Annex Ure i i Specific Requirements of the Contract

ENGINEERING SERVICES INDIAN OIL CORPORATION INDIAN OIL CORPORATION INDIAN OIL CORPORATION INDIAN OIL CORPORATION

LTD.LTD.LTD.LTD. PANIPAT NAPHTHA CRACKER

SPECIFIC REQUIREMENTS OF THE SPECIFIC REQUIREMENTS OF THE SPECIFIC REQUIREMENTS OF THE SPECIFIC REQUIREMENTS OF THE CONTRACTCONTRACTCONTRACTCONTRACT

RPNC101660RPNC101660RPNC101660RPNC101660 DATE OF DATE OF DATE OF DATE OF REV./REVREV./REVREV./REVREV./REV ANNEXUREANNEXUREANNEXUREANNEXURE----IIIIIIII 10.07.12 /00

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Specific Requirements of the Contract

Name of Work: Annual Rate Contract (ARC) for execution of Mechanical & Civil works for process modification schemes in Units areas (Part-A) and Offsite areas

(Part-B) of Panipat Naphtha Cracker. Following are the major jobs to be carried out in this contract.

�� Process modification schemes in Unit Area (Part-A) �� Process modification schemes in offsite and CPP Area (Part-B).

This Annexure containing ‘Specific Requirements of the Contract’ shall be read in conjunction with the other Technical Documents, Standards/codes mentioned herein and general contract conditions (GCC). Wherever any portion of the GCC and/or of other technical document and/or other standards/codes mentioned herein is repugnant to and/or at variance with any provisions of this annexure, then unless different intention appears, the provision(s) of this annexure shall be deemed to override the provision(s) of GCC and other technical documents and/or other standards/codes mentioned herein only to the extent that such repugnancy or variance cannot be reconciled with the provisions in GCC and other technical documents and/or other standards/ codes mentioned herein. This annexure shall also be considered as an extension or supplementary part to the ‘Schedule of Rates’ (SOR). Wherever in this annexure a mention has been made for contractor to be liable to arrange for and/or supply anything, and/or perform any work, it would be deemed that the contractor within the costs of the SOR items should discharge such liabilities, without any extra financial implication to the owner. If any contradiction appears between SOR and this annexure, the latter will supersede and shall prevail over the former, to the extent of such variance. The bidder should also possess the experience in civil works like pipe sleeper, foundation of rotary & static equipments etc. In case the bidder does not posses such experience in their own name then they can engage a back-up party who possess the experience of above civil works. 1.0 Brief Description of jobs:

The work in this contract is to be executed in Panipat Naphtha Cracker Complex. The completion time of the job shall be 12 month from the date of handover of site.However,In case the services were found satisfactory at the end of contract period,owner at their discretion may extended the contract for 12 month or part thereof at same rate and terms & conditions.Hence the quoted rate shall be valid for 24 monts. If required, Contractor has to work on Round – the-Clock basis to meet the completion target for which no extra payment will be made.





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2.0 Specific Requirements of the Job:

The following technical and commercial requirements are specific to this job and the contractor shall take note with attention and care, as no deviation shall be allowed during execution of the contract. Contractor shall be liable to arrange and engage without any extra financial implication to the Owner for the requirements mentioned hereunder as it shall be construed that the Contractor in the quoted rates of the concerned SOR shall have included costs of all such requirements.

2.1 The scheme job has to be executed simultaneously at number of places whereever

required. The contractor has to be accordingly be ready to mobilise for at least four places at a time, wherever job’s demands.

2.2 The Contractor shall be liable to engage only those welders, who are qualified and holders of valid certificate, issued by Inspection Department of any of the IOCL Refineries or EIL. In other words, the Contractor shall not waste time in getting his welders tested and qualified after mobilization at site. Otherwise the welder shall have to appear for the Welder’s Qualification Test as directed by our Inspection Deptt. Only IOCL qualified welder will be allowed to do job for this contract including the tacking job.

2.3 It shall be noted that the Contractor has to execute all the piping under the inspection of

Inspection Department of Panipat Naphtha Cracker. No inspection by any external body/agency shall be involved.

2.4 Major jobs involved in the contract are:

2.4.1 Execution of CS/AS/SS piping including handling / erection.

2.4.2 Dismantling of pipes.

2.4.3 Wrapping & coting of underground piping.

2.4.4 Fixing/Removal of Flanges & blinds.

2.4.5 Installation /Removal of Flanged Valves/Monitors/HVLRs etc.

2.4.6 Radiography.

2.4.7 Dye Penetrant Test.

2.4.8 Hydrotest of pipelines of the executed pipe & associated existing piplines.

2.4.9 Painting of pipelines and equipments, Gas cutting of CS/SS plates.

2.4.10 Fabrication and Errection of structurals like pipe supports,plateforms,davits,

Stairs,cage etc.

2.5 It shall also be noted that for the safety point of view, Argon welding may be done on

some joints in piperacks as per advice from production & execution deptt. It shall be construed that the Contractor has included in his quotation the costs for such argon welding. No separate payment will be made to the contractor.





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2.6 Wherever the Contractor shall be required to put up scaffolding for execution of many

kinds of activities required for the Jobs under this contract, it shall be construed that he has included the cost of all such scaffolding in his quotation. Prime responsibility of arranging the scaffolding material lies with the Contractor.

2.7 The contractor shall be required to mobilize all kinds of hauling equipment and crane for

erection of heavy static equipment. In case contractor wishes to take from owner any other crane or hydra, the same can be spared to contractor depending on availability and at the prevailing hire charges at the time of requisitioning.

2.8 The Owner shall try to provide electrical power generally at one locations in bulk. However, further distribution with all safety precaution is responsibility of the contractor. Arrangement of suitable distribution/switch board, cables etc. required for terminating the bulk supply is the responsibility of the Contractor .

2.9 For fabrication and installation of Metal Inserts that are supposed to be inserted into

RCC pipe supports, the Contractor shall be paid for the same by operating the item for Steel Structural.

3.0 Scope of Some Major Items:

3.1 Carbon Steel, Alloy Steel and Stainless Steel Piping:

These items are applicable for all sizes of pipes. The scope of this item includes performing all pre-fabrication activities like cutting, grinding, aligning, fitting-up, forming, shaping, welding, etc. under the stage-wise inspection of Owner’s Inspection Department / authorized Inspection Agency, handling & erection, aligning the pre-fabricated parts in position, completing each pipe-work from one termination point to the other as per satisfaction of engineer-in-charge.

The piping executed shall be paid based on the unit specified (running meter or joints) against each type (Hydrocarbon and Non-Hydrocarbon) and size in the SOR. The job shall be executed at all heights and shall be inclusive of the provision of scaffolding.

The scope of this item ( running meter or joint basis) will also include the following: –

i) Cutting of pipe threads on pipes up to 40 mm NB, wherever required. ii) Fabrication of odd-degree elbows of any size by cutting & grinding standard

elbows issued by owner.

iii) Handling, erection & alignment of the pipeline.





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iv) Cutting of all gaskets required in pipe work.

However, for the item being operated on running meter basis, the following additional activities is also included , without any extra financial implication.

a. Installation of socket welded valves of all kinds, in the pipe-work up to 40 mm NB including vents & drains.

b. Installation of orifice assemblies, pressure gauges, in-line strainers, line-mixers

and other in-line instruments. No separate payment will be made against the above-mentioned job elements, if not specified other wise. However, for piping modification involving less than 3 mts Piping/blinding of pipe with cap/ flange and fabrication of mitrebend and reducer, if required. The payment will be made on piping joint basis.

If welding operation is completed as per the approved execution drawing on any pipe-work that has to be modified or re-routed due to a fault not attributable to the contractor, the contractor has to modify or re-route the identified pipe-work once again as per the revised execution drawing and the payment for modification work will be made to the contractor based on the unit specified for each type and size. No separate payment will be made against cutting, handling, re-handling, positioning, aligning, grinding, etc., performed on the modified pipe-work. Within the scope of this item, the contractor will also be liable to furnish one copy each of all drawings issued, including the GAD and isometric drawing by the owner, duly incorporating all the changes actually effected while executing the piping work at site. Owner shall use these corrected drawings to prepare the as-built drawings for future record and reference. Owner shall withhold 5% (Five percent) of payment against this item till the contractor furnishes the above said corrected drawings. Type of joints and pipe-to-fitting joints for different sizes – Pipe-to-pipe joints up to 40 mm NB: Socket weld type Pipe-to-fitting joints upto 40 mm NB: Socket weld type Pipe-to-pipe joints and pipe-to-fitting joints: Direct butt weld type joints beyond 40

mm NB





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Note:

The owner shall Endeavour to supply all the bends & reducers, specifically in smaller sizes (up to 12"), that are required for the piping covered in this tender. For fabrication of bends / reducers in higher sizes, and in case bends or reducers are required to be fabricated for smaller sizes, by the contractor, then the following shall be the mode of payment For fabrication of mitre bends & reducers of all sizes in other areas of the project, the following shall be the mode of payment - Mitre Bends of 3 welds, 4 piece construction � Rate for pipe joint for corresponding size & material multiplied by 3. Mitre Bends of 4 welds, 5 piece construction � Rate for pipe joint for corresponding size & material multiplied by 4. Reducer (Concentric or Eccentric) � Rate for pipe joint of corresponding size & material multiplied by 2.25. Reinforcement pad � Rate for pipe joint of corresponding size & material multiplied by 2.

3.2 Installation / Removal of Valves:

This item will be operated for making payment towards installation of Gate, Globe, Ball and Check Valves at all levels as per the requirement of approved execution drawings beyond the size of 40 mm NB. The payment for this item shall be made based on the weight of the valves installed in the fabricated / erected pipe. An indicative weight of the different kinds of valves is given in the table No-1. Total weight of the valves in the fabricated / erected piping shall be calculated from the tables. For Monitors and HVLRs weight will be provided by our F&S.

3.3 Dye Penetrant Test:

The unit of payment for this item will be Inch Dia exposed to DP test. (Unit indicated as ” in the Schedule of Rates should be read as Inch Dia). This item will be operated as per the prescribed NDT Requirements pertaining to the piping classes and directions of Engineer-in-Charge.

3.4 Hydrotest of pipeline:

The scope of this item is as per the SOR. This item is applicable for testing of executed / existing pipelines.





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3.5 Radiography:

This item shall be operated on all butt-welded joints subjected to radiography as per the NDT requirements specified by inspection department, based on inch-diameter of piping radiographed. (Unit indicated as”in the Schedule of Rates should be read as Inch Dia). It may please be noted that radiography for all the joints, where heat treatment is required, is to be done after the heat treatment only (Post SR). If contractor, for their own convenience, will do the radiography before the heat treatment (Pre-SR), such radiography shall not be paid and the same has to be done by the contractor at their own cost, without any extra financial implication to IOCL.

3.6 Fabrication of reinforcement pad:

This item shall be operated during fabrication of reinforcement pad when a branch connection is to be provided from the main header. The rates of this item shall be paid based on the branch size and number of branch fabricated. The scope of this item includes cutting, grinding, edge preparation, preparation of hot jobs, welding, cleaning including testing and completion of the jobs as instructed by engineer-in-charge.

3.7 Painting (Pipes):

The job shall include supply of all raw materials like primer and finish paints of required specifications and other consumables, all tools & tackles, machinery, scaffolding materials, cleaning arrangements / materials, labour & supervision and all other enabling jobs to complete the work strictly as per technical specification of the tender. The job shall be carried out at all heights. The rates are inclusive of the cost of scaffolding. Following technical requirements shall govern-

1. The paint shall be procured only from Asian Paints, Berger Paints, Shalimar Paints and Jenson & Nicholson.

2. The paint shall be procured in sealed containers having the requisite stamp /

marking of the manufacturer. To ensure quality, before use the sealed containers will be checked by Owner’s inspectors or Engineer-in-charge.

3. The DFT (Dry Film Thickness) recommended by the manufacturer shall be strictly

maintained during painting. The total DFT shall be the manufacturer recommended DFT times the number of coats.

4. Bare lines shall be totally painted with Zinc Phosphate primer, and finish coat with

synthetic Enamel paint of the respective recommended shade.





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3.8 Fabrication & erection of pipe supports / Platforms / Davits / Stair case etc. :

This item will be operated for fabrication and installation of structural work in all platforms, non-integral pipe support (supports which are not directly welded to pipe), pipe crossover, stairs, walkways, etc. This item will also be operated for all kinds of general structural work and pipe supports that are not directly welded to pipe line or pressure vessel. The pipe support beams or other kinds of pipe support structure may be required at any height. All these steel works shall be paid for against this item. This item does not include supply of MS Structural Steel plates / sections, etc. Owner shall supply structural steel as free-issue items.

This item will be operated for fabrication and installation of rotating equipment

3.9 Wrapping / Coating of U/G piping :

This item will be operated for wrapping /Coating of U/G piping wherever required.Wrapping /Coating will be done on all the mentioned pipe sizes as detailed in SOR and as per directions of E-I-C..





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Table – 1

a): Approx. Weight of Carbon Steel Gate valves

Valve

Class 150 Class 300 Class 600 Class 900 Class 1500

Size Approx.Wt. Approx.Wt. Approx.Wt. Approx.Wt. Approx.Wt.

Fl. B/W Fl. B/W Fl. B/W Fl. B/W Fl. B/W

50 (2”) 21 19 25 23 42 36 - - 128 115

65 (21/2”) 32 27 48 34 - 138 126 255 245

80 (3”) 35 27 53 41 67 63 216 196 315 285

100 (4”) 53 43 78 55 119 112 426 375 643 570

125 (5”) 75 64 135 105 - - 723 625 1258 1120

150 (6”) 87 77 158 111 252 225 1173 1040 2008 1760

200 (8”) 139 118 234 186 418 365 1792 1610 2963 2580

250 (10”) 210 198 355 284 652 554

300 (12”) 302 271 495 400 1100 984

350 (14”) 410 365 750 620 1600 1465

400 (16”) 520 490 958 850 1955 1760

450 (18”) 690 665 1310 1075 2075 1840

500 (20”) 900 865 1640 1525 2150 1960

600 (24”) 1410 1375 2460 2075 3620 3180 * Depends on flange dimentions ** Fl-Flanged; B/W- Butt Weld. *** Weights are in kg

b): Approx. weight of Carbon Steel Globe Valves

Valve Class 150 Class 300 Class 600 Class 900 Class 1500

Approx.Wt. Approx.Wt. Approx.Wt. Approx.Wt. Approx.Wt.

Size FL B/W FL B/W F/L B/W FL B/W FL B/W

50(2”) 23 20 33 28 42 38 - - 110 85

65 (21/2”) 35 - 46 - - - 138 120 255 195

80(3”) 41 38 58 50 75 60 216 180 315 265

100(4”) 66 62 97 84 136 116 426 395 - -

150(6”) 118 110 186 164 245 195

200(8”) 207 195 329 296 546 466

250(10”) 335 320 520 471 756 656

300(12”) 495 470 705 634 1086 896 * Fl-Flanged; B/W- Butt Weld. ** Weights are in kg NOTE: For Ball Valves, same weight as of globe valve may be considered for the purpose of payment.





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c ): Approx. weight of Carbon Steel Check Valves

Valve Class 150 Class 300 Class 600 Class 900 Class 1500

Approx.Wt. Approx.Wt. Approx.Wt. Approx.Wt. Approx.Wt.

Size Fl. B/W Fl. B/W Fl. B/W Fl. B/W Fl. B/W

50(2”) 21 19 24 19 35 30 - - 69 53

65(21/2”) 24 20 - - - - - - - -

80(3”) 34 30 45 36 55 46 88 70 118 89

100(4”) 49 42 70 56 92 70 162 131 177 134

150(6”) 88 79 151 129 204 161 336 275 566 467

200(8”) 168 154 242 210 323 260 673 569 892 728

250(10”) 280 260 333 284 550 455 938 789 1730 1447

300(12”) 413 382 450 378 790 680 1480 1280 2580 2157

350(14”) 509 466 659 556 - -

400(16”) 580 524 873 747 - -

450(18”) 635 583 1090 900 - -

500(20”) 925 855 1360 1176 - -

600(24”) 150

0 1403 1850 1573 - - * Fl-Flanged; B/W- Butt Weld. ** Weights are in kg ***Swing Check valve is considered.

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(Confirmed & Accepted by Bidder)