mechanical & piping works -...

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HINDUSTAN PETROLEUM CORPORATION LIMITED

LPG PROJECTS

HINDUSTAN BHAWAN, 3RD FLOOR8, SHOORJI VALLABHDAS MARG

BALLARD ESTATEMUMBAI – 400 001

TENDER DOCUMENT FOR

MECHANICAL & PIPING WORKS

AT

PAMPORE LPG PROJECT

9000072-HB-12001

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INDEX

1. INTRODUCTION

2. INSTRUCTIONS TO BIDDERS

3. SPECIAL TERMS AND CONDITIONS

4. TECHNICAL SPECIFICATIONS

5. SCHEDULE OF ITEMS

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INTRODUCTION

Hindustan Petroleum Corporation Limited (HPCL) proposes the augmentation of capacity of LPG Bottling Plant atPampore, Jammu & Kashmir. This tender is initiated for FABRICATION & LAYING OF FIRE HYDRANT /

SPRINKLER SYSTEM, LPG PROCESS PIPING, UTILITY PIPING AND OTHER ALLIED WORKS at this LPGBottling Plant project.

1. ADDRESS OF THE LOCATION

HINDUSTAN PETROLEUM CORPORATION LTD.LPG Bottling PlantNear Gas Turbine Plant,PamporeJammu & Kashmir

CONTACT PERSONS

Mr. Aijaj Ahmad Kachroo, Ph.No:+91 1933-223103, Mob.No: +91 9419002230Mr. M.N. Murthy / Mr. M.S. Lavendra (022-22637077 / 22637081)

2. SCOPE OF WORK:

The scope of work is defined in detail under the schedule of quantities & technical specifications. The variousstructures covered under the scope of this tender are detailed below. However the scope specified below is onlyindicative but not exhaustive and the vendor is required to carryout any other scope as per the site requirement withinthe items available under this tender.

1. LPG Process piping of all sizes2. Fire Hydrant pipeline3. Utility piping for service water & air lines4. Structural steel & Tubular steel works for pipe racks / bridges, platforms, stairs, pipe supports, hangers, etc.5. Sand Blasting & painting works.6. Equipment erection & commissioning7. Civil works required for the above jobs partly or fully as per HPCL requirements8. Other works as directed by HPCL Site-in-charge9. Supply of material as per the detailed job schedule.

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INSTRUCTIONS TO BIDDERS

If there is any contradiction between various sections of the tender booklet, the Schedule of Quantities shall hold overthe Special Terms & Conditions, which shall hold over the General Terms & Conditions.

Name of person at tenderer’s office to be contacted for any clarification regarding this job:

1. Name :

2. Designation :

3. Phone Nos. :

4. Fax No. & e-mail id :

5. Address for correspondence :

GENERAL :

1. All materials required for the job will have to be arranged by the contractor meeting the relevant codesspecifications and of approved make.

2. The contractor will have to make his own arrangement to transport the required materials outside and insidethe working place and leaving the premises in a neat and tidy condition after the completion of the job to thesatisfaction of the HPCL Engineer.

3. The contractor will have to arrange for safe keeping of his materials and should provide necessary securityarrangements for safe guarding the materials. HPCL will not be responsible for any claims with regard tothis.

4. The tenderers are advised to visit the site and get acquainted with the site conditions. HPCL will not provideany Roads, infrastructure such as power, water, lighting etc. at site. Vendor has to make their ownarrangements for transportation of material, movement of heavy equipment at site.

5. The tenderers should note the site conditions before quoting. The site will be offered on AS IS WHERE ISfor the execution of this job and it will be sole responsibility of the vendor to ensure that they abide by thevarious rules, regulations, bye-laws and other statutory requirements, etc imposed by the Government /semi-Government and / or other local authorities governing execution of this job.

6. When the person signing the tender is not sole proprietor, the necessary Power of Attorney authorising theperson to act on behalf of the proprietor or Organisation should be produced / attached with the tender in theUnpriced Bid.

7. The tenderers should study the various tender conditions / documents etc carefully before submitting theiroffers. If there are any doubts, they should get clarifications from HPCL, Mumbai in writing but this shall notbe a justification for submission of late tenders or extension of due date of the tender.

8. All entries and rates in the tender form must be written in permanent ink or typewritten. Erasures, overwritingor corrections, if any, should be attested under the full signatures of the tenderer. All rates should be both infigures and words. The total amount should be given both in figures and words in the tender form. In case ofany difference, the rate expressed in words will be taken as authentic.

9. As far as possible, the tenderers should endeavor not to stipulate any counter terms / conditions ormodifications of tender clauses and should quote strictly as per tender conditions. This will assist in properevaluation of each offer. However, should there be any specific comments in respect of any Clause, thesame may be highlighted in a separate deviation schedule in the Unpriced Bid.

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10. HPCL reserves the right to reject offers not meeting its technical requirements and commercial conditions.

11. HPCL shall not be bound to accept the lowest tender and reserves right to accept any or more tenders inpart. Decision of HPCL in this connection shall be final.

12. HPCL reserves the right to accept any tender in whole or in part or reject any or all tenders without assigningany reason.

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SPECIAL TERMS & CONDITIONS

1. COMPLETION PERIOD: 4 (Four) MONTHS

It shall be defined as below:(To be read together with clause 5.b. of General Terms & Conditions)

4 (Four) Months from the date of receipt of LOI or the date of advise to start the work by MANAGER-

LPG PROJECTS–HQO / Site-In-Charge LPG PLANT, whichever is later.

2. DEFECTS LIABILITY PERIOD:12 months from the date of completion of the entire job.(To be read together with clause 5.n. of General Terms & Conditions)

3. WATER:Contractor has to make his own arrangement for the water required to carryout the job. HPCL shall notprovide the same.

4. POWER:The contractor has to arrange for power on his own, at no extra cost to HPCL.

5. LABOUR:Contractor shall make his own arrangements for the accommodation of labors.

6. TIME EXTENSION:

Time extension, if required on any account will have to be brought to the notice of HPCL at least 1 (one)month in advance from the date of scheduled job completion with proper details & justification.(To be read together with clause 5.d of General Terms & Conditions)

7. All statutory registrations / licences to be submitted to the Engineer in charge prior to commence the works.

8. REPORT OF ACCIDENT :

In case of any accidents, the contractor shall report the incident as required by Factories rules to theconcerned authorities. He will be fully responsible for the same including any expenses for medicaltreatment or compensation or any other charges required to be borne.

9. TENDER QUANTITIES :

Tender quantities appearing in the schedule of rates are only indicative quantities. Exact quantities of eachitem shall be ascertained by the Contractor. Only such ascertained quantities shall be procured. Thecontractor shall obtain necessary approvals before any quantity is brought to site. For getting approval, heshall submit break-up of quantities to Owner.

The contractor should submit the expected final quantities against the P.O. within one month from the dateof commencement of job.

10. MATERIALS ISSUED BY OWNER

The Owner will issue free, subject to the provisions of General Conditions, following:

• All equipment to be erected as listed in the Schedule of Rates.

• All fire hydrants, monitors, hoses etc.

• All material for erection of Pipelines on M.S Structure like Steel, Bolts, Clamps etc. has to be supplied byContractor.

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• All material given in Schedule of rates shall be supplied by the Contractor in consultation with Engineer-In-Charge, as per the requirement of work. Test Certificates etc. of all the material has to be supplied by theContractor. All material supplied shall be Inspected by TPIA approved by Engineer-In Charge.

• All materials shall be issued at Owner's Stores or any other issue point of the Owner within the Project Site.Further all such materials shall be used for permanent works only and not for making templates, temporaryworks / structures etc.

• The contractor shall bear all costs for transportation of materials from issue point to work site, handling andcustody return of surplus materials / scrap to Owner. Storage Points within Plant premises, and orwastage beyond permissible limits.

• The contractor shall make his own review of the total requirements of the pipes, fittings, valves etc. andfurnish within two weeks after the issue of LOI / Award of Contract / Issue of Drawings duly approved forConstruction, a complete list of pipes, fittings and other items which are to be issued by owner. FabricationDrawings of all Supporting Structures shall be prepared by the Contractor & submitted to HPCL site forapproval prior to start of work. The Drawings shall be approved & Returned within two weeks from the dateof receipt by HPCL.

11. EXCESS MATERIALS

• On completion of the work, the contractor shall submit "Material Reconciliation Statement" for all materialsissued by the owner.

• Every month the contractor shall submit an account for all the materials issued by the owner, in the proformaprescribed by the Engineer-in-charge.

• The following wastage limit is permissible. The percentage allowance shall be accounted on the basis oferected weights / approved fabrication drawings, as mentioned below :

Unaccountable Pipes (size wise) 0.75%Pipe Fittings, Studs etc., NIL.

• All unused materials shall be the property of the owner and shall be returned by the contractor at his cost tothe storage points designated by the Engineer-in-charge. Contractor shall be responsible for properweighing / measurement of the surplus materials to be returned to the store. All Unaccounted Material shallbe recovered at double the landed Cost of the material.

• The contractor shall not use the unused section obtained during the course of construction for fabricatingtemporary supports, packing materials wedges, shims etc. If the contractor fails to return the surplusmaterials to the owner's designated place as aforesaid whether issued free of cost or on chargeable basisinitially, the owner will charge the contractor for such unreturned surplus materials at double the LandedCost of the material.

12. CONDITIONS FOR ISSUE OF MATERIALS

• All materials issued by the owner to the contractor shall be preserved against deterioration and corrosiondue to poor or improper storage while under contractor's custody. Any damages / losses suffered, onaccount of non-compliance with the requirements stipulated herein, shall be considered as losses suffereddue to willful negligence on the part of the contractor and he shall be liable to compensate the owner for thelosses suffered at rates i.e., landed cost of materials to the owner plus 100% to cover overheads.

• Various equipment / materials intended for installation will be received by the owner in unpacked, crated,packed or loose condition and will be stored in the warehouse and open yards in and around the job site. Ingeneral, materials will be issued to the contractor in as received condition.

• All materials supplied by the owner shall be duly protected by the contractor at his own cost with theappropriate preservative like primer, coating, grease etc. Pipes shall be stacked according to theidentification marks and the stacks shall be arranged in sleeper supports, at l east 300 mm above ground.The contractor shall check that valves, fittings and specials are not subject to corrosion from hydrostatic testliquid, remaining saturated in the packing. Any such conditions when detected should be brought to the

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notice of the Engineer-in-charge and remedial measures taken as directed. Small and medium size pipefittings shall be stored in racks constructed for this purpose, in a covered godown. When large size pipefittings are to be stored, these may be kept in the open on surfaced storage yards with proper woodensupports.

• All machined surface shall be properly greased and should be maintained and protected from damages.Opening of equipment, machinery, valves etc., shall be kept blocked / covered with blinds to prevent entry offoreign matter.

• As far as possible materials shall be transported to the site of erection only just prior to their actual erectionand shall not be left lying around indefinitely.

13. CONTRACTOR'S SCOPE OF SUPPLY

• The contractor shall supply at his cost, all materials required except for items issued by owner as stated in1.8 above, for completing the work as per drawings and specifications and rendering the system suitable forcommissioning and operation. Items to be supplied by contractor are generally, but not limited to thefollowing :

i) All consumables such as gases, welding rods (approved makes) etc.ii) Shim, wedges and packing plates wherever required.iii) Thread seal, Teflon tape for threaded joints.iv) Spool pieces, blinds, plugs, gaskets and other materials required for testing.v) Structural steel including bolts, clamps, required for platforms / supports of pipes etc. All materials

and items supplied by contractor shall be new and of reputed make, meeting the requirementsspecified in the relevant technical specifications / standards.

vi) HPCL will not issue Form 31 for the supply items.

14. SPECIAL TERMS OF PAYMENT

14.1 PIPING WORKS INCLUDING FLANGED JOINT SECTIONS

• 30% - Against RA bills after the piping is prefabricated i.e. after welding with fittings, pipes etc. iscompleted.

• 40% - After erection, alignment and tightening of nuts, bolts & gaskets etc. is completed.

• 30% - After the lines are flushed and Hydro-tested / Pressure Tested drained and dried, completed.

14.2 ERECTION OF VALVES, FIRE FIGHTING EQUIPMENT AND ABOVE GROUND EQUIPMENT

• 20% after Initial Hydro-test of Valves & carrying out necessary repairs if required.

• 60% against monthly progress bills after cleaning of valves and installation in position, joints made up withall bolts and nuts.

• 20% after lines are flushed, pressure tested, drained and dried, incl. test for satisfactory performance of thevalves.

14.3 PIPE SUPPORTS, PLATFORMS, LADDERS ETC.

• 50 % on supply of material & submission of Manufacturer's test certificates, for material procured bycontractor.

• 50 % after completion of the item.

14.4 PAINTING

• 50% - On cleaning and primer painting, against monthly progress bills.

• 50% - On final painting with writing on lines as specified.

16 MEASUREMENT

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16.1 Payments will be based on the actual measurements jointly taken by the Owner's representative and thecontractor. All payments shall be made on the basis of actual measurements only.

16.2 Measurements of weights shall be in metric Tonnes corrected to the nearest kilogram.

16.3 Linear Measurements shall be in metres corrected to the nearest centimeters.

16.4 Equipment Erection: Payment will be made, on the basis of equipment erected including all the accessoriesas per manufacturer's drawings / data sheets etc., based on unit rate quoted. Where the rates are on unitweight basis, payment will be based on total weight of equipment being that given in manufacturer's drawing/ data sheets / packing list etc.

16.5 PIPING

i) Payment will be made on linear measurement, along the central axis of the pipe line including bendsetc.

ii) Valves and safety valves 40 NB and smaller in size, shall be included in this measurement. Branchconnections shall be measured from the outer surface of the header.

iii) Installation of valves 50 NB and above in size, shall be paid for separately as per the terms of payment.

iv) For fabrication of mitre bend, reducers (concentric and eccentric) and tees from the pipes, payment willbe on numbers of such specials at the rates given separately in schedule of rates. However, theerection of mitre tees, bends and reducers shall be part of piping erection work and the rates for pipingwill be paid along with piping of large diameter except in case of funnels where they are welded only tosmaller diameter pipe for which payment will be made along with pipe of such smaller dia.

v) For branch pipe connections, namely for puncturing of a larger dia pipe to connect a smaller dia. pipe,payment will be made for smaller dia pipe upto cut edge as per rates given in schedule of quantities.No extra payment shall be made for making opening in the larger dia pipe. Any dismantling and erectionof all sizes of valves including any repacking of glands etc., and similar operations necessary forflushing, testing calibration, etc. will be carried out by the contractor without any extra cost. Variation inindividual quantities of valves fittings etc., shown in the Bill of Materials / Drawings, shall not be causefor revision of prices, and the quoted rate shall be valid for such variations.

vi) Fabrication of spool pieces, piping connections etc. for temporary use to facilitate erection, flushing andtesting may be made by him from pipes and plates issued by owner. Such work, however, will not bepaid for separately and the quoted rate shall be inclusive of such costs.

vii) Contractor shall supply and provide the necessary couplings, earthing plugs, LPG lines etc. Thesehowever will not be paid for separately and the quoted rates shall be inclusive of such costs.

viii) All hot bends, fabricated tees, reducers, branch connections, shall be fabricated and erected as per therequirements at no extra cost. The quoted rates shall be inclusive of all such work. This, however, willnot apply to the fabricated fittings for which separate rates have been called for in the schedule of rates.

ix) The quoted rates shall be inclusive of costs of all tests and inspections.

x) The quoted rates shall be inclusive of costs of all tests and inspections.

16.6 PIPE SUPPORTS & MISCELLANEOUS STRUCTURES

i) Payment for steel work shall be made on the basis of admissible weight of the structure accepted theweight being determined as described in sub-clause below.

ii) The rate for fabrication shall include preparation of drawings, fabrication and erection of pipe supports,platforms, ladders, walkways etc., as per specification and direction of the Engineer-in-charge. Therate for erection shall include scaffolding, temporary supports, tools and tackles, grouting etc.

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iii) The weight for payment will be assessed from the approved fabrication drawings and the respective billof materials prepared by the contractor and approved by the Engineer-in-charge. The weight ofstructural material / plate shall be calculated wherever necessary on the basis of IS Codes.

iv) Grating shall be paid on the basis of area as determined from the dimensions given on drawings/bill ofmaterials. Full deductions shall be made for all openings above 300 mm size skews.

v) Welds, bolts, nuts, washers etc., shall not be measured. Rate for structural steel work shall be deemedto include the same.

vi) No other payment either for temporary works connected with this contract or for any other item such aswelds, shims, packing plates etc., shall be made. Such items shall be deemed to have been allowed forin the rates quoted for steel work. Shims and packing plates shall not be considered for computation ofweights.

16.7 PAINTING16.7.1 PIPES:

i) Payment will be made on linear measurement along the centre line through flanges, and all types offittings and valves of all types.

ii) Rates for painting of pipes shall be inclusive of painting of all types of pipe supports including guides,shoes, saddles, clamps etc. all types of fittings. No separate measurement or payment will be made forproviding colour bands, hazard signs, fluid description, arrows etc. and the rates quoted for painting willbe deemed to include all these costs.

16.7.2 Equipment

i) No separate payment will be made for the equipment which has been supplied painted and may needtouch up / repair painting. The quoted rate for erection shall be inclusive of such work.

ii) For any other equipment, requiring complete painting by the contractor, the payment shall be on thebasis of admissible area to be painted at rates quoted for the same.

17. PRE-COMMISSIONING

i) System testing / start-up (pre-commissioning) for the various systems in the plant would be carried out underthe supervision of the owner. The contractor shall furnish, as part of his work at no additional cost, onround the clock basis, skilled personnel and supervision, to carry out the same. The number and category ofskilled personnel to be deployed by the contractor shall be decided by the Engineer-in-charge in advanceand the contractor shall provide such personnel as and when required by him.

ii) System testing would include all valves, machinery and other miscellaneous equipment and piping whichhave been already tested, in a particular system. System tests would be carried out by owner, either withwater or with any other medium, and during these tests, the systems should be brought to the respectiveoperating pressure / vacuum. All tools, tackles (except some special tools) shall be provided by thecontractor along with the skilled personnel. Defects noted during these tests shall be rectified by thecontractor at his own cost, if the defects are attributable to the contractor's work.

iii) After completion of system the start up (pre commissioning) shall be commenced and any defects noticed inthe plants during the start-up, which are attributable to the contractor shall be attended to by the contractorat his own cost, as and when they are brought to his notice by the owner. The owner shall have the right tohave these defects rectified at the risk and cost of the contractor if he fails to attend to these defectsimmediately. After the operating conditions are fully achieved in all the plants and the requirements stated inthe General Conditions of Contract are fulfilled, the contractor would be eligible for applying for completioncertificates.

iv) Where the works are carried out at the cost of the contractor, the Engineer-in-charge would recover twicethe actual cost incurred towards labour, supervision and materials, consumables or otherwise. This includesoverheads and all such amounts payable by him shall be deducted from pending bills or the securitydeposits.

18. DOCUMENTS

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18.1 Contractor shall submit four copies of all required documents as follows for owners review and approval.i) Welding procedure specification within 2 weeks of order.ii) Welding procedure qualification report at least two weeks before the commencement of welding work.iii) Welding qualification report within one week after conducting the tests.iv) Any other records as required by the Engineer-in- charge.

18.2 The contractor shall submit four copies of each of the following as part of completion documents.i) Welding procedure and welder qualification record.ii) All approved procedures and drawings.iii) Pipeline sketch giving all the details regarding the pipe specifications, identification number of shop

fabricated pieces, field weld, welded joints. Joints radiography electrodes used, welder's identificationagainst each joint executed, and any other relevant details as may be necessary.

iv) Electrodes and material test certificates from the manufacturer.v) Hydro test reports.vi) Flushing reports.vii) Any other reports required by the Engineer-in-charge.

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TECHNICAL SPECIFICATIONS:

(SHALL BE READ TOGETHER WITH THE NOMENCALTURE OF INDIVIDUAL ITEMS AS PER THESCHEDULE OF ITEMS)

TECHNICAL SPECIFICATION FOR PIPE WORK

1.0 SCOPE :

1.1 All the items of work covered under this tender shall be carried out as per the specifications,drawings and details to be furnished to the Contractor. However, the Engineer-in- charge / SiteEngineer reserves the right at any time to give additional / alternate specifications andinstructions for erection of any particular work and the Contractor shall execute such works inaccordance with such additional / alternate specifications and instruction of Site Engineer.

1.2 All acts, deeds, matters and things required to fulfill the Contractor's obligations and to full fillmunicipal and or other statutory requirements for due execution of the work shall be deemed tobe included in the scope of work.

2.0 TRANSPORTATION :

2.1 The work of transportation of Owner's supplied materials / equipment includes the following:-

a) All works and operations necessary to lift and to remove the materials / equipment from Owner'sdesignated stockpiles / store-yards / godown, loading, handling, transporting safely to theconstruction site and unloading by suitable means as approved by the Engineer-in-charge / SiteEngineer.

b) Supply, procurement, mobilization and deployment of all labour, materials, equipment andmachinery necessary for lifting, removing, transporting and unloading the Owner's suppliedmaterials / equipment to the work sites.

c) The contractor at his own cost shall arrange to store / stock materials / equipment brought fromOwner warehouse etc. to work site in such a manner that they are protected from dirt, rain waterand other foreign matter.

d) It shall be the duty of the contractor to handle the equipment, valves, pipes and fittings, coatedlining material etc., in such a manner that no damage is done to them. The contractor should alsoensure that no damage while handling is done on other materials.

e) All other acts, deeds, matters and things whatsoever ancillary, auxiliary or incidental to the aboveincluding but not limited to the grading and creation of temporary approaches / accesses and rampsetc., as may be required.

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f) Transportation of excess material from site to warehouse including loading/unloading and stackingas directed by owners / consultants.

3.0 LIFTING OF EQUIPMENT:

3.1 The Contractor shall be responsible for organising the lifting of the equipment in the propersequence, so that safe and orderly progress of the work is ensured. Rigging procedures for allmajor lifts (upto 5.0 MT) and maximum crane capacity shall be submitted by the Contractor to theSite Engineer. However, approval to rigging procedure proposed by the contractor shall not relievethe Contractor from his responsibility.

3.2 The slings used for lifting various loads shall be tested by a test load before carrying out actualinstallation. The weight of the test load shall be 50% higher than the weight of the equipment to belifted.

4.0 FABRICATION & ERECTION OF ABOVE GROUND AND UNDERGOUND PIPING

4.1 This specification covers the requirements for fabrication, erection, installation and testing ofabove ground / underground piping system.

4.2 Fabrication, installation/erection and assembly shall be done as indicated in the Process andInstrument diagram and piping layout drawings.

4.3 Contractor shall promptly notify Engineer-in-charge of any defective or damaged material,materials that are not as per specification and materials that differ in any manner from thedesignations in the drawings.

5.0 CODES AND STANDARDS :

In these specifications reference is made to the following standards and Codes, and all otherrelevant standards, the latest issues of which shall be used.

ANSI B 31.3 : Code for Petroleum Refinery Piping.

API 1104 : "Standard for Welding Pipelineand Related Facilities."

ASME SECTION IX : Code for Welding Qualification.

IS : 823 : Standards for Procedure for Manual Metal Arc Welding

6.0 FABRICATION :

The piping drawings specify the shape and dimensions of pipe and piping components sufficient forfabrication.

The dimensions indicated on the drawings are true and contain no allowance for weld gaps.

Gaskets less than 1.5 mm thick (1/16" M) are ignored in dimensional computations.

All pipe branches shall be at 90 degree, unless otherwise indicated on the drawings.

Pipe cuttings shall be accurate, smooth and true to template, Slag & cutting dross shall be removedbefore fitting.

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Installation & protection during fabrication of the components shall be in accordance with themanufacturer's installation instructions.

Branch connections shall be made by Site Fabricated intersections, couplings etc. as indicated in thedrawings and as directed by Engineer-in-charge.

Material which have been damaged or found to have defects shall not be used in fabrication exceptthat minor surface marks may be dressed provided that the nominal wall thickness is notencroached upon after considering the manufacturing tolerances defined in the appropriationmaterial codes. Insert patching or cuts or dents or pounding of dents shall be prohibited.

The Contractor shall provide facility to fabricate reinforcement pads, flanges, mitred fittings such asbends, reducers etc., whenever required by Engineer-in-charge, by using pipes supplied byowner. All other materials, consumable, etc. shall be provided by contractor.

Fabrication piping, valves, fittings, sections of piping etc. shall be thoroughly cleaned. All sand, dirt orother foreign matter shall be removed. The ends of completed sections of pipeline shall beclosed with suitable blinds, caps or other approved methods. All fabricated piping shall beprotected against rust and corrosion pending erection, by the Contractor at his own cost.

7.0 TOLERANCES :

7.1 In addition to tolerances contained within the applicable codes or standards of the respectivematerial the following shall also apply.

7.2 For pipes subjected to internal pressure, the difference between maximum and minimum outsidediameter at any section across the axis of bent portions shall not exceed 5% of the nominaloutside diameter. Wall thickness of the pipes after bending shall not be less than 87.5% of thenominal wall thickness.

7.3 All linear dimensions involved in the relative position of branches, bosses, flanged ends,instrument tapping and change in the direction to each other, shall be maintained within + 3 mm(+ 1/8").

7.4 All angular dimensions of bends and branches shall be maintained within + 1/4 degree.

7.5 Misalignment of flanges from the indicated position shall be within 1.5 mm (1/16").

7.6 Alignment of flanges and branch welding ends measured across any diameter shall not deviatefrom the indicated position more than 2.5 mm per meter (1/32" per foot) of diameter.

7.7 Flange faces shall be perpendicular to the axis of the pipeline.

8.0 PREPARATION OF PIPE AND OTHER FITTINGS :

8.1 Prior to aligning pipe for welding, the ends of the pipe shall be machine bevelled. Beveldimensions shall be as per applicable codes.

8.2 The bevelled ends of each joint of the pipe shall be thoroughly cleaned of paint, rust, mill scale,dirt or other foreign materials to avoid defects in the completed welds by methods approved bythe site Engineer.

8.3 Any foreign matter or obstruction remaining inside the pipe shall be removed by appropriatemeans.

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8.4 Coupling and half coupling shall be accurately shaped and set on to suit the contour of the runpipe.

8.5 Pipes shall be properly supported and aligned by jigs or clamps as required in order to precludeextraneous loads and minimise strains during taking.

8.6 Small tack welds i.e. between 12.5 mm (1/2") and 18 mm (3/4") in length penetrating to thebottom of the groove may be used in fitting up.

8.7 Unless otherwise specified all pipe to pipe joints shall be butt welds.

8.8 Pipes with a wall thickness of 6 mm (1/4") and greater shall not have internal misalignment ofpipe wall exceeding 1.5 mm (1/16").

8.9 Pipes with a wall thickness less than 6 mm (1/4") shall not have internal misalignment of pipewall exceeding 25% of pipe wall thickness.

8.10 When misalignment is greater than the above, component shall be aligned by drifting, rolling ormachining in accordance with the Code, ensuring that the nominal wall or minimum wall thicknessis not encroached upon after considering the manufacturing tolerances defined in the appropriatematerial specifications.

9.0 WELDING:

9.1. Welding Equipment:-

No welding process or procedure shall be adopted without prior approval of Engineer-in charge.Unless otherwise specified, welding shall be done in accordance with the codes API-1104.All welding machines, transformers/Diesel generators as may be required, line up clamps, bevelling

machines and other equipment used in connection with the welding work must be satisfactory and mustbe kept in good mechanical condition so as to produce sound welds.

9.2 Welding Process :-

9.2.1 Welding under this specification shall be done with following welding process subject to theapproval of Engineer-in-charge / representatives.

a) Manual Metal Arc Process.b) Oxy - acetylene Welding Process.

9.2.2 Automatic or semiautomatic welding shall be made only with the specific approval of theEngineer-in-charge, of the entire procedure and material.

9.2.3 Combination of the welding process of usage of electrodes of different classes or makes in aparticular joint, shall be adopted only after the welding procedure has been duly qualified andapproved by the Engineer-in-charge.

9.3 Root Pass : -

9.3.1 Root Pass shall be made with respective electrodes mentioned in the electrodes specifications.The size of the electrode shall not be greater than 3.25 mm (10 SWG). Welding may be donewith direct current with due regards to polarity and current values recommended by the electrodemanufacturers. Upward techniques shall be adopted for welding pipes horizontally fixed inposition. For thickness less than 3 mm and pipe size 50 mm NB and below Oxy-acetylenewelding is recommended.

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9.3.2 The soundness of weld depends to a large extent on complete fusion of the root edges. Hencethe root pass of butt joints shall be such as to achieve full penetration. The depth of incompletepenetration shall not exceed 0.8 mm or 0.2 times wall thickness. The total length of suchimperfections shall not exceed 38 mm in any 150 mm of weld length.

9.3.3 Welding shall not be interrupted during the root-pass, other than change of electrode or change ofwelder's position.

9.3.4 Each interruption of welding and on completion of each run, craters, weld irregularities and slagshall be removed by grinding.

9.3.5 During the process of welding, displacements, shocks, vibrations or stresses shall be carefullyavoided in order to prevent weld cracks.

9.3.6 Fillet welds shall be made by shielded metal arc process regardless of the thickness and class ofmaterial. Electrode size shall not exceed 3.25 mm.

9.4 Joint Finishing: -

9.4.1 When the welding is completed, butt joints shall have a capping (cover pass) so as to havegradual notch-free finish and good fusion at the joint edges.

9.4.2 The welds shall be free from undercuts and any other defects and shall have regular appearance.

9.4.3 Welder's number shall be stamped clearly on each and every joint, adjustment to the weld inorder to identify the welder if defects are found after tests.

9.5 Inspection and Test :-

9.5.1 Owner's representative / agency appointed by the Owner will have free access to all workingplaces for inspection of procedures, quality etc., during working periods. Contractor shall provideall assistance to carryout such inspections.

9.5.2 All prefabricated as well as field welded joints shall be subjected to visual examinations. DyePenetration (DP) test will be done on all the joints of seamless pipelines which shall be followedby 10% radiographic examinations.

9.5.3 Visual examination shall be 100% on all the joints and shall reveal surface defects such asmisalignment, excessive reinforcement, concavity of the welds, shrinkage, cracks, inadequatepenetration, undercuts and surface porosity.

9.5.4 Radiographic examination shall be carried out on joints selected by Engineer-in-charge. Thiswill be 10 % on LPG Lines on a random basis. However, depending the number of welders, andjoints welded by each welder exceeds 100 Joints, 10% random will remain unchanged. But aminimum number of 5 joints in full shall be radiographed from each welder's joints if total numberof joints done by any welder is found below 100 joints of any size.

9.6 Radiographic Inspection :

The extent of radiography inspection coverage is as follows:

9.6.1 Radiographic examination shall be carried out as per API Code 1104 / ASTM-E-94. The qualityof radiographic examination, acceptable limits, repair and removal of defects shall be as perASTM-E-142 and ANSI B31.3 Cracks and lack of fusion shall not be permitted. The contractorshall be responsible for carrying out radiography, rectification of defects and re-radiography, of

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the rectified. He shall make weld necessary arrangements for the equipment as well asradiographic films for the satisfactory completion of the job.

9.6.2 The welding engineer of the agency carrying out radiographic examination shall submit theradiographs together with his findings, report and recommendation as to the acceptability orotherwise of welds radiographed to the site engineer. The site engineer's or his representative'sdecision as to the acceptability or otherwise of the welds irrespective of the opinion or advicetendered by the welding engineer shall be final and binding upon the contractor.

9.6.3 The independent agency to be appointed by the contractor for radiographic inspection shall beappointed only with the prior approval of the Owner/Consultant.

9.6.4 All the joints of seamless pipes will be subject to DP Test (100%).

9.6.5 Radiographic examination shall be carried out on joints to be specified by Engineer-in- charge.This will be 10% on LPG Lines on random basis.

9.7 Qualification of Welders and Procedure Tests : -

9.7.1 Only skilled welders shall be employed.

9.7.2 Welders shall be properly qualified in accordance with the requirements of API 1104/ASMESection IX or IS:823.

9.7.3 For carrying out the welding tests the contractor shall furnish the welding equipment andelectrodes. Test specimens, 2 1/2 cm in width, shall be cut from the nipple at right angle to theweld. The test specimens shall be subjected to tensile, root bend, face bend and neck breaktests. These tests shall be arranged by the Contractor at his own cost but shall be witnessed byEngineer-in-charge or his representative.

9.7.4 The manner of performing the test and the results required shall be in accordance with the codeAPI-1104.

9.7.5 In the event that satisfactory results are not obtained the welder shall not be employed on the job.

9.7.6 Welding Procedure qualification tests shall be carried out in accordance with job requirementsand the relevant requirements laid down in the above said Codes. The Contractor shall submitthe welding procedure to the Engineer-in-charge who will check and approve the weldingprocedure after conducting the necessary tests, prior to start of production welding. Standardtests shall be performed in all cases. In addition to these standard tests, tests like macroexamination, hardness test, dye penetration examination, Charpy V notch and U notch impacttests, etc. shall be carried out on specimens depending on the type of base material, operatingconditions and requirement laid down in specification. It shall be the responsibility of theContractor to carry out all such tests.

9.8 STENCILLING OF WELDS :-

9.8.1 All welds shall be marked by the welders according to number assigned to them by theContractor who will furnish to the Engineer-in-charge a record of all number assigned. Shouldany welder leave during the course of the job, his stamp shall be avoided and shall not beduplicated on the job.

9.8.2 No punch or steel stenciling will be permitted.

9.9 WELDING PROCDEDURE: -

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9.9.1 The pipe shall be aligned so that the longitudinal mill weld in the pipe is on the top 90 Degree ofthe pipeline (except on vertical bends) and in such a way that the longitudinal mill welds arestaggered not less than 45 degree.

9.9.2 Welding surfaces shall be thoroughly cleaned so as to be dry and free from paint, oil, rust, scaleand other materials detrimental to weld quality. Each bead shall be cleaned of scale, oxides, dirt,slag and other impurities before any succeeding weld passes are made.

9.10 DEFECTS

9.10.1 Defects revealed by visual inspection, D.P. Test & Radiographic inspection of welds shall berepaired / rectified by the Contractor at his cost to the satisfaction of the Site Engineer. Therepaired portion shall be re-examined by radiography. The repairs carried out shall meet theapproval of the Site Engineer.

9.11 WELDING CONSUMABLES :

9.11.1 Base Material : -

In general, the piping materials used are of Carbon Steel conforming to the followingspecifications:

Pipes :

IS-1239 / IS-3589 - ERW Heavy (Utility Lines)A 106, Gr. B (LPG Lines)

Fittings:

A-234 Grade WPB B.W. LPG & Utility Lines

A-105, S.W & BW Forged LPG & Utility Lines

MITRE Fittings:

To be fabricated from pipes supplied by HPCL by contractor for sizes specified in the schedule.

Flanges :

SORF - A-105 150#/300# as per ANSI B16.5.

Filler Material :

The contractor shall use welding rods, electrodes, as mentioned below:

Material Welding Process Filler Metal--------------------------------------- -----------------------

Root Final

Pipe {A 106 Gr. B) E 6010 E7018

{IS-3589/{IS-1239 E6010 E6013

Flanges {A 105 E6010 E7018{IS:2062 E6010 E6013

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Contractor shall consider reputed makes like Advani Orlikon, Esab D & H. or Honavar for electrode.

Welding Rods and Electrodes:

a. The electrodes shall be stored properly by the contractor to prevent moisture absorption and shall behandled in such a manner as to avoid damage to the coating. Manufacturer's instruction in thisconnection shall be strictly followed.

b. All low Hydrogen type electrodes shall be completely dry when used. These shall be pre dried insuitable ovens at controlled temperature of 200 - 250 Degree Celsius for not less than four hours andthen used on the job.

c. Electrodes, wire and flux, when used shall be free of rust, oil, grease, earth or any other matter, whichcould be harmful for the quality of welding.

d. Electrodes of following makes shall be used :

1) Advani Oerlikon2) D & H3) ESAB4) Honavar

9.11.2 The welding consumables used shall meet requirements of the relevant codes and shallproduce a deposit which is compatible in chemical analysis and similar in mechanical propertiesto the parent material.

9.11.3 Only consumables which have received the prior approval of Engineer-in-charge shall be used.

9.11.4 Before proceeding with welding, Contractor shall submit for approval to site Engineer, Type,brand and size for each batch of consumables for use in each class of piping.

9.11.5 Different grades of electrodes shall be completely separated. The Contractor shall havefacilities available for storing and testing electrodes at recommended temperature wherespecified. The consumables shall be stored and handled at all times during construction so asto avoid damage to them and to the containers in which they are transported. Those in open inopen containers shall be protected from excessive moisture changes. Electrodes, filler wiresand fluxes that show signs of damage or deterioration shall not be used.

9.12 Inspection of Pre-Fabricated Piping :-

9.12.1 Pipe work that has been done shall be checked with the relevant drawings and other relateddocuments to verify that it, as fabricated, complies with dimensions and specifications.

9.12.2 Fabrication shall have dimensions falling within the tolerances defined earlier.

9.12.3 All welds shall be visually examined and shall also be subjected to radiographic inspection asprovided above.

9.12.4 Contractor shall provide tools / instruments like spirit levels, dumpy levels, scale, tapes,gauges, calipers etc. for taking levels & measurements whenever required by Engineer-in-charge.

9.13 Protection : -

9.13.1 When necessary the external surfaces of all fabricated pipe work shall be painted with rustpreventer or base primer to provide a protective coating against rust during transit or storage.

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9.13.2 Flanges and pipe ends, fitting, other components are to be protected by blank flanges andplastic caps against mechanical damage and ingress of dust, dirt and water, wherevernecessary.

9.13.3 While lifting externally coated pipes properly constructed webbing or fabric slings must be usedso as to avoid mechanical damage to the coating.

10.0 ERECTION :

10.1 The gaskets used during testing provided by the Contractor and these shall be removed afterthe hydrostatic testing and new gaskets for permanent retention shall be fixed only afterflushing of the lines. New gaskets shall be provided by HPCL.

10.2 All shop fabricated piping shall be routed and located in accordance with the approved pipingdrawings. Utmost care shall be taken so that during erection no damage will be done to theadjacent, valves etc.

10.3 Stud bolts and nuts for the LPG line flange joints shall be as per following standards :

STUDS : A 193, Grade B7

NUTS : A 194, Grade 2H,

10.4 Gaskets shall be CAF material (Permanite 081 or equivalent), thickness as specified, for flangesof 150# and higher rating and 3 mm thickness when plate flanges are used in low pressureapplication.

10.5 The assembly of various piping components shall be done so that the completed erected pipingconforms to the requirement of this specification good engineering practice as well as meets therequirements of the engineering drawings.

10.6 While bolting gasketed flanged joints, the gaskets shall be properly located to remain on thegasket sealing and tightened by hand to ensure that the gasket is centered. Tightening by toolsmust be in diagonally and clockwise in increments of 1/4, 1/2 of total load.

10.7 All bolts shall extend completely through their nuts by a least 2 threads to a maximum of 3 mmprojection.

10.8 All screwed connections will be secured by Teflon tapes. Minimum length of engagements forpipe threads shall be as per the requirements of relevant standards. The Contractor shall installall fittings, required for vents and drains valves of all sizes of on-line instruments (P.I. & T.I.) etc.as detailed on the drawings. However, panel mounted instruments shall be installed byinstrument Contractor.

10.9 Mismatch and Prefabricated Piping :-

Any mismatch found from shop welded piping, such as flange joints falling on pipe supports (rack) orflanged joint of an adjacent piping interferes, drain point falling on supports etc. shall be promptly rectified& installed by the Contractor.

10.10 Supports, Guides and Anchors : -

10.10.1 For line size 50 NB and above the type and location of pipe supports are indicated on thedrawing. For site run piping 40 mm NB and below the type and locations of the supports will be decidedby the Contractor in consultation with the Engineer-in- charge / representatives.

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10.10.2 Where additional or temporary supports are required to be provided for erection or testing, theseshall be provided by the Contractor without any extra cost to Owner.8.10.3 Field supports, `U' clamps and special supports are to be provided by the piping Contractor.Welding of guides, shoes, pipes saddles to the pipes shall be within the scope of piping Contractor.

11.0 CLEANING & FLUSHING :

11.1 Cleaning of Fabricated / Erected Piping :-

11.1.1 All piping, valves and fittings shall be cleaned thoroughly inside and outside using detergent(quality approved by Owner) before erection.

11.1.2 All field fabricated piping shall be cleaned at the completion of fabrication. Care shall be taken tosee that all burrs, welding icicles, and weld spatter are removed by reaming, chipping, filling or to hermeans. All foreign materials such as cement, mortar, sand, heavy oil film and lose scale shall beremoved from the interior of pipe by thoroughly flushing with water.

11.1.3 All equipment, on-line instruments etc. shall be isolated by closing of valves or slip blinds toprotect such items before flushing and cleaning operation is started.

11.1.4 Strainer baskets and similar items shall be removed from the lines before cleaning and replacedimmediately after cleaning / flushing.

11.2 Protection & Cleaning of Valves :-

11.2.1 All possible precaution shall be taken to prevent dirt, grease, or other foreign matters entering thevalve. All foreign particles shall be removed by wiping with clean linen cloth and protected with suitableblinds till the valves erected.

12.0 HYDROSTATIC TEST AND PROCEEDURE :

12.1 Before carrying out the hydrostatic testing all line shall be thoroughly cleaned.

12.2 The pressure gauges to be used in testing shall be checked at instruments shops or with any otheroutside agency designated by Owner / Contractor. It shall be the responsibility of the Contractor to getthe calibration of pressure gauges done.

12.3 Line shall be slowly filled with water. It shall be ensured that no air pockets will be left over in theline.

12.4 All equipment such as pumps, vessels, relief valves, pressure gauges etc. shall be disconnectedfrom the piping or isolated by blinds or blanked off during the test.

12.5 All prefabricated and field welded lines shall be tested to the following pressures. Lines shouldhold the pressure for at least half an hour prior to inspection. All butt joints shall be inspected for leaksunder pressure.

12.6 After erection of the pipe lines all the extended / modified lines if any up to nearest isolation valveor any other point as modified by the Engineer-in-charge for the purpose of this specification shall besubjected to the same conditions as above.

12.7 When an existing line or portion thereby modified, cut or welded, this shall be tested once again.The nature of the test and test pressure shall be same as above.

12.8 New lines connected with the existing lines will be tested by providing suitable blanks beforehooking-up. Such lines shall be drained, flushed and kept ready for hook-up.

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12.9 Valves installed on field welded line shall be considered as a part of piping and the whole systemshall be tested to the specified test pressure one side of the valve in shut-off position shall be unboltedduring the test in order to inspect the valve seating from the open end.

12.10 Existing piping which has not been relocated or modified be isolated by blinds or blanked offduring the test.

12.11 Temporary line laying/connection with the existing system for testing purpose be carried out at noextra cost to Owner.

12.12 When it is impracticable to isolate the piping to be tested, the condition for the test shall bedetermined jointly by the Owner's and Contractor's representatives.

12.13 The Engineer-in-charge shall be notified well in advance by the Contractor of all testing and suchtesting shall be witnessed by Engineer-in-charge / representatives.

12.14 Tests shall be considered complete only after Engineer-in- Charge gives approval and records theline number.

12.15 All lines shall be drained fully after hydrostatic, testing and closed with suitable blinds to prevententry of dust or any foreign particles.

13.0 TEST RECORDS:-

13.1 Records shall be maintained for each piping system after testing. These records shall contain thefollowing information:

a) Date of Test.b) Identification of Piping Tested (Line Number).c) Test Fluid.d) Approval by Owner / Consultant / Representatives.

14.0 FLANGE BONDING & GROUNDING:-

14.1 On all LPG Lines, provision for electrical bonding shall be provided on all flanged joints. Copperflat strips of suitable width shall be used for bonding as per drawings. Grounding from such bonding shallbe spaced at about every 75 m. (Grounding shall be carried out by Electrical Contractor).

SPECIFICATION FOR MECHANICAL EQUIPMENT ERECTION

1.0 GENERAL

This specification describes a general outline for the installation of the equipment involved. The fieldcircumstances shall be taken into consideration and methods suitable to the site conditions shall beadopted in consultation with and concurrence of the erection supervisor, erection manuals andinstructions. The successful accomplishment of the project is greatly influenced by the team work,workmanship and skill of the workers and supervisors. The Contractor shall employee only such workersand supervisors who have considerable experience of similar work, temperamentally in good harmonyand co-operation.

2.0 SCOPE OF WORK

The work under this contract shall include furnishing of all labour, tools, erection equipment, consumablematerials and other necessary materials not provided by owner. He shall also provide other services

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required to take delivery of the equipment supplied by the owner at the site, transport them to the site oferection, unpack, clean, assemble, install, test and start up for commissioning all equipment as hereinspecified and shown on the drawings. The work of erection / installation, test and trial runs has to becarried out in accordance with the manufacturer's instruction and / or drawings, sketches/diagrams, andinstructions given by the Engineer-in-charge.

The contractor shall also provide necessary labour and tools and tackles for unloading the equipmentfrom trucks, trailers, etc., whenever these are received at site, during the tenure of contract.

3.0 RECEIVING HANDLING OF EQUIPMENT

3.1 All equipment issued to the contractor as free issue item from stores of the Employer orEmployer's agencies shall be checked by the contractor for the equipment crates, boxes being intact, inthe presence of Employer and shall be accepted by the contractor for the storage and safe custody.These equipments shall be loaded, transported, unloaded and stored in the manner approved byEmployer and the contractor shall be responsible for the safety of the equipment during loading,unloading, transportation and storage.

3.2 Whenever the equipment is received in wooden crates / boxes the contractor shall carefullydismantle these crates / boxes and store all timber and packing materials as required by employer. Allsuch packing materials shall remain the property of Employer.

3.3 It shall be the responsibility of the Contractor to study the requirements of installation andinstructions for commissioning of the same, by employing skilled technicians experienced in the type ofservices required. The Contractor shall be fully responsible for the safe custody of the equipment tocommissioning and handing over of the same to the Employer.

4.0 PRECAUTIONS TO BE TAKEN BY CONTRACTOR

4.1 The Contractor shall take adequate care and precautions to prevent loss / damage ofmaterial and equipment while in his custody. The responsibility of the contractor starts from the time ofwithdrawal of equipment / material from Employer's custody till handing over the same to Employer aftercomplete erection and testing and surplus material / equipment are accounted for and accepted by theEmployer / consultant's engineer. In case of loss or damage to any item or part thereof while in thecustody of the contractor, he shall be liable to pay cost of replacement of such item/damaged part and/orcost of repairs to be carried out.

4.2 During the execution of the work the Contractor shall at his own cost keep structures, materialsand equipments adequately and safely braced by struts, guys and any other approved means as requiredtill installation is satisfactorily completed. The Contractor shall design, provide and erect the struts, guys,shoring, bracing, planking support in such way that they do not interfere with work of other agencies andshall not damage or cause distortion to other works executed by him or other agencies.

4.3 Openings for level gauges, thermowells and other instruments shall be protected during and aftererection.

4.4 All accessories like pressure gauge, temperature indicators, safety valves, etc. shall be taggedand kept separately till erection.

4.5 All flange connections and openings shall be kept blanked with wooden covers to prevent entry offoreign matter, if not provided by the manufacturers.

5.0 ERECTION OF EQUIPMENT

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5.1 The Contractor shall make careful check of all the equipment before erection and ensure thatprotective greases and wrapping applied on the machined surface and other parts by the equipmentsupplier for protection during transportation and storage are intact. Any defects noticed shall be reportedand corrective action taken. Special care shall be taken by the Contractor for bearings, rotating parts,etc. to prevent seizing. Generally, the packages shall not be opened until required for installation.Orientation of all the foundations, elevations, lengths, positions of anchor bolts and diameter of holes inbase plates, supporting saddles of equipment, etc., shall be checked by the Contractor well in advance.Minor rectification work like chipping of foundation shall be carried out by the Contractor after obtainingprior approval of the Employer / Consultant's Engineer. The Contractor will be provided with necessaryequipment drawings of the related areas.

5.2 The Contractor shall also check the nozzle orientation on vessels / tanks and see theircompliance with the drawings and specifications supplied. Any discrepancy shall be brought to the noticeof Employer / Consultants Engineer and start work only after his approval.

5.3 Rigging procedures of all major lifts above 5 MT and at maximum crane capacity, shall besubmitted by Contractor for approval of the Employer/Consultants' Engineer. However, such approvalsshall not relieve the Contractor from the responsibility of safe rigging and lifting of the equipment,machinery etc.

5.4 Drilling and tapping of holes in base plates, fixing of couplings on shaft after enlarging the pilotbores to correct size with keyways, etc. and dowelling including provision of dowel pins or similararrangement for retaining the alignment shall be carried out by Contractor, as part of erection work.

5.5 All joints shall be assembled without undue stresses. Flanges must be parallel and correctlyaligned.

5.6 The Contractor shall study in details the complete work with the help of relevant drawings,specifications and equipment supplier’s special requirements specified in his instructions manual. TheContractor shall prepare detailed procedures, outlined sequence of operation, prepare time schedule foreach operation and seek approval of Employer / Consultants' Engineer.

5.7 Wherever necessary the Contractor shall remove the anticorrosive coating applied on themachine / equipment by the supplier, carefully and completely with light oil approved by the Employer /Consultants' Engineer.

5.8 After checking orientation and overall dimensions of the foundations, location and sizes of anchorbolts, shape of foundation shall be checked as per foundation drawing with reference to the equipmentcentre line.

5.9 On the chipped and prepared foundation surface, the contractor shall set up liners for installationand centering of equipment. Liners shall be so arranged that the load of equipment is uniformly andexactly distributed to the foundation. Liners shall be placed as near as possible to both sides of anchorbolts. Where distance between anchor bolts is too long additional liner shall be set up in between. Theheights of each liner shall be measured on the basis of standard level bench mark. The liners shall befixed with approximate grouting material.

The upper surface of the foundation shall be watered sufficiently, at least 24 hours prior to setting ofliners, to ensure good adhesion of grouting material.

5.10 The Contractor shall assemble, couple, fix, fit, install, level, align and grout theequipment/materials on foundations, structures, platforms, floors, etc., as the case may be. He shall bolt,weld, cut, drill, rivet and brace all components and fix them rigidly with one another on the foundationsupports etc.

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5.11 All necessary shims scaffolding, temporary supports, staging, grouting, sand, etc. required forerection of the equipment shall be provided by Contractor.

5.12 The Contractor shall assemble position and fix all internals of the equipment.

6.0 ASSEMBLY, LEVELLING & ALIGNMENT

6.1 Some of the equipment will be shipped by suppliers in knocked down condition. All drive motors,etc. will be shipped separately. The contractor shall assemble all such parts and sub-assemblies as perthe manufacturer's/ supplier's/employer/consultant engineer's instructions.

6.2 The contractor shall assemble, position and fix all internals of the equipment.

6.3 Method of lifting and handling of equipment and its sub-assemblies shall be thoroughly discussedby the contractor with the engineer-in-charge. The equipment wherever required shall be levelled fortemporary setting using screw jacks at the lower parts of common bed.

6.4 The contractor shall re-check the clearances of the part indicated by the engineer-in-charge at thetime of erection.

6.5 The centering or alignment of the equipment is done by the supplier in his factory. However,there are chances of this alignment getting disturbed during transportation of the equipment. Thecontractor shall, therefore recheck the alignment and take remedial steps as per the instructions given inthe installation manual of suppliers or as advised by Engineer-in-charge, if any misalignment is observed.For motor driven equipment the driving and driven shafts shall be fully aligned, deflection and facedeviation of the shafts shall individually be measured and it shall be confirmed that values are within thetolerances. All readings of the inspection shall be properly recorded and submitted to Engineer-in-charge. All alignment shall be done with Master level gauge, dial Gauge etc. which will be arranged bythe Contractor.

6.6 After completion of alignment, the equipment shall be erected in accordance with procedureapproved by Engineer-in-charge / Manufacturer. After perfect alignment of driven shaft is achieved theseshall be coupled and base plates shall be cleared for grouting. Care shall be taken during grouting to seethat the base plate level and alignment are not disturbed.

7.0 THE EQUIPMENT ARE CLASSIFIED AS FOLLOWS :

(A) Static equipment like tanks, vessels.

(B) Dynamic or rotary equipment like pumps, compressors, etc.

7.1 Erection of Static Equipment.

7.1.1 Installation and centering of vessel, shall generally carried out in the order as given below :-

( i ) Set liners on prepared foundations.( ii) Place vessel on the liners and set anchor bolts.(iii) Carry out provisional centering, levelling and alignment by shims and packing (however

positioning of the vessel shall be accurately carried out.(iv) Fix the foundation bolts by pouring mortar into anchor pockets.( v ) Carry out completely the centering for level by tightening the anchor bolts and allow for groutingof vessel.

7.1.2 Where the vessel having flat bottom is directly placed on the foundation, the vessel shall beinstalled without excessive concentrated force against bottom plate. The equipment foundation shall bechecked by the contractor for dimensions, position (center marking), height (level marking), disorder in the

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foundation concrete, such as abnormal concentration of aggregates, porous state size of anchor bolt,damage if any or rust of threaded parts, etc.

7.1.3 The foundation shall be thoroughly cleaned after chipping. Liners shall be placed as near aspossible to both sides of each anchor bolt. If wedge liners are used for complete centering respectivegradient of the wedge liners shall be within 1/20 and two wedge liners shall be in back to back position, soas to make their top and bottom faces flat and parallel. Oil and other foreign matters stuck on surface ofliners shall be entirely removed. Centering shall be carried out by center marking and level markingscribed on the foundation. Centering of vessel for level and perpendicularity shall be carried out in bothdirections intersecting at right angles on the same plans.

7.1.4 Prior to installation of the vessel, the contractor shall check the following with the Engineer-in-charge supplier's drawing / instruction manual:

(i) Whether hydraulic or pneumatic pressure testing of vessel required.

(ii) Whether cleaning of inside of vessel is necessary.

(iii) Whether anticorrosive treatment for internal surface of vessel is necessary.

(iv) Whether piping, instrument, etc. are to be connected to the vessel.

Foreign matter such as rust on contact face of flanges of nozzles, manholes, etc., shall be completelyremoved.

After obtaining approval from Engineer-in-charge, that the vessel has been erected in accordance withthe requirement including various tolerance of the specification, the equipment shall be released forgrouting.

7.2 Erection of Rotary Equipment - (Pumps, Compressors, etc.) :

7.2.1 All equipment will be supplied in either three individual parts, as -

(i) Pump or Compressor.

(ii) Motor or Engine.

(iii) Base Plate.

The base plate may be either common or separate. They shall be erected on prepared foundation by theContractor and levelled with packing plates, shims and wages with the help of precision levels and otherinstruments. The pump and the driver shall then be coupled and aligned. After alignment the equipmentshall be grouted by the Contractor.

Final alignment shall be done after all piping connections are made. Tolerances for alignment shall bemaintained as specified in the manufacturer's instruction manual, to ensure that piping connections do notinduce any stresses on the equipment. The alignment shall be checked by the Contractor bydisconnecting the piping or in the working condition or in both conditions. Any connection necessary forproper alignment in ambient and working conditions shall be carried out by the contractor as per theinstructions of the site-in-charge.

7.2.2 Levelling shall be carried out on four corners of the base plate ends for both the directions ofshaft and at right angle to the shaft.

7.2.3 The alignment of the unit shall be carried out on the basis of the finished surfaces, which are asnear as possible to the centre of the shaft.

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7.2.4 Where adjustment between shaft and coupling is required for their fitting, the adjustmentsshall be carried out to the coupling and not to the shaft.

7.2.5 The alignment of the unit shall be carried out until complete alignment of driving and driven shaftis obtained. While aligning, the deflection and face deviation of the driving and driven shaft shallindividually be measured and should conform to the allowable limits specified by supplier in hisdrawing/instruction manual.

7.2.6 After completion of alignment, it shall be conformed that the shaft can be rotate smoothly andfreely by hand.

7.2.7 After connection of piping, the alignment of the pump shall be rechecked. Any misalignmentinduced by the piping connections shall be corrected by adjusting piping.

7.2.8 Running test of motor, diesel engine shall be performed with no load and it shall be confirmedthat vibrations, sound and temperature are not abnormal.

7.2.9 After running test of motor or engine, the driver and the driven unit shall be coupled withconfirmation of rotating direction of unit and motor.

7.2.10 Trial running of the assembled unit shall be performed and it should be confirmed that vibration,sound and temperature readings are within the acceptable limits specified by the supplier.

7.3 TRIAL RUNS :

7.3.1 All pumps will be subjected to trial runs. The duration of trial runs shall be 72 hours continuous.Prior to carrying out trial runs, the equipment will be subjected to necessary checkups by the Engineer-in-charge and trial runs shall be commenced only after Engineer-in-charge's approval.

Contractor shall provide as part of the work necessary stilled personnel for conducting the trial runs. Theduration of the trial runs may be extended, if it is considered necessary in the opinion of the Engineer-in-charge and the contractor shall provide personnel for such extended period also without extra charge.Final inspection of bearings etc., shall be carried out by the contractor, after the machinery is subjected totest, as part of testing.

During trial runs, details such as bearing temperatures, cooling water inlet and outlet temperatures,temperatures in the lube oil system, outlet pressure, etc., shall be recorded, wherever necessary, by thecontractor. Test Reports shall be prepared in the approved proforma, by the contractor, containing all theabove details and submitted to the Engineer-in-charge as part of the completion document.

8.0 LIST OF EQUIPMENT TO BE ERECTED

8.1 The type of static and dynamic equipment to be installed is given in the Schedule of Rates. TheContractor shall fill in the applicable rates in the columns provided.

9.0 MISCELLANEOUS STEEL

All bolts, anchor bolts, nets, lock washers, supports and other miscellaneous items not furnished by theequipment supplier or by the Employer or otherwise called for in this specification shall be supplied by theContractor. Before installing the equipment the contractor shall verify location of bolts and if discrepancyexists he shall notify the Employer.

10.0 GROUTING

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10.1 Grouting of anchor bolts, holes, pockets and under base plates or under equipment, have beenbroadly classified into two categories:

(A) Non-shrinking Grout(B) Ordinary Grout.

A. Non-shrinking Grout

Non-shrinking grout consists of :-One (1) Part of Ordinary Portland Cement,One (1) Part of clean dry well graded sand,One (1) Part of Ferro grout or similar additive approved by the Engineer-in-charge,

minimum amount water just enough to make the mix place able.

Non-shrinking grout shall be generally used for grouting the following equipments -

i) All vertical tanks.ii) All horizontal vessels.iii) Rotating equipments, Pumps, Compressors.

B. Ordinary Grout

Ordinary grout consists of one (1) part of Portland Cement, two (2) parts of clean, dry well graded sand,minimum amount of water just enough to make the mix placeable.

Ordinary grout shall be generally used for grouting the following equipments:

i) All structural framework.ii) All other miscellaneous foundations.

The grouting material shall solidly fill the spaces to be grouted and permanently retain the original volumeso that the base plates are held firmly in the set position. The amount of water used in the mixture shallbe kept to a minimum just enough to make the mixture placeable and for the grout to have a consistencytoo stiff for the grout to flow.

The top of the foundation shall be clean and free of all laitance, loose particles, oil, grease, etc. shall bewetted thoroughly leaving no puddles prior to grouting. All trapped pockets shall be repaired usingordinary grout. Under no account shall neat cement be used for grouting.

11.0 PLACEMENT

a) All anchor bolt holes shall be completely filled with grout.

b) The finished surface shall be floated smooth and shall slope away from the base plate (approximately1:25).

c) After the initial set is over the grout shall be kept thoroughly wet for a minimum period of 5 days.

d) During grouting care shall be taken to ensure that the base plate level and the alignment is notdisturbed and that no honey-combing takes place in the grout.

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SPECIFICATION FOR STRUCTURAL WORK, PIPE SUPPORTSAND OTHER STRUCTURES

1.0 SCOPE OF WORK

The work covered consists of supply, fabrication and erection of structural steel, pipe racks, pipe supportsplatforms, ladders, walkways, U-bolts/clamps, etc. and in strict accordance with the specification andapplicable drawings.

2.0 GENERAL

The current rules and practices set forth in the specifications for the design fabrication and erection ofstructural steel for buildings of the Indian Standard Institute (IS 800-1962) shall govern this work, exceptas otherwise noted on the drawings or as otherwise specified. All structural steel shall conform to IS 226-1975 and other relevant IS specifications on welding.

3.0 SHOP DRAWINGS

The Contractor shall submit three (3) copies of fabrication and erection drawing showing erectionsequence, for approval, and no fabrication work shall be undertaken until written approval is obtainedfrom Engineer-in-charge. The Contractor shall submit five copies of approved shop and erectiondrawings to Engineer-in-charge for his record.

4.0 FABRICATION

All workmanship shall be to the best practice in modern structural shops.

a) Straightening

All material shall be clean and straight. If straightening or flattening is necessary it shall be done by aprocess approved by Site Engineer and in a manner that will not damage the material. Sharp kinks orbends shall be the cause for rejection.

b) Gas Cutting

The use of a hand cutting torch is permissible if the metal being cut is not subject to substantial stressduring the operation. Gas cut edges subject to substantial tensile stress shall be cut by a mechanicallyguided torch, or if hand cut, shall be carefully examined and any nicks cutting shall be carefully examinedand any nicks cutting shall be cleaned, reasonably square, and free from any distortion and should theinspector find it necessary, the edges shall be subsequently ground.

c) Holes

Holes for rivets or unfinished bolts shall be 1.5 mm larger in diameter than the nominal diameter of therivet or bolt. If the thickness of the material is not greater than the nominal diameter of the rivet or boltplus 3 mm the holes may be punched.

If the thickness of the material is greater than the diameter of the rivet or bolt plus 3 mm the holes shall beeither drilled or subpunched, 3 mm less in diameter and reamed to required size. The die for allsubpunched holes, and the drill for all sub-drilled holes, shall be at least 1.5 mm smaller than the nominaldiameter of the rivet or bolt.

d) Bolting

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All turned and fitted bolts shall be parallel throughout the barrel within the tolerance of only minus - 13unless otherwise specified and faces of heads and nuts bearing on steel work shall be machined. Allsuch bolts shall be provided with washers not less than 6 mm thick, so that when the nut is tightened, itshall not bear on unthreaded body of the bolt.

In all cases, where the full bearing area of the bolt is to be developed, the threaded portion of bolt shouldnot be within the thickness of the parts bolts together. The threaded portion of each bolt shall projectthrough the nut by at least one thread. Tapered washers shall be provided for all heads and nutsbearings on bevelled surfaces.

e) Welding

Welds shall be made only by operators who have been previously qualified by tests. A welder shallproduce satisfactory evidence of his ability to do a given type of work, and shall prove his ability toproduce a connection of the strength required. Evidence of welder qualifications tests shall be producedif required by Architect and Engineers.

Surfaces to be welded shall be free from loose scale, slag, rust, grease, paint and other foreign materials,and shall be wire brushed and cleaned prior to welding.

Parts to be fillet welded shall be brought into as close contact as practicable and in no event be separatedmore than 5 mm, if the separation is 1.5 mm or greater, the size of the fillet welds shall be increased bythe amount of the separation.

Abutting parts to be butt-welded shall be carefully aligned together within 3 mm gap. Welding sequenceshall be followed to avoid needless distortion, and minimize shrinkage stresses. All welding work has tobe carried out as per IS-816.

f) Connections

Connection shall be as shown on the drawings. Where details are not given, standard beam connectionshall be followed. In any case connections shall be strong enough to develop the full strength of themember and shall be approved by Site Engineer. One sided, or eccentric connections will not bepermitted, unless they are shown in detail on the drawing and are approved by Engineer-in-charge.

All shop connection shall be bolted or welded as approved by Site Engineer.

Welded connections shall be made only where indicated on the drawings or approved by Engineer-in-charge. Holes shall not be made or enlarged by flame, nor will flame cut of unfair holes in the shop or inthe field be acceptable. Grout holes shall be provided in the steel members as shown in the drawingsand holes shall be provided in members to permit connection of supported items.

g) Assembly

All parts assembled for bolting or welding shall be in close contact and all bearing stiffeners shall beartightly at both top and bottom without being drawn or caulked. All parts of bolted or welded membersshall be well pinned or bolted and rigidly held together while bolting or welding.

h) Clearance

The erection clearance for cleated ends of members connecting steel to steel should preferably be notgreater than 1.5 mm at each end. The erection clearance, at ends of beams without cleats should be notmore than 3 mm at each end, but where for practical reasons, greater clearance is necessary suitabledesigned seating should be provided.

5.0 INSPECTION

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Material and workmanship at all times shall be subject to inspection by Site Engineer. All inspection asfar as possible shall be made at the place of fabrication and the contractor shall co-operate with inspectorand permit access for inspection to all places where work is being done.However, such inspection shall not relieve the contractor of his responsibilities to furnish satisfactorywork.Materials or workmanship not conforming to provisions for the specifications may be rejected at any timedefects are found during the progress of the work.

6.0 ERECTION

Structural steel shall be erected in accordance with IS 800 -1962. Crane rails shall be as detailed ondrawings and designed to permit horizontal adjustments of the rails. Rail joints shall be provided withspliced bars.Field bolts (except high strength bolts) in work which will be exposed to the weather upon completionshall be dipped into red lead paint just before they are put in place. Loose column base plates andbearing plates for beams and similar members shall be supported to proper elevation before erecting thesupported members. Attached base plates and bearing plates shall be supported on wedges or shimsuntil the supported members have been plumbed or otherwise properly positioned and shall then begrouted in place.

7.0 LADDERS AND RUNGS

Contractor shall provide and install all iron ladders and rungs where indicated and as detailed on thedrawings. He shall also include base plates, fastenings, anchor bolts, guard rails / rings, safety chains,etc.

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SPECIFICATIONS FOR PAINTING OF PIPELINES &STRUCTURAL / TUBULAR STEEL

All the pipelines (both ERW & Seamless pipelines) supplied by HPCL/vendor and Structural steel /Tubular steel supplied by the vendor shall be sand blasted up to grade SA 2.5 as per Swedish standardSIS 055900 and the painting has to be carried out as detailed below:(a) Surface preparation : Grade SA 2.5

(B) PRIMER PAINTING:

EPILUX 4 HB Zinc Phosphate Primer of BERGER or equivalent make of ASIAN / NEROLAC / SIGMA

No. of coats : 1Paint thickness (DFT) : 35 microns (minimum)

(c) MID COATING :

EPILUX 4 MIO coating of BERGER or equivalent make of ASIAN / NEROLAC / SIGMA

No. of coats : 1Paint thickness (DFT) : 75 microns (minimum)

(d) FINISH PAINT :Synthetic enamel paint (first quality) of approved make & colour (BERGER / ASIAN / NEROLAC / SIGMA)

No. of coats : 2Paint thickness (DFT) : 25 microns per each coat (minimum)

TECHNICAL SPECIFICATIONS

FOR CIVIL WORKS

GROUP - 1

EARTHWORK IN ROADS AND BUILDING WORKS

1.0 SCOPE:

This specification covers the general requirements of earthwork in excavation in different materials, filling inareas as shown in drawing, back-filling around foundations and in plinths, conveyance and disposal ofsurplus spoils or stacking them properly as shown on the drawings & as directed by ENGINEER and alloperations covered within the intent & purpose of this specification.

2.0 APPLICABLE CODES:

The following Indian Standard Codes, unless otherwise specified herein, shall be applicable. In all cases, the latestrevision of the codes shall be referred to :

a) IS - 783 - Code of Practice for laying of concrete pipe.

b) IS -1200 -Method of Measurement of Building Works.

c) IS - 3764 - Safety code for excavation work

d) IS -6313 (Part II)-Pre-constructional Chemical Treatment Measures.

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3.0 GENERAL:

3.1 CONTRACTOR shall furnish all tools, plants, instruments, qualified supervisory personnel, labour, materials,any temporary works, consumables, anything and everything necessary, whether or not such items are specificallystated herein, for completion of the job in accordance with specification and requirements.

3.2 CONTRACTOR shall carry out the survey of the site before commencing excavation and set properly alllines and establish levels for various works such as earthwork in excavation for foundations, plinth filling, roads,drains, cable trenches, pipelines, etc. Such survey shall be carried out by studying thoroughly the drawings for theexisting plant and modus operandi shall be discussed with ENGINEER. Ground levels shall be taken and properlyrecorded by the CONTRACTOR and shall be checked and certified by ENGINEER. If required, grown shrubs etc.,have to be cut to take levels at no additional cost.

3.3 The excavation shall be done to correct lines and levels. This shall also include, where required, propershoring to maintain excavations and also the furnishing, erecting and maintaining of substantial barricades aroundexcavated areas and warning lamps at night to ensure safety.

3.4 The rates quoted shall also include for dumping of excavated materials in required heaps, riprap with regularslope as directed by ENGINEER, within the lead specified and leveling the same so as to provide naturaldrainage. Soil excavated shall be stacked properly as directed by ENGINEER. As a rule, all softer materialshall be laid along the centre of heaps, the harder and more weather resisting materials forming the casingon the sides and the top.

4.0 CLEARING:

The area to be excavated, and/or filled shall be cleared of fences, plants, bushes, vegetation, slush, etc. and otherobjectionable matter. The materials so removed shall be disposed off as directed by ENGINEER. Where earth fill isintended, the area shall be stripped of all loose / soft patches, top soil containing objectionable matter / materialbefore fill commences.

5.0 EXCAVATION:

5.1 All excavation work shall be carried out manually or by mechanical equipment, as directed by ENGINEER.

5.2 Excavation for permanent work shall be taken out to such widths, lengths, depths, and profiles of P.C.C. asare shown on the drawings or such other lines and grades as may be specified by ENGINEER. Initially excavationshall be carried out to a depth 150 mm above the final level. The balance shall be excavated with special care. Softpockets shall be removed even below the final excavation, if so instructed by ENGNEER, and shall be carried out justprior to laying the P.C.C.

5.3 CONTRACTOR may, to facilitate his work or for similar other reasons excavate and also backfill later, if soapproved by ENGINEER, at his own cost, outside the lines shown on the drawings or directed by ENGINEER. Shouldany excavation be taken below the specified elevation, CONTRACTOR shall fill it up, with concrete of the gradespecified on drawings, up to the required elevation. No extra shall be paid to CONTRACTOR on this account.

5.4 All excavations shall be done to the minimum dimensions as required for safety and working facility.However, prior approval of ENGINEER shall be obtained by CONTRACTOR in each individual case, for the methodhe proposes to adopt for the excavation including dimensions, side slopes, de-watering, disposal, etc. This approval,however, shall not in any way relieve CONTRACTOR of his responsibility for any consequent loss or damage. Theexcavation must be carried out in the most expeditious and efficient manner. Side slopes shall be as steep as willstand safely for the actual soil conditions encountered. Every precaution shall be taken to prevent slips. Should slipsoccur, the slipped material shall be removed and the slope dressed to a modified stable one. Removal of the slippedearth will not be paid for.

5.5 Excavation shall be carried out with such tools, tackles and equipment as described here in before.

6.0 FILL AND BACKFILLING:

6.1 GENERAL:All fill material will be subject to ENGINEER's approval. If any material is rejected by ENGINEER CONTRACTORshall remove the same forthwith from the site at no extra cost to the OWNER. Surplus fill material shall be deposited /disposed off as directed by ENGINEER after the fill work is complete.

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No earthfill shall commence until surface drain have been properly intercepted, or otherwise dealt with, as directed byENGINEER.

6.2 MATERIAL:Only selected excavated materials shall be used as backfill. Fill material shall be free from clods, salts, sulphates,organic or other foreign material. All clods of earth shall be broken or removed.

6.3 If any selected fill material is required to be borrowed, CONTRACTOR shall make arrangements for bringingsuch material from outside borrow pits. The material and source shall be subject to prior approval of ENGINEER. Theapproved borrow pits area shall be cleared of all bushes, plants, rubbish, etc. Top soil containing salts / sulphate andother foreign material shall be removed. The materials so removed shall be disposed off, as directed by ENGINEER.

6.4 FILLING IN PITS AND TRENCHES AROUND FOUNDATIONS OF STRUCTURES, WALLS ETC.:As soon as the work in foundations has been accepted and measured, the spaces around the foundations,structures, pits, trenches, etc. shall be cleared of all debris and filled with earth in layers not exceeding 15 cm., eachlayer being watered, rammed and properly consolidated, before the succeeding one is laid. Each layer shall beconsolidated to the satisfaction of ENGINEER. Earth shall be rammed with approved mechanical compactionmachines. Usually no manual compaction shall be allowed unless ENGINEER is satisfied that in some cases manualcompaction by tampers cannot be avoided. The final backfill surface shall be trimmed and levelled to proper profile,as directed by ENGINEER and/or shown on the drawings.

6.5 PLINTH FILLING:

6.5.1 Plinth filling shall be carried out with approved material as described herein before in layers not exceeding15 cm, watered and compacted with mechanical compaction machines. ENGINEER may, however, permit manualcompaction by hand tampers in case he is satisfied that mechanical compaction is not possible. When filling reachesthe finished level, the surface shall be flooded with water, unless otherwise directed, for at least 24 hours, allowed todry and then the surface again compacted as specified above to avoid settlements at a later stage. The finished levelof the filling shall be trimmed to the level/slope specified.

6.6 SAND/MURUM FILLING IN PLINTH AND OTHER PLACES:At places backfilling shall be carried out with local sand / murum if directed by ENGINEER. The sand / murum usedshall be clean medium grained and free from impurities. The filled-in-sand / murum shall be kept flooded with waterfor 24 hours to ensure maximum consolidation. Any temporary work required for contain the sand / murum underflooded condition shall be to CONTRACTOR'S account. The surface of the consolidated sand / murum shall bedressed to required level or slope. Construction of floors or other structures on fill shall not be started untilENGINEER has inspected and approved the fill.

6.7 FILLING IN TRENCHES:

6.7.1 Filling in trenches for pipes and drains shall be commenced as soon as the joints of pipes and drains havebeen tested and approved by ENGINEER. The back-filling material shall be properly consolidated by watering andramming, taking due care that no damage is caused to the pipes.

6.7.2 Where the trenches are excavated in soil, the filling from the bottom of the trench to the level of the centreline of the pipe shall be done by hand compaction with selected approved earth in layers not exceeding 8 cm;backfilling above the level of the centre line of the pipe shall be done with selected earth by hand compaction or otherapproved means in layers not exceeding 15 cm.

6.7.3 In case of excavation for trenches, the filling upto a level 30 cm above the top of the pipe shall be done withfine materials, such as earth, sand, murum, etc. The filling upto the level of the centre line of the pipe shall be doneby hand compaction in layers not exceeding 8 cm whereas the filling above the centre line of the pipe shall be domeby hand compaction or by approved means in layers not exceeding 15 cm. The filling from a level 30 cm above thetop of the pipe to the top of the trench shall be done by hand or other approved mechanical methods, as directed byENGINEER.

6.7.4 Filling of the trenches shall be carried simultaneously on both sides of the pipe to avoid unequal pressure onthe pipe.

7.0 MEASUREMENT AND PAYMENT:

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7.1 All excavation shall be measured net. Dimensions for the purpose of payment shall be reckoned on thehorizontal area of the P.C.C. at the base for foundations of the walls, columns, footings, tanks, rafts, or otherfoundations / structures to be built, multiplied by the mean depth from the surface of the ground in accordance withthe drawings and duly recorded ground levels. Excavation in side slopes will not be paid for. CONTRACTOR maymake such allowance in his rates to provide for excavation in side slopes keeping in mind the nature of the soil andsafety of excavation for fixing shuttering etc.

7.2 Backfilling as per specifications as specified and directed for the sides of foundations of columns, footings,structures, walls, tanks, rafts, trenches, etc. with excavated material will not be paid for separately. It shall be clearlyunderstood that rates quoted for excavation shall include stacking of excavated material, if required, within specifiedlead, backfilling with selected earth in layers of 150 mm, compacting, etc. and transporting the surplus excavatedmaterial outside plot limits.

7.3 Payment for fill inside trenches, plinth or similar filling with selected excavated material will be made for onlycompaction as specified/directed by ENGINEER. Cost of all other operations shall be deemed to have been includedin the rates quoted. Payment for this work will be made based on measurement of plinth/trench dimensions filled. Theplinth/ground levels shall be surveyed before commencement of earthwork for this purpose.

7.4 Actual quantity of consolidated filling shall be measured as per the levels before and after filling and paid for incubic metres.

7.5 CONTRACTOR's rate shall include the cost of shoring, strutting, and de-watering, if required.

GROUP – 2

CEMENT CONCRETE AND ALLIED WORKS

1.0 SCOPE:

This specification covers the general requirements for concrete to be used on jobs using on-site productionfacilities including requirements in regard to the quality, handling, storage of ingredients, proportioning,batching, mixing & testing of concrete, and also requirements in regard to the quality, storage, bending andfixing of reinforcement. This also covers the transportation of concrete from the mixer to the place of finaldeposit and the placing curing, protecting, repairing and finishing of concrete.

2.0 APPLICABLE CODES AND SPECIFICATIONS:

The following specification, standards and codes shall form a part of this specification. All standards,tentative specifications, codes of practice, referred to herein, shall be the latest editions including allapplicable official amendments and revisions.In case of discrepancy, if any between this specification and those referred to in the following, the latter shallgovern.

APPLICABLE I.S. SPECIFICATIONS AND CODES OF PRACTICE:

I.S, 12269–Specification for High Strength Ordinary Portland Cement Grade 53.

I.S, 8112–Specification for High Strength Ordinary Portland Cement Grade 43.

I.S. 1489-Specification for Portland Pozzolona Cement

I.S. 383 - Specification for coarse and fine aggregates from natural source for concrete.I.S. 2386 - Method of test for aggregates (Part I to VIII) for concrete.

I.S. 516 - Method of test for strength of concrete.

I.S. 1199 - Method of sampling and analysis of concrete.

I.S. 3025 - Method of sampling and test (Physical and chemical) for water & waste water.

I.S. 432 - Specification for mild steel (Part I & II) and medium tensile steel bars and hard drawn steel wire forconcrete reinforcement.

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I.S. 1139 - Specification for hot rolled mild steel and medium tensile steel deformed bars for concretereinforcement.

I.S. 1566 - Specification for hard drawn steel wire fabric for concrete reinforcement.

I.S. 1786 - Specification for TMT (thermo mechanically treated) Steel bars for concrete reinforcement.

I.S. 2645 - Specification for integral cement waterproofing compound.

I.S. 456:2000 - Code of practice for plain and reinforced concrete.

I.S. 3370 - Code of practice for concrete (Parts I-IV) structures for storage of liquids.

I.S. 2502 - Code of practice for bending and fixing of bars for concrete reinforcement.

I.S. 2571 - Code of practice for laying in situ cement concrete flooring.

I.S. 3696 - Safety code for scaffolds and (Part I & II) ladders.

I.S. 1200 - Method of measurement of building & civil engineering works.

3.0 GENERAL:

3.1 The quality of materials & method and control of manufacture and transportation of all concretework irrespective of mix, whether reinforced or otherwise, and shall conform to the applicable portions of thisspecification.

3.2 ENGINEER shall have the right to inspect the source of material, the layout and operation ofprocurement and storage of materials, the concrete batching and mixing equipment, and the quality controlsystem. Such an inspection shall be arranged and ENGINEER's approval obtained, prior to starting ofconcrete work.

4.0 MATERIALS FOR STANDARD CONCRETE:

The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard typePortland cement, clean sand, natural coarse aggregate, clean water, and admixtures, if specially called foron drawings and/or specifications.

4.1 CEMENT:

4.1.1 Unless otherwise specified cement shall be OPC / PPC of approved make in 50 kg bags. The useof bulk cement will be permitted only with the approval of ENGINEER. Changing of brands or type of cementwithin the same structure will not be permitted.

4.1.2 CONTRACTOR shall make his own arrangements for the storage of adequate quantity of cement.If supplies are arranged by OWNER, cement will be issued in quantities to cover work requirements of onemonth or less, as deemed fit by the ENGINEER and it will be the responsibility of CONTRACTOR to ensureadequate and proper storage Cement bags shall be stored in a dry enclosed shed (storage under tarpaulinwill not be permitted), well away from the outer walls and insulated from the floor to avoid contact withmoisture from ground & walls, and so arranged as to provide ready access. Damaged or reclaimed or partlyset cement will not be permitted to be used and shall be removed from the site. Not more than 12 bags shallbe stacked in any tier. The storage arrangement shall be approved by ENGINEER. Consignment of cementshall be stored as received and shall be consumed in the order of their receipts at site. Cement will be testedas per schedule of testing given in the tender document & manufacturer’s test certificate alone will notsuffice.

4.1.3 Cement held in storage for a period of ninety (90) days or longer shall be tested. Should at any timeENGINEER have reasons to consider that any cement is defective, then irrespective of its origin, date ofmanufacture and/or manufacturer's test certificate, such cement shall be tested immediately atCONTRACTOR's cost at a National Test Laboratory/approved laboratory and until the results of such testsare found satisfactory, it shall not be used in any work. CONTRACTOR shall not be entitled to any claim ofany nature of this account.

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4.2 AGGREGATES:

4.2.1 a) "Aggregate" in general designates both fine and coarse inert materials used in the manufactureof concrete.

b) "Fine Aggregates" are aggregates most of which pass through 4.75 mm IS sieve.

c) "Coarse aggregates" are aggregate most of which retain on 4.75 mm IS sieve.

4.2.2 All fine and coarse aggregate proposed for use in the work shall subject to ENGINEER's approvaland after specific materials have been accepted, the source of supply of such material, shall not be changedwithout prior approval of ENGINEER.

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

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

4.2.5 STORAGE OF AGGREGATES:All coarse and fine aggregate shall be stacked separately in stock piles in the material yard near the worksite to avoid intermixing of different aggregates. Contamination with foreign materials and earth duringstorage and heaping the materials shall be avoided. The aggregates must be of specified quality not only atthe time of receiving at site but more so at the time of loading into the mixer. Rakers shall be used for liftingthe coarse aggregates from stock piles. Coarse aggregates shall be piled in layers not exceeding 1.20metres in height to prevent coning or segregation. Each layer shall cover the entire area of the stock pilebefore succeeding layers and started. Aggregates that have become segregated shall be rejected. Rejectedmaterial after remixing may be accepted, if subsequent tests demonstrate conformity with requiredgradation.

4.2.6 SPECIFIC GRAVITY:Aggregates having specific gravity below 2.6 (saturated surface dry basis) shall not be used without specialpermission of ENGINEER.

5.0 FINE AGGREGATES:

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

5.1 MACHINE MADE SAND:Machine made sand will be acceptable, provided the constituent rock gravel composition shall be sound,hard, dense, inorganic, un-coated and durable against weathering.

5.2 SCREENING AND WASHING:Sand shall be prepared for use by such screening or washing or both, as necessary, to remove allobjectionable foreign matters while separating the sand grains to the required size fraction.

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

Percent by WeightUncrushed Crushed

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

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

PERCENTAGE PASSING FOR

I.S. Sieve Grading Grading Grading GradingDesignation Zone-I Zone-II Zone-III Zone-IV

10.00 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100

2.36 mm 60- 95 75-100 85-100 95-100

1.18 mm 30- 70 55- 90 75-100 90-100

600 micron 15- 34 35- 59 60- 79 80-100

300 micron 5- 20 8-30 12- 40 15- 50

150 micron 0- 10 0- 10 0-10 0- 15

Where the grading falls outside the limits of any particular grading zone of sieves, other than 600 micron I.S. sieves,by total amount not exceeding 5%, it shall be regarded as falling within that grading zone. This tolerance shall not beapplied to percentage passing the 600 micron I.S. Sieves or to percentage passing any other sieve size on thecoarser limit of Grading Zone I or conforming to Grading Zone IV shall be used. Sand used for preparing concreteshall belong to Grading Zone-II.

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

6.0 COARSE AGGREGATES:

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

6.1 SCREENING AND WASHING:Natural gravel and crushed rock shall be screened and / or washed for the removal of dust coating, if sodemanded by ENGINEER.

6.2 GRADING:

The pieces shall be angular in shape and shall have granular or crystalline surfaces. Friable, flaky andlaminate pieces, mica and shale, if present, shall be only in such quantities that will not, in the opinion ofENGINEER, affect adversely the strength and/or durability of concrete. The maximum size of coarseaggregates shall be specified on relevant drawings. The maximum size of coarse aggregates shall in nocase be greater than 1/4 of the minimum thickness of the member, provided that the concrete can be placedwithout difficulty so as to surround all reinforcement thoroughly and fill the corners of the form. Plums above150 mm and upto any reasonable size can be used in plain mass concrete work of large dimensions upto amaximum limit of 20% by volume of concrete when specifically approved by ENGINEER. For heavilyreinforced concrete members, the nominal maximum size of the aggregates shall be 5 mm less than the

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minimum clear distance between the reinforcing main bars, or 5 mm less than the minimum cover to thereinforcement, whichever is smaller. The amount of fine particles occurring in the free state or as looseadherent shall not exceed 1% when determined by laboratory sedimentation tests as per IS: 2386. After 24hours immersion in water, previously dried sampled shall not have gained more than 10% its oven dryweight in air, as determined by I.S. 2386.

6.3 FOREIGN MATERIAL LIMITATIONS:The percentages of deleterious substances in the aggregate delivered to the mixer shall not exceed thefollowing:

Percentage by weight Uncrushed Crushed

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

ii) Coal and lignite 1.00 1.00

iii) Clay lumps 1.00 1.00

iv) Soft fragments 3.00 -

v) Total of all the above substances 5.00 5.00

7.0 WATER:

Water used for both mixing and curing shall be free from injurious amounts of deleterious materials. Potablewaters are generally satisfactory for mixing and curing concrete.

8.0 REINFORCEMENT:

8.1 SUPPLY:

The reinforcement shall be TMT bars conforming to IS : 1786-1985

Substitution of reinforcement will not be permitted except upon written approval from ENGINEER.

8.2 STORAGE:The reinforcement shall not be kept in direct contact with the ground but stacked on top of an arrangementof timber sleepers or the like.

If the reinforcing rods/bars have to be stored for a long duration, they shall be coated with cement washbefore stacking and / or be kept under cover or stored as directed by ENGINEERS. Fabricatedreinforcement shall be carefully stored to prevent damage, distortion, corrosion and deterioration.

All reinforcement shall be clean, free from grease, oil, paint, dirt, loose mill scale, loose rust, dust,bituminous material or any other substances that will destroy or reduce the bound. All rods shall bethoroughly cleaned before being fabricated. Pitted and defective rods shall not be used. All bars shall berigidly held in position before concreting. No welding of rods to obtain continuity shall be allowed, unlessapproved by ENGINEERS.

8.3 LAPS :Laps and splices for reinforcement shall be as shown on the drawings. Splices in adjacent bars shall bestaggered and the locations of all splices, except those specified on the drawings, shall be approved byENGINEER. The bars shall not be lapped unless the length required exceeds the maximum available lengthof bars at site.

8.4 BENDING :Reinforcing bars, supplied bent or in coils, shall be straightened before they are cut to size. Straightening ofbars shall be done in cold and without damaging the bars. This is considered as a part of reinforcementbending fabrication work and contractor's rates are deemed to include this work.

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All bars shall be accurately bent according to the sizes and shapes shown on the detailed working drawings.They shall be bent gradually by machine or other approved means. Reinforcing bars shall not bestraightened and re-bent in a manner that will injure the material; bars containing cracks or splits shall berejected. They shall be bent cold, except bars of over 25 mm in diameter which may be bent hot ifspecifically approved by ENGINEER. Bars which depend for their strength on cold working, shall not be benthot. Bars bent hot shall not be heated beyond cherry red colour (nor exceeding 84 deg C) and after bendingshall be allowed to cool slowly without quenching. Bars incorrectly bent shall be used only if the means usedfor straightening and re-bending be such as shall not, in the opinion of ENGINEER, injure the material. Noreinforcement shall be bent when in position in the work without approval, Whether or not it is partiallyembedded in hardened concrete. Bars having kinks or ends other than those required by designed shall notbe used.

8.5 FIXING:Reinforcement shall be accurately fixed by any approved means and maintained in the correct positionshown in the drawings by the use of blocks, spacers and chairs as per IS 2502 to prevent displacementduring placing and compaction of concrete. Bars intended to be in contact at crossing points shall besecurely bound together at all such points with 16 gauge annealed soft iron wire. The vertical distancesrequired between successive layers of bar in beams or similar members shall be maintained by theprovisions of mild steel spacer bars at such intervals that the main bars do not perceptibly sag betweenadjacent spacer bars.

8.6 COVER:Clear concrete cover for reinforcement shall be as stated on drawings.

The correct cover shall be maintained by cement mortar blocks or other approved means. Reinforcement forfootings, grade beams and slabs on subgrade shall be supported on precast concrete blocks as approvedby ENGINEER. The use of pebbles or stones will not be permitted.

The 28 days crushing strength of cement mortar cubes / precast cover blocks shall be at least equal o thespecified strength of concrete in which these cubes / blocks are embedded.The minimum clear distance between reinforcing bars shall be in accordance with IS 456:2000, or as shownin drawings.

8.7 INSPECTON:

Erected and secured reinforcement shall be inspected and approved by ENGNEER prior to placement ofconcrete.

8.8 PAYMENT:For payment of work done under this item shall be made as per Special Terms & conditions., The unit ratefor reinforcement shall include all wastage, binding wire, etc. for which no separate payment shall be made.Laps as shown on drawings or as approved by ENGINEER and minimum number of chairs and spacer barsto keep the reinforcement in place and approved by ENGINEER shall be measured and paid for.

9.0 STEEL SHAPES ENCASED IN CONCRETE:

Structural steel columns, beams, girders and bracings to be encased in concrete shall be unpainted. Theencasing shall be done in concrete with 10 mm maximum size aggregate. The steel member will have aminimum cover of 50 mm unless otherwise indicated on the drawings. Where the clean cover to steel ismore than 75 mm, mild steel bar and concrete with 20 mm coarse aggregate shall be used.

10.0 MIXING:

Concrete shall be mixed in mechanical mixer (with hopper). The mixer should comply with IS 1791 and IS12119. The mixer shall be fitted with water measuring devices. The mixing shall be continued until there is auniform distribution of the material and the mass is uniform in colour. If there is segregation after unloadingfrom the mixer, the concrete should be remixed. For guidance, the mixing time shall be at least 2 minutes.For concrete of grades M 20 or lower, "Nominal Mix Concrete" as specified in IS: 456:2000 is to be used.Whether reinforced or otherwise, all concrete to works to be carried out under this specification shall bedivided into the following classification.

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Minimum Compressive Strength Of 15 Cm Cubes At 7 And 28 Days After Mixing, Conducted In Accordance With IS:516

Grade Works Test Maximum Size LocationKg/sq.cm aggregate in mm

______________________________________________________________________________at 7 at 28days days

______________________________________________________________________________

M20 135 200 20 As indicatedon drawing

M15 100 150 20 - do -

M10 70 100 40 or 20 -do-

Mix Proportioning and Cement Consumption For Concrete:

Min and Max cement content will be as per IS 456: 2000.

11.0 SAMPLING AND TESTING CONCRETE IN THE FIELD:

11.1 Facilities required for sampling materials and concrete in the field, shall be provided byCONTRACTOR at no extra cost.

11.2 SAMPLING AND TESTING CONCRETE IN THE FIELD:Test cubes of each grade of concrete shall be made as specified in IS: 456:2000. Such samples shall bedrawn on each day, for each grade of concrete & during each concreting operations. Of each set of 6 cubes,three shall be tested at 7 days age and three at 28 days age. The laboratory test results shall be tabulatedand furnished to ENGINEER. ENGINEER will accept the concrete according to `Acceptance Criteria'specified in the IS 456:2000.

11.3 CONSISTENCY:Slump tests shall be carried out as often as demanded by ENGINEER invariably from the same batch ofconcrete from which the test cubes are made. Slump test shall be done immediately after sampling.

12.0 ADMIXTURE:

12.1 WATERPROOFING COMPOUND:Where specified and approved by ENGINEER, waterproofing compound conforming to IS: 2645, shall beadded in quantities recommended by manufacturer and specified by ENGINEER.

13.0 PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL, INSPECTION AND APPROVAL.

13.1 Before the concrete is actually placed in position, the inside of the formwork shall be inspected to see thatthey have been cleaned and oiled. Non-staining oil shall be used as approved by ENGINEER. Temporaryopening shall be provided to facilitate inspection, especially at bottom of columns and wall forms, to permitremoval of say dust, wood shavings, binding wire, rubbish, dirt, etc. Openings shall be placed or holes drilledso that these materials and water can be removed easily. Such openings/holes shall be later suitablyplugged.

13.2 The various trades shall be permitted ample time to install drainage and plumbing lines, floor and trench,drains, conduits, hangers, anchors, inserts, sleeves, bolts, frames and other miscellaneous embedment tobe cast in the concrete as indicated on the drawings or as is necessary for the proper execution of the work.CONTRACTOR shall co-operate fully with all such agencies and shall permit the use of scaffolding,formwork, etc. by other trades at no extra cost.

13.3 All embedded parts, inserts, etc. supplied by OWNER or CONTRCATOR shall be correctly positioned andsecurely held in the forms to prevent displacement during placing and vibrating of concrete.

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13.4 All anchor bolts shall be positioned and kept in place with the help of properly manufactured templatesunless specifically waived in writing by ENGINEER. The use of all such templates, fixtures shall be deemedto be included in CONTRACTOR's rates.

13.5 Reinforcement and other items to be cast in concrete shall have clean surfaces that will not impair bond.

13.6 Prior to concrete placement all work shall be inspected and approved by ENGINEER and, if foundunsatisfactory, concrete shall not be poured until after all defects have been rectified at CONTRACTOR'scost.

13.7 Approval by ENGINEER of any all materials and work as required herein shall not relieve CONTRACTORfrom his obligation to produce finished concrete in accordance with the drawings and specifications.

13.8 RAIN OR WASH WATER:No concrete shall be placed in wet weather or on a water covered surface. Any concrete that has beenwashed by heavy rains shall be entirely removed, if there is any sign of cement and sand having beenwashed away from the concrete placed. To guard against damage which may be caused by rains, the worksshall be covered with tarpaulins immediately after the concrete has been placed and compacted beforeleaving the work unattended. Any water accumulated on the surface the newly placed concrete shall beremoved by approved means and no further concrete shall be placed thereon on until such water isremoved. To avoid flow of water over/around freshly placed concrete, suitable drains and sumps shall beprovided.

13.9 BONDING MORTAR:Immediately before concrete placement begins, prepared surfaces except formwork, which will come incontact with the concrete to be placed, shall be covered with the bonding mortar.

14.0 CLEANING OF EQUIPMENT:

All equipment used for mixing, transporting and placing of concrete shall be maintained in clean condition.All pans, buckets, hoppers, chutes, pipelines & other equipment shall be thoroughly cleaned after eachperiod of placement.

15.0 PROCEDURE FOR PLACING OF CONCRETE:

15.1 ENGINEER'S APPROVAL OF EQUIPMENT & METHOD:Before any concrete is placed, the entire placing program consisting of equipment, layout, proposedprocedures and methods shall be submitted to ENGINEER for approval, if so demanded by ENGINEER andno concrete shall be placed until ENGINEER's approval has been received. Equipment for conveyingconcrete shall be of such size and design as to ensure a practically continuous flow of concrete duringdepositing without segregation of materials, considering the size of the job and placement location.

15.2 TIME INTERVAL BETWEEN MIXING AND PLACING:Concrete shall be placed in its final position before the cement reaches its initial set and concrete shallnormally be compacted in its final position within thirty minutes of leaving the mixer, and once compacted, itshall not be disturbed.

15.3 AVOIDING SEGREGATION:Concrete shall, in all cases, be placed as near as practicable directly in its final position, and shall not be re-handled or caused to flow in a manner which will cause segregation loss of materials, displacement ofreinforcement, shuttering or embedded inserts or impair its strength. For locations where direct placement isnot possible, and in narrow forms, CONTRACTOR shall provide suitable drop and "Elephant Trunks" toconfine the movement of concrete. Special care shall be excercised when concrete is dropped from aheight, especially if reinforcement is in the way, particularly in columns and thin members.

15.4 PLACING BY MANUAL LABOUR:Except when otherwise approved by ENGINEER, concrete shall be placed in the shuttering by shovels orother approved equipment. It should be handled in a manner to preclude segregation. Care should be takento avoid displacement of reinforcement or movement of form work. As a general guidance, the maximumpermissible free fall of concrete may be taken as 1.5 m.

16.0 COMPACTION:

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16.1 Concrete shall be compacted during placing, with approved vibrating equipment until the concretehas been consolidated to the maximum practicable density, is free of pockets of coarse aggregates and fitstightly against all form surfaces, reinforcement and embedded fixtures. Particular care shall be taken toensure that all concrete placed against the form faces and into corners of forms or against hardenedconcrete at joints is free from voids or cavities. The use of vibrators shall be consistent with the concrete mixand caution excercised not to over vibrate the concrete to the point that segregation results, and waterappears on the top surface.

16.2 USE OF VIBRATORS:The exact manner of application and the most suitable machines for the purpose must be carefullyconsidered and operated by experienced men. Immersion vibrators shall be inserted vertically at points notmore than 450 mm apart and withdrawn when air bubbles cease to come to the surface. Immersion vibratorsshall be withdrawn very slowly. In no case shall immersion vibrators be used to transport concrete inside theforms. Particular attention shall be paid to vibration at the top of a lift e.g. in a column or wall.

16.3 PENETRATION OF VIBRATOR:The immersion vibrator shall penetrate the layer being placed and also penetrate the layer below while theunderlayer is still plastic, to ensure good bond and homogeneity between the two layer sand prevent theformation of cold joints.

16.3.1 VIBRATION AGAINST REINFORCEMENT:Care shall be taken to prevent contact of immersion vibrator with reinforcement steel and/or embeddedparts. Immersion vibrators shall not be allowed to come in contact with reinforcement steel after start ofinitial set. They shall also not be allowed to come in contact with forms of finished surfaces.

16.4 STONE POCKETS AND MORTAR PONDAGES:The formation of stone pockets or mortar pondage in corners and against faces of forms shall not bepermitted. Should these occur, they shall be dug out, reformed and refilled to sufficient depth and shape forthorough bonding, as directed by ENGINEER.

16.5 PLACING CONCRETE THROUGH REINFORCING STEEL:When placing concrete through reinforcing steel, care shall be taken to prevent segregation of the coarseaggregate. Where the congestion of steel makes placing difficult, it may be necessary to temporarily movethe top steel aside to get proper placement and restore reinforcing steel to design position.

16.6 BLEEDING:Should bleeding of free water on top of concrete being placed into the form occur, the conditions causingthis defect shall be corrected before further concreting is resumed.

17.0 CONSTRUCTION JOINTS AND KEYS:

17.1 Concrete shall be placed without interruption until completion of the part of the work between predeterminedconstruction joints, as specified hereinafter. Time lapse between the pouring of adjoining units shall be asspecified on the drawings or as directed by ENGINEER.

17.2 If stopping of concreting become unavoidable anywhere, a properly formed construction joint shall be madewhere the work is stopped. Joint shall be either vertical or horizontal unless otherwise shown on drawings. Incase of an inclined or curved member, the joint shall be at the right angles to the axis of the member.Vertical joints in walls shall be kept to a minimum. Vertical joints shall be formed against a stop board;horizontal joints shall be level and wherever possible, arranged so that the joint lines coincide with thearchitectural features of the finished work. Battens shall be nailed to the form work to ensure a horizontalline, and if directed, shall also be used to form a grooved joint. For water storage tank walls and similarwork, joints shall be formed as per IS: 3370. Concrete that is in the process of setting shall not be disturbedor shaken by traffic either on the concrete itself or upon the shuttering. Horizontal and vertical constructionjoints and shear keys shall be located and shall conform in detail to the requirements of plans, unlessotherwise directed by ENGINEER. Where not described, the joint shall be in accordance with the following:

17.2.1 COLUMN JOINTS:In a column, the joint shall be formed 75 mm below the lowest soffit of the beams including haunches, if any.In flat slab construction, the joint shall be 75 mm below the soffit of column capital. At least 2 hours shall

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elapse after depositing concrete in columns, piers or walls, before depositing in beams, girders or slabssupported thereon.

17.2.2 BEAM AND SLAB JOINTS:Concrete in a beam/girder shall be placed throughout without a joint, however, if provision of a joint isunavoidable, the joint shall be vertical and between quarter and third points of the spans unless otherwiseshown on drawings. Where a beam intersects a girder, the joint in the girder shall be offset a distance equalto twice the width of the beam and additional reinforcement provided for shear, if required. the joints shall bevertical throughout the full thickness of the concrete member. A joint in a slab shall be vertical and parallel tothe principal reinforcement. Where it is unavoidable at right angles to the principal reinforcement, the jointshall be vertical and at the middle of the span.

17.3 JOINTS IN LIQUID RETAINING STRUCTURE:Vertical construction joints in watertight construction will not be permitted unless indicated on the drawings.Where a horizontal construction joint is required to resist water pressure, special care shall be taken in allphases of its construction to ensure water-tightness.

17.4 DOWELS:Dowels for concrete work, not likely to be taken up in the near future, shall be encased in concrete as perdrawings and as directed by the ENGINEER.

18.0 TREATMENT OF CONSTRUCTION JOINTS ON RESUMING CONCRETING:

A stiffer mix shall be used for the top lift of horizontal pours to avoid laitance. All laitance and loose stonesshall be thoroughly and carefully removed by wire brushing/hacking and surface washed. Just beforeconcreting is resumed, the roughened joint surface shall be thoroughly cleaned and loose matter removedand then treated with a thin layer of cement grout of proportion specified by ENGINEER and worked wellinto the surface. The new concrete shall be well worked against the prepared surface before the groutmortar sets. Special care shall be taken to obtain thorough compaction and to avoid segregation of theconcrete along the joints / plane.

19.0 CURING, PROTECTING, REPAIRING AND FINISHING:

19.1 CURING:All concrete shall be cured by keeping it continuously damp for the period of time required for completehydration and hardening to take place. Preference shall be given to the use of continuous sprays, or pondedwater, continuously saturated covering of sacking, canvas, hessians or other absorbent materials, orapproved effective curing compounds applied with spraying equipment capable of producing a smooth,even-textured coat. Extra precautions shall be excercised in curing concrete during cold and hot weather asoutlined hereinafter. The quality of curing water shall be the same as that used for mixing concrete.

19.2 CURING WITH WATER:Fresh concrete shall be kept continuously wet for a minimum period of 10 days from the date of placing ofconcrete, following a lapse of 12 to 14 hours after laying concrete. The curing of horizontal surfaceexposed to the drying winds shall however begin immediately after the concrete surface within 1hour after concrete has set. Water shall be applied to formed surface immediately upon the removal offorms. Quantity of water applied shall be controlled so as the prevent erosion of freshly placed concrete.

19.3 CONTINUOUS SPRAYING:Curing shall be assured by use of an ample water supply under pressure in pipes, with all necessaryappliances like hose, sprinkle and spraying devices. Continuous fine mist spraying or sprinkling shall beused, unless otherwise specified or approved by ENGINEER.

19.4 CURING EQUIPMENT:All equipment and materials required for curing shall be on hand and ready for use before concrete is

placed.

20.0 PROTECTING FRESH CONCRETE:

Fresh concrete shall be protected from the element, from defacement & damage due to constructionoperations by leaving forms in place for an ample period as specified later in this specification. Newly placedconcrete shall be protected by approved means such as tarpaulins from rain, sun & winds. Steps asapproved by ENGINEER shall also taken to protect green concrete from damage by debris, excessive

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loading, vibration abrasion or contact with other materials, etc. that may impair the strength and/or durabilityof the concrete. Workmen shall be warned against and prevented from disturbing green concrete during itssetting period. If it is necessary that workman enter the area of freshly placed concrete, ENGINEER mayrequired that bridges be placed over the area.

21.0 REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE:

21.1 Immediately after the shuttering is removed, the surface of concrete shall be very carefully gone over and alldefective areas called to the attention of ENGINEER who may permit patching of the defective areas, byCONTRACTOR, or also reject the concrete unit, either partially or in its entirety, at no additional expenses toOWNER. Holes left by form bolts, etc. shall be filled up and made good with mortar composed of one part ofcement to one and half parts of sand passing 2.36 mm I.S. sieve after removing any loose stones adheringto the concrete. Mortar filling shall be struck off flush at the face of the concrete. Concrete surfaces shall befinished as described under the relevant items of work.

21.2 Superficial honeycombed surfaces and rough patches shall similarly be made good immediately afterremoval on shuttering, in the presence of ENGINEER and superficial water and air holes shall be filled in.The mortar shall be well worked into the surface with a wooden float. Excess water shall be well worked intothe surface with a wooden float. Excess water shall be avoided. Unless instructed otherwise by ENGINEER,the surface of the exposed concrete placed against shuttering shall be rubbed down immediately removal ofshuttering to remove the fine or other irregularities, care being taken to avoid damage to the surface.Surface irregularities shall be removed by grinding.

21.3 If reinforcement is exposed or honeycombing occurs at vulnerable positions, e.g. ends of beams or columns,it may be necessary to cut out the member completely or in part and reconstruct. The decision ofENGINEER shall be final in this regard. If only patching is necessary, the defective concrete shall cut out tillsound concrete is reached (or to a minimum depth of 25 mm) the edges being cut perpendicular to theaffected surface or with small undercut, if possible. Anchors, tees or dovetail slots shall be provided,whenever necessary, to attach the new concrete securely in place. An area extending several centimetresbeyond the edges and the surface of the repaired voids shall be saturated with water for 24 hoursimmediately before the patching material is placed.

21.4 USE OF EPOXY:The use of epoxy for bonding fresh concrete used for repairs will be permitted upon written approval ofENGINEER. Epoxies shall be applied in strict accordance with the instructions of the manufacturer.

21.5 METHOD OF REPAIR:Small size holes having surface dimensions about equal to the depth of hole, holes left after removal of formbolts, grout insert holds and slots cut for repair of cracks shall be repaired as follows. The hole to be patchedshall be roughened and thoroughly soaked with clean water until absorption stops.

A 5 mm thick layer of grout of equal parts of cement and sand shall be well brushed into the surface to bepatched, followed immediately by the patching concrete which shall be well consolidated with a wooden float& felt slightly protruding of the surrounding surface. The concrete shall be built up in 10 mm thick layers.After an hour or more, depending upon weather conditions, it shall be worked off flush with a wooden floatand a smooth finish obtained by wiping with hessian, using a steel trowel for this purpose. The mix forpatching shall be of the same materials and in the same proportion as that used in the concrete beingrepaired although reduction in the maximum size of the coarse aggregates may be necessary and the mixshall be kept as dry as possible, as directed by ENGINEER.

Mortar filling by air pressure (grouting) shall be used for repair of areas too large and/or too shallow forpatching with mortar. Patched surfaces shall be given a final treatment to match the colour and textures ofthe surrounding concrete. White cement shall be substituted for ordinary cement, if so directed byENGINEER, so match the shade of patch with the original concrete. No payment whatsoever shall be madeto the CONTRACTOR on account of repair work.

21.6 CURING OF PATCHED / REPAIR WORK:The patched areas shall be covered immediately/with an approved non-staining, water saturated materialsuch as gunny bags, etc. as stated earlier which shall be kept continuously wet and protected against sunand wind for a period of 24 hours. Thereafter the patched area shall be kept wet continuously by fine sprayor sprinkling for not less than 14 days.

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22.0 FORMWORK:

22.1 The formwork shall consist of shores, bracings sides of beams and column, bottom of slabs, etc. includingties, anchors, hangers, inserts, etc. complete which shall be properly designed and planned for the work.False work shall be so constructed that vertical adjustments can be made to compensate for take up andsettlements. Wedges may be used at the top or bottom of timber props, but not at both ends, to facilitatevertical adjustment or dismantling of the formwork.

22.2 DESIGN OF FORMWORK:The design and engineering of the formwork as well as its construction shall be the responsibility ofCONTRACTOR. If so instructed, the drawings and/or calculations for the design of the formwork shall besubmitted to ENGINEER for approval before proceeding with work, at no extra cost to OWNER.ENGINEER's approval shall not, however, absolve the CONTRACTOR of his full responsibility for the designand construction of the formwork. The design shall take into account all the loads, vertical as well as lateral,that the form would be carrying, including live and vibration loadings.

22.3 TOLERANCES:Tolerance is a specified permissible variation from lines, grades or dimensions given on drawings. Notolerances specified for horizontal or vertical building lines or footings shall be construed to permitencroachment beyond the legal boundaries. Unless otherwise specified, the following tolerance will bepermitted.

Tolerance for R.C. Buildings:

Variation from the plumb:

a) In the lines and surfaces of columns, piers, walls and in arises 5 mm per 2.5 m or 25 mm whichever isless:

b) For exposed corner columns and other conspicuous lines:

In any bay of 5 m maximum - 5 mm

In 10 m or more - 10 mm

Variation from the level or from the grades indicated on the drawings:

a) In slab soffits, ceilings, beam soffit, and in arises:

In 2.5 m - 5 mm

In any bay or 5 m maximum - 8 mm


For exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines:



Variation of the linear building lines form established position in plan and related position of columns, wallsand partitions.



Variation in cross-sectional dimensions of columns and beams and in the thickness of slab and walls.

Minus - 5 mm

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Plus - 10 mm

Footings:

a) Variation in dimensions in plan

Minus - 5 mm

Plus - 50 mm

b) Misplacement or eccentricity :

2% of footing width in the direction of misplacement but not more than 50 mm.

c) Reduction in thickness

Minus - 5% of specified thickness subject to a maximum of 50 mm.Tolerances in other Concrete Structures:

a) All structures

Variation of the constructed linear outline from established position in plan.

In 5 m - 10 mm


Variation of dimensions to individual structure features from established positions.


In buried construction - 50 mm

Variation from level or grade indicated on drawings in slab, beams, soffits, horizontal grooves and visible arises.

In 2.5 m - 5 mm

In 7.5 m or more - 10 mm

In buried construction - Twice the above amounts.

Variation in cross-sectional dimensions of columns beams, but tresses, piers and similar members.

Minus - 5 mm; Plus - 10 mm

a) Variation in the thickness of slabs, walls, arch sections and similar members


b) Footing for columns, piers, walls, buttresses and similar members

Variation of dimensions in plan


Misplacement or eccentricity:

2% of footing width in the direction of misplacement but not more than 50 mm.

Reduction in thickness : 5% of specified thickness subject to a max. of 50 mm.

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Tolerances in fixing bolts shall be as follows:

Anchor bolts without sleeves Plus/Minus 1.5 mm in plan.

Anchor bolts with sleeves Plus/minus 5.0 mm in elevation.

For bolts upto and including 28 mm dia plus / minus 5 mm in all directions.

For bolts 32 mm dia and above, plus / minus 3 mm in all directions.For Embedded parts plus / minus 5 mm in all directions.

22.4 TYPE OF FORMWORK:Formwork may be of timber, plywood, metal, plastic or concrete. For special finishes the formwork may belined with plywood, steel sheets, oil tempered hard board, etc. Sliding forms and slip forms may be used withthe approval of ENGINEER.

22.5 FORMWORK REQUIREMENTS:Forms shall conform to the shapes, lines, grades and dimensions, including camber of the concrete ascalled for on the drawings. Ample studs, walers, braces, ties, straps, shores, etc. shall be used to hold theForms in proper position without any distortion whatsoever until the concrete has set sufficiently to permitthe removal of forms. Forms shall be strong enough to permit the use of immersion vibrators. The shutteringshall be close boarded. Timber shall be well seasoned free from sap shakes, loose knots, worm holes,warps or other surface defects in contact with concrete. Faces coming in contact with the concrete shall befree from adhering grout, plaster, paint projecting nails, splits or other defects. Joints shall be sufficientlytight to prevent loss of water and fine material from concrete.

Plywood shall be used for Exposed Concrete surfaces, where called for Sawn and wrought timber may beused for unexposed surfaces. Inside faces of forms for concrete surfaces which are to be rubbed finishedshall be planed to remove irregularities or unevenness in the face. Formwork with linings will be permitted.

All new and used material for lumber shall be maintained in a good condition with respect to shape, strength,rigidity, water tightness, smoothness and cleanliness of surfaces. Form lumber unsatisfactory in any respectshall not be used and, if rejected by ENGINEER, shall be removed from the site.

Formwork, during any stage of construction showing signs of distortion or distorted to such a degree that theintended concrete work will not conform to the exact contours shown on the drawings, shall be repositionedand strengthened. Poured concrete affected by the faulty formwork, shall be removed in its entirety and theformwork corrected, as directed by ENGINEER, prior to placing new concrete.

Excessive provision of camber to compensate for shrinkage settlement, etc. that may impair the structuralstrength of members will not be permitted.

Forms for substructure concrete may be omitted when, in the opinion of ENGINEER, the open excavation isfirm enough to act as the form. Such excavation shall be slightly larger than that required by the drawings tocompensate for irregularities in excavation and to ensure concrete cover and the design requirements.

Forms shall be so designed and constructed that their removal will not damage the concrete. Face formworkshall provide true vertical and horizontal joints, conform to the architectural features of the structure as tolocation of joints and be as directed by ENGINEER.

When exposed smooth or rubbed concrete finishes are required, the forms shall be constructed with specialcare so that the resulting concrete surfaces require a minimum finish.

22.6 BRACINGS, STRUTS AND PROPS:

Shuttering shall be braced, strutted, propped and so supported that it shall not deform under weight andpressure of the concrete and also due to the movement of men, equipment and other materials. Bamboosshall not be used as props or cross bearers.

The shuttering for beams and slabs shall be so erected that the shuttering on the sides of the beams andunder the soffit of slabs can be removed without disturbing the beam bottoms. Re-proping of beams shallnot be done except when props have to be reinstated to take care of construction loads anticipated to be in

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excess of the design load. Vertical props shall be supported on wedges or other measures shall be takenwhereby the props can be gently lowered vertically while striking the shuttering.

If the shuttering for a column is erected for the full height of the columns, one side shall be left open and builtup in sections as placing of concrete proceeds, or windows may be left for pouring concrete from the sidesto limit the drop of concrete to 1.0 m or, as directed by ENGINEER.

22.7 MOULD OIL:

Care shall be taken to see that the faces of formwork coming in contact with concrete are perfectly cleanedand two coats of mould oil or any other approved material applied before fixing reinforcement and placingconcrete. (Burnt lube oil will not be allowed). Such coating shall be insoluble in water, non-staining and notinjurious to the concrete. It shall not become flaky or be removed by rain or wash water. Reinforcement and /or other items to be cast in the concrete shall not be placed until coating of the forms is complete. Adjoiningconcrete surfaces shall also be protected against contamination from the coating material.

22.8 CHAMFERS AND FILLETS:All corners and angles exposed in the finished structure shall be formed with mouldings to form chamfers orfillets on the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise specified,shall be 20 mm x 20 mm. Care shall be excercised to ensure accurate moulding. The diagonal face of themoulding shall be planed or surfaced to the same texture as to form to which it is attached.

22.9 VERTICAL CONSTRUCTION JOINT CHAMFERS:Vertical construction joints on faces which will be exposed at the complication of the work shall bechamfered as above except where not permitted by ENGINEER for structural or hydraulic reasons.

22.10 WALL TIES:Wire ties passing the walls shall not be allowed. In their place bolts passing through sleeves shall be used.

22.11 REUSE OF FORMS:Before reuse, all forms shall be thoroughly scrapped, cleaned, nails removed, holes that may leak suitablyplugged and joint examined and when necessary, repaired and the inside retreated to prevent adhesion tothe satisfaction of ENGINEER. Warped lumber shall be resized. CONTRACTOR shall equip himself withenough shuttering to complete the job in the stipulated time.

22.12 REMOVAL OF FORMS:

22.12.1 CONTRACTOR shall record on the drawing or a special register, the date upon which the concrete is placedin each part of the work and the date on which the shuttering is removed there from.

22.12.2 Under no circumstances shall forms be struck until the concrete reaches strength of at least twice the stressdue to self weight and any construction/erection loading to which the concrete may be subjected at the timeof striking formwork, as directed by ENGINEER.

22.12.3 In normal circumstances (generally where temperatures are above 20 deg. C), forms may be struck afterexpiry of the following periods, where ordinary Portland cement is used and adequate curing is done:

TYPE OF FORMWORK MIN. PERIOD BEFORE STRIKING FORMWORK

a) Walls columns and vertical sides of beams. 16 to 24 hours as directed by the ENGINEER.

b) Slabs (Props left under) 3 days

c) Beam soffits (Props left under) 7 days

d) Removal of props under slabs:

i) Spanning upto 4.5 m. 7 days

ii) Spanning over 4.5 m. 14 days

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e) Removal of props under beams:

i) Spanning upto 6 m. 14 days

ii) Spanning over 6 m. 21 days

Striking shall be done slowly with utmost care so to avoid damage to rises and projections and without shockor vibration, by gently easing the wedges. If after removing the form work, it is found that timber has beenembedded in the concrete, it shall be removed and made good as specified earlier.

22.12.4 Reinforced temporary openings shall be provided as directed by ENGINEER to facilitate removal offormwork which otherwise may be inaccessible.

22.12.5 Tie rods, clamps, form bolts, etc. which must be entirely removed from walls or similar structures, shall beloosened not sooner than 24 hours nor later than 48 hours after the concrete has been deposited. Tiles,except those required to hold forms in place, may be removed at the time. Ties withdrawn from walls andgrade beams shall be pulled towards the inside face. Cutting ties back from the faces of walls and gradebeams shall not be permitted.

22.12.6 For liquid retaining structures, to sleeves for through bolts shall be used, nor shall through bolts be removedas indicated in 24.12.5. The bolts, in this case, shall be cut at 25 mm depth from the surface and then thehole shall be made good by sand cement mortar of the same proportion of the concrete, just after strikingthe formwork.

23.0 FOUNDATION BEDDING, BONDING AND JOINTS:

23.1 All surfaces upon or against which concrete will be placed shall be suitably prepared by thoroughly cleaning,washing and dewatering, as indicated on the plans or as directed by the ENGINEER, to meet the varioussituations encountered in the work.

23.2 Soft or spongy areas shall be cleaned out and backfilled with either a soil-cement mixture, lean concrete orclean sand, till compacted to a minimum density of 90% Modified Proctor, unless otherwise mentioned inSchedule of Quantities.

23.3 PREPARATION OF EARTH STRATA OF FOUNDATIONS:All earth surfaces upon or against which concrete is to be placed, shall be well compacted and free fromstanding water, mud or debris. Soft, yielding soil shall be removed and replaced with suitable earth, sand ormurrum well compacted as directed by ENGINEER. Wherever specified, lean concrete shall be provided onthe earth stratum for receiving concrete. The surface of absorptive soils, against which concrete is to beplaced shall be moistened thoroughly so that no moisture will be drawn from the freshly placed concrete,and later shall help to cure the concrete.

23.4 PREPARATION OF CONCRETE SURFACES:The preparation of concrete surfaces upon which additional concrete is to be placed later, shall preferablybe done by scarifying and cleaning, while the concrete is between its initial and final set. This method shallbe used wherever practicable and shall consist of cutting the surface with picks and stiff brooms and by useof an approved combination of air and water jet as directed by ENGINEER. Utmost care shall be excercisedin performing this work to avoid removal of too much mortar and the weakening of the surface by looseningof aggregates.

When it is not practicable to follow the above method, it will be necessary to employ compressed air toremove laitance and roughen the surface.

The final required result shall be a pitted surface from which all dirt, unsound concrete, laitance and glazedmortar have been removed.

23.5 BONDING TREATMENT (MORTAR):

23.5.1 After rock or concrete surface upon which new concrete is to be placed have been scarified, cleaned andwetted, as specified herein, they shall receive a bonding treatment, immediately before placement of theconcrete.

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23.5.2 The bonding medium shall be a coat of cement-sand mortar. The mortar shall have the same cement-sandproportions as the concrete which shall be placed thereon. The water-cement ratio shall be determined bysite conditions and as approved by ENGINEER.

23.5.3 Bonding mortar shall be placed in sufficient quantity to completely cover the surface about 5 mm thick forconcrete surfaces. It shall be brushed or broomed over the surface and worked thoroughly into all cracks,crevices and depressions. Accumulations or puddles, if mortar shall not be allowed to settle in depressions,shall be brushed out to a satisfactory degree, as approved by ENGINEER.

23.5.4 Mortar shall be placed at such a rate that it can be brushed over the surface just in advance of placement ofconcrete. Only as much area shall be covered with mortar, as can be covered with concrete before initial setin the mortar takes place. The amount of mortar that will be permitted to be placed at any one time, or thearea which it is required to cover, shall be in accordance with ENGINEER's directions.

23.6 CLEANING AND BONDING FORMED CONSTRUCTION JOINTS:Vertical construction joints shall be cleaned as specified above or by other methods as approved byENGINEER. In placing concrete against formed construction joints, the surfaces of the joints, whereaccessible, shall be coated thoroughly with the specified bed-joint bonding mortar immediately before theyare covered with concrete, or by scrubbing with wire brooms dipped into the fresh concrete. Where it isimpracticable to apply such a mortar coating, special precautions shall be taken to ensure that the newconcrete is brought into intimate contact with the surface of the joint, by careful pudding and spading with aidof vibrators and suitable tools.

23.7 EXPANSIION AND CONTRACTION JOINTS:Provision shall be made for expansion and contraction of concrete by use of special type joints located asshown on the drawings. Construction joint surfaces shall be treated as per specifications, drawings or asdirected by ENGINEER.

24.0 HOT WEATHER REQUIREMENT:

24.1 All concrete work performed in hot weather shall be in accordance with IS: 456:2000, except as hereinmodified.

24.2 Admixture may be used only when approved by ENGINEER.

24.3 Adequate provisions shall be made to lower concrete temperatures by cool ingredients, eliminatingexcessive mixing, preventing exposure of mixers and conveyors to direct sun-light, the use of reflective painton mixers, etc. The temperature of the freshly placed concrete shall not be permitted to exceed 38 degreeCelsius.

24.4 Consideration shall be given to providing shade aggregate stockpiles from direct rays of the sun andspraying stockpiles with water, use of cold water when available and burying, insulating shading and/orpainting white the pipe lines & water storage tanks.

24.5 In order to reduce loss of mixing water, the aggregates, wooden forms, subgrade, adjacent concrete andother moisture absorbing surfaces shall be well wetted prior to concreting. Placement and finishing shall bedone as quickly as possible.

24.6 Extra precautions shall be taken for the protection and curing of concrete. Consideration shall be given tocontinuous water curing and protection against high temperatures and drying hot winds for a period of atleast 12 days immediately after concrete has set and after which normal curing procedures may beresumed.

25.0 PRECAST CONCRETE:

25.1 Precast concrete shall comply with IS: 456:2000 and also with following:

All precast units shall be cast on a suitable bed or platform with firm foundation and free from wind.CONTRACTOR shall be responsible for the accuracy of the level or shape of the bed or platform. A suitableserial number and the date of casting shall be impressed or painted on each unit.

25.2 STRIKING FORMS:

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Side shutters shall not be struck in less than 24 hours after placing concrete and no precast unit shall belifted until the concrete reaches strength of at least twice the stress to which the concrete may be subjectedto at the time of lifting, as directed by ENGINEER.

25.3 PRECAST UNITS:The lifting and removal of precast units shall be undertaken without causing shock, vibration or unduebending stresses to or in the units, before lifting and removal takes place, CONTRACTOR shall satisfyENGINEER or his representative that the methods he proposes to adopt for these operations will notoverstress or otherwise affect the strength of the precast units. The reinforced side of the units shall bedistinctly marked.

25.4 CURING:All precast work shall be protected from the direct rays of sun for at least 14 days after casting and duringthat period each unit shall be kept constantly watered or preferably be completely immersed in water if thesize of the unit so permits. Otherwise curing practice as given earlier shall be followed.

26.0 SLOTS, OPENINGS ETC.:Slots, openings or holes, pockets, etc., shall be provided in the concrete work in the positions indicated inthe drawings or as directed by ENGINEER. Any deviation from the approved drawings shall be made goodby CONTRACTOR at his own expense without damaging any other work. Sleeves, bolts, inserts, etc. shallalso be provided in concrete work where so specified.

27.0 GROUTING:

27.1 STANDARD GROUT:

The proportions of grout shall be such as to produce a flowable mixture consistent with minimum watercontent and shrinkage. The grout proportions shall be as specified on drawings and as directed byENGINEER.

a) Sand shall be such as to produce a flowable grout without any tendency to segregate.

b) Sand, for general grouting purposes, shall be graded within the following limits:

Passing IS: 2.36 mm sieve 95 to 100%

Passing IS: 1.18 mm sieve 65 to 95%

Passing IS: 300 micron sieve 10 to 30%

Passing IS: 150 micron sieve 3 to 10%

c) Surface to be grouted shall be thoroughly roughened and cleaned of all foreign matter and laitance.

d) Prior to grouting, the hardened concrete surfaces to be grouted shall be saturated with water.

Forms around base plates shall be reasonably tight to prevent leakage of the grout.

Adequate clearance shall be provided between forms and base plate to permit grout to be worked into place properly.

Grouting, once started, shall be done quickly and continuously to prevent segregation, bleeding and breakdown ofinitial set. Grout shall be worked from one side of one end to the other to prevent entrapment of air. To distribute thegrout and to ensure more complete contact between base plate & foundation and to help release entrapped air, linkchains can be used to work the grout into plate.

Grouting through holes in base plats shall be by pressure grouting, variations in grout mixes and procedures shall bepermitted if approved by ENGINEER.

27.2 SPECIAL GROUT:Special grout, where specified on the drawings, shall be provided in strict accordance with themanufacturer’s instructions/specifications on the drawings.

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28.0 INSPECTION:All materials, workmanship and finished construction shall be subject to the continuous inspection andapproval of ENGINEER.

All materials supplied by CONTRACTOR and all work or construction performed by CONTRACTOR andrejected as not in conformity with the specifications and drawings, shall be immediately replaced at noadditional expense to the OWNER, and to the entire satisfaction of the ENGINEER.Approval of any preliminary materials or phase of work shall in no way absolve the CONTRACTOR from hisresponsibility of supplying concrete and/or producing finished concrete in accordance with the specificationsand drawings.

All concrete shall be protected by the CONTRACTOR against damage until finally accepted by the OWNERor his representative.

29.0 CLEAN UP:Upon the completion of concrete work, all forms, equipment, construction tools, protective coverings and anydebris resulting from the work shall be removed from the premises.

All the debris i.e. empty containers, scrap wood, etc, shall be removed daily, as directed by ENGINEER.

The finished concrete surfaces shall be left in a clean condition to the entire satisfaction of the ENGINEER.

30.0 PAYMENT:

30.1 The unit rate for concrete work under various categories shall be all inclusive of all related work and noclaims for extra payment on account of such items as leaving holes, embedding, inserts, etc., shall beentertained. no extra claim shall also be entertained due to change in the number, position and/ordimensions of holes, slots or openings, sleeves, inserts or on account of any increased lift or scaffolding,etc. All these factors shall be taken into consideration while quoting the unit rates.

30.2 Payment of concrete will be made on the basis of unit rates quoted for the respective items in the Scheduleof Quantities. No deduction in the concrete quantity will be made for reinforcements, inserts, etc. andopening less than 1/20 of a sq.m. in area where concrete is measured in sq.m. & 1/50 OF Cu.M whereconcrete is measured in cu.m. Similarly the unit rates for concrete work shall be inclusive or exclusive ofshuttering as provided for in the Schedule of Quantities. Where formwork is paid for separately, it shall bevery clearly understood that payment for formwork is inclusive of formwork, shuttering, shoring, propping,scaffolding, etc. complete.

30.3 PAYMENT for beams will be made for the quantity based on the depth being reckoned from the underside ofthe slabs and length measured as the clear distance between supports. Payment for columns shall be madefor the quantity based on height reckoned upto the underside of slabs.

30.4 The unit rate for precast concrete members shall include formwork, mouldings, finishings, hoisting andsetting in position including setting mortar, provision of lifting arrangements, etc. complete.

Reinforcement shall be measured and paid for separately as per Schedule of Quantities.

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TECHNICAL SPECIFICATIONS FOR SUPPLY OF MATERIAL

TECHNICAL SPECIFICATION FOR FLANGES

1.0 SCOPE :

This specification covers the technical requirements for flanges required for LPG Bottling Plants ofHindustan Petroleum Corporation Ltd.

2.0 CODES AND STANDARDS :

Codes and standards pertaining to flanges are as mentioned below. References shall be made tolatest edition of such documents.

Description : Carbon Steel FlangesMaterial : SA-105Dimensional std. : ANSI B16.5 (Serrated)

3.0 SCOPE OF SUPPLY :

Scope of supply includes manufacture, inspection, packing and delivery to Project sites as mentioned.

4.0 SCHEDULE OF QUANTITY :

Approximate quantity of flanges (SORF / FF and Blind) required as per this specification are indicated inthe Attachments. The quotation shall be for unit (Rs./piece), which shall be applicable for increased ordecreased quantity.

5.0 MATERIAL:

Flanges shall conform to SA-105.

6.0 DIMENSIONAL STANDARDS :

For all flanges, dimensional standards shall conform to ANSI B 16.5 raised face as well as blind.

All flanges shall have serrated face finish.

7.0 RATING :

For all flanges shall be as per the items specified.

8.0 INSPECTION AND ACCEPTANCE TEST:

All flanges shall be thoroughly inspected for dimensional accuracy, uniform surface, edge preparationetc. They shall be within the permissible tolerances limits specified in the relevant standards.Third Party Inspection Agency shall inspect flanges for compliance with standards at the manufacturer'sworks.

9.0 MARKINGS :

All the flanges shall be marked, as per the requirements of ANSI B 16.5.

10.0 DOCUMENTS :

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Material Test Certificates for physical and chemical compositions shall be furnished for all flanges. It shallbe possible to correlate the test certificates with the heat numbers stamped on all the flanges. All thedocuments, test certificates shall be submitted in original transparencies and six readable good qualityprints before final dispatch of materials.

11.0 PACKING AND FORWARDING :

All flanges shall be cleaned and properly packed, such that there will be no damage in transit, especiallyto the facing and welded ends.

12.0 DELIVERY :

Vendor should deliver the materials to the specified destination / place. Vendor should mention the bestdelivery period.

13.0 Vendor shall include charges for third party inspection in his quoted rates.

14.0 Approved agencies for inspection are M/s. IGIS (BV), Lloyds, RITES, PDIL, IRS,DNV.

SPECIFICATIONS FOR STUDS WITH TWO NUTS

A. STUDS & NUTS : FULLY THREADED STUDS CONFORMING TO ASTM-A-193 GR. B7, WITH TWO HEX NUTS CONFORMINGTO ASTM-A-194 GR. 2H.

B. MATERIAL OF :CONSTRUCTION

a. Studs : AI S1 4140

b. Nuts : Class IV to IS 2004

c. Dimensions & Tolerance : Stud – Fully Threaded: Nut - As per IS 1364(S)

d. Threaping : Coarse Pitch to 6G/6H to IS 4218

e. Whether Thread gauged : Yes.

f. Special Treatment : All Studs & Nuts to be cleaned &oiled before despatch.

C. TESTS TO BE PERFORMED :

a. Tensile Strengthb. Agingc. Proof Loadd. Chemical Testse. Dimensional Check.

D. SCOPE OF THIRD PARTY INSPECTION:

a. All tests stated in C. However, for Chemical Tests, only review of Test Certificates to be carriedout.

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E. APPROVED THIRD PARTY INSPECTION AGENCY:

BVIS / BAX COUNSEL / RITES / EIL / LLOYDS.

TECHNICAL SPECIFICATION FOR PIPE FITTINGS

1.0 SCOPE

This specification covers the technical requirements for pipe fittings required for LPG BottlingPlants of Hindustan Petroleum Corporation Ltd.

2.0 CODES AND STANDARDS

Codes and Standards pertaining to fittings are indicated later in the enquiry.

3.0 SCOPE OF SUPPLY

Scope includes supply of bought out items inspection, packing and delivery of pipe fittings toproject sites as mentioned.

4.0 SCHEDULE OF QUANTITY

Approximate quantity of fittings, required as per this specification are indicated in the Attachment.The quotation shall be for unit numbers (Rs./piece) , which shall be applicable for increased ordecreased quantities.

5.0 MATERIAL

1) For fittings of sizes 50 mm NB to 500 mm NB = SA 234 Grade WPB2) For fittings of sizes 40 mm NB and below = SA 1053) For screwed fittings upto 150 mm NB = IS 1239 Part II

Galvanised.

6.0 DIMENTIONAL STANDARDS

For B.W. fittings of sizes 50 mm NB : ANSI B16.9and above

For S.W. Fittings of sizes 40 mm NB : ANSI B 16.11and below

For Galvanised Screw Fittings : IS 1239 Part II

7.0 RATINGS

Wall thickness of fittings is indicated in terms of schedule of connected pipes for B.W. fittings andANSI (Pounds) racings for S.W. Fittings which are given below. PIPE FITTINGS QUOTEDSHALL CONFORM TO FOLLOWING STANDARDS:

---------------------------------------------------------------------------------------Sr.No. DESCRIPTIONSTANDARDS

---------------------------------------------------------------------------------------1. 90 DEG. ELBOWS SA 234 GR WPB

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450 NB to 50 NB ANSI B 16.0

2. 90 DEG ELBOWS 30000. A 10540 NB TO 15 NB ANSI B 16.11

3. 45 DEG ELBOW SA 234.GR WPB250 NB TO 50 NB ANSI B 16.9

4. TEE SA 234 GR. WPB300 X 100 TO 50 X 25 ANSI B 16.9

5. TEE 3000#, A 10540 X 40 TO 15 X 15 ANSI B 16.11

6. 45 DEG ELBOW 3000#, A 10540 NB TO 15 NB ANSI B 16.11

7. REDUCERS SA 234 GR. WPB400 X 100 TO 50 X 25 ANSI B 16.9

8. REDUCERS 3000#, A 10540 X 25 TO 25 X 15 ANSI B 16.11

9. COUPLINGS, 3000#, A 105CAPS, SOCKETS, PLUGS ANSI B 16.11

10. NIPPLES A 106 GR. B.

11. UNIONS BS-3799

8.0 INSPECTION

All the fittings shall be thoroughly inspected for dimensional accuracy, uniform surface, edgepreparation, bevel angle etc. They shall be within permissible units specified in the relevantstandards.

9.0 MARKINGS

All fittings shall be marked as per the requirements of respective codes. All fittings shall bemarked as per the requirements of respective codes.

DOCUMENTSMaterials test certificates for physical and chemical properties shall be furnished for all the fittings.

PACKING AND FORWARDING

All fittings shall be cleaned and properly packed such that there will be no damage in transitespecially to the beveled ends of fittings.

DELIVERY

Vendor should deliver the materials to the specified destination / place. Vendor should mention the bestdelivery period.

Vendor shall include charges for third party inspection in his quoted rates.

Approved agencies for inspection are M/s IGIS (BV), Lloyds, RITES, PDIL.

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SCHEDULE OF ITEMS

DETAILED JOB SCHEDULE

MECHANICAL & PIPING WORKS AT PAMPORE LPG PLANT

ITEMNO

DESCRIPTION UNIT QTY

SECTION-I: SEAMLESS PIPELINE WORKS

FABRICATION & ERECTION OF SA 106 SEAMLESS PIPES

Transportation of piping items of all sizes from HPCL's storage point to worksite/work shop for fabrication, including cutting, beveling the edges of the pipesand fittings to match with the mating edges, welding, threading, transportation ofthe fabricated pipes to the erection place and laying of pipes of all types andthickness over sleepers, overhead racks & at all elevations, connecting with existingnozzles by welding flanges or threading or fitting, welding the elbows, reducers,tees, branch connections, reinforcement pads, flanges, gaskets, nuts, bolts, washers,providing necessary tapping for pressure gauges etc, hydrostatic testing of thepipeline to the specified pressure, rectification of any leakage & re-testing of pipelinesto the specified pressure, draining of the water, providing all inputs such as labour,materials, equipments and consumables necessary to perform the work andcompleting the work in all respects in accordance with the drawings, specificationsand instructions of site engineer.

1 250 NB RMT 125

2 200 NB RMT 50

3 100 NB RMT 200

4 80 NB RMT 410

5 50 / 40 NB RMT 2206 25 / 20 / 15 NB RMT 30

NOTE FOR ITEM NO. 1 to 6

(a) For Process pipes of ASTM A-106 Gr.B material, E6010 electrode for root run &E7018 for filler and final layer shall be used. Grinding to white metal surface after

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root run for all process pipeline joints to be carried out.

(b) Valves of all types, strainers, on line instruments etc. 40mm and below shall beconsidered as part of the respective piping sizes for quantities certification.

(c) All LPG lines' weld joints shall be 100% tested for Dye Penetration. Aftercompletion of root runs welding random radiography of 10% maximum or a minimumof 5 joints from each welder, whichever is more, shall be carried out by the Contractorwithin the rates quoted for piping. In case of defects observed during 10 %radiography, repairs shall be carried out and Radiography shall be taken after repairsat no extra cost. In addition to this, for each joint recommended for repairs, two jointsas advised by EIC shall be subjected to Radiography and results analyzed in order toinvestigate any problems in the process.

(d) After completion of fabrication, all LPG lines have to be Hydrotested to a pressureof 28 kg/sq.cm. Gasket for all LPG pipeline should be metallic gaskets only

(e) Providing of 25mm x 3mm copper jumper for all flange joints, including bending,drilling to the required size, applying black enamel paint for the strip etc complete asper the instructions of EIC at no extra cost.HYDROTESTING & ERECTION OF VALVES IN LPG PIPELINES (item Nos 7 - 17)

Taking delivery of all types of valves, strainers, hydrant posts & valves, monitorsand other on line equipments from HPCL's store, hydro-testing of all the valves to therequired pressure (28 kg/sq.cm) & transporting of the same to the work site,installation of valves and online equipments by flange / socket weld for all ratingsincluding assembly of valve accessories if any, completing the work in all respect inaccordance with the drawings, specifications, manufacturer's installation instructions& directions of Engineer-In- Charge.

Remote Operated Valves of 300 PSI excluding erection of Air reservoir which will bepaid separately under equipment erection works.

7 250 NB ROV Nos 6

8 100 NB ROV Nos 4

9 80 / 50 NB ROV Nos 8

10 3-way Valve 250 NB Nos 1

11 3-way Valve 100 NB Nos 1

12 3–way Valve 80 NB Nos 1

Wheel operated / Lever operated Gate / Ball / Globe Valve / Strainer / NRV / AutoRecirculation Valve

13 250 / 200 NB NOS 8

14 150 / 100 NB NOS 15

15 80 / 50 NB NOS 25INSTRUMENT HOOK UP (for Item Nos 16 to 17)Installation of instruments at locations as per drawing / instruction of Engineer-in-charge complete worksuch as receiving from Owners’ place , taking upt o erection point, cutting the main pipe, welding of halfcoupling, valves etc. with E-7018 electrodes, DP Test, hydro test etc. as per attached drawings.

16 Pressure gauge 15 NB NOS 5

17 Erection of drain / Vent 25/20/15 NB NOS 5

18

COPPER STRIPS: Supplying and installing 3 mm thick copper strips, includingcutting, drilling, bending, transporting to actual location and applying black enamelpaint for LPG pipe earthing to the Grid where ever required and as per instructions ofEIC.

KG 100

SECTION-II MS ERW PIPELINE WORKS for fire hydrant pipeline, Sprinklersystem, service water lines & Air lines.

FABRICATION OF PIPELINE ABOVE GROUND ( PIPE AS PER IS 1239 / IS 3589)For Item Nos 19 to 23

Transportation of piping items of all sizes from HPCL's storage point to work

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site/work shop for fabrication, including cutting, beveling the edges of the pipesand fittings to match with the mating edges, welding, threading, transportation ofthe fabricated pipes to the erection place and laying of pipes of all types andthickness over sleepers, overhead racks & at all elevations, connecting with existingnozzles by welding flanges or threading or fitting, welding the elbows, reducers,tees, branch connections, reinforcement pads, flanges, gaskets, nuts, bolts, washers,providing necessary tapping for pressure gauges etc, hydrostatic testing of thepipeline to the specified pressure, rectification of any leakage & re-testing of pipelinesto the specified pressure, draining of the water, providing all inputs such as labour,materials, equipments and consumables necessary to perform the work andcompleting the work in all respects in accordance with the drawings, specificationsand instructions of site engineer.

19 250 NB RMT 200

20 150 NB RMT 50

21 80 NB RMT 30

22 50 / 40 NB RMT 250

23 25 / 20 / 15 NB RMT 30

NOTE FOR ITEM NO: 19 to 23

(a)

Wherever bends, elbows, reducers and tees of any sizes are supplied by HPCL, thesame will not be considered separately for payment purpose and will be included inthe linear measurement of the respective pipelines for quantity certification. Noseparate payment will be made for the welding of any reinforcement pads for tees ofany sizes. Hence contractor to quote accordingly.

(b)For air lines (15 NB) contractor is advised to specifically consider cold bending &threading of the pipe joints, wherever it is necessary.

(c)Fixing of valves of all types, strainers, online equipments / instruments etc of 40 mmNB and below will be considered as part of the respective piping sizes for quantitycertification.

(d)

For Fire water and service piping of IS 1239/ IS 3589 material, Electrodes shall be E6010 for the root run and E6013 for filler & final layer. (Grinding of all joints after rootrun up to white metal surface before filler & final welding.

HPCL may supply any part of pipe quantity of seamless CS pipes instead ofIS1239/IS 3589 material.

(e)All Fire water lines have to be hydro tested to a pressure of 16 kg/sq.cm aftercompletion of fabrication. Air lines & drinking/service water lines at 12 kg/cm².

FABRICATION & LAYING U/G PIPELINE (For Item Nos 24)

Transportation of piping items of all sizes from HPCL's storage point to worksite/work shop for fabrication, including cutting, beveling the edges of the pipesand fittings to match with the mating edges, welding, threading, transportation ofthe fabricated pipes to the erection place and laying of pipes of all types andthickness over sleepers, overhead racks & at all elevations, connecting with existingnozzles by welding flanges or threading or fitting, welding the elbows, reducers,tees, branch connections, reinforcement pads, flanges, gaskets, nuts, bolts, washers,providing necessary tapping for pressure gauges etc, hydrostatic testing of thepipeline to the specified pressure, rectification of any leakage & retesting of pipelinesto the specified pressure, draining of the water, providing all inputs such as labour,materials, equipments and consumables necessary to perform the work andcompleting the work in all respects in accordance with the drawings, specificationsand instructions of site engineer.

The scope of work also includes:

(a) Providing wrapping, coating of pipe lines as per enclosed specification Holidaytesting (spark test) 100% as per IS-4682 Section 5, Clause No. 20.2. Annexure F tobe conducted for coated pipes.

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(b) Excavation in any type of soil except hard rock to achieve clear cover of 1.0 Mtrover the pipes or as directed by Engineer –In-Charge, earth work for trenches &valve pits, dewatering, shoring, strutting if necessary, dressing of sides, levelingand preparing soft earth bed before lowering of pipeline.

(c) Welding of tie in pipe joint.

(d) Coating of joints and field bends with coal tar enamel coating as per specification.

(e) Back filling of soil and making the ground level after compaction.

Laying of underground piping using coated and wrapped pipes as above.

24 250 NB RMT 20

Erection of Fire fighting equipment

25150 NB Deluge Valves including all accessories like solenoid valves, pressuregauges, drain, vents, water-gong, air-filter-regulator and all other accessoriesprovided with the Deluge valve

Nos. 1

26 D.H. Hydrants Nos. 5

27 Water Monitors Nos. 5

28 Hose boxes with hoses Nos. 5

29 Erection of Fire extinguishers 10 kg Nos 10NOTE:-

(a)Fixing of all valves of any type, strainers, and other online equipments of 40 mm NBand below will be considered as a part of the respective pipeline for quantitycertification and hence will not be paid separately.

(b) All the valves have to be hydro tested before installation to a pressure of 16 kg/sq.cm.

Fabrication of Mitred Elbows, reducers, Tees etc. (Item Nos 30 to 31)

Transportation of pipes of all sizes from HPCL's store to work site / work shopand fabrication of mitered elbows, reducers and equal tees, wherever applicablefrom base pipe (HPCL's scope of supply) as per standards. Branching of a pipefrom a higher size pipe will neither be considered as a tee nor paid separately.

Supply includes all consumables and completing all such works in all respects as perthe specifications, drawings and as directed by Engineer-In-Charge. Electrodes shallbe as specified in item no.1 and 100% D.P. Test shall be carried out on all fabricatedfittings.Branch connection

30 150 NB Nos. 5

31 100 NB Nos. 5

Painting of Pipeline (For Item Nos 32 to 38)

Supply of complete materials for coating & painting and applying on all abovegroundcarbon steel pipes both Seamless and ERW, MS Pipes, equipment etc. conforming tothe specifications. Surface preparations for pipes, structure, equipment etc. includingnecessary tools and / or machinery for blast cleaning up to S 2.5 with approvedabrasive material shall be within the scope of Contractor and the rates quoted forpainting shall be inclusive of all such preparation prior to painting. Blast cleaning andPainting shall be done as per attached specifications.

Pipe size

32 250 nb RMT 325

33 200 nb RMT 50

34 150 nb RMT 50

35 100 nb RMT 150

36 80 nb RMT 410

37 50 / 40 nb RMT 250

38 25 nb & Below RMT 100

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39 Supply & Fixing of 15mm equal tees & quartzoid bulbs

Supply & Fixing of quartzoid bulbs using Teflon tape in the equal tees of size 15mmerected in compressed air line of 15mm at all elevations including cutting of thepipeline, welding of Tee at about 3M c/c in 15NB pipe as per detailed drawing.The compressed air line is to be hydrotested after fixing the tees at 12 kg / cm

2

pressure.

Nos 50

40 Supply & Fixing of 15mm Half coupling & Sprinkler nozzles

Supply & Fixing of Sprinkler nozzles using Teflon tape in Half couplings of size15mm erected in fire hydrant line of 50 / 32 mm at all elevations including cuttingof the pipeline, welding of Coupling about 3M c/c as per detailed drawing. Thehydrant line shall be hydrotested after fixing the coupling etc complete

Nos 50

SECTION III- SUPPLY OF MATERIALS (For Item Nos 41 to 68)

Supply of various Materials (for both process and utilities) as per type, specifications,sizes given below. Where THIRD PARTY INSPECTION is required, the same ismentioned against the item. Approved Third party Inspection Agencies are: BVIS /LLOYDS / BAXCOUNSEL / RITES / IRS / EIL

METALLIC GASKETS: TPI REQUIRED

S.S. metallic spiral wound gaskets dimensional standard API-601, 300 # RF,inner ring of SS with CAF filler and C.S. outer ring. (Gaskets shall confirm toSS304/0.175” thk spiral wound with compressed asbestos filter & 1/8” CS guideto be located within Bolts), of make IGP Engineers or approved equivalentmake.

41 250NB No 10

42 200NB No 10

43 150NB No 10

44 100NB No 10

45 80NB No 10

46 50NB No 10

CAF GASKETS: TPI not required

Supply of CAF gaskets of 3 mm thick cut to suitable size to suit the flangesdiameter with smooth finish of M/s Champion jointing limited make as per IS-2712 - 1979 Grade W/3 or equivalent.

47 250nb Nos 10

48 150nb Nos 10

STUD AND NUTS: TPI REQUIRED

C.S. high tensile stud with two hex nuts. Material A-193 Gr.B7/A-194 Gr. 2H.Dimensional standard ANSI B 18.2.1 & 18.2.2.

49 M28 x 170 Long Nos 100

50 M24 x 140 Long Nos 100

51 M22 x 140 Long Nos 100

52 M20 x 140 Long Nos 100

53 M18 x 120 Long Nos 100

54 M16 x 110 Long Nos 100

55 M14 x 90 Long Nos 100

56 M12 x 70 Long Nos 100

57 M10 x 70 Long Nos 100

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58 Supply of 3000# 1 side thrd Tee 15 NB Nos 40

59 Supply of 3000# 1 side thrd Elbow 15 NB Nos 40

60 Supply of MS ERW Pipe HD 50 NB MT 25



PRESSURE GUAGES: TPI REQUIRED

Supply of Weatherproof Pressure Gauges with IP 55 Protection having 15 mmMale connection from approved vendors of HPCL such as “PRICOL / GLUCK /M.GURU” (All glycerin filled).

63 Supply of Pressure Gauge 0-25 kg/sq cm (150mm dial) Nos 4



66 Reducer coupling S/w 25 x 20 Nos 20



Air Filter Regulators: TPI not required Nos 2

69Supply and fixing of Air filter Regulators of “FESTO” / “ROTEX” make with built inpressure gauge , Outlet pressure range - 10 kg/sqcm, inlet and outlet connection: 1/2inch BSP Female along with guarantee certificate from Manufacturer.

SECTION IV: MISCELLANEOUS WORKS

STRUCTURAL STEEL WORK

70 Structural steel

Supply, fabrication and erection of structural steelwork for pipe rack bridges, stairs,platform. walkways,, hand railings, and all types and sizes of pipe supports such asshoes, guides, saddles, cleats, stanchion, U-clamps, hangers etc., cutting, threadingand sizing to match the pipe line sizes from 15 mm to 600 mm with nuts, washers,bolts, machinery etc. contractor shall make necessary dimensional sketches ofsupports to suit the pipe line sizes and locations. All supports are to be erected inconsultation with EIC & from the general arrangement of piping drawings. Structuralsteel shall conform to IS: 2062. Note: Procurement of steel shall be done only afterwritten permission from the Engineer In charge as required at the site.

TM 3

71

Tubular Steel :Supply, fabrication and erection of all types and sizes of tubular/ steelfor fabrication of pipe supports such as shoes, guides, saddles, cleats, stanchion, U-clamps, hangers, overhead pipe racks etc., including gas cutting, bending to thespecified profile, cutting, threading and sizing to match the pipe line sizes from 15mm to 600 mm with nuts, washers, bolts, machinery etc. contractor shall makenecessary dimensional sketches of supports to suit the pipe line sizes and locations.All supports are to be erected in consultation with EIC & from the generalarrangement of piping drawings. Tubular steel shall conform to IS: 1161 unless otherspecified in drawing. Note: Procurement of steel shall be done only after writtenpermission from the Engineer In charge as required at the site.

TM 1

NOTE FOR ITEM NO: 70 & 71

All the nuts, bolts, washers, check nuts, expansion bolts etc. required for structuralsteel erection will be supplied by the contractor and these will be paid in kilograms atrates quoted for structural steel, hence bidder to quote accordingly.

72 Gratings

Supply, fabrication and erection of steel grating with hold fasteners including blindingof all cuts edges by welding suitable flat bars, to match the platform ladder tread etc.including painting with two coats of anticorrosive black paint over two coats of zincchromate red oxide primer of approved make and quality.

TM 0.5

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73

Chequered Plates : Supply, fabrication and fixing in position MS checkered plates 6mm thick welded or bolted in floors, platforms, stair steps, landings, including cuttingor opening etc. including painting with two coats of anticorrosive black paint over twocoats of zinc chromate red oxide primer of approved make and quality.

TM 0.25

74

Supplying and placing Foundation bolts: Supply and fabrication of foundation boltswith heavy hexagonal head nuts of various size and lengths including painting withtwo coats of synthetic enamel paint / aluminum paint over two coats of zinc chromatered oxide primer of approved make.

kgs 100

75

Supplying and placing U Bolts: Supply, fixing in position aligning galvanized CS ‘U’bolts (material IS: 2062 Gr. A/B) with two G.I. nuts and washers for clamping ofpipelines and washers of suitable diameters and lengths as per drawing / instructionof EIC.

kgs 100

76Supplying and placing Anchor fasteners: Supply, fixing of anchor fasteners 12mmdia x 100mm Long wherever required & as per instructions of EIC.

Nos 50

77Supplying and placing MS inserts in concrete like MS plates, angle channel, or anyother structural section as per specifications, and as directed by EIC

TM 0.25

78

Painting of tubular / structuralsteel: Painting of Structural / tubular Steel Supply of complete materials for coating &painting and applying on steel structures. Surface preparations for structuresincluding necessary tools and / or machinery for blast cleaning with approvedabrasives shall be within the scope of Contractor and the rates quoted for paintingshall be inclusive of all such preparation prior to painting. Blast-cleaning and Paintingshall be done as per attached specifications.

MT 3

Civil Jobs

Excavation works

Earthwork in excavation to the required profile for all types of soil (other than hardrock) including shoring, strutting, de-watering, if any, breaking the clods transportingthe excess excavated material within plant premises, including backfilling to therequired level & transporting including spreading the earth, leveling, etc. & includingsupply of labour, equipment, tools etc. complete as per drawings and directed byOWNER / CONSULTANT.

79 Depth upto 1.5 m CUM 100

Concrete Works

Providing, mixing and laying blinding layer of RCC / P.C.C. for any thickness belowfootings, for pipe supports / sleepers etc., at all depths & heights, with 40 / 20 mm anddown graded coarse aggregates including curing, shuttering etc. complete.

80 PCC 1:3:6 CUM 5

81 RCC 1:2:4 for Pipeline Pedestals etc CUM 50

82 Reinforcement TM 4

Supplying transporting, stacking, straightening, cleaning, cutting, bending, placing,tying in position (including providing 16 gauge annealed binding wire) reinforcementas per drawing, specifications & as directed by OWNER / CONSULTANTS (The rateshall be applicable for any height & depth). High strength deformed to IS 1786:1985 ,Fe 415

83Supply and fixing 20 mm dia MS Bar for pipeline pedestals including welding theanchor dowels, placing in position, aligning to required level, etc complete

TM 0.25

84Dismantling of Seamless pipelines of dia 150 & 100 mm including cutting, transportingto designated place inside the plant area, stacking etc complete. All LPG lines shallbe de-gassed, flushed with water etc before starting the hot work for dismantling

RMT 200

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85Dismantling of Seamless pipelines of dia 80 / 50 including cutting, transporting todesignated place inside the plant area, stacking etc complete. All LPG lines shall bede-gassed, flushed with water etc before starting the hot work for dismantling

RMT 200

86

Dismantling of Valves / strainers / NRV of sizes 200 & 150 mm dia from the linesincluding removing, transporting to designated place inside the plant area, stackingetc complete. All LPG lines shall be de-gassed, flushed with water etc before startingthe hot work for dismantling.

Nos 25

87

Modification of Seamless Pipe 250 & 200 NB Joints for installation of 4 way / 3 wayvalves including cutting the existing LPG lines, welding of Tee / elbow etc., welding offlanges, carrying out all tests etc complete. Installation of valves shall be paid as perrelevant item. Payment shall be made for every full joint which is cut andfinished with welding.

Nos 5

88


Nos 5

89


Nos 10

90

Modification of ERW Pipe 200 NB Joints for installation of valves including cutting theexisting pipe lines, welding of Tee / elbow etc., welding of flanges, carrying out alltests etc complete. Installation of valves shall be paid as per relevant item. Paymentshall be made for every full joint which is cut and finished with welding.

Nos 5

91

Modification of ERW Pipe 100/80 NB Joints for installation of valves including cuttingthe existing pipe lines, welding of Tee / elbow etc., welding of flanges, carrying out alltests etc complete. Installation of valves shall be paid as per relevant item. Paymentshall be made for every full joint which is cut and finished with welding.

Nos 10

92

Modification of ERW Pipe 50 NB & Below Joints for installation of valves includingcutting the existing pipe lines, welding of Tee / elbow etc., welding of flanges, carryingout all tests etc complete. Installation of valves shall be paid as per relevant item.Payment shall be made for every full joint which is cut and finished withwelding.

Nos 10

mechanical & piping works -...

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