 To 1Group No. : 1 To 1Thick of Coupon : 12 mmThickness Range : 12 to 16 mmFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 7018 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 4 Consumable Insert : NoneMake : ESAB/ADVANI/D&H

POSITION (QW 405)Position of Groove : 1G Position of Fillet : 2FAWS No. (CLASS) : -

3.15 / 4 mm



PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : REVERSE Initial / Interpass Cleaning : Wire BrushingAmperage : 90 TO 190 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT (1,2) SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (3) SMAW E7018 4 120 to 190 24 to 28SUB. PASS (4) SMAW E7018 4 120 to 190 24 to 28FINAL (5,6) SMAW E7018 3.15 100 to 135 20 to 24APPROVAL

NAME :

SIGNATURE :

DATE :

mm / minCurrent & Voltage Travel Speed


REVERSE 100 to 150

Pass No. Welding ProcessFiller Material

Type & Pol.

REVERSE 90 to 120

REVERSE 90 ot 120REVERSE 100 to 150


CLIENT :LOCATION :


Type : LAP FILLET

Backing : NO FIG 6



POSITION (QW 405)Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -

3.15 / 4 mm



PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Electrode-Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 90 TO 190 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS SMAW E6013 4 90 to 190 24 to 28FINAL SMAW E6013 4 90 to 190 24 to 28APPROVAL

NAME :

SIGNATURE :

DATE :

Pass No.Travel Speed

mm / min

80 to 120

Welding ProcessFiller Material Current & Voltage

STRAIGHT


STRAIGHT 90 to 150STRAIGHT 90 ot 150

Type & Pol.


CLIENT :LOCATION :


Type : LAP FILLET

Backing : NO FIG 7






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)

3.15 / 4 mm



POSITION (QW 405)Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Electrode-Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 90 TO 190 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT (1) SMAW E7018 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E7018 4 90 to 190 24 to 28FINAL (3,4) SMAW E7018 4 90 to 190 24 to 28APPROVAL

NAME :

SIGNATURE :

DATE :

Pass No.Travel Speed

mm / min

80 to 120

Welding ProcessFiller Material Current & Voltage

REVERSE


REVERSE 90 to 150REVERSE 90 ot 150

Type & Pol.


CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 8






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)


3.15 / 4 mm


POSITION (QW 405)Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Electrode-Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS SMAW E7018 4 90 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :



Type & Pol.Travel Speed

mm / min



CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 9






P. No. : 1 To 1

Group No. : 1 To 1





3.15 / 4 mm


AWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ONE SIDE CONT.ROOT (1) SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E6013 4 90 to 190 24 to 282nd STITCH FILLET 100 (100) 100ROOT (1) SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E6013 4 90 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :


90 to 150

STRAIGHT


STRAIGHT 80 to 120STRAIGHT


80 to 12090 to 150

STRAIGHT


CLIENT :LOCATION :


Type : LAP FILLET







P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)


3.15 / 4 mm


POSITION (QW 405)Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT (1) SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E6013 4 90 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :



mm / min

80 to 120STRAIGHT 90 to 150

Type & Pol.

STRAIGHT


CLIENT :LOCATION :


Type : LAP FILLET







P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)

3.15 / 4 mm








APPROVAL

NAME :

SIGNATURE :

DATE :

Filler Material Current & Voltage Travel SpeedType & Pol. mm / min



Pass No. Welding Process


CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 11






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)Position of Groove : - Position of Fillet : 3FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NA


3.15 / 4 mm


Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ONE SIDE CONT.ROOT (1) SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E6013 3.15 90 to 190 24 to 282nd SITCH FILLET 100 (100) 100ROOT (1) SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E6013 3.15 90 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :

Note : 1) For 5mm to 16mm joint separate WPS has to be made using E7018 Rod 2) Inner joint bulk head shall have doublers plate



STRAIGHT 90 to 150


STRAIGHT

Type & Pol.

STRAIGHT 80 to 120

80 to 120STRAIGHT90 to 150


CLIENT :LOCATION :


Type : LAP FILLET

Backing : NO FIG 7






P. No. : 1 To 1

Group No. : 1 To 1




3.15 / 4 mm



AWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Electrode-Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 90 TO 190 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ONE SIDE CONT.ROOT (1) SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E6013 3.15 90 to 190 24 to 282nd SITCH FILLET 100 (100) 100ROOT (1) SMAW E6013 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E6013 3.15 90 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :

90 to 150






WPS NO.:DATE :

PQR NO.:CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 12






P. No. : 1 To 1

Group No. : 1 To 1




3.15 / 4 mm



Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single





APPROVAL

NAME :

SIGNATURE :

DATE :

Filler Material Current & Voltage Travel SpeedType & Pol. mm / min



Pass No. Welding Process

WPS NO.:DATE :



Type : T FILLET

Backing : NO FIG 13






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)


3.15 / 4 mm


GAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




INSIDEROOT (1) SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (2) SMAW E7018 4 130 to 190 24 to 28OUTSIDEROOT (1) SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (2) SMAW E7018 4 130 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :

Note : Joint at the point where Outer rim & Lap of Bottom Deck plate meet shall be like a) Bottom deck has to be made Sq Butt joint for 100 mm length WPS Pg (a) should be submitted separately Hence Joggly not needed



REVERSE 90 to 150


REVERSE

Type & Pol.

REVERSE 80 to 120

80 to 120REVERSE90 to 150


CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 14


WELDING PROCESS `` SMAW TYPE : MANUAL




P. No. : 1 To 1

Group No. : 1 To 1





3.15 / 4 mm


PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single





APPROVAL

NAME :

SIGNATURE :

DATE :



STRAIGHT 90 to 150


STRAIGHT

Type & Pol.

STRAIGHT 80 to 120

80 to 120STRAIGHT90 to 150


CLIENT :LOCATION :


Type : DOUBLE V BUTT

Backing : NO FIG 15






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)Position of Groove : 3G Position of Fillet : NAAWS No. (CLASS) : UPHILL



3.15 mm

PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 130 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT (1) SMAW E7018 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E7018 3.15 90 to 130 24 to 28SUB. PASS (3,4) SMAW E7018 3.15 90 to 130 24 to 28AFTER BACK CHIP1ST PASS SMAW E7018 3.15 90 to 130 24 to 28FINAL SMAW E7018 3.15 90 to 130 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :


Type & Pol.

REVERSE 90 to 125REVERSE

mm / min

90 to 125


REVERSE 80 to 100



CLIENT :LOCATION :


Type : LAP FILLET

Backing : NO FIG 16






P. No. : 1 To 1

Group No. : 1 To 1






3.15 / 4 mm

Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Electrode-Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single





APPROVAL

NAME :

SIGNATURE :

DATE :

Note : L 75 X 75 X 8 only has to be used


90 to 150





CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 17






P. No. : 1 To 1

Group No. : 1 To 1






3.15 mm

AWS No. (CLASS) : - PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ONE SIDE CONT.ROOT (1) SMAW E7018 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E7018 3.15 90 to 190 24 to 282ND SIDE STITCH FILLET 100 (100) 100 ROOT (1) SMAW E7018 3.15 80 to 120 20 to 24SUB. PASS (2) SMAW E7018 3.15 90 to 190 24 to 28

APPROVAL

NAME :

SIGNATURE :

DATE :







CLIENT :LOCATION :


Type : Single V Full Pen Butt Joint

Backing : NO FIG 18

Backing Material Type / Grade : Chip Back to Sound metal & reweld





P. No. : 1 To 1

Group No. : 1 To 1


Thickness Range : 1.76 to 20 mmFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 6013 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 2 Consumable Insert : NoneMake : ESAB/ADVANI/D&H

POSITION (QW 405)Position of Groove : 3G Position of Fillet : NAAWS No. (CLASS) : UPHILLPREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NA



3.15 mm

Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : String / WeavingVolts : 18 to 20 Orifice or Gas Cup Size : NAElectrical Polarity : Electrode - Negative Initial / Interpass Cleaning : Wire BrushingAmperage : 100 TO 120 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT SMAW E6013 3.15 90 to 95 22 to 24 0.275HOT PASS SMAW E6013 3.15 90 to 95 18 to 20 0.238FILLING SMAW E6013 4 100 to 120 18 to 20 0.238CAPPING SMAW E6013 3.15 90 to 95 22 to 24 0.275AFTER BACK CHIPSUB PASS SMAW E6013 3.15 90 to 95 18 to 20 0.238FINAL SMAW E6013 4 100 to 120 22 to 24 0.275

APPROVAL

NAME :

SIGNATURE :

DATE :


STRAIGHT 65 to 90


STRAIGHT 85 to 90

STRAIGHT 65 to 90


STRAIGHT 85 to 90

STRAIGHT 85 to 90

STRAIGHT 65 to 90

DATE :


CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 19






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)


3.15 / 4 mm







APPROVAL

NAME :

SIGNATURE :

DATE :

STRAIGHT 90 to 150


STRAIGHT 80 to 120




CLIENT :LOCATION :


Type : SQUARE BUTT WITH BACKING STRIP

Backing : YES FIG 20






P. No. : 1 To 1

Group No. : 1 To 1



POSITION (QW 405)

3.15 / 4 mm



POSITION (QW 405)Position of Groove : - Position of Fillet : 2FAWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : REVERSE Initial / Interpass Cleaning : Wire BrushingAmperage : 90 TO 190 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT (1,2) SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (3) SMAW E7018 4 120 to 190 24 to 28SUB. PASS (4) SMAW E7018 4 120 to 190 24 to 28FINAL (5,6) SMAW E7018 3.15 100 to 135 20 to 24APPROVAL

NAME :

SIGNATURE :

DATE :


REVERSE 90 to 120REVERSE 100 to 150REVERSE 100 to 150REVERSE

Current & Voltage Travel SpeedType & Pol.

90 ot 120

mm / minPass No. Welding Process

Filler Material

WPS NO.:DATE :



Type : SQUARE BUTT W/BACKING PLT. FOR COD

Backing : YES FIG 21



POSITION (QW 405)Position of Groove : 1 G Position of Fillet : - AWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)

3.15 / 4 mm



GAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : REVERSE Initial / Interpass Cleaning : Wire BrushingAmperage : 90 TO 190 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT (1,2) SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (3) SMAW E7018 4 120 to 190 24 to 28SUB. PASS (4) SMAW E7018 4 120 to 190 24 to 28FINAL (5 TO 10) SMAW E7018 3.15 100 to 135 20 to 24APPROVAL

NAME :

SIGNATURE :

DATE :

Note : WPS for 10mm to insert plate joint should be submitted separately


REVERSE 90 to 120REVERSE 100 to 150REVERSE 100 to 150REVERSE

Current & Voltage Travel SpeedType & Pol.

90 ot 120

mm / minPass No. Welding Process

Filler Material

WPS NO.:DATE :



Type : SQUARE BUTT W/BACKING PLT. FOR COD

Backing : YES



POSITION (QW 405)Position of Groove : 1 G Position of Fillet : - AWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NA



3.15 / 4 mm

ANNULAR TO CLEAN OUT BOTTOM JOINT

Preheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : REVERSE Initial / Interpass Cleaning : Wire BrushingAmperage : 90 TO 190 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single




ROOT (1) SMAW E7018 3.15 100 to 135 20 to 24SUB. PASS (2) SMAW E7018 4 120 to 190 24 to 28FINAL (3 TO 4) SMAW E7018 3.15 100 to 135 20 to 24APPROVAL

NAME :

SIGNATURE :

DATE :

REVERSE 100 to 150



REVERSE 90 ot 120HINDUSTAN PETROLUEM CORP. LTD

REVERSE 90 to 120


CLIENT :LOCATION :


Type : T FILLET

Backing : NO FIG 9






P. No. : 1 To 1

Group No. : 1 To 1


Thickness Range : 6 mm OUTER RIM TO BOTTOM DECK LAP JOINTFILLER MATERIAL (QW 404)Spec. No. (SFA) : 5.1 Filler Size :AWS No. (CLASS) : E 6013 Electrode Flux Type : -A. No.: : 1 Backing / Storage : As per Manuf. Std.F. No.: : 2 Consumable Insert : NoneMake : ESAB/ADVANI/D&H




3.15 / 4 mm

AWS No. (CLASS) : -PREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp. (Min) : NA Temperature : NAInterpass Temp. (Max) : NA Time : NAPreheat Maint : NA Other : NAGAS (QW 408)Shielding Gas : NA Flowrate : NAPercentage Comp. : NA Gas Backing : NATrailing : NA Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode : DC String of weave Bead : StringVolts : 20 to 28 Orifice or Gas Cup Size : NAElectrical Polarity : Straight Initial / Interpass Cleaning : Wire BrushingAmperage : 80 TO 180 Method of back gauging : GrindingTungsten Electrode Size & Type : NA Oscillation : NAMode of Metal Transfer (GMAW) : NA Contact Tube to work distance : NAElect. Wire - Feed,Speed,Range : NA Multiple of Single Pass (/ side) : MultipleOther : NA Multiple of Single Electrode : Single





APPROVAL

NAME :

SIGNATURE :

DATE :






WPS NO.:

DATE

WPS NO.:

CLIENT : HINDUSTAN PETROLEUM CORPORATION LTD.LOCATION :

JOINT DESIGN (QW-402) SKETCH / DETAIL:TypeBackingBacking material Type / GradeWELDINHG PROCESS TYPE MANUALBASE METALS (QW 403)Material Specification To IS 2062 / EQ.Type / Grade No. To GR.BP. No. To 1Group No. To 1Thick of CouponThickness RangeFILLER MATERIAL (QW 404)Spec. No. (SFA) Filler Size : 3.15 / 4 mmAWS No. (CLASS) Electrode Flux Type : -A. No. : Backing / Storage : As per Manuf. Std.F. No. : Consumable Insert : NonMakePOSITION (QW 405)Position of Groove Position of Fillet : NAWeld ProgressionPREHEAT (QW 406) POST WELD HEAT TREATMENT (QW 407)Preheat Temp.(Min) Temperature : NAInterpass Temp.(Max) Time : NAPreheat Maint Others : NAGAS (QW 408)Shielding Gas Flowrate : NAPercentage Comp. Gas Backing : NA

NANA

NANA

ESAB/ADVANI/D&H

3GUPHILL

5.1E 601312

16 mm6 mm

SWAM

IS 2062 / EQ.GR.B1

SQ. BUTTNO FIG 1 (A)NA


Percentage Comp. Gas Backing : NATrailing Purging : NAELECTRICAL CHARACTERISTICS (QW 409) TECHNIQUE (QW 410)Current Mode String or weave Bead : String / WeavingVolts Orifice or Gas Cup Size : NAElectrical Polarit Initial / Interpass Cleaning: Wire BrushingAmperage Method of back gauging : GrindingTungsten Electrode Size & Type Oscillation : NAMode of Metal Transfer (GMAW) Contact Tube to work distance: NAElect. Wire - Feed,Speed,Range Multiple or Single Pass ( / Side): MultipleOther Multiple or Single Electrode : Single

Travel Speed Electrode : SEE TABLEPeening NA

WELDING PROCEDUREPass No. Welding Process Heat Input

Class Dia Amps Range Volts Range mm / min kj / mm

AFTER BACK CHIP E6013

Type & Pol.

DC18 to 30STRAIGHT80 TO 140NA

NANA

Filler Material

NA

NANA

HINDUSTAN PETROLEUM CORPORATION LTD

JOB PROCEDURES FOR TANKAGE WORK

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TANKAGE WORKS �

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HINDUSTAN PETROLEUM CORPORATION LTD

JOB PROCEDURES FOR TANKAGE WORK

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TITLE PROCEDURE FOR FABRICATION & ERECTION OF

TANKAGES BY JACKING UP METHOD

JOB PROCEDURE FOR FABRICATION & ERECTION OF TANKAGE BY JACKING METHOD

1. SCOPE: This procedure covers detailed activities for fabrication, erection and testing of the

storage tanks, and also equipment & manpower required for the same. All the tasks / activities need to be carried out with atmost care with good workmanship and in accordance with the specifications to achieve satisfactory completion of the whole activities.

2. PURPOSE: The purpose of this document is to follow proper methodology to carry out the

activities in a proper sequence for fabrication, Erection and Testing of the storage tanks.

3. REFERENCE: API 650 ASME Sec IX ASME Sec V Tender Specification.i.e. 18-3188-99-02-V-02-001-A4; VSS004; 18-3188-00/Z-00-

001; 18-3188-99-00-V.02-005-A4 etc Approved Drawing / Specification.

4. RESPONSIBILITY: The responsibility of implementation of this procedure rests with Construction

Manager of M/S Vishal Structurals Pvt. Ltd.

5. METHOD OF CONSTRUCTION: 5.1 IDENTIFICATION OF MATERIALS

Each Piece of Plates, fittings or any other component of tankage system shall be clearly identified by marking heat no. on the part (e.g.: IS 2062 Gr.B, H.No.-XXX) using hard punching.

Each weld joint shall be marked with joint Number with Welder Number. 5.2 FABRICATION WORK

All fabrication work involving material identification, marking, cutting, rolling and welding shall be done in accordance with this job procedure, API 650 (Latest edition), JE Spec and tender documents. The workmanship shall be good in every respect meeting all safety, QC & NDT requirements, with the coordination of Engineer-In-Charge. Prepared by

CONTRACTOR

Concurred by

Name : Design:

Hindustan Petroleum Crop. Ltd.

Approved by

Name : Design:

Hindustan Petroleum Crop. Ltd

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TITLE PROCEDURE FOR FABRICATION & ERECTION

OF TANKAGES BY JACKING UP METHOD

� Lay all the plates, Structural & pipes in such a way prior to fabrication to facilitate proper checking of dimensions & heat no.

� Mark the components as per the drawings. 5.2.1 ANNULAR & BOTTOM PLATE FABRICATION:

� Mark the plates as per drawing � Carry out the cutting operation after proper inspection. � All the cutting operation shall be carried out by Gas Cutting. � Grind the cut edges smooth to remove burrs and slag. � Stack the plates at designated place in the fabrication yard in proper

sequence. � Backing – strip shall be fitted and tacked with annular plate as per drg. � After completion of the fabrication under side of annular and bottom plates shall

be blast cleaned and painted as per the specification to the satisfaction of the engineer-in-charge.

� Check the Joint Position, Root gap for welding after welding Inspection by weld visual & NDT as per API 650 / Tender document.

5.2.2 SHELL PLATE FABRICATION � Lay all the plates in the open area such a way easy for marking and cutting. � Mark the plates as per drawing and to the satisfaction of Engineer-in-charge. � The cutting operation includes beveling shall be carried out by gas cutting

method on all the four sides. � Grind the cut edges smooth to remove slag and burr. � The edge prepared plates shall be shifted by hydra crane to the rolling area. � The plates shall be fed to rolling m/c. by means of hydra crane & proper lifting

tools and tackles.

Prepared by

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Concurred by

Name : Design:


Approved by

Name : Design:


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� The plate shall be rolled as per drawing details and the radius shall be checked

using Template. � Proper care shall be taken for the smooth curvature. � 36’’ Long (5 to 6mm thk.) Template shall be used to check rolling curvature

accurately. � The Template shall be checked and cleared by inspection authority. � The rolled plates shall be inspected and shall be within 03mm. of tolerance

limit. � The rolled plates shall be shift to shot blasting yard to carryout the shot blast

as per JE specification. � Final profile and dimensions check shall be carried out before sent for rection.

5.2.3 ROOF PLATE FABRICATION

� Mark the roof plate as per drawing � All the cutting operation as per requirement shall be carried out after getting

the clearance from the inspection authority. � All the cutting operation shall be carried out by gas cutting method on all the

four side. � Grind the cut edges smooth to remove burrs &slag. � Structural item of the roof shall be fabricated as per drawing. � These roof plates shall be shifted to blasting yard to carryout the blasting and

painting.

Prepared by

CONTRACTOR .

Concurred by

Name : Design: Hindustan Petroleum Crop. Ltd.

Approved by

Name : Design: Hindustan Petroleum Crop. Ltd

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5.2.4 APPURTENANCES

� Mark the required items of the Appurtenances as per the drawing. All the cutting operation as per requirement shall be carried out after getting the clearance from inspection authority.

� All the cutting operation shall be carried out by gas cutting method. � Grind the cut edges smooth to remove burrs & slag. � Flanges face to be covered with a suitable cover to protect from damage

during handling, fabrication and transportation. � The entire shell nozzle, roof appurtenance, i.e. flanges, flanges to pipe

joint and other requirements etc. Shall be fabricated as per approved drawings.

� All the fabrication and welding activities shall be carried out after the stage wise inspection wherever required.

� The N.D.T requirements as per code specification.

5.2.5 SPIRAL STAIRWAY, HAND RAILING � All the structural items shall be straightened before marking and cutting. � Mark the components as per drawing. � All the cutting operation, as per requirement shall be carried out after getting

the clearance from inspection authority. � All the cutting operation shall be carried out by gas cutting method. � Grind the cut edges smooth to remove burrs & slag. � Fabrication such as fitting, welding, drilling, etc. Shall be carried out as per

drawing and after the clearance from inspection authority. � After fabrication all these structural items shall be blasted and painted as per

requirement.

5.3 ERECTION: 5.3.1. ANNULAR PLATE LAYING

Check the level of foundation as per specification API 650 clause 8.4.2. Latest edition. After getting clearance for annular plate laying, mark the 0o, 90o, 180o, 270o co- ordinates on the foundation from the reference point. Lay the annular plate as per approved drawing.

Prepared by

CONTRACTOR .

Concurred by Name : Design: Hindustan Petroleum Crop. Ltd.

Approved by Name : Design: Hindustan Petroleum Crop. Ltd

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� Out radius of the annular plate shall be in positive side (5 to 10 mm.) in order to achieve the final required radius after weld shrinkage.

� Orientation of the annular plate joint shall be as per approved -drawing. � Fit up of annular plate's joints shall be carried out using proper jigs and fixtures as

shown in drawing. � Care shall be taken while fit-up, such that there should not any gap between

annular plate and backing-strip. � Annular plates joints welding shall be carried out by welding alternative joint at four

quadrants. � Qualified welders shall be engaged for the welding work according to WPS. � If any defect found the defect weld shall be removed by grinding and re-weld and

conduct the LPT check test. Repeat the sequence until the defect cleared. � Complete the welding, clean the final weld surface by wire brushing and grinding. � Remove the jigs and fixtures which were used for fit-up of the annular joint and

grind the tack. � Radiography shall be taken as per API-650 Sec-6.

5.3.2 BOTTOM PLATE LAYING:

� Lay the center plate on the foundation top as per drawing. � With co-ordination of Centre plate lay the bottom plates sequentially as per drg. � Laps shall be maintained while the fit-up of short seam and long seam as per drg. � Temporary tack weld to be carry out on the Long-seam to avoid uneven

movements, while the fit-up and welding of short-seam. � Short seam welding will be carried out alternatively to avoid distortion. � After the completion of short-seam welding, remove the temporary tacks on the

Long- seam by grinding to facilitate the long-seam fit-up. � Short seam welding will be carried out alternatively to avoid distortion. � After the completion of short-seam welding, remove the temporary tacks on the

Long- seam by grinding to facilitate the long-seam fit-up.

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� Minimum laps shall be maintained while the fit-up of long-seam as per approved drg.

� Joggling shall be carried out by hammering wherever it necessary. (Three plate Joining junction.)

� Before starting the welding, channels shall be tacked along the long-seam to avoid the distortion.

� After completion of shot seam welding long seam welding will be carried out alternatively to avoid distortion.

� Qualified welder shall be engaged and welding shall be carry out as per approved WPS.

� After Completion of welding thoroughly clean the weld ‘joint by wire brushing and grinding.

� Sketch to annular plate joint shall be welded only after shell to bottom joint welding. � All the bottom plate's joints vacuum box test shall be carried out as per approved

procedure and code specification. � If any defect found the defect weld shall be removed by grinding and re-weld and

conduct the vacuum box test. Repeat the sequence until the defect cleared.

5.3.3. SHELL COURSE ERECTION � After the completion of welding of Annular plates and bottom plates, mark the tank

inner radius on the annular plates. � Fix 25 Nos. of erection stools at the equal interval on the annular plates & transfer

the inside tank diameter on the stools. � The top one shell courses shall be erected by conventional method. � Balance shell courses shall be erected by hydraulic jack method. � The rolled shell plates shall be shifted to the tank foundation area stacked around

the periphery by using hydra crane. � Proper care shall be taken while handling the rolled plates. � Care shall be taken that the shell plate erected to the diameter marked on the

annular plate. � Jigs and fixtures shall be use to align the shell plates. � Complete the fit up except the final joint which shall be fitted and weld after

completion of the welding of the other joints. (To avoid the shrinkage)

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� Peaking to be checked after the fit-up of the vertical joints. Peaking shall be within the tolerance as per API - 650. (Tolerance 1/2")

� Peaking shall be checked at top, middle and bottom of the vertical joints using a Sweep board of 36” long.

� Plumbness shall be checked for the verticality of the shell course at every 60° and shall be within the tolerance (tolerance 1/200 of the total shell height)

� For perfect verticality, channels shall be provided at the regular interval inside of the shell course (3 to 5 meters) Providing the channels shall be facilitates the alignment last shall course.

� Tack welds of the fitted vertical joints shall be ground smooth. � Offer for inspection and get clearance from Engineer-in-charge for the vertical

fit-up Complete the first side welding by using qualified welders. � Care shall be taken while the welding to avoid the peaking and the roundness

distortion � After completion of first side welding, back-chip shall be carried out for sound metal

from other side of the weld by grinding. � Back-chipped grooves shall be offered for inspection before starting the welding. � Complete the 2nd side welding using qualified welders. � Joint Nos. & welder No. shall be marked on both side of the weld .joint. � Care shall be taken to avoid the peaking and roundness distortion. � Clean weld joints from both sides by wire brushing and grinding. � After completion of welding from both sides remove all the temporary jigs and

fixtures and flush grind the tacks. (Do the weld fill up wherever required) and the portion checked by D.P.test.

� Check the peaking, plumb ness, circumference and the radius, offer for inspection to the satisfaction of the Engineer-in-Charge.

� Erect last shell course plate on top of the erected shell plate, 3mm thick spacers shall be kept between first and last but one shell course plates to maintain horizontal seam gap.

� Erection channels shall be fixed between last but one shell course plates and last shell course plates at regular intervals to align and hold the last shell in vertical position.

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� After all the shell plates for last shell course is erected, fit-up the vertical joint using jig plates which has been fixed during erection and tack weld the joints.

� Check peaking at vertical joints of shell using a sweep board of 36" wide, acceptable tolerance shall the as per API-650 clause 5.5.4 (local deviation shall not exceed 1/2")

� Complete welding of last course vertical seam inside after getting clearance from the Engineer-in-charge.

� Back chip & welding shall be carried out following as same as for other shell course to the satisfaction of Engineer - in - Charge.

� After completion of welding, weld visual, peaking & circumference shall be checked out and recorded to the satisfaction of Engineer - in-Charge.

� Fit up the Horizontal seam between top shell courses and tack welded, remove the spacers provided during erection, tack weld shall be ground smooth and ensure that the tacks are sound and there are no defects like cracks and porosity etc.

� Check peaking at vertical joints of shell using a sweep board of 36" wide, acceptable clearance shall be as per API 650 clause 5.5.4 (local deviation shall not exceed 1/2") Using a vertical sweep board 36" long, check banding at horizontal joints. Deviation shall not exceed 1/2".

� Check Verticality of the last shell course, Verticality (plumb ness) tolerance shall be as per API - 650 clause 5.5.2 (max. out of plumbness at the top of the shell relative to the bottom of the shell not to exceed 1/200 of total shell height from top of last shell to Bottom)

� While welding care shall be taken for banding and the roundness. � Back-chip shall be carried out by grinding for the sound metal and to the

satisfaction of Engineer-in-Charge. � Complete the 2nd side welding and clean the joint thoroughly from both sides by

grinding and wire brushing. � Check banding, plumb ness and recorded in the approved format to the

satisfaction of Engineer - In-Charge. � Offer weld visual to the satisfaction of Engineer-In-Charge. . � Mark the RT spots as per the instruction of the Engineer -In-Charge, and complete

the RT as per API - 650 Sec-6 requirements.

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� Offer the RT film for reviewing to the Engineer-In-Charge, and if any repair occurs the repair spot shall be repaired by grinding for the sound metal, Re- weld the repair spot as per code API -650 sec-6 requirements.

� Take the repair spot RT and re offer for the inspection to the satisfaction of Engineer-In- Charge

� Spiral staircase Erection shall be carried out as per drawing including brackets. � Remove all the temporary cleats and tacks by grinding. � Install jacks as per requirement and the distance between the jacks shall not be

more than 3.5 meter. Connect the power pack and check the total system is ready for erection of the shell.

� Install the jacking cleats on the bottom shell course (inside) and weld soundly the cleats to the shell. Roof structure & Roof shall be erected then start jacking.

� Start jacking of the assembly of top two shell course along with the wind girder. Lift till the required space for the lower shell course plate width + Erection chair height. (400~450 mm)

� Erect the lower shell course by using the Hydra crane for shifting and position the plates.

� Alignment and fit up shall be carried out by using jigs and fixture and as per drawing offer the fit up for inspection.

� Followed by welding, weld visual, peaking and plumb ness before and after as mentioned above for the top two shell courses.

� After completion of the welding lower down the jacked up assembly on top of 3rd shell from top.03 mm thick spacer shall be kept between 3rd and 2nd shell from top to maintain the Horizontal joint gap.

� Fit up the Horizontal joint between 3rd and 2nd shell courses from top using jigs and fixtures and tack weld, remove the spacers provided during erection. Tack shall be ground smooth, check the banding and record. Offer fit up and banding to the satisfaction of Engineer-In-Charge.

� Followed by welding, banding & plumb ness before and after welding shall be carried out as mentioned for the above Horizontal joint.

� RT shall be carried out and cleared before the next lifting � Portion of the spiral stairway shall be erected as per drawing

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� After clearance from inspection, the jacking cleats shall be fitted to 3 rd shell from top course plates and the total assembly shall be jacked up by required height for erection of the all the shell courses.

� In the same manner erect all the shell courses and spiral stairway. � The 1st shell course plates shall be erected, provide min. 6 mm thick packing plates

at required location in each shell plate to facilitate proper welding of the bottom most portion of the vertical joint. This packing plate shall not be removed until commencement of shell to annular fit up. Leave the final shell plate open by providing angular frame in order for deck plate shifting and working.

� After completion of welding of vertical seams of the 1st shell course by following abovementioned process and the Horizontal joint between the shell courses 1 and 2 shall be aligned by lowering the jacks and the fit up shall be carried out.

� Follow the above-mentioned process for the horizontal joint welding and clearance.

� RT shall be carried out as per API-650 Sec.6 � Shell to annular plate joint shall be carried out using jigs and fixture. � After getting fit up clearance for welding, root weld shall be carried out from

inside. � After completion of inside welding clean the weld thoroughly by wire brushing,

grinding and buffing. � The shell to bottom joint area from both sides shall be cleaned thoroughly to carry

out the chalk-diesel test. � Apply chalk solution from inside. Apply diesel by a hand spray pump from out side. � Hold it as per instruction of the Engineer-In-Charge and check the root weld for

any defect. � If any defect found the defect shall be repaired by grinding the defect area for the

sound metal plus 150mm from both end of the defect. � Conduct the chalk - diesel test on the repair spot. Carry out the whole process until

the repair cleared to the satisfaction of Engineer - In – Charge.

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� After completion of shell to bottom out side welding visual inspection will be

carried out to the satisfaction of the Engineer-In-Charge. � On completion of shell to bottom welding / NDT and having completed all erection

and welding work on the tank inside related to the roof and roof structure, all unwanted materials and scrap shall be removed from inside of the tank.

� RT of vertical and horizontal joint shall be completed. � Sketch to annular plate joint fit up shall be carried out and complete the welding. � Vacuum box test the shall be carried out for the bottom plate short seam, long

seam and sketch to annular plate joint. � If any repair occurs the same shall be repaired and re-tested as per the approved

procedure and API-650.

5.3.4 ERECTION OF CONE ROOF PLATES AND STRUCTURES

� After completion of the Top two shell courses erection, fit up, welding and curb ring fit up & welding shall be done.

� Erect the fabricated Centre Drum, Roof Truss, and cross girders as per drawing. � Complete the welding of Roof structure by approved welders and as per approved

WPS. � Erect and Lay the Roof plates on the structure as per the Drg. � While fit up of the short seams and long seams Lap to be maintained as per Drg � Weld the short seams by welding alternative joint or sequence mentioned in the

Drg.to prevents the distortion. � Provided proper support lengthwise of the long seam and weld the joints as per

Drg. sequence. � Roof Nozzles and top shell nozzles fit-up and welding shall be carryout as per the

approved drawing and subsequently it has to be correlated with the concern piping drawing.

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5.3.5 APPURTENANCES INSTALLATION

� Flanges to pipe joint shall be prefabricated and required NDT shall be completed before erection.

� Mark the nozzle location as per drawings. Cut the openings by gas cutting after proper Inspection-by-inspection authority.

� Erect the nozzles as per the orientation & the elevation shown in the drawing. � Install RF. pads wherever required before nozzle erection � Suitable jigs & fixtures shall be provided to prevent the distortion during the

welding. � After completion of bottom shell course welding shell nozzles shall be marked as

per drawing and offer for inspection. � Cut open the nozzle opening, install the RF. Pads and erect the nozzles

(prefabricated) as per drawing. � Orientation, elevation & projection shall be maintained as per drawing and offer for

the inspection clearance. � Proper care shall be taken for the welding by providing jigs & Fixtures to prevent

distortion. � Welding shall be as per WPS and to be welded by the qualified welder. � Man-Hole neck shall be fabricated and the longitudinal joint shall be radio

graphed. � All the RF Pad weld shall be pneumatically tested at an pressure of 1.05 Kg/Cm2 � RF. Pad pneumatic test shall be carried out to the satisfaction of the engineer-in-

charge. � All the shell nozzles final weld from both sides and RF. Pads welds shall be

inspected by visually and by LPT, to the satisfaction of the engineer-in-charge.

Prepared by

CONTRACTOR .

Concurred by Name : Design:


Approved by Name : Design:


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6. PROPOSED PLANT AND MAJOR EQUIPMENT PLANT /EQUIPMENT /TOOLS / TACKLES

� Hydra 10MT / 12MT capacity. � Welding transformers /Rectifiers 400 a & 600 a Welding generators. � Radiography source Ir 192. � Test Pump. � Water pump � Transporting Equipment. � Plate bending Machine. � Pipe Bending Machine � Hydraulic Jack 12 MT [with power pack & accessories] and other

required equipment. � Grinding machine [AG - 7, AG - 4, GQ – 4 & FF2] � Gas cutting equipment [Pug cutting m/c & hand cutting m/c] � Vacuum pump and vacuum box with Gauge. � Vernier Caliper � Lifting Tools & Tackles and Derrick � Mother & Portable Oven � All Measuring Tape (30 M, 15 M, 5M, 3M.) � Piano Wire, Plumbob (Heavy weight) � Viewer � Aluminum Ladder -4 Nos. � 12v Hand lamp set for all four tanks. � Exhaust fan for all four tanks. � DG set with panel board separately for welding Rectifiers and Grinding. � Elcometer Pr.Gauge, Air-Compressor etc.

7. MAN POWER � AS PER REQUIREMENT

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Concurred by


Approved by


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8. QUALITY ASSURANCE & QUALITY CONTROL This shall be followed and maintained with the compliance / adherence to the drawings, procedure and code specification. Records shall be kept in the relevant check sheet and formats duly signed by all the concerned departments.

9. SAFETY � Tested & certified Lifting equipments should be used for lifting and shifting

purpose. � Safety Precautions should be followed during fabrication and erection as per JE

specification. � Welding cables and power cables to be laid properly as per IE rules and local state

govt. rules. � Proper house keeping and clean condition shall be maintained in the fabrication

shop and site as per requirement.

10. RECORDS � Foundation hand over report � Material Inspection Records � Electrode, Consumables etc. verification record � Welding Inspection report � NDT reports � Test reports

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TITLE RADIOGRAPHIC EXAMINATION PROCEDURE.

RADIOGRAPHIC EXAMINATION PROCEDURE 1. SCOPE:

The scope of this procedure shall apply to all radiographic examinations carried out during the execution of the Tankage Re-Erection work Phase-II with a special emphasis on radiation safety.

2. PURPOSE: The purpose of this procedure is to ensure that the radiographic images produced

are acceptable quality and that all radiographic examinations are performed in a safety policy, project specifications, quality control plan (SEP-Q1-001) and applicable codes.

3. REFERENCE:

ASME V Nondestructive Examination-Boiler & pressure vessel Code ASME B31.3 Process Piping ASME IX Welding and Bracing Qualification

API 650 Welded Steel tanks for Oil Storage. SNT-TC-1A Recommended Practice for Nondestructive Testing Personnel Qualification & Certification. API 1104 Standard for welding pipelines and related facilities.

4. RADIATION SAFETY 4.1 General

The radiographic technician (radiographer) shall be fully trained / qualified, and shall be fully aware of the hazards of radiation. Human body tissue will be severely damages if they are over exposed to radiation and even small amount of exposure on a daily basis, with insufficient recovery periods, will eventually produce a serious deterioration in health. All possible safety precaution shall always be taken to avoid unnecessary exposure. Prior to commencing any radiation work on site, emergency procedures shall be established. All radiographic discipline personnel who are involved with working with ionizing Radiation shall � Take all reasonable safety precautions. � Not knowingly expose either themselves or any other person to radiation

greater than is absolutely necessary for the purposes of their work.

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� Make full and proper use of all personal protection equipment provided. � Report any defects to radiographic equipment to his employer immediately

upon discovery. 4.2 Controlled areas Radiography shall only be undertaken in designated and clearly identified

”controlled areas”. These areas shall be identified and sealed by the use of the following as a minimum � Radiation tape Barriers-which surround and seal off the controlled area in its

entirety. � Radiation Hazard Warning Signs in English. � The sign shall be a minimum size of 450 x 450 mm. � These shall be positioned every 30 meters around the periphery of the

controlled area. � Flashing yellow lights to indicate radiation hazard area, these shall be

positioned adjacent to warning signs. Under no circumstances shall non radiographic discipline (unclassified)

personnel cross or enter the barriers to a controlled area. Any infringement of this safety rule / regulations concerning controlled areas will

result in the immediate removal of the individual concerned and expulsion from the Tankage Project.

4.3 Radioactive isotope The container in which radioactive isotopes are housed shall be lockable and

sealed. They shall be manufactured from expended uranium or similar materials, to international safety standards. These containers shall be re-certified as safe to use every of 26 months (maximum).The senior radiographic technician on site shall hold the keys at all times (other than usage).The whereabouts of all radioactive isotopes on site shall be logged and known at all times.

5. QUALIFICATION OF EXAMINATION PERSONNEL

The qualification of examination personnel shall be in accordance with SNT-TC-1A or an alternative system specifically accepted by owner.

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6. EQUIPMENT AND MATERIALS 6.1 Film Radiographs shall be made using industrial radiographic films that are available to

meet the required quality of radiographs. AGFA /KODAK made D4 or equivalent film to be used for 6 mm to 19 mm thick materials.

6.2 Identifying screen

The function of the lead intensifying screens is to reduce exposure times by the emission of electrons and secondary radiation in reaction to the primary radiation source and at the same time reduce film fogging by acting as a filter for the absorption of back scattered radiation.

The lead screens used shall be clean and in good condition, with a thickness of 0.125 mm (front) and 0.25 mm (rear), and shall be in direct contact with the radiographic film.

6.3 IQI (Image Quality Indicator)

Pentameter shall be either the hole type or the wire type and shall consist of those in Table 1 for hole type and those in Table 2 for wire type.

6.4 Radiation source Iridium 192 will be used as a radiation source.

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Table .1.Hole Type IQI Designation, Thickness and Hole Diameters, in

Penetrameter Penetrameter 1T Holes 2T Holes 4T Holes

Designation Thickness Diameter Diameter Diameter 5 0.005 0.010 0.020 0.040 7 0.007 0.010 0.020 0.040 10 0.010 0.010 0.020 0.040 12 0.012 0.012 0.025 0.050 15 0.015 0.015 0.030 0.060 17 0.017 0.017 0.035 0.070 20 0.020 0.020 0.040 0.080 25 0.025 0.025 0.050 0.100 30 0.030 0.030 0.060 0.120 35 0.035 0.035 0.070 0.140 40 0.040 0.040 0.080 0.160 45 0.045 0.045 0.090 0.180 50 0.050 0.050 0.100 0.200 60 0.060 0.060 0.120 0.240 80 0.080 0.080 0.160 0.320 100 0.100 0.100 0.200 0.400 120 0.120 0.120 0.240 0.480 160 0.160 0.160 0.320 0.640 200 0.200 0.200 0.400 …….

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Table .2. Wire IQI Designation and Wire Diameters, in

ASTM Wire Set Diameter

0.032

0.004

A 0.005

0.006

0.008

0.010

0.013

0.016

B 0.020

0.025

0.032

0.040

C 0.050

0.063

0.080

0.100

0.126

0.160

0.200

D 0.250

0.320

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7.PROCESSING REQUIREMENTS 7.1 Quality of radiographs All radiographs shall be free from mechanical, chemical or other artifacts to be

extent that they cannot mask or be confused with the image of any discontinuity in the object being radiographed. Such artifacts include but are not limited to:

[a] Fogging [b] Processing defects such as water or chemical marks. [c] Scratches, Finger marks, crimps, static smudges or tears [d] Loss of details due to poor film Contrast. [e] False indication due to defective screens.

7.2 Processing Manual (According to SE-94) 7.2.1 Preparation :– No more film should be processed that can be accommodated with a

Minimum separation of ½ “. Hangers are loaded and solutions stirred before starting development.

7.2.2 Start of development :- Start the timer and place the films into the developer tank. Separate

to a minimum distance of ½ “ and agitate in two directions for about 15 seconds.

7.2.3 Development:- Normal development is 5 to 8 minutes at 68° F (20° C) 7.2.4 Agitation:- Shake the film horizontally and vertically, ideally for a few seconds each

minute during development. This will help develop evenly. 7.2.5 Rinsing:- Rinse the films with vigorous agitation in clear water. 7.2.6 Fixing:-

The Films must not touch one another in the fixer. Agitate the hangers vertically for about 10 seconds and again at the end of the first minute, to ensure uniform and rapid fixation. Keep them in the fixer until fixation is complete (i.e. at least twice the clearing time),but not more than 15 minutes in relatively fresh fixer. Frequent agitation will shorten the time of fixation.

7.2.7 Fixer Neutralizing:- Use hypo eliminator or fixer neutralizer between fixation and washing.

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7.2.8 Washing:-

Washing is very slow below 60° F(16° C).When washing at temperature above 85° F(30° C),care should be exercised not to leave films in the water too long. The films should be washed in batches without contamination from new film brought over from the fixer. If pressed for capacity, as more films are put in the wash, Partially washed film should be moved in the direction of the inlet.

7.2.9 Wetting Agent:- Dip the film for approx. 30 seconds in a wetting agent added clear water. 7.2.10 Drying:-

Take Precaution to tighten film on hangers, so that it cannot touch in the dryer. Too hot a Drying temperature at low humidity can result in uneven drying and should be avoided.

8.EXAMINATION PROCEDURE:- 8.1. Surface Preparation

The weld ripples or weld surface irregularities on both the inside (where accessible) and outside shall be removed by any suitable process to such a degree that the resulting radiographic image due to any irregularities cannot mask or be confused with the image of any discontinuity.

8.2. RT request Upon completion and visual acceptance of a weld that is subject to radiography,

the controlling engineer shall make a request for radiographic examination. The request shall be entered into the schedule for radiographic examination and

forwarded to the radiographic technicians for execution. 8.3. Controlled area Radiography shall only be performed at such times as the work site is clear of all

non radiographic discipline personnel and the area of exposure shall be designated a ‘ controlled area’

Prior to commencing exposure of the isotope, all safety precautions and requirements as stated in 4.0 radiation safety shall be implemented.

The area in which the isotope is to be exposed shall be treated as a ’controlled area’ and only classified personnel may enter.

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The boundaries of this ‘controlled area’ shall be identified with radiation tape barriers, warning signs (in both English and Hindi) and flashing lights.

8.4.Marking on the weld The radiographer shall identify the weld to be radiographed and mark the weld. 8.5. Film identification Each radiograph shall be uniquely identified by means of lead numbers and

letters. The lead letters and numbers shall not encroach into the weld area and shall not interfere with the interpretation of the radiograph in any way. The following information shall be displayed on each radiographic film as a minimum:

--- Project name --- Company name --- Line number, drawing number or piece number. --- Weld number --- Repair identification number(where applicable) --- Welder identification number --- Date of radiograph --- Joint thickness and diameter 8.6. Location markers Location markers, which are to appear as radiographic images on the film, shall

be placed on the part, not on the exposure holder. Their location shall be permanently marked on the surface of the part being radiographed when permitted, or on a map, in a manner permitting the area of interest on a radiographed to be accurately traceable to its location on the part.

8.7. Direction of radiation The direction of the central beam of radiation should be centered on the area of

interest whenever practical.

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8.8. Film handling Care shall be taken to ensure that both exposed and unexposed films are kept

segregated and are stored in such a manner as that they shall not be subjected to radiation, excessive heat, dirt, fumes, etc.

8.9. Radiographic technique 8.9.1 Single wall technique

In the single wall technique, the radiation passes through only one wall of the weld, which is viewed for acceptance on the radiograph.

8.9.2 Double wall technique When it is not practical to use a single wall technique, one of the following

double wall techniques shall be used. [a] Single wall viewing

For welds in components, technique may be used in which the radiation passes through two walls and only the weld on the film side wall is viewed for acceptance on the radiograph.

When complete coverage is required for circumferential welds, minimum of three exposures taken 120 deg. to each other shall be made.

[b] Double wall viewing For welds in components 3.1/2 in. or less in nominal outside diameter, a technique may be used in which the radiation passes through two walls and the weld in both walls is viewed for acceptance on the same radiograph.

For double wall viewing, only a source side penetrameter shall be used. [1] For welds, the radiation beam may be offset from the plane of the weld at an

angle sufficient to separate the images of the source side and film side portions of the weld so that there is no overlap of the areas to be interpreted.

When complete coverage is required, a minimum of two exposures taken 90 deg. To each other shall be made for each joint.

[2] As alternative, the weld may be radiographed with the radiation beam

positioned so that the images of both walls are superimposed. When complete coverage is required, a minimum of three exposures taken

at either 60 deg. To 120 deg. To each other shall be made for each joint.

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8.10. Geometric unsharpness Unless otherwise specified in the applicable job order or Contract, the geometric

unsharpness shall not exceed the following limits: Material Ug Thickness (in.) Maximum (in.) Under 2 0.020

2 trough 3 0.030 Over 3 trough 4 0.040 Greater than 4 0.070 8.11. IQI Selection

The designed hole penetrameter with essential hole or designed wire diameter shall be as specified in Table 3.

8.11.1.Weld with reinforcements The thickness on which the penetrameter is based is the nominal single wall

thickness plus the estimated weld reinforcement not to exceed the maximum permitted by the referencing Code Section. Backing rings or strips are not be considered as part of the thickness in penetrameter selection.

The actual measurement of the weld reinforcement is not required. 8.11.2.Weld without reinforcements The thickness on which the penetrameter is based is the nominal single wall

thickness. Backing rings or strips are not to be considered as part of the thickness in

penetrameter selection.

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Table.3 IQI Selection

Normal Single-wall Material Thickness Range, in.

Penetrameter

Source Side Film side

Hole Type Designation

Essential Hole

Wire Diameter, in

Hole Type Designated

Essential Hole

Wire Diameter, in

Up to 0.25 incl. 12 2T 0.008 10 2T 0.006 Over 0.25 through 0.375 15 2T 0.010 12 2T 0.008 Over 0.375 through 0.50 17 2T 0.013 15 2T 0.010 Over 0.50 through 0.75 20 2T 0.016 17 2T 0.013 Over 0.75 through 1.00 25 2T 0.020 20 2T 0.016 Over 1.00 through 1.50 30 2T 0.025 25 2T 0.020 Over 1.50 through 2.00 35 2T 0.032 30 2T 0.025 Over 2.00 through 2.50 40 2T 0.040 35 2T 0.032 Over 2.50 through 4.00 50 2T 0.050 40 2T 0.040 Over 4.00 through 6.00 60 2T 0.063 50 2T 0.050 Over 6.00 through 8.00 80 2T 0.100 60 2T 0.063 Over 8.00 through 10.00 100 2T 0.126 80 2T 0.100 Over 10.00 through 12.00 120 2T 0.160 100 2T 0.126 Over 12.00 through 16.00 160 2T 0.250 120 2T 0.160 Over 16.00 through 20.00 200 2T 0.320 160 2T 0.250

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8.11. Placement of penetrameters 8.11.1.Source side penetrameter(s) The penetrameter(s) shall be placed on the source side of the part being

examined, except for the condition described in 8.11.2 8.11.2. Film side penetrameter(s) Where inaccessibility prevents hand placing the penetrameter(s) on the

source side, the penetrameter(s) shall be placed on the film side in contact with the part being examined.

A lead letter ”F” , at least as high as the penetrameter indication number(s), shall be placed adjacent to or on the penetrameter(s), but shall not mask the essential hole where hole penetrameters are used.

8.11.3.Penetrameter location for welds—hole penetrameters The penetrameter(s) may be placed adjacent to or on the weld.

The identification number(s) and, when used, the lead letter ”F” shall not be in the area of interest.

8.11.4. Penetrameter location for welds—wire penetrameters

The penetrameter(s) shall be placed on the weld so that the length of the wires is perpendicular to the length of weld.

The identification number(s) and, when used, the lead letter ”F” shall not be in the area of interest.

8.12. Number of penetrameters

For components where one or more film holders are used for an exposure, at least one penetrameter image shall appear on each radiographed except as outlined in 8.12.2.

8.12.1. Multiple penetrameters If the requirements of 9.3.2 are met by using more than one penetrameter,

one shall be representative of the lightest area of interest and the other the darkest area of interest: the intervening densities on th radiograph shall be considered as having acceptable density.

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8.12.2. Special cases [1] For cylinder vessels where the source is placed on the axis of the object

and one or more film holders are used for a single exposure of a complete circumstance, at least three penetrameters shall be spaced approximately 120 deg.apart.

[2] For cylinder vessels where the source is placed on the axis of the object and four or more film holders are used for a single exposure of section of the circumference, at least three penetrameters shall be used.

One penetrameter shall be in the approximate center of the section exposed and one at each end

When the section of the circumference exposed exceeds 240 deg. the rules of [1] above apply. Additional film locations may be required to obtain necessary penetrameter spacing: otherwise at least one penetrameter image shall appear on the each radiograph.

[3] For spherical vessels, where the source is located at the centre of the vessel and one or more film holders are used for a single exposure of a complete circumstance, at least three penetrameters shall be spaced approximately 120 deg. apart.

For other welds radiographed simultaneously, one additional parameter is shall be placed on each other weld.

[4] For segments of spherical vessels where the source is located at the centre of the vessel and four or more films holders are used for a circumferential weld, at least three penetrameters shall be used. One penetrameter shall be in the approximate centre of the portion exposed and one each end.

When the portion exposed exceeds 240 deg., the rules of [3] above apply. Additional film locations may be required to obtain necessary penetrameter spacing; otherwise, at least one penetrameter image shall appear on each radiograph.

8.13. Shims A shim of material radiographically similar to the weld metal shall be placed between the part and the penetrameter, if needed, so that the radiographic density throughout the area of interest is no more than minus 15 % from the radiographic density through the penetrameter.

The shim dimensions shall exceeds the penetrameter dimensions such that the outline of at least three sides of the penetrameter image shall be visible in the radiograph.

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9. EVALUTION 9.1. Quality of radiographs All radiographs shall be free of mechanical, chemical, handling related or other

blemishes to the extent that they do not mask and are not confused with the image of any discontinuity in the area of interest of the object being radiographed. If any doubt exists as to the true nature of an indication exhibited by the film, the radiograph shall be rejected and re-shot.

9.2. Viewing facilities for radiographs Viewing facilities shall provide subdued background lighting of an intensity that

will not cause troublesome reflections, shadows or glare on the radiograph. Equipment used to view radiographs for interpretation shall provide a variable light source sufficient for the designated wire to be visible for the specified density range.

9.3.Radiographic density 9.3.1 Density Limitations The transmitted film density through the radiographic image of the body of

appropriate hole penetrameter or adjacent to the designated wire of a wire penetrameter and the area of interest shall be 2.0 minimum and 4.0 maximum.

9.3.2 Density variation [a] General

If the density of the radiograph anywhere through the area of interest varies by more than minus 15% or plus30 % from the density through the body of the hole penetrameter or adjacent to the designated wire of a wire penetrameter within density limitations, then an additional penetrameter shall be used for each exceptional area or areas and the radiograph taken.

[b] With Shims When shims are used the plus 30 % density restriction of [a] above may be

exceeded, provided the required penetrameter sensitivity is displayed and the density limitation are not exceeded.

9.4. IQI sensitivity Radiography shall be performed with a technique of sufficient sensitivity to

display the hole penetrameter image and the specified hole, or the designated wire of a wire penetrameter, which are essential indication of the image quality of the radiograph. The quality levels required using wire Penetrameters shall be equivalent to the 2-2T level of method E 142/ or practice E1025, ASME Sec V Article 22 for hole type penetrameters. The table T-276 Article 2 Sec V Provides a list of various hole type IQI’s and the diameter of the wires of corresponding EPS (Equivalent Penetrameter Sensitivity) with the applicable 2T holes in the IQI.

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9.4. Excessive scatter A lead letter “B” shall be attached to the back of each film holder during each exposure to determine if backscatter radiation is exposing the film

If a light image of the “B” appears on a darker background of the radiograph, protection from backscatter is insufficient and the radiograph shall be considered unacceptable.

10. ACCEPTANCE CRITERIA

Radiographs shall be interpreted only in those areas in which Penetrameter(s) have established that a suitable radiographic technique has been used The following acceptance criteria shall be applied according to applicable code section.

[a] ASME B 31.3 [b] ASME Sec VIII Div 1 UW- 51 or UW- 52 [c] ASME Sec VIII Div.2 AI-510 [d] API 650 XI th Edition cl.8.1.5 11. RECORDS The following radiographic records shall be maintained as agreed upon between

the client and Visual 11.1 Sketch 11.2 Weld repair documentation 11.3 Film used 11.4 Thickness of material 11.5 Source to film distance 11.6 Film interpretation record shall contain as the minimum following information 11.6.1. Disposition of each radiograph (acceptable or rejected) 11.6.2. If rejected, cause for rejection (slag, crack, Porosity, LOP,LOF etc) 11.6.3. Surface indication verified by visual examination (grinding marks, weld ripple,

spatter etc.) 11.6.4. Signature of the film interpreter 12. ATTACHMENTS 12.1 Sketch showing location markers and arrow markers 12.2 Radiation warning Sign Board. 12.3 Sample radiographic Report.

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TITLE PROCEDURE FOR VACUUM BOX TEST

VACUUM BOX TEST PROCEDURE

1. SCOPE The objective of the vacuum box technique of bubble leak testing is to locate leaks in a pressure boundary that cannot be directly pressurized. This is accomplished by applying a solution to a local area of the pressure boundary surface and creating a differential pressure across that local area of the boundary causing the formation of bubbles as leakage gas passes through the solution.

2. PURPOSE The purpose of this procedure is provide a guide line to carry out the Vacuum

box test to check soundness of annular joints, bottom( long seam & short seam) and welding joints for annular plates.

3. REFERENCE CODE 1. API-650 (Latest edition) 7.3.4 & 8.6 Eleventh edition 2. ASME Sec-V . 4. EQUIPMENT

4.1. The Vacuum box test is performed by using a box with visible window of fiber glass (i.e.6” Wide by 30” long metallic box with a fiber glass). The open bottom is sealed against the tank surface by a sponge rubber gasket. The test scheme shall have suitable connections, necessary valve and calibrated Vacuum gauge. The gauge shall have a range of 0 psi to 15 psi or equivalent Pressure limits such as 0 in.Hg to 30 in.Hg.

4.2. The Test scheme shall be demonstrated with sample test block by application bubble solution at site before conduction the test on the job. The bubble forming solution shall produce a film that does not break away from the area to be tested, and the bubbles formed shall not break rapidly due to air drying or low surface tension, soaps or detergents designed specifically for cleaning shall not be used for the bubble forming solution.

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4.3. A vacuum can be drawn on the box by any convenient method, such as

connection to a gasoline or diesel motor intake manifold or to an air ejector or special vacuum pump. The gauge shall register a partial vacuum of at least 2 psi ( 4in.Hg)(15KPa) below atmospheric pressure.

4.4. Bubble forming solution (Brand name / Type will be furnished prior to execution) to be established vide 4.2 & to be recorded.

5. PERSONAL

The personnel shall be competent and have through knowledge in performing this method.

6. SURFACE PREPARATION

The surface to be examined and all adjacent areas shall be cleaned thoroughly and free from all dirt, grease, lint, scale, welding flux, weld spatters, paint, oil and other extraneous matter that could obstruct surface openings or otherwise with the examination. Prior to vacuum testing all joints shall be checked visually.

7. PROCEDURE

The temperature of the surface of the part to be examined shall not be below 400F( 50C) nor above 1250F( 500C) The weld seam on the test shall be applied with a bubble solution for detecting leaks prior to placing vacuum box. The foaming shall be minimized by means of uniform application of bubble solution. The gauge shall at least register a partial Vacuum of 21 Kpa or 3 Lbf/in2 for inspection of the joints An Overlap of 2” minimum for adjacent placement of the Vacuum box shall be given for each subsequent examination. The required partial vacuum shall be maintained for at least for 10 seconds examination time stop watch to be used after reaching the 21 KPA / Designated vacuum.

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8. EVALUATION

Bubbles produced by air sucked through the welded seam can detect the presence of defect. The tested areas are accepted only when no continuous bubbles formation is observed. A minimum light intensity of 1000 lux is required for conducting the examination.

9. REPAIR/RETEST Defects in welds shall be repaired by chipping, grinding or melting out the

defects from one side or both sides of the joints, as required and rewelding. Only the cutting out of defective joints that is necessary to correct the defects is required.

After repairing retest of Vacuum box test shall be carried out.

10. CLEANING After test the area shall be thoroughly cleaned for the further activities.

11. INSPECTION REPORT

The test shall be carried out in presence of the HPCL Engineer. Upon satisfactory inspection, a report shall be prepared as per HPCL

approved format.

12. SAFETY Safety shall be followed as per HSE specification during test.

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TITLE LIQUID PENETRANT EXAMINATION

PROCEDURE.

LIQUID PENETRANT EXAMINATION PROCEDURE

1. SCOPE:

The scope of this procedure shall apply to all liquid penetrant examinations carried out during the execution of Tankage Ph II Mahul

2. PURPOSE: The purpose of this procedure is to ensure that liquid penetrant examinations

are performed in accordance with the project specification, quality control plan (SEP-QI-001) and applicable codes.

3. REFERENCE:

ASME V Nondestructive Examination - Article 6. ASME B31.3 Process Piping API 650 Welded Steel tanks for Oil Storage.

SNT-TC-1A Recommended Practice for Nondestructive Testing Personnel 4. QUALIFICATION OF EXAMINATION PERSONNEL The qualification of examination personnel shall be in accordance with SNT-

TC-1A or an alternative system specifically accepted by owner. 5. MATERIALS Penetrant materials used shall belong to the same manufacturer and family

of particular type of Penetrant used batch Certificates for Penetrant materials shall be maintained.

5.1. Visible, solvent-removable penetrants 5.2. Solvent removers 5.3. Developers

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PROCEDURE.

6. PROCEDURE 6.1. GENERAL The liquid penetrant examination method is an effective means for detecting

discontinuities which are open to the surface of nonporous metals and other materials.

6.2.TEMPERATURE LIMIT It shall be ensured that the temperature of penetrant materials and the surface

of the materials to be tested shall be between 600 F to 1250 F(160 F to 520 F)

6.3. SURFACE PREPARATION The surface to be examined and all adjacent areas shall be dry and free of all

dirt, grease, lint, scale, welding flux, weld spatter, paint, oil and other extraneous matter that could obscure surface openings.

6.4.DRYING AFTER PREPARATION After cleaning, drying of surfaces to be examined shall be accomplished prior

to application of the penetrant.

6.5. APPLICATION OF PENETRANT The penetrant is applied on the surfaces to be examined by spraying. A liquid fluorescent or visible dye Penetrant is applied evenly over the surface being tested and allowed to enter discontinuities open to surface.

6.6. PENETRATION TIME Penetrant dwell time shall be minimum 10 min. and maximum 60 min. Ref. Table T-672 ASME Sec V Article 6.

6.7. REMOVAL OF EXCESS PENETRANT Excess solvent removable penetrants shall be removed by wiping with a cloth

or absorbent paper, repeating the operation until most traces of penetrant have been removed. The remaining traces shall be removed by lightly wiping surface with cloth or absorbent paper moistened with solvent. To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent. Flushing the surface with solvent, following of the penetrant and prior to developing, is prohibited

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PROCEDURE.

6.8. DRYING AFTER EXCESS PENETRANT REMOVAL Following the removal of excess penetrant, the surface will dry quickly by

normal evaporation. 6.9. DEVELOPING Prior to applying non-aqueous developer to the surface, the developer shall be

thoroughly agitated to ensure adequate dispersion of suspended particles. Developer shall be applied by spraying. 6.10. DEVELOPING TIME AND INTERPRETATION

The developer causes the bleed-out of the entrapped Penetrant out of the discontinuity staining the developer. The surface is then examined visually to determine Presence or absence of indications.

Final interpretation shall be made within 7 to 30 min. after a wet developer coating is dry. Adequate illumination is required to ensure adequate sensitivity during the examination and evaluation of indications.

7. ACCEPTANCE CRITERIA

All indication shall be evaluated in terms of the following applicable acceptance criteria.

[a] ASME B 31.3 [b] ASME Sec VIII Div 1,APPENDIX-VIII [c] API 650 [d] T-676 Article 6 ASME Sec V 8. SAFETY

Penetrant materials are highly volatile, relatively toxic and may cause skin irritation. Use adequate ventilation at all times and avoid prolonged skin contact. Penetrant materials aerosol cans should be kept out of direct sunlight or areas in excess of 1300F.

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TITLE PROCEDURE FOR OIL-CHALK TEST

OIL-CHALK TEST PROCEDURE

1. SCOPE: This test procedure shall be used to check the weld joint of shell to annular plate.

2. PURPOSE: The purpose of this procedure is provide a necessary guide line to carry out oil-

chalk test to check the weld joint of shell to annular plate. 3. SURFACE PREPARATION:

The surface to be examined and the adjacent area within at least 1” shall be cleaned thoroughly, must be dry and free from dirt, oil, grease, scale, welding flux, spatters, paint and other foreign matter that could obstruct surface openings or otherwise interfere with the examination.

4. APPLICABLE CODE:

API 650 Sec (Clause 7.2.4 (d)) / ASME Section V article 6). 5. PROCEDURE:

After completion of root weld from inside of the shell to bottom joint, apply wet chalk solution by brush on the root weld uniformly.

Allow the weld joint to dry thoroughly and then spray diesel/ kerosene on the opposite side of the weld (outside) by using the hand spray pump.

6. INSPECTION AND ACCEPTANCE CRITERIA:

After the application of the penetrant oil, hold it as per the instruction of the Engineer-in-charge. (Duration time - 4 hrs for light diesel ,high flash point penetrating oil) API 650 Cl 7.2.4 (d) Edition XIth.

Examine the root weld visually for the evidence of wicking.

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TITLE PROCEDURE FOR OIL-CHALK TEST

7. REPAIR AND RETEST: If any defect found then the same shall be repaired as per the approved

procedure. Re examine the repair spot and additionally minimum 150mm. for repair spot on both directions. Repeat the process until there is no evidence of leaking.

After completion of the test thoroughly clean the joint from both sides for the further welding.

8. INSPECTION REPORT: Test shall be carried out jointly and to the satisfaction of the Engineer-in-charge.

Test to be recorded in the approved format.

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TITLE PROCEDURE FOR PNEUMATIC PRESSURE TEST

PNEUMATIC PRESSURE TEST

1. SCOPE The objective of the pneumatic pressure testing is to locate leaks in the welds

of the reinforcement plates to shell plates and pontoons of floating roof .This is accomplished by applying a soap solution to a local area of the pressure boundary surface and creating a differential pressure across that local area of the boundary causing the formation of bubbles as leakage gas passes through the solution.

2. PURPOSE

The purpose of this procedure is provide a guide line to carry out the Pneumatic pressure test to check soundness of welds of the reinforcement plates to shell plate and the welds of roof seam of cone roof tank.

3. REFERENCE CODE 1. API-650 (Latest edition) (7.3.4) Eleventh Edition 2.TABLE I-1021 of ASME Section V, July 1, 2008 Edition. 4. EQUIPMENT

4.1. The test scheme shall have suitable connections, necessary valve and calibrated pressure gauge. The gauge shall have a range of 0 psi to 15 psi or equivalent Pressure limits such as 0 in.Hg to 30 in.Hg.

4.2. An air pressure can be created by any convenient method, such as

connection to a gasoline or diesel motor intake manifold or to an air ejector or pump.

4.3. Gases: The test gas will normally be air; however inert gases may be

used. 4.4. Bubble solution: As per ASME-V, I-1032.

5. PERSONAL

The personnel shall be competent and have thorough knowledge in performing this method.

Prepared by

CONTRACTOR

Concurred by


Approved by


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PROJECT LONI REVAMPING PROJECT


6. SURFACE PREPARATION

The surface to be examined and all adjacent areas shall be cleaned thoroughly and free from all dirt, grease, lint, scale, welding flux, weld spatters, paint, oil and other extraneous matter that could obstruct surface openings or otherwise with the examination. Prior to pneumatic pressure testing, joint shall be checked visually.

7. PROCEDURE SHELL APPURTENANCES- REINFORCEMENT PLATES TO SHELL PLATES WELDS

The temperature of the surface of the part to be examined shall not be below 400F( 50C) nor above 1250F( 500C) Make 6mm diameter-screw threaded Tell tale hole in the reinforcement pads before its welding to shell and shell appurtenances. The reinforcements pads shall be tested by applying up to 2 psi in the pressure gauge between the tank shell and reinforcement plates on each opening using tell tale hole Use soap suds on welds between reinforcement plate to shell, reinforcement plate to appurtenances to shell plate if any defect noticed. Repair the defective weld and repeat the test till entire satisfaction. Close the tell tale with a bolts or screw.

8. INDICATION OF LEAKAGE: The presence of continuous bubble growth on the surface of the material indicates leakage through an orifice passage(s) in the region under examination.

Prepared by

CONTRACTOR

Concurred by


Approved by


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PROJECT LONI REVAMPING PROJECT


A minimum light intensity of 1000 lux is required for conducting the examination.

9. REPAIR/RETEST

Defects in welds shall be repaired by chipping, grinding or melting out the defects from one side or both sides of the joints, as required and rewelding. Only the cutting out of defective joints that is necessary to correct the defects is required.

After repairing retest of Pneumatic pressure test shall be carried out.

10. CLEANING After test the area shall be thoroughly cleaned for the further activities.

11. INSPECTION REPORT

The test shall be carried out in presence of the Engineer In charge /HCPL Inspector.

Upon satisfactory inspection, a report shall be prepared as per HPCL approved format.

12. SAFETY

Safety shall be followed as per HSE specification during test. 13. Acceptance Criteria: The area under test is acceptable when no continuous bubble formation is observed.

Prepared by

Vishal Structurals Pvt. Ltd.

Concurred by


Approved by


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PROJECT

TITLE JOB PROCEDURE FOR HYDRO TEST / WATER FILL

UP TEST

JOB PROCEDURE FOR HYDROTEST/WATER FILLUP TEST 1. SCOPE This test procedure shall be carried out to detect the leak in shell weld joints and to

observe the load stabilization of liquid in interval level height. 2. PURPOSE The purpose of this procedure is providing the guideline and sequential steps for the

hydro test / water fill up test for the tank. 3. CHECK LIST

� After completion of the erection, welding and NDT the following points shall be checked before testing.

� All the mechanical activities completion in respect of the drawing and HPCL Specification and code requirements.

� Radiography completion including repairs. � The entire NDT test like chalk-diesel test, LPT, RF .Pad pneumatic test, vacuum box

test completion. � Finally mechanical clearance from the Engineer-In-Charge shall be taken before

Hydrotest in approved format 4. TEST MEDIA Test media shall be in iron free water, which is clean and free of silt i.e.; Portable

water 5. PROCEDURE

� Proper arrangement shall be carried out for the water filling (pipe connection from the water resource point and providing valves and NRV wherever required.

� markers shall be provided on the shell, 500 mm from the bottom to check tank settlement. Size shall be 50 X 50 X 6mm angle and 100 mm long. The nos. of setting marker shall be minimum 8 Nos or as per the approved Drg.

� Code : API 650 (7.3.6) Eleven Edition

Prepared by

CONTRACTOR .



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PROJECT


UP TEST

� Settling markers shall be provided at every 300 outside the tank at a height of 500

mm from the top of annular plate. � Setting marker shall be welded and initial level reading shall be taken with respect

to the permanent benchmark using dumpy level / Total station � Shell settlement measurements shall be made after tank erection, prior to

hydrotesting and during water filling at 1000 mm intervals up to maximum filling height of tank.

� The levels taken before water filling called as initial level of the tank and shall be record in an approved format.

� The water filling height shall be restricted to the max. Liquid Level or up to the curb angle.

� The water filling shall be carried out in four stages (25%, 50%, 75% & 100% of the max liquid level of the tank)

� Any leaks observed in the shell joint during the hydro test shall be noted and repaired with the water level min. of 300mm below the leak spot.

� The repaired shall be carried out as per the procedure and tank test shall be recommenced.

� After each stage of filling, a load stabilization period shall be observed as minimum 24 hours max between each stage of filling.

� During the stabilization period the settlement reading shall be observed and recorded jointly with HPCL Engineer-In-Charge through dumpy level only.

� Filling rate shall be not exceed 5 meters per day. � After completion of the water filling the water load shall be maintained for 24

hours. After 24 hours the final settlement reading shall be recorded jointly with engineer-In-Charge.

� Tank shall be emptied at a maximum water level variation rate of 5 meters per day. Care shall be taken that top manholes are open during empty operation of conical roof tanks.

� If salt water is used then corrosion inhibitor should be sprayed (mixed) prior to filling / after hydro test the tank should be thoroughly cleaned with sweat water.

Prepared by

CONTRACTOR .



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PROJECT


UP TEST

6. CLEANING

After draining the water the tank shall be thoroughly cleaned, free from dirt and foreign materials and shall be dried by air.

7. RECORDS

Records shall be prepared and submitted to Engineer in-charge for approval. 8. SAFETY

All Safety precaution shall be taken during water fill up test.

9. REFRENCE (A) API 650 (B) OISD 129 (C) PO Tech Specification Note : Permanent B M shall be min. 50Mtr away from Tank shell

Prepared by

CONTRACTOR .



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PROJECT

TITLE JOB PROCEDURE FOR SURFACE PREPARATION BY

SHOT BLAST CLEANING AND APPLICATION OF

PAINTS

JOB PROCEDURE FOR SURFACE PREPARATION BY COPPER SLAG BLAST CLEANING AND APPLICATION OF

PAINTS

1. SCOPE This procedure defines the requirements for surface preparation, selection &

application of paint on external surface of pipes & structural steel, ducts, Tanks and other items to be installed / constructed at LONI revamping project.

2. PURPOSE The purpose of this procedure is to carry out the shot blasting & primer painting of

all the tanks structures & pipes, ducts etc. in a systematic way to minimize available errors and to provide guide lines for best achievement in shot blasting & primer painting at LONI revamping project.

3. STANDARD & SPECIFICATION 1. Surface preparation standard should be Swedish Standard Institution SIS-05

5900-1967/ SA 2 ½.This standard contains photographs of the various standards which is required for inspection purpose by the Engineer-In-Charge.

2. Painting Specification ( as per the technical specs of tender document) 4. EQUIPMENT

To perform this above work the following Equipment / Materials are required from our end.

1. All Tools 2. Spray Gun 3. Air Hose 4. Hopper 5. Air Filter Compressor of capacity

Prepared by

CONTRACTOR .



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PROJECT



PAINTS

6. EIcometer

7. Abrasive Paper such as good quality surface with an abrasive powder glass, sand/Flint/emery paper of different rating shall be used

8. Cu Slag 9. Air Compressor of capacity 5.6 m3 - 7 m3 10. Brushes (Good quality Nylon bristles with long & flexible bristles shall be used) 11. Paints

5. SURFACE PREPARATION All the tack weld should be grinded and welding slag, spatters should be

cleaned. The Surfaces shall be Cu Slag blast cleaned by using Cu slag blasting. All other contaminants: oil, grease etc. shall be removed by use of an aromatic solvent. The surface shall be cleaned using copper slag of approved quality meeting tender specifications, at appropriate distance and angle depending of nozzle size maintaining constant velocity and pressure. The blasting nozzle should be venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzles orifice may vary from 3/16 ” to 3/4 ” .On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a grey white metallic luster. Primer or first coat of paint shall be applied within maximum 4 hrs of surface Preparation. Compressor will be oil less compressor. Air pressure will be 7.00 Kg/Sq. Cm, distance & angle of the nozzle will depend on nozzle size maintaining constant velocity & pressure. Compressed air shall be free from moisture & oil. There will be one barricading in between sand blasting & painting yard. Cu slag blasting work will not be performed when relative humidity beyond 85 %. After blasting, surface will be inspected by photograph in SIS-05 5900-1967 Code of SA 2 ½.

Prepared by

CONTRACTOR .



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PROJECT



PAINTS

6. SELECTION OF PAINT

Selection of Paint system shall be as per Tender Specification

7. PAINT APPLICATION 7.1 PRIMER PAINTING

Blasted surface will be primed with one complete application of primer within 4 hrs of blasting. Primer paint will be Approved Vendor make as per painting specification. Application of each coat will be continuous and uniform. Primer application will be performed by Spray Gun. Primer painting DFT thickness will be checked as per specification.

7.2 INTERMEDIATE AND FINAL COAT. Each coat shall be in proper state of cure or dryness before the application of

succeeding coat. Manufacturer instruction shall be followed for inter coat interval and application.

8. REPAIR OF DAMAGE PAINT SURFACE

8.1. Quickly remove the Primer from damaged area by emery paper and mechanical scrapping to expose the white metal.

8.2. Paint application as per specification.

9. DOCUMENTATION 9.1. A written QAP with Procedure qualification trials and for the actual work. 9.2. Results of measurements of temperatures, relative humidity, surface Profile,

Film thickness, holiday detection, adhesion tests with signature of appropriate authority.

9.3. Type of testing equipments and calibration. 9.4. Code & batch numbers of paint material used.

Prepared by

CONTRACTOR .



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PROJECT



PAINTS

10. INSPECTION AND TESTING 10.1. All painting materials including Primers and thinners brought to site by Contractor

for application shall be produced directly from manufactures as per specification and shall be accompanied my manufacture’s test certificates.

10.2.The Painting work shall be subject to inspection by HPCL at all times. In particular following stage wise inspection will be performed and Contractor shall offer the work for inspection and approval at every stage before proceeding to the next stage. The record of inspection shall be maintained in the registers / report. Stages of inspection as follows:

[a] Surface Preparation [b] Primer application [c] Each Coat of Paint. D.F.T shall be checked and record after application of each coat and extra coat of

paint should be applied to make up the D.F.T specified without any extra cost to owner.

11. FINISH COAT COLOUR & COLOUR CODING Finish coat and colour coding shall be applicable as per HPCL approved

documents.

12. SAFETY Safety Precaution shall be followed as per HSE manual / specification. 13. Acceptance Criteria a) Surface Preparation: surface will be inspected by photograph in SIS-05 5900-1967 Code of SA 2 ½. ( contractor shall manage the photograph). b) Painting : DFT readings using digital Elcometer ( calibration certificate to be submitted to HPCL) as per the tender technical specifications.

Prepared by

CONTRACTOR .



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PROJECT

TITLE PROCEDURE FOR BITUMEN CARPETING

1. SCOPE This work shall consist of construction in Anticorrosive layer, layer of Premixed Carpet and a layer of Seal Coat over the tank foundation pad.

2. PURPOSE The purpose of this document is to state the requirement of material,

workmanship and construction procedure to be followed during the execution of tank pads works.

3. MATERIALS Bitumen: Bitumen to be used for bitumen macadam shall conform of 60 / 70 grade as per IS: 73

4. PROCEDURE

Anti – corrosive layer will consist of screened coarse sand mixes with 155/6 bitumen or equivalent (8 to 10 % by volume). Sand shall be clean, dry coarse, hard, sharp, free from all impurities and shall conform to IS: 383.

Bitumen shall be heated to a temperature 1750 C to 1900 C with 3% kerosene if required and sand shall be thoroughly mixed with it in mixing drums to give a uniform mixture and shall be laid over the pad in line, grade and levels as shown on drawings.

The anticorrosive layer shall be then tamped to form hard mass of uniform 50 mm thickness.

For Premix Carpet, Sand shall be as per specification. The stone chipping shall be of hard black trap. It shall be obtained from approved quarry. The grading of stone shall be 12 mm and down size.

Prepared by

CONTRACTOR .





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PROJECT

TITLE PROCEDURE FOR BITUMEN CARPETING

Bitumen required for the work shall be 60/70 grade as per IS: 73 or its equivalent quality used for premix work.

The anticorrosive layer on which the premix is to be laid shall be thoroughly cleaned of all dust and loose materials. A coat of heated bitumen at the rate of 1 Kg / m2 shall be uniformly applied. The binder bitumen 60/70 shall be heated to required temperature with 3 % to 4 % kerosene if required and mixed with some chipping of size as given below at a rate of 6 m3 of stone chips per 100 m2 area and shall be mixed until the asphalt is well coated over all the particles of aggregate. The grading of stone chips shall be normally 3:2 (60% of aggregate of 12 mm size and 40 % of aggregate of smaller size upto 6 mm). The premix carpet shall be laid in 2 layers of 45 mm & 30 mm thickness and 12 mm thick seal coat layer. Each layer shall thoroughly rolled and compacted to the satisfaction of the owner/ consultant. After compacting and laying the first layer of 45 mm, a tack coat of hot bitumen at the rate of 1 kg/m2 shall be uniformly applied to the surface by means of sprayer and the second layer of 30 mm thick shall be laid tamped and compacted to the satisfaction of Owner / Consultant.

Sand shall be spread evenly on the final surface at the rate of 0.5 m3 per 100 m2.

A seal coat 12 mm thick shall be laid over Premix Carpet layer using bitumen

60 / 70 @ 100 kg / 100 m2 of surface area & mixing with stone chips of size 6 mm @ 0.92 m3 / 100 m2 of surface area as per correct grade and camber and compaction of the layers done using plate compactor.

Prepared by

CONTRACTOR .




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PROJECT

TITLE INSPECTION TEST PLAN FOR TANK FABRICATON

1.0 GENERAL

The enclosed ITPs shall be followed for the works to be performed by the Contractor under this Tender. The provisions indicated for stagewise inspection by HPCL are a minim um and the contractor shall develop a detailed ITP and obtain approval for the same prior to commencement of work. Contractor to carry out 100% examination of all activities.

2.0 LEGEND HP: Hold point;

A point which require sin section / verification and acceptance by HPCL before any further processing is permitted. The Contractor shall not process the activity/ item beyond a Hold point without written approval by HPCL.

W: Witness Point; An activity which requires witnessing by HPCL when the activity is performed.

Rw: Review of Contractor’s documentation.

S: Surveillance Inspection by HPCL; Monitoring or making observations to verify whether or not materials/ items or services conform to specified requirements. Surveillance activities may include audit, inspections, witness of testing, review of quality documentation & records, etc.

WC: 100% examination by Contractor.

Responsibility for execution of the inspection/ testing is with the Contractor. Prepared by

CONTRACTOR .



��DOC NO DATE

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03 OF 07

PROJECT


S. No. ACTIVITY

VISHAL HPCL

STORAGE TANKS

A. PRIOR OF FABRIATION 1. Acceptance of the tanks foundation WC HP

2. Incoming Material

� Owner’s Supply WC Rw � Contractor’s supply, including check testing

WC WC

Rw HP

3.

Welding Filler Material Approval /Qualification a) Manufacturing Test Certificate/Documents b) Testing, if any i) Carbon Steel

WC*

WC

Rw*

W

4. WPS/PQR(Sample Copy attached from Previous HPCL Site Records) a) Procedure:

i) WPS to be written for all the Weld Joints for for Bottom /Shell/Fl. Roof/A ppertunance etc

b) Testing : i) Carbon Steel WC HP c) Approval of Final WPS / PQR WC HP

5. a) Welder performance Qualification Test b) Certification& Approval of welder

WC WC

W HP

6. Review of joint numbering in drawings mention

Reference of 4.a.i.

WC

HP

7. Suitability of plate bending machine WC

Rw

8. Fabrication, erection, testing procedure for job WC

HP

B FABRICATION / ERECTION OF BOTTOM

WC

HP

1. Plate size, marking and cutting

WC

W

2. Blast cleaning & painting of underside of bottom plates

WC

HP

Prepared by

CONTRACTOR .




��DOC NO

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PROJECT


S. No. ACTIVITY

VISHAL HPCL

3. Plate layout, overlap and fit up

WC

S

4. Sequence of welding

WC

S

5. Size and positioning of backing plate for annular plates

WC

W

6. Banking of electrodes

WC

S

7. Inter-pass cleaning

WC

S

8. Visual check of welding

WC

W

9. DPT/RADIOGRAPHY of annular plate butt welds and bottom plate butt welds (As applicable)

WC

HP

10. Vacuum box test for bottom plate welding

WC

HP

SHELL 1. Plate size, marking and cutting

WC

Rw

2. Plate binding, curvature check, stacking

WC

W

3. Shell course alignments and fit-up of vertical and circumferential joints before welding

WC

W

4. a)Check Shell diameter @0,45,90,135,180,225,270,315,360 & circumference for circularity with strapping tap, perpendicularity, straight edge before welding and documenting (Each Shell wise & w.r.t. precede & ascend)

WC

HP

5. Visual check of welding and back chipping

WC

W

6. a) inner side welding visual check b) Check shell diameter @0,45,90,135,180,225,270,315,360

& circumference for circularity with strapping tap, perpendicularity, straight edge before welding and documenting (Each Shell wise & w.r.t. precede & ascend)

WC WC

W HP

7. Location size and alignment of nozzles and other openings

WC

HP

Prepared by

CONTRACTOR .

Concurred by Name : Design: Hindustan Petroleum Crop.

Ltd.



��DOC NO

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PAGE NO

05 OF 07

PROJECT


S. No. ACTIVITY

VISHAL HPCL

8. R.F. pads fit-up / welding

WC

W

9. PWHT of shell, RF pads, nozzles, manhole etc (If Applicable)

WC

W

10. Radiography marking (for random radiography only)

WC

HP

11. Curb angle and Wind girder fit-up / welding

WC

W

12. DPT of Nozzles, etc. (as applicable)

WC

W

13. RF pads pneumatic test

WC

HP

14. Shell to bottom fit-up

WC

HP

15. Shell to bottom I/S welding root run visual/ oil chalk test

WC

HP

16. Shell to bottom O/S welding visual and PT

WC

W

17. Fabrication and erection of stair ways

WC

S

18. Radiography a) Radiography interpretation b) Check shot for Radiography

WC WC

HP HP

FLOATING ROOF

1. Temporary staging, spacing and levels

WC

Rw

2. Plate size, straightening and cutting

WC

Rw

3. Plate layout, overlap, fit-up welding

WC

Rw

4. Availability of approved calculations for design of buoys

WC

HP

5. Buoys / pantoon fabrications

WC

S

6. Vacuum testing of roof – plates welds

WC

HP

Prepared by

CONTRACTOR .





��DOC NO

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PAGE NO

06 OF 07

PROJECT


S. No. ACTIVITY

VISHAL HPCL

7. Location of sleeve support

WC

S

8. Pad plate welding with roof and sleeve support

WC

S

9. Fixing and welding of Buoys

WC

W

10. Initial – Lift

WC

W

11. Support Fixing through sleeve

WC

S

12. Seal welding of support sleeve from beneath after dewatering

WC

S

13. Air test of Buoys / Pantoons

WC

HP

14. Pantoon welding

WC

S

15. Location, fixing and welding of man-holes, drains etc.

WC

W

16. Shell to pontoon clearance

WC

HP

17. Air Test of Pontoons for Leakproofness

WC

HP

18. Seal fixing

WC

HP

19. Floating Roof testing, as required e.g. flooding etc.

WC

HP

20. Primary roof drains installation & testing

WC

HP

C.

TESTING

1. Correctness testing arrangements especially size of Blind Flanges / vents/ drains/ temporary piping

WC

HP

2. Mechanical/ Inspection clearance

WC

HP

3. Earthing of ladder & shell

WC

W

4. Settlement reading through Dumpy Level during water filling

WC

HP

Prepared by

CONTRACTOR .

Concurred by Name : Design: Hindustan Petroleum Crop.

Ltd.



��DOC NO

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PAGE NO

07 OF 07

PROJECT


S. No. ACTIVITY

VISHAL HPCL

5. Hammer test

WC

HP

6. Air pressure test

WC

HP

7. Vacuum test

WC

HP

8. Roof collapsibility test in case of floating roof ranks Vis-a-vis to FR Dessign approved

WC

HP

9. Calibration of tanks from statutory authorities

WC

Rw

INSPECTION & TEST DOCUMENTS

Review Test and Inspection documents

WC

Rw

Prepared by

CONTRACTOR .



JOB PROCEDURE H.P.C.L

SUBMITTED BY CHECKED BY (FOR HPCL)

APPROVED BY (FOR HPCL)

1. SCOPE:

� The scope of this procedure shall apply to all reinforced cement concrete works carried out during the execution of the civil works Tankage Erection job.

2. PURPOSE:

� The purpose of this procedure is to ensure the high quality of the concrete casted and thus it shall meet all the strength requirements as per tender specifications and all relevant IS codes, the casted structures have perfect geometry as per the approved drawings etc all complete.

3. REFERENCE:

� IS 456

4. JOBS PRIOR TO RCC WORKS:

� Getting the constructional drawings approved from HPCL EIC. � Fixing of Centre line & levels with respect to HPCL coordinates &

Bench Marks with Total Station. � Carrying out of Excavation up to required depth and proper rolling

and compaction of virgin soil up to maximum satisfaction of HPCL EIC and getting it tested.

� Supply and filling of murrum as per specifications in layers of 200 mm and compaction of each layer to 95% modified proctor density.

� Machine mixing of aggregates, sand, cement and water as per mix proportion specified in tender specifications, carrying out of PCC to specified thickness, compaction using plate vibrator and curing.




5 RCC WORKS:

A) MARKING � Marking points and measuring the slope of Apron and beam slope

(it should be towards the drain connection point in 1:100) getting hold point clearance from HPCL.

B) FORM WORK

� Submission of design/plan for shuttering and props.

� Approved quality formwork to be provided as per HPCL approved drawings. The forms shall be butting with each other in straight lines, the corners of the boards being truly at right angles. Maximum care shall be taken to make the form work watertight. The contactor shall be permitted reuse of forms brought new on the work for exposed concrete work as specified below.

� Plywood Forms 6 Reuses (Max.) � Steel Forms 10 Reuses (Max.)

� The Engineer – in – Charge may, at his absolute discretion, order removal of any forms considered unfit for use in the work irrespective of the number of uses specified above.

� Inside dimensions to be marked�

C) REINFORCEMENT STEEL.

� Visual inspection of the steel supplied for manufacturing defects at field.

� The sample piece will be taken out from above supplied steel; the same will be tested at designated laboratories for all the tests as given in attached specifications. The test reports have to be submitted before the placement of concrete.

Note: Tests shall be repeated for every 02 MT of each size (dia).

� Submission bar bending schedule prepared by contractor for approval to HPCL EIC




� Reinforcement shall be straightened, cut and bent to shape and dimension as shown in the bar bending schedule approved by HPCL. Straightening, Cutting and bending of bars shall be as per IS 2502.

� All reinforcement shall be fixed in the correct position, adequate no. of cover blocks/ spacers have to be provided and shall be properly supported to ensure that displacement will not occur when the concrete is placed and compacted.

� The reinforcement shall be tied at every intersection by two standards of 20 SWG black soft annealed binding wire Note: cover blocks should have the same cement sand contents as the concrete which shall be placed and have a size of 40 X 40 mm and thickness equal to the specified cover. Note: When reinforcement bars are placed in two or more layers, the vertical distance between the horizontal bars shall be maintained by introducing spacer bars at 1 to 1.2 m center to center.

� Counting authorized laps and chairs.

� Tolerance: Unless otherwise directed by the Engineer-in-Charge, reinforcement shall be placed within the following tolerance:�

�

For effective depth 200mm or less + 10 For effective depth more than 200mm + 15 mm �

D) CONCRETING

� Mix design � The mix shall be designed to produce the grade of concrete having

the required workability and characteristic strength. � The design mix shall be conforming to the guidelines of IS: 10262 � Mix design with supportive laboratory tests shall be submitted to

the Engineer-in-Charge for approval

� Batching




� During proportioning concrete, based on the results from Design Mix, the quantity of both cement and aggregate shall be determined by mass. Note: a reasonable number of bags shall be weighed periodically to check the net mass.

� Water shall be either measured by volume in calibrated tanks or mass;

� All measuring equipment shall be mentioned in a clean serviceable condition, and their accuracy periodically checked

� Mixing � The mixing of concrete shall be strictly carried out in an approved

type of mechanical concrete mixer. � Mixer shall comply with IS: 1791 � The mixing shall be continued until there is a uniform distribution

of the material and the mass is uniform in colour and consistency � Mixing time shall be as indicated in the following table

Capacity of Mixer Minimum Mixing Time 2 m3 or less

3 m3

5 m3

1 ½ minutes

2 ½ minutes

3 minutes � All records and charts for the batching and mixing operation shall

be prepared and maintained by the Contractor as per the instructions of the Engineer-in-Charge

� Hand mixing of concrete shall be permitted with the addition of 10% more cement.

� For highly lean concrete, hand mixing may be permitted by the Engineer-in-Charge as a special case. Ten percent (10%) extra cement shall have to be added to the normal mix when mix by hand

� Transportation & Placing � The entire concrete placing program including transportation

arrangements, deployment of requirement lay out proposed




procedures and methods, shall be submitted to the Engineer-in-Charge 24 hours prior to concreting, for approval

� No concreting shall be placed until his approval has been received � Concrete shall not be placed until the formwork, the placement of

reinforcing steel, embedded parts, pockets etc. have been inspected and approved by the Engineer-in-Charge

� Concreting shall not be started unless the electrical conduits, pipes, fixtures etc. wherever required are laid by the concerned agency

� Before concreting, the Contractor shall provide, fabricate and lay in proper position all metal inserts anchor bolts, pipes etc as per relevant drawings and directions of Engineer-in-Charge.

� All concrete shall be conveyed from the mixer to the place of final deposit as rapidly as possible in suitable buckets, dumpers, containers or conveyors which shall be mortar leak tight.

� Concrete shall be discharged by vertical drop only and the drop height shall not normally exceed 1.5 meter

� Unless otherwise approved concrete shall be placed in single operation to the full thickness of foundation rafts, slabs, beams and similar members. Concrete shall be placed continuously until completion of the part of the work between approved construction joints or as directed by the Engineer-in-Charge.

� Compaction � Concrete shall be thoroughly compacted with vibrators of pin

dimensions 3” and 4” and fully worked around the reinforcement, embedded fixtures and into corners of form work before setting commences and shall not be subsequently disturbed

� The vibrators shall be of immersion type with operational frequency ranging between 8,000 and 12,000 vibrations per minute.

� All vibrators shall comply with IS: 2505. � Screed board concrete vibrators or concreting vibrating tables or

form vibrators conforming to IS: 2506, 2514 and 4656,




respectively may also be used where specifically required and directed by Engineer-in-Charge.

� The vibrator shall be withdrawn slowly. � The spacing shall provide some overlapping of the area vibrated at

each insertion. � Curing � Concrete shall be cured by keeping it continuously moist wet for

the specified period of time. � Curing shall be started after 8 hrs. of placement of concrete, and in

hot weather after 4hrs. � The water used for curing shall be of the same quality as that used

for making of concrete. � Curing shall be assured by use of an ample water supply under

pressure in pipes with all necessary appliances such as hose, sprinkles etc.

� A layer of sacking, canvas, Hessian, of other approved materials which will hold moisture for long periods and prevent loss of moisture of the concrete shall be used as covering

� Exposed surfaces of concrete shall be maintained continuously in damp or wet conditions for at least the 1st 7/10 days after placing of concrete.

� For curing the concrete in pavement floors, flat roofs or other level surfaces, the ponding method of curing is preferred after the expiry of first 24hrs during which (i.e. 1st 24 hrs) the concrete shall be cured by use of wet sacking, canvas Hessian etc.

E) ACCEPTANCE CRITERIA

� The concrete shall be deemed to comply with the strength requirements if:




� every sample has a test strength not less than the characteristic value;

� The strength of one or more samples though less than the characteristic value, is in each case not less than the greater of:

1. The characteristic strength minus 1.35 times the standard

deviation; And

2. 0.80 times the characteristics strength; and the average strength of all the samples is not less than the characteristics strength plus

{1.65 -- (1.65/(n)1 / 2)} x S.D.

� Rebound hammer test and compressive strength test of extracted cores meet strength requirements as per mix design.

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DOC NO V

DATE

PAGE NO 03 OF 05

PROJECT TANKAGE JOB AT LONI TERMINAL

TITLE JOB PROCEDURE FOR Puncture TEST / Rain water

FILL UP TEST

JOB PROCEDURE FOR PUNCTURE/FLOATATION/RAIN WATER

ACCUMULATION TEST 1. SCOPE This test procedure shall be carried out to check the buoyancy and design of floating

roof vis-à-vis fabrication and under conditions of testing: a. Single deck and any two adjacent pontoon compartments punctured and flooded in

single deck pontoon roofs and any two adjacent compartments punctured and flooded in double deck roofs, both roof types with no water or live load.

b. 250 mm of rainfall in a 24 our period over the full horizontal tank area with the roofs intact.

2. PURPOSE The purpose of this procedure is to check the design compatibility w.r.t. fabricated

and erected roof under testing. 3. CHECK LIST

� After completion of the erection, welding and NDT, Pneumatic testing, diesel chalk testing of outer rim, visual checking of welds (100%) and rectification if any the following points shall be checked before testing.

� All the mechanical activities completion in respect of the drawing and HPCL Specification and code requirements.

� NRV in central roof drain to be checked. � The entire NDT test like chalk-diesel test, LPT, RF .Pad pneumatic test, vacuum box

test completion. � Punctures with couplings fitted in the deck and adjacent pontoons to be ensured

before commencing of Hydrotesting. � Puncture test to be carried out when roof is in highest position. � Finally mechanical clearance from the Engineer-In-Charge shall be taken before

Puncture test in approved format. 4. TEST MEDIA Test media shall be in iron free water, which is clean and free of silt i.e.; Portable

water. 5. PROCEDURE For puncture test:

� Initial reading of a. RIM SPACE (atleast at 08 POINTS) to be taken. b. Location of rolling ladder (drum) w.r.t. shell to be taken and spirit level on ladder

staircase. c. Deck immersion and rim position w.r.t. tank shell should be noted. d. Water fill height to be noted.

� Out of two adjacent pontoons one to be punctured and time to be noted along with the height of water column coming out of hole ( this shall help in evaluating the final height of water after fillup).

� Again after the water settles down and no more significant change seen note the time taken and check for any leakage in adjacent pontoon, then repeat the points ( a to d) and puncture next ( adjacent) pontoon.

� Again note the readings (repeat as above). � After that puncture the central deck and repeat the procedure and steps a to d. For Rain water fill: 1. Blind the NRV and fill the central deck till 10” and keep the same for one day without

Puncture test condition and with puncture test condition. NOTE: NRV to be opened thereafter to see the water flow afterwards from roof drain and time taken to remove the water.

� Code: API 650 APPENDIX C.

6. CLEANING

After draining the water the tank shall be thoroughly cleaned, free from dirt and foreign materials and shall be dried by air.

7. RECORDS

Records shall be prepared and submitted to Engineer in-charge for approval in approved format. 8. SAFETY

All Safety precaution shall be taken during the test.

9. REFRENCE (A) API 650 (B) PO Tech Specification

Prepared by

CONTRACTOR .



��

DOC NO VS

DATE

PAGE NO 04 OF 05

PROJECT TITLE

TANKAGE JOB AT LONI TERMINAL

JOB PROCEDURE FOR HYDRO TEST / WATER FILL

UP TEST

ACCEPTANCE CRITERIA:

1. At each stage of water filling the time taken in water settling and Tilting should be in conformance to the approved floating roof design within the mentioned tolerances of all the variables like RIM SPACE, TILTING, TIME TAKEN TO WATER FILL.

2. For rain water fill test the water filled should overflow on ED and for the period of 24 hrs the water should in no case come out of deck outer rim (i.e. immersion should be as per design for water).

3. The time taken by the roof drain water to come out from central roof drain sump should be in conformance to the design and code requirements ( Appendix C, API 650).

NOTE: After the completion of test the punctures should be blinded and DP tested for leakage when roof at lowest position( after Hydrotesting if welded, else coupling should be seal tighted.

Prepared by

CONTRACTOR .



��

DOC NO DATE

PAGE NO

05 OF 05

PROJECT TANKAGE JOB AT LONI TERMINAL


UP TEST

Prepared by

CONTRACTOR .



�

QUALITY

ASSURANCE

PROGRAMME

CONTENTS

______________________________________________________________

CLAUSE DESCRIPTION

1.0 INTRODUCTION

2.0 DEFINITIONS

3.0 SCOPE OF WORK BY CONTRACTOR

4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS

1.0 INTRODUCTION

This specification establishes the Quality Assurance requirements to be met by Contractors (including turnkey contractors) and vendors.

In case of any conflict between this specification and other provisions of the contract / purchase order, the same shall be brought to the notice of HPCL, at the stage of bidding and shall be resolved with HPCL, prior to the placement of order.

2.0 DEFINITION

2.1 Bidder

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

2.2 Correction

Action taken to eliminate the detected non-conformity.

2.3 Preventive Action

Action taken to eliminate the causes of a potential nonconformity, defect or other undesirable situation in order to prevent occurrence.

2.2 Process Set of inter-related resources and activities which transform inputs into outputs.

2.3 Special Process Process requiring pre-qualification of their process capability.

1.0 SCOPE OF WORK BY CONTRACTOR

1.1 Prior to award of contract

1.1.1 The bidder shall understand scope of work, drawings, specifications and standards etc., attached to the tender / enquiry document, before he makes an offer.

1.1.2 The bidder shall submit milestones chart showing the time required for each milestone activity and linkages between different milestone activities along with overall time period required to complete the entire scope of work.

1.1.3 The bidder shall develop and submit manpower and resource deployment chart.

1.1.4 The bidder shall submit, along with the bid, a manual or equivalent document describing / indicating / addressing various control / check points for t he purpose of quality assurance and the responsibilities of various functions responsible for quality assurance.

2.0

2.1 After the award of contract

The bidder shall submit the schedule for submission of following documents in the kick-off meeting or within two weeks of the placement of order, whichever is earlier.

• Quality plan for all activities, required to be done by the bidder, to accomplish offered scope of work.

• Inspection and test plans, covering various control aspects. • Job procedures as required by HPCL/Owner.

Various documents submitted by the bidder shall be finalized in consultation with HPCL. Here it shall be presumed that once a bidder has made an offer, he has understood the requirements given in this

specification and agrees to comply with them in totality unless otherwise categorically so indicated during pre-award stage through agreed deviation / exception request. All quality assurance documents shall be reviewed by concerned HPCL functional groups and the bidder shall be required to incorporate all comments within the framework of this specification at this stage of the contract. It is also obligatory on the bidder that he obtains approval on every quality assurance document, before he starts using a particular document for delivery of contracted scope of work. Participation of HPCL/Owner in review / approval of quality plan / QA documents does not absolve the contractor of the contractual obligations towards specified and intended use of the product (or service) provided by him under the contract.

2.2 During job execution

4.2.1 During job execution, the bidder shall fully comply with all quality documents submitted and finalized / agreed against the requirements of this specification. Approval of HPCL on all these documents shall be sought before start of work.

4.2.2 Bidder shall produce sufficient quality records on controlled / agreed forms such that requirements given in this specification are objectively demonstrates.

4.2.3 Bidder shall facilitate HPCL/Owner during quality / technical audits at his works / sites.

4.2.4 Bidder shall discharge all responsibilities towards enforcement of this specification on all his sub-contractors for any part of the scope which is sub-contracted.

3.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS

5.1 The bidder shall nominate an overall in-charge of the contract titled as “Project Manager” for the scope of work of agreed

contract. The name of this person shall be duly intimated to HPCL,

including all subsequent changes, if any. HPCL shall correspond only with the project manager of the bidder shall be responsible for co-ordination and management of activities with bidder’s organization and all sub-vendors appointed by the bidder.

5.2 After award of work the bidder may review augmentation of manpower and resources deployment chart (submitted earlier), detail it out, if so consented by HPCL/Owner and resubmit the same as “Issued for implementation”.

5.3 The bidder shall plan the contract scope of work on quality plan format

such that no major variation is expected during delivery of contract scope of work. These quality plan shall be made on enclosed format complete in all respect. The quality plan shall be assumed to be detailing bidder’s understanding and planning for the contract / offered scope of work. The bidder shall plan the type of resources including various work methodology which he agrees to utilize for delivery of contract scope of work.

5.4 The bidder is required to review the contract at all appropriate stages to evaluate his capabilities with respect to timely and quality completion of all activities pertaining to contracted scope of work and shall report to HPCL/Owner of constraints, if any.

5.5 The design activities, if any, performed during delivery of contract scope of work shall be so controlled that the output is reliable enough. It is expected that during development of design, the bidder shall take recourse to detailed checking, inter departmental reviews and documented verification methods.

5.6 For all documents which the bidder is likely to utilise for delivery of contract scope of work, a system must exist which assures that latest / required version(s) of the document(s) is available at all location / point of use.

5.7 In case the bidder decides to sub – contract any part / full of the contract scope of work (without prejudice to main contract condition), the bidder shall

- Evaluate the technical and financial capabilities and past performance of the sub-contractor(s) and their products and/or services before awarding them with the sub-contracted scope of work. Selection of a sub-contractor should meet HPCL approval in documented form.

- Requirement of this specification shall be enforced on sub-contracted agency also. The bidder shall choose sub-contractor based on their capability to meet requirements of this specification also.

NOTE : It may so happen that, in a given situation, a sub-contractor may not have a system meeting the requirements of this specification. In all such eventualities, bidder may lend his system to sub-contractor for the contract such that sub – contractor effectively meets the requirements of this specification. In all such cases HPCL shall be duly informed.

5.8 Bidder shall establish methodology such that the materials supplied by the owner / HPCL shall be suitably identified in such a manner that either through identification or some other means, sufficient traceability is maintained which permits effective resolution of any problem reported in the outputs.

5.9 Critical activities shall be identified and the bidder is required to have documented methodologies which he is going to utilize for carrying out such activities under the contract scope of work. Wherever it is difficult to fully inspect or verify the output (special process) bidder shall pre-qualify, the performers and methodologies.

5.10 All inspections carried out by the bidder’s surveillance inspection staff shall be in conformity to quality plans and / or inspection and test plans. All inspection results shall be duly documented on controlled / agreed forms such that results can be co-related to specific product, that was inspected / tested.

5.11 All inspection, measuring & test equipments (IMTEs) shall be duly calibrated as per National / International standards / codes and only, calibrated and certified IMTEs shall be utilized for delivery of contract scope of work.

5.12 All outputs / products delivered against contract scope of work shall be duly marked such that their inspection status is clearly evident during all stages / period of the contract.

5.13 All non-conformities (NCs) found by the contractor’s inspection / HPCL surveillance staff shall be duly recorded, including their disposal action. The deficiencies observed during stage of the product, shall be recorded

and resolved suitably. Effective corrective and preventive action shall be implemented by the bidder for all repetitive NCs, including deficiencies.

5.14 All deficiencies noticed by HPCL’s representative(s) shall be recorded on a controlled form such deficiencies shall be analyzed by the bidder and effective and appropriate correction, corrective and preventive actions shall be implemented. Bidder shall intimate HPCL/Owner of all such corrective and preventive action implemented by him.

5.15 Bidder shall establish appropriate methodologies for safe and effective handling, storage, preservation of various materials / inputs encountered during delivery of contract scope of work.

5.16 Bidder shall prepare sufficient records for various processes carried out by him for delivery of contract scope of work such that requirements of this specification are objectively demonstrate. In case HPCL/owner finds that enough objective evidence / recording is not available for any particular process, bidder shall be obliged to make additional records so as to provide sufficient objective evidence. The decision of HPCL/owner shall be final and binding on such issues.

5.17 The bidder shall arrange internal quality audits at quarterly intervals, to independently assess the conformance by various performers to the requirements of this specification. The findings of such assessment shall be duly recorded and a copy shall be sent to HPCL/owner for review.

For all special processes, bidder shall deploy only qualified performers. Wherever HPCL observes any deficiency, the bidder shall arrange the adequate training to the performer(s) before any further delivery of work.

�

QUALITY ASSURANCE PLAN FOR CONSTRUCTION OF STORAGE TANKS CUSTOMER : DATE : CONTRACTOR : QAP NO. : PROJECT : PAGE : SL. NO. DESCRIPTION OF ITEMS CHARACTERISTICS TO

BE CHECKED CAT TYPE/METHOD OF CHECK

EXTENT OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE STANDARDS

FORMAT OF RECORDS

AGENCY REMARKS P W V MATERIAL IDENTIFICATION 1. Plate for tanks, nozzle neck 10" and

above and structurals 1 Physical, chemical

properties, heat treatment.

M Physical & Chemical Tests.

As per Specification

APPD DRGS/ DATA SHEET

IS 2062 GR. B,C & GR. A for structurals SA 370

MILL TC 3 3/1 1,2 For IOC supplied material

2 Dimensions and surface quality

M Meas. & Visual 100% APPD DRGS/ DATA SHEET

ASTM A 6,A20 IR 2 1

3 Lamination free M Visual, UT/MPT (if reqd.)

All edges API 650 ASME Sec. VII Div. I

MFTRS TC & IR

3 1 Not reqd. for structurals.

2. Pipes for nozzle 1 Physical, chemical properties, heat treatment

M Physical & Chemical Tests

As per specification


A 106GR B/C, API 5L Gr. B

MFTRS TC 3 1* 1,2 *If specified in WO

2 Dimensions and surface quality


ANSI B 36.10/API 5L

IR

2 1

3. Flanges for nozzles 1 Physical, chemical properties, heat treatment

M Physical & Chemical Test



ASTM A 105 & A 181

MILL TC 3 3/1 1,2

2 Dimensions & surface quality


ANSI B 16.5 IR 2 1 1,2

4 Pipe fittings 1 Physical, chemical properties, heat treatment




As per WO/ ASME SA 234

MFTRS TC 3 3/1



ANSI B 16.9 IR 2 1 1

5 Bolts, nuts for nozzle flanges & structurals

1 Physical, chemical properties, heat treatment




ASTM A 193 & 194/ IS 1367 C. L. 4.4.6

MFTRS TC 3/2 2,1



ANSI B 1.1/B 1.2/ B 18.2.2

IR 2 1 IOC to witness 10% random meas & 100% visual.

SL. NO.

DESCRIPTION OF ITEMS CHARACTERISTICS TO BE CHECKED

CAT TYPE/METHOD OF CHECK

EXTENT OF CHECK

REFERENCE DOCUMENTS


FORMAT OF RECORDS

AGENCY REMARKS P W V

IN PROCESS: 6. Welding procedure specification

proposed Correctness M Scrutiny 100% WPS WPS-ASME

SEC. IX WPS 2 1 To be checked

and approved by IOC before tests.

7 Welding procedure qualification test and record

Desired property of welding, establishing correctness of welding variables


100% WPS ASME – SEC IX

ASME WPS & PQR Formats

2 1,2

8 Welders Performance Qualification

Ability of welders to make sound weld

M Radiography 100% WPQ ASME SEC IX ASME WPQ format

2 1,2

9 Plate cutting for bottom, shell & roof

Dimensions, checking diagonal & squaring

M Meas. & Visual 100% Cutting Layout Plan

APPD. DRGS. IR 2 2 1

10 Rolling of Plates Dimensions & Shape

M Meas./ Visual 100% APPD. DRGS. APPD. DRGS. IR 2 2 1

11 Fittments of weld joints Alignment, Edge preparation, root gap, cleanliness along seam

CR Visual, Meas, Plumpness

100% APPD. DRGS. APPD. DRGS. IR 2 2,1 H

12 Root run after back gauging of Butt weld joints

Free of flaw M Visual 100% API 650 API 650 IR 2 2,1

13 Finished Butt weld joints 1 Smoothness and Reinforcement

M Visual 100% API 650 API 650 IR 2 2,1

2 Internal Flaws CR Radiography API 650 & WO

API 650 & WO ASME Sec. VIII Div. I, UW-51b

IR 2/3 2,1 1 H

3 Peaking/ Banding/ Circularity

M Meas/Plump 100% API 650 API 650 IR 2 2,1

14 All Lap Joints of Bottom Plates 1 Lay out, Edge Prepn M Visual 100% API 650 API 650 IR 2 2,1 2 Welding M Visual, Vacuum

Test, Pneumatic Test

100% API 650 API 650 IR 2 2,1

SL. NO.



EXTENT OF CHECK

REFERENCE DOCUMENTS


FORMAT OF RECORDS

AGENCY REMARKS P W V

15 Bottom plates sand blasting underside painting

1 Cleanliness/ Surface Profile

M Visual / Meas. 100% WO Painting Spec. IR 2 1,2

2 Coating thickness M DFT, Elcometer 100 % WO Painting Spec. IR 2 1,2 16 Nozzle to flange & nozzle to

shell Dimension,

Orientation of nozzle, projection, elevation, fittment

M Visual, Plumb, Meas

100% APPD. DRGS/ API 650

API 650/ APPD. DRGS

IR 2 1,2

17 RF Pad/ Nozzle to Shell Leak tightness M Pneumatic soap suds

100% API 650 API 650 IR 2 1,2

18 Shell to Annular plate 1 Weld soundness M Visual/ Meas. 100 % APPD DRGS API 650 IR 2 1,2 2 Leak tightness

M Penetrant/ 100% API 650 API 650 IR 2 1,2

19 Deck plate lap joints 1 Fitment, dimensions Slope

M Visual/ Meas. 100% APPD DRGS API 650 IR 2 1,2

2 Weld Soundness M Visual/ Penetrant

100% API 650 API 650 IR 2 1,2

20 Rim bulk head compartment 1 Fitment / Dimension M Visual & Meas 100% APPD DRGS API 650 IR 2 1,2 2 Welding M LPT/Pneumatic

100 % API 650 API 650 IR 2 1,2

21 Splice joints of rafters/columns Dimensions & Welding

M Visual & Meas. 100% APPD DRGS/ API 650

API 650 IR 2 1,2

22 Appurtenances, leg supports fabricated appurtenances

Alignment, Dimension, Weld soundness

M Visual /Meas. 100% APPD DRGS API 650 IR 2 1,2

23 Central Sump 1 Fitment M Visual / Meas. 100% APPD. DRGS. API 650 IR 2 1,2 2 Weld soundness

M DPT/ & Visual 100% API 650 API 650 IR 2 1,2

24 Piping for fire water/foam system 1 Layout & fitment M Visual, Meas. 100% APPD. DRGS. APPD. DRGS. IR 2 1,2 2 Welding quality M Root DPT &

Final welding Visual

100% APPD. DRGS. APPD. DRGS. IR 1 1,2 1 10% of DPT shall be witness by 1

SL. NO.



EXTENT OF CHECK

REFERENCE DOCUMENTS


FORMAT OF RECORDS

AGENCY REMARKS

P W V 25 Inspection prior to release for

hydro-test, Inside/Outside welding surface, External Internal attachment

Completeness, cleanliness, overall dimension, plumpness orientation, radiography etc.

CR Visual, Random Meas., Verification of all records

100% APPD. DRGS, DATA SHEET

APPD. DRGS. DATA SHEET, API 650

IR 2 1

26 Final inspection during hydrotest Leak tightness verticality

CR M

Hydrotest Plump

100% Every 30°

APPD. DRGS APPD. DRGS

API 650 API 650

IR IR

2 2

1,2 1,2

27 Final assembly Settlement M Meas. Every 30° APPD. DRGS OISD 129/ BS 3659

IR 2 1,2

28 Buoyancy test, Floatation test, Deck puncture test

Smooth Floatation leak tightness

CR M

Hydrotest Submersion Measurement

100% 100%

APPD. DRGS API 650

API 650 API 650

IR IR

2 2

1,2 1,2

29 Rain water test Deck CR Water filling on deck

100% API 650 Spec. API 650 Spec. IR 2 1,2

30 Calibration Capacity wrt Filling height

M Meas. & Certification

100% APPD. DRGS IS 2007/2008

IS 2007/2008 Cali. Chart 3 1,2

31 Cleaning Cleaning external & internal after hydrotest

M Visual 100% Technical Specification

Technical Specification

IR 2 2,1

32 Painting/ Stamping 1 Surface Preparation M Visual 100 % Approved Procedure

Approved Procedure

IR 2 2,1 2 Surface Finish M Mech. Gauge Random 3 Coating Thickness

M Elco. Meter Random

33 QA & QC Documentation Overall quality, Data Keeping

M Review of all TC, IR for previous stages

100% Technical Specifiation

Technical Specifications & applicable codes

IR 2 1

SL. NO. DESCRIPTION OF ITEMS CHARACTERISTICS TO

BE CHECKED CAT TYPE/METHOD OF CHECK

EXTENT OF CHECK

REFERENCE DOCUMENTS


FORMAT OF RECORDS

AGENCY Remarks P W V

STANDARD BOUGHT-OUT

ITEMS

34 Gauge hatch 1 Physical & Chemical Properties

M Physical, Chemical Tests

Random AS PER SPEC. APPD. DRGS.

As per spec. APPD. DRGS

MFTRS TC 3,2 1,2

2 Dimension M Visual & Meas. 100% APPD. DRGS. DATA SHEET

APPD. DRGS. DATA SHEETS

MFTRS TC 3,2 1,2

35 Sprinkler nozzle/ Foam maker Dimension & Surface Quality


Random APPD. DRGS & SPEC.

APPD. DRGS & Spec.

MFTRS TC 3,2 1,2

36 Foam seal & Accessories 1 Physical & Chemical Properties



APPD. DRGS & Spec.

MFTRSTC 2 1

2 Dimension M Meas. & Visual 100% APPD. DRGS & SPEC.

APPD. DRGS & Spec.

MFTRS TC 3,2 1,2

37 Flame arrestor/ Breather valve 1 Physical & Chemical Properties



APPD. DRGS & Spec.

MFTRSTC 2 1

2 Dimension M Meas., Visual 100% APPD. DRGS & SPEC.

APPD. DRGS & Spec.

IR 2 1

P PERFORMED BY 1. HPCL AUTHORISED REPRESENTATIVE CR : CRITICAL W WITNESSED BY 2. VENDOR QC M : MAJOR V VERIFIED & REVIEWED BY 3. SUB AGENCY/ SUB VENDOR (IF APPLICABLE & APPROVED) IR : INSPECTION RECORD TO BE MAINTENED BY STS H HOLD TILL CLEARED BY 1 MEAS. : MEASUREMENT