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SPECIFICATION OF FABRICATION OF HIGH PRESSURE SYSTEM IN MAIN

EJECTOR DRIVE GAS CIRCUIT INCE-20 HAT FACILITY

1.0 INTRODUCTION

The ISRO Propulsion Complex (IPRC) is involved in testing of Cryogenic and earth

storable engines and stages for ISROs space program. In this regard, for conducting

development and acceptance testing of CE20 Engine, CE-20 HAT Test facility is already

established at Mahendragiri. The main system of the facility is Vacuum system, Diffuser

Ejector system and cooling water system

The augmentation work is planned in Main Ejector drive gas system which consists of

High Pressure GN2 cylinders of 2 m3 capacity, High Pressure Pipe lines, Fluid

components, and low pressure pipe circuits. This Fluid circuit is connected with the Main

Ejector which will be operated during the HAT test to create vacuum. In order to carryout

this augmentation of these circuits pipes, Fittings and flow components are procured from

various agencies.

The main objective of this piping contract is to carry out insitu fabrication, erection,

testing of fluid circuits with pipes and flow components. These works will be carried out

under the supervision of IPRC Engineers.

In general, the Contractor‟s scope of work shall comprise the following, however the

detailed scope of work including the work quantity are given in SECTION 3 respectively.

:

Deployment of man power and equipments/tools/consumables required for

completion of the works under the contract.

Transportation of Free issue materials from department‟s stores to work site.

Erection and commissioning including alignment of high pressure cylinders in the

approved site

Fabrication & welding of pipe lines with existing pipe circuits and erection of flow

components.

Co-ordination for inspection (stage & final) with Quality control division of IPRC

and completion of fabrication & testing of piping.

Necessary documentation such as preparation of as-built pipeline layout &

isometric drawings, etc.

Some of the Key Words Used in this Document are Defined as Follows:

“Department” shall mean and include the President of India acting through the

Director, IPRC and any representative(s) of the Department duly authorised on his

behalf.

“Bidder” shall mean the individual or firm or company whether incorporated or

not, chosen by the Department to this tender enquiry.

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“Contractor” shall mean the individual or firm or company whether incorporated or

not, chosen by the Department for under-taking the works and shall include the

legal personal representatives of such individuals or the persons composing such

firm or company, or the successors of such firm or company and the permitted

assignee of such individual or firm(s) or company.

“Contract” shall mean the formal agreement to be executed between the President

of India and the bidder, whom the Department may choose, based on the

documents forming this tender enquiry and acceptance thereof by the bidder and

together with the documents as referred to therein including the specifications,

designs, drawings and instructions issued from time to time by the Department.

“Site” shall mean the land and or other places at Mahendragiri on which work is to

be executed under the contract, which may be allotted by the Department for the

purpose of carrying out the work.

“Free Issue Materials” shall mean all the items required for realising work,

including raw materials, semi-finished & finished products & sub-assemblies,

which are supplied by the Department or their sub-contractors or bought-out from

their sub-vendors, such as flow components, pipes, pipe fittings, instruments and

consumables.

“Contract Manager” means the engineer, who is responsible for the execution of

the work under this contract on the part of Department.

“Inspector” shall mean the representative of Quality Control wing (QC-AIT) of

the Department.

2.0 SITE LOCATION AND CLIMATIC CONDITIONS

SITE LOCATION

The works are to be carried out, at CE-20 HAT facility which is located at TCT in ISRO

Propulsion Complex (IPRC), Mahendragiri, Tirunelveli District, TamilNadu.

IPRC, Mahendragiri is situated at Kavalkinaru, Tamil Nadu which is about 60 Km from

Tirunelveli and at about 20 Km from Nagercoil. The site is on Madurai – Kanyakumari

National Highway (NH7). At Mahendragiri, CE-20 HAT facility is located at about 4km

from the Main Entrance and is connected by black topped road of minimum width of 3.5

meters with one meter berm on either side.

CLIMATIC CONDITION

CE-20 HAT is in a hilly terrain at an elevation of about 157.5 meters above MSL. The

climatic conditions at Mahendragiri are tropical and windy with occasional gusts. The

maximum wind speed is 120km/hr with 3 sec, gust. Normal monsoon period is June-July

and October- November. The contractor will have to provide protective arrangement

against wind, and rain which they may think necessary, to carry out the work

continuously.

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3.0 SCOPE OF WORK

3.1 GENERAL

The scope of work of this contract in brief, includes the following.

Transportation of free issue materials from Department‟s storage yard to

work site.

Erection of high Pressure cylinders.

Mounting of prefabricated Manifolds, brackets, etc.

Fabrication, welding (SS & CS), cleaning, radiography, installation and

testing of pipe lines for High Pressure system as per the General Fabrication

Procedure given in the contract document.

Fabrication of structural (MS) supports, access platforms and cross over

bridges based on the site condition.

Providing minor civil works like construction of pedestal for pipe supports,

excavation of existing concrete floor & pavements, grouting, etc.

Providing static electricity earthing for the pipe lines.

Painting of structures and supports and colour coding of pipe lines.

Preparation of as built piping layout and Isometric drawings.

Documentation

3.1.1 RESPONSIBILITY OF CONTRACTOR

The responsibility of the contractor includes, but not limited to providing the

followings;

Deployment of labourers like helper, welder, fitter, rigger, supervisor, works

manager, etc in sufficient numbers to complete the works within the

stipulated time.

Transport vehicles for contractor‟s labourers, equipments & materials.

Construction of temporary shed/room for carrying out fabrication works and

storage of tools, welding machine, dark room for radiography, etc.

Trucks, cranes, fork lift, chain pulley block, slings, hooks, metal ropes, etc.

for transporting the packages & materials from Department‟s storage yard to

work site.

Tools and tackles for the installation of pipe lines and flow components at

work site.

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Welding machine (TIG & Arc), drilling machine, grinding machine, pipe

bending machine, etc.

Equipments and materials for radiographic testing such as X-ray machine /

Gamma ray source, penetrameter, X-ray film, etc.

Consumables such as Argon gas, Oxygen gas, Acetylene gas and LPG for

welding, filler wire, electrodes, wire brush and hack saw blades, etc.

Consumables such as cleaner (acetone),dye, developer, etc. for Dye-Penetrate

(DP) testing.

Chemicals (Iso Propyl alcohol) for degreasing.

Chemical for Pickling & Passivation.

Necessary clamps, packing materials (CAF sheet) to be placed between

clamps & pipe and pipe & pipe supports, etc.

Supply of structural materials, fabrication and erection of structural supports,

access platforms, etc.

Construction of earth pit including supply of required materials.

Supply of earthing strips and pipes (G.I/Aluminium material) and providing

static electricity earthing.

Minor civil works such as construction of PCC, RCC pedestals &

foundations for pipe supports, including supply of materials, etc.

Painting of structures, colour coding of pipes including supply of primers and

paints, etc.

3.1.2 RESPONSIBILITY OF DEPARTMENT

Furnishing of piping layout and isometric drawings.

Identifying working space for construction of temporary shed/room for

storage of contractor‟s tools machines, etc.

Supply of Pipes, Fittings & Flow components.

Supply of Gaseous Nitrogen (GN2) for pneumatic testing and Gaseous

Helium (GHe) for MSLD leak testing.

Supply of electricity on free of cost.

Supply of water on free of cost.

Inspection by Quality Control (QC) division & site supervision by

Department.

3 DETAILED DESCRIPTION OF WORKS

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3.1 GENERAL

This portion of the Contract deals with equipment mounting, pipeline fabrication &

erection and testing of Main Ejector Drive Gas Circuit. The Main Ejector Drive gas

System consists of

High Pressure Cylinders (GN2)

High Pressure Circuits (400 bar)

Low Pressure Circuits

Charging side Circuits

TEG Ejector Circuits

Main Ejector

The free issue materials required for piping works such as equipments, components,

pipes and fittings are to be taken delivery from the stores of the Department and

transported safely to the site by the contractor. The scope of work in this contract in brief

includes the following. However the details of each work are dealt in the respective

sections of subsequent pages.

3.2 PIPING LAYOUT & ISOMETRIC DRAWINGS

The complete set of piping layout drawings and Isometric drawing shall be provided at

the time of execution of the contract. The pipelines are to be laid at the ground level,

over the pedestals provided and on the test stand structure at different elevations. The

complete piping layout will be supplied to the contractor at the time of execution of the

contract. The contractor shall prepare the isometrics based on the piping layout supplied

to them.

The pipe segments of length varying from 2 to 6 meters will be supplied and they shall

be fabricated to the required length for installation. Elbows, bends and Tee connections

are to be welded with the pipe lines wherever they are required. Mitre joints shall be

provided with the approval of the department wherever standard elbows and bends are

not supplied. The weld joints are described in the piping layout/Isometric drawings

distinctly. At ground level, concrete pedestals embedded with mild steel plates are to be

provided for supporting the pipelines. The support elements such as MS angles /

channels have to be welded on the embedment in the concrete floor/pedestals.

The pipeline supports shall be provided as per the details given in the piping layout

drawings. Wherever such details are not specified, the supports shall be provided in

general for every two metre length of pipeline and essentially near the elbows/bends/Tee

connections with the approval of the department.

3.3 DETAILS OF WORK.

3.3.1 ERECTION OF HIGH PRESSURE CYLINDERS

The High Pressure GN2 cylinders of 2 m3 capacity, 400 bar(a) (along with the support)

weighing 4 tonne is to be erected on the RCC foundation provided at CE-20 HAT

facility. The overall dimensions are given below. All the materials as listed below

including the Cyinders will be supplied by the Department to the contractor on free of

cost.

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SL DESCRIPTION OVERALL SIZE (mm) QTY

1 GN2 cylinders Ø559 mm OD x 10885 mm length 72

nos

2 Assembly frames with

brackets 760 mm X 660 mm

72

nos

3 Withdrawal side

manifold 4

The scope of work includes moving the cylinders nearer to the existing pedestal, making it

horizontal, position it on the existing foundation pedestal, final alignments and mounting

of all accessories. The price agreed upon under this heading shall be lump sum for all the

works including the erection of cylinders, its prefabricated manifolds, structural supports,

conducting leak check after alignment, Truck for transportation, suitable Cranes for

material handling, along with operators, labourers and other tools & tackles shall be

arranged by the contractor.

The Department has already constructed a RCC foundation pedestal for the erection of

cylinders. At present 32 cylinders are in assembled condition with pipe lines at a distance

of 100 m from the foundation pedestal. The remaining 40 cylinders are kept in the storage

yard which is 3 km away from the pedestal. The cylinders are to be positioned

horizontally on the RCC foundation provided at the Facility. The foundation is located

near the CE-20 sea level bay in TCT. The necessary tools, equipments/lifting mechanisms,

metal shims, etc shall be arranged by the contractor for the alignment of cylinders. The

procedure for handling & erection shall be prepared by the contractor and submitted to

Department at the time of erection work. After getting approval from the Department, the

contractor shall execute the erection work.

3.3.2 Requalification of Cylinders

The scope of work includes disassembly of 32 cylinders from the existing high pressure

circuit and transports the cylinders to the requalification facility which is 3 km away from

the test stand. The 40 no‟s of GN2 cylinders which are kept ½ kms from the

requalification facility to be transported to requalification facility. All the 72 nos of re-

qualified cylinders shall be transported to the cylinder yard for erection. The necessary

tools, equipments/lifting mechanisms, metal shims, trucks etc shall be arranged by the

contractor.

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3.3.2 WORK QUANTITY

The quantity of work under each work item is given below; such as, the pipeline

fabrication, erection of flow components, welding, cleaning, etc shall be carried out as per

the General Fabrication Procedure given under Section No.5 of the contract document.

Estimation of Fabrication activities in High Pressure System

Work

Item Description of work

Schedule

number

Unit of

Measurement Estimated Qty.

1. Erection of Cylinders Ton 350

2. Erection of Flow

components Ton 24

3. SS butt welding and

DPT Sch40/40S

Inch- Diameter

joint 3100

4. SS butt welding and

DPT Sch 80/80S

Inch- Diameter

joint 80

5. SS butt welding and

DPT Sch 160

Inch- Diameter

joint 1200

6. SS butt welding and

DPT Sch XXS

Inch- Diameter

joint 250

7. SS butt welding and

DPT

250NB

50mm tck

Inch- Diameter

joint 750

8. SS butt welding and

DPT

150 NB, 30 mm

tck

Inch- Diameter

joint 600

9. SS butt welding and

DPT

DN100

25mm tck

Inch- Diameter

joint 200

10. SS tube butt welding &

DPT

Tube OD ≤ OD

8.0mm Per joint 100

11. SS tube butt welding &

DPT

OD 10.0, 12.0

& 12.7mm Per joint 150

12. SS Socket welding and

DPT including tubes Sch40/40S

Inch- Diameter

joint 500

13. SS Socket welding and

DPT Sch 160

Inch- Diameter

joint 500

14. SS Socket welding and

DPT

Sch XXS &

higher thickness

Inch- Diameter

joint 500

15. SS mitre welding and

DPT Sch40/40S

Inch- Diameter

joint 300

16. CS/MS butt welding

and DPT Sch40/40S

Inch- Diameter

joint 200

17. CS/MS butt welding

and DPT Sch 80/80S

Inch- Diameter

joint 200

18. Mobilisation charges

for X-ray radio -

graphy / Gamma ray

- Lump Sum 10

19. Radio-graphic test with

X-ray / Gamma ray Sch40/40S

Inch- Diameter

joint 3120

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20. Radio-graphic test with

X-ray / Gamma ray Sch 80/80S

Inch- Diameter

joint 100

21. Radio-graphic test with

X-ray / Gamma ray Sch 160

Inch- Diameter

joint 1200

22. Radio-graphic test with

X-ray / Gamma ray Sch XXS

Inch- Diameter

joint 250

23. Radio-graphic test with

X-ray / gamma ray

DN250

50 mm tck

Inch- Diameter

joint 750

24. Radio-graphic test with

X-ray / gamma ray

DN 150, 30 mm

tck

Inch- Diameter

joint 600

25. Radio-graphic test with

X-ray / gamma ray

DN100

25 mm tck

Inch- Diameter

joint 200

26. Hydraulic Pressure test - Inch-metre 1200

27. Pneumatic Pressure test - Inch-metre 1500

28. Chemical cleaning - Inch-metre 1800

29. Installation of pipelines - Inch-metre 1800

30. Painting of surface with

primer & enamel paint

using brush

- Squared metre 50

31. Dismantling of pipeline

assemblies - Inch-metre 2500

32. Retrieval of pre-welded

fitting and components -

Inch-diameter

joint 5000

33. Fabrication of

structural works - Kilogram 7500

34. Fabrication of

structural works with

material supply

- Kilogram 2000

35. Dismantling of

structural material - Kilogram 5000

36. Minor civil works -

PCC - Cubic metre 5

37. Minor civil works -

RCC - Cubic metre 5

38. Lettering on flow

components/

equipments

- Height of letter£

40 mm 1000

39. Lettering on flow

components/

equipments

-

Height of letter

> 40 mm & £

100 mm

1000

40. Lettering on flow

components/

equipments

- Height of letter

> 100 mm 1000

41. Pipe bending - Inch diameter 130

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4.0 INSPECTION & QUALITY CONTROL

4.1 GENERAL

All the works under this contract shall be inspected by the QC-CEIT wing of department.

Works under this item comprise inspection, mounting and alignment of equipments and

components, complete piping works. Inspection of mounting works includes checking,

measuring and marking of co-ordinates, equipment leveling, leak checking etc. Inspection

of piping works include stage by stage inspection of handling, cleaning & degreasing,

rigging, all procedures adopted in weld joint preparation, filler wire material, alignment of

pipes, fit-up welding, fabrication, fixing of supports, installation and testing of all the pipe

lines as per the drawings supplied by the department or supplied by the contractor which

are duly approved by the department.

This also includes the verification of procedures, techniques and methodology adopted by

the contractor in the DPT and radiographic examination of weld joints, checking the

radiography films, checking of weld joints, Dye Penetrant Test(DPT) of the weld joints,

etc. All procedures involved in the total piping fabrication, erection, testing and

commissioning shall be submitted in the detailed form to QC-CEIT wing of department

for checking of compliance with the relevant codes and standards and acceptance.

However, the department has the final authority to issue written approval, clearances and

certificates of the work in consultation with the contract manager wherever necessary.

4.2 WELDING PROCEDURE AND WELDER PERFORMANCE

Welding procedure & welder performance qualification tests shall be carried out in

accordance with section IX of ASME. The procedure qualification & welder qualification

tests have to be conducted for welding of the following similar / dissimilar materials. The

welder qualification and weld procedure qualification test shall be carried out under the

inspection of Quality Assurance (QC-CEIT) wing of department.

Materials required for the qualification tests namely pipes and filler wires shall be

arranged by the contractor.

The size of pipe welds range from 6mm NB to 300mm NB and thickness of the pipes

range from 1 mm to 50 mm. Welding procedure & welder qualification tests have to be

carried out with pipes of as recommended by QC-CEIT. High Pressure pipe fabrication

shall be carried out as per chapter IX of ASME B 31.3. Test procedure, specimen

preparation, NDT testing, tensile test, bend test etc shall be done as per sec IX of ASME

and any other requirement specified by the department at the time of execution of the

work.

4.3 INSPECTION

Inspection of welding works will be carried out generally in the following manner:

Preliminary check

Checking of welding procedure

Checking of the quality of weld joints

Preliminary checks

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Checking of the engagement of qualified welder for the work. Checking of the

qualification or other allied operating personnel.

Checking the state of the appliances, instruments and devices used for welding

and inspection.

Checking the quality of welding materials, their correspondence with the

certificates and their storage conditions.

Checking the quality of preparation of the weld joint. Measuring the weld

geometry and checking the fit-up assembly for conformance to the required

norms.

Checking of Welding Procedure

Checking of the adherence to the qualified procedure.

Monitoring and Recording all the essential parameters for each weld.

Checking the quality of the weld joints

External inspection of the weld joint.

Dye penetrant test.

Radiography examination.

Pressure testing for the qualification of weld joints

4. 4 NORMS OF QUALITY CONTROL

4.4.1 GENERAL CONDITIONS

All weld joints shall be subjected to external examination to detect weld

defects.

The quality norms with acceptance limits for external examination of piping

are as per ASME.

All the SS Butt Weld joints shall be subjected to 100% X-ray examination.

CS Butt Weld joints shall be subjected to 10% X-ray examination. Such weld

joints will be identified for test by the inspection personnel of the Department.

Radiography examination of the weld joints shall be done only after

elimination of defects detected by the external inspection.

- The heat affected zone adjacent to the weld joint for a minimum of 20 mm on

either side of the weld shall also be subjected to inspection.

- The visual inspection of the weld joints shall be performed for the complete

length using magnifying glass with a minimum of 4 times magnification. The

weld joint shall also be inspected internally wherever it is accessible.

- Radiography examination of the weld joints shall be done only after

elimination of defects detected by the external inspection.

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- The quality of welds made for pipe supports and welds inaccessible for

radiography shall be ensured by means of checking of preparation of edges,

weld geometry, welding procedure, and DP testing and external inspection.

4.5 ELIMINATION OF WELD DEFECTS

- Elimination of weld defects shall be carried out operation by operation in the

presence or with the concurrence of the inspection personnel and the

supervising agency.

- The acceptance norms specified for the weld joints are applicable for the

rectified weld joint also.

- The weld joints which are found to be defective in X-ray examination or

strength test or leak test or vacuum leak proof ness test shall be subjected to

the same type of check/testing repeatedly after rectification work until all the

checks / tests are passed successfully.

- The elimination of such defects which are not defined in this document shall

be done as per the norms stipulated by the inspection personnel consultation

with the supervising agency at the time of execution of the work.

- Length of the defective segment is to be determined before preparation of the

edges for re-welding and the width of the edge preparation is determined by

the nature of the defect.

- Width of the weld after re-welding shall not exceed double the width of the

weld existed earlier.

- Weld sagging, under cuts and hollows between beads shall be eliminated by

welding again over the defective place after polishing such spots to get bright

metallic surface.

- For repairing joints with incomplete fusion, inclusions, cracks etc. (internal

weld defects) the material shall be removed till the defects are completely

eliminated from the job and then re-welding shall be done.

- The repair of weld joints by re-welding at the same place is allowed only up to

2 times.

- After elimination of defects, the pipeline shall be purged with GN2.

- During repair works in the defective joints, ensure chips, dust and other

contaminations do not enter into the pipelines.

- Subject the repaired welds to repeated checks as well as tests for strength, leak

proofness etc.

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-

5.0 GENERAL FABRICATION PROCEDURE

5.1 PIPE BENDING

The rate shall be quoted per pipe/tube bend for different sizes. The rates shall be

quoted separately for each group of schedules /thickness.

The work under this item covers all operations necessary to produce satisfactory pipe

bends up to 90o with stainless steel pipes/tubes. Works involved under this item shall

be handling, measuring, setting-up, supply and operation of hot and cold bending

equipments, etc. The contractor shall normally be permitted to carry out “Cold”

bending. However, the Department reserves the right, in certain instances, to call for

hot bending. Unless otherwise specified, all bends shall be formed with a radius

measured to the centre line of the pipes equal to three times the nominal pipe

diameter. The quantity for payment under this category shall be the number of bends

finally made as required by the Department irrespective of process.

5.2 WELDING AND DP TESTING

The scope of work for weld joints includes all operations associated with making each

joint, including cleaning, marking-out, cutting, profiling, bevelling, grinding, aligning,

fitting-up, tack welding, cleaning, chipping, pre-heating (if necessary), placement of

wind shields, weather protection, necessary scaffolding if any and final welding

together with final cleaning of welds, post-heating and DP testing. The choice, grade

and make of the welding electrodes and filler wires shall got approved by the Quality

assurance wing(QC-CEIT) of the Department.

After tack-welding, the alignment of the fit-up shall got approved by Quality division

of the Department before proceeding with final welding. DP testing shall be carried

out for the root and final passes of the welding in the presence of Quality assurance

(QC-CEIT) of the Department. Welding rods, filler wires, argon purging gas and

chemicals required for DP testing, Acetone cleaner, SS wire brush, dye, developer, etc

shall be brought by the contractor and be included under this item.

5.2.1 STAINLESS STEEL BUTT WELDING

The welding shall be carried out by gas-purged Tungsten Arc Welding (GTAW/TIG)

process with Argon gas (purity 99.99%) purging both inside and on the weld zone in

outside of the pipe. The following welding is typical, but not limited to the work

covered by this item:

a. Pipe to butt weld fittings and flow components

b. Butt weld fittings to butt weld fittings and flow components

c. Pipe to pipe and half sleeves of pipes

5.2.2 STAINLESS STEEL SOCKET WELDING

The welding shall be performed by (GTAW/TIG) process with Argon gas purging on

the weld zone in outside surface of pipe. This welding involves, but not limited to

welding of straight pipe to socket weld fittings, valves and half sleeves of pipes.

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5.2.3 STAINLESS STEEL MITRE WELDING

This work involves all the operations including bevel-cutting of pipes to the required

number & angle and welding the bevel-cut pieces to form a bend. The final bend

angle may be required up to 90o. One “Mitre joint” means making a bend up to 90

o by

welding together 2 or more bevel-cut pieces, as may be required. The rates quoted per

“Joint” shall include the number of bevel-cuttings and the number of welds required to

make a bend. The welding shall be performed by (GTAW/TIG) process with Argon

gas purging both inside and outside the pipe.

5.2.4 CARBON/MILD STEEL BUTT WELDING AND DPT

The root pass shall be carried out by TIG welding process with complete purging

inside the pipe with argon gas. After the DPT clearance of the root subsequent passes

of the welding shall be carried out by Shielded Metal Arc Welding (SMAW). The

following welding is typical, but not limited to the work covered by this item:

a. Pipe to butt weld fittings and flow components.

b. Butt weld fittings to butt weld fittings and flow components.

c. Pipe to pipe.

5.3 RADIOGRAPHY

The rates shall be quoted per weld joint /Inch Dia radio graphed for different range of

sizes, but irrespective of schedules and material. The mobilisation charges for the X-

ray machine shall be quoted separately.

This item is indented to cover all the operations and arrangements such as supply of X-

ray machines, penetra-meters, screens, films, necessary scaffoldings if any, etc.,

required for performing radiography of welds. 100% of the stainless steel butt weld

and mitre weld joints along with heat affected zone shall be radio graphed.

Radiography shall be conducted as per the relevant procedures and codes. In all

radiography films, 2-2T sensitivity level shall be achieved. The quoted rates shall

include supply of good quality film and developing charges of film. The developed

film shall be handed over to the Department with the joint identification number

marked on the film. During the inspection, if any defect is found, it shall be the

responsibility of the contractor to rectify the defect or re-execute the work with out

additional charge for both welding and radiography.

It is required to carry out the radiography of joints using X-ray machines only. The

joint(s) which are inaccessible for X-Ray machine shall be carried out by Gamma-Ray

source of 2-2T sensitivity level. However the decision (“inaccessible for X-Ray”)

shall be taken only by the Department.

5.4 INSTALLATION OF PIPELINES

The work covered under this item include all the works required for proper installation

and testing (hydro or Pneumatic) of pipelines, such as transportation, handling, rigging,

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scaffolding, lifting and alignment of pipes with flow components and fittings in their

respective positions and on to their respective supports and temporary connections

made for testing.

The work also involves connecting pair of flanges such as the flange between a pipeline

and a flanged valve by tightening the fasteners and screwing the threaded fittings like

pressure gauges, threaded interface valves, adaptors, etc, with a mating component.

However, the weld joints will be paid separately under the heading welding and DP

testing. There shall be no limitations on the number of flanged or threaded connections

per metre length of the pipe line installed.

The installation of pipelines at test stand structure shall be carried out at an elevation

ranging from test stand pavement level to 30m level at different orientation / positions.

It is the responsibility of the contactor for arranging tools, tackles and necessary

scaffolding if any for completing the work.

The pressure test of pipe lines shall be carried out either by water or by gaseous nitrogen

at ambient temperature. The decision for Hydro test or Pneumatic test will be taken by

the Department. Department on free of cost will supply required water and Gaseous

Nitrogen at a specific point. It is the responsibility of the contractor to bring all materials

required for Hydro/Pneumatic test such as pressure regulators, manifolds, hoses,

adaptors, hydro test pump etc,. Snoop solution required for finding leak in joints during

pneumatic test will be provided by the Department.

No payment will be made for the temporary scaffolding for installation and temporary

Pneumatic / Hydraulic connections made for testing. The payment for the work

done under this item will be made only when the pipe line is properly located ,

permanently supported and tested (Pneumatic /Hydro) in its final position in the field.

The rate shall be quoted for metre length of different range of sizes of pipeline actually

installed and tested.

5.5 INSTALLATION OF FLOW COMPONENTS

Installation of all flow components such as E.P valves, manual valves, control valves,

filters, flow meters, etc. is based on their weight. The installation charges shall not be

paid for flow components weighing less than 100 kg.

The weight for each flow component will be provided by the Department from the

records of sub-vendor from whom the flow components were bought. If the contractor

is not agreeing the weight provided by the Department, then it shall be the

responsibility of contractor to arrange for weighing the flow component using a

standard weighing machine / method agreeable to Department before commencing the

installation.

The work shall include transportation, handling, rigging, scaffolding, lifting and

alignment of flow components with pipes and fittings in their respective positions and

on to their respective supports. The installation of flow components at test stand

structure can be carried out at an elevation ranging from test stand pavement level to 6

m level at different orientation / positions. No payment will be made for the temporary

scaffolding for installation and temporary Pneumatic / Hydraulic connections made for

testing. The payment for the work done under this item will be made only when the

flow component is properly located , permanently supported and tested (Pneumatic

/Hydro) along with pipeline in its final position in the field.

15

5.6 CHEMICAL CLEANING

The rates shall be quoted to `inch-metre‟ of the pipeline cleaned. The rates quoted

shall include the cost of all chemicals, SS wire brushes, pumps etc. After

hydrostatic/pneumatic testing, the surfaces of all stainless steel pipelines shall be

cleaned as per the following procedure:

5.6.1 MECHANICAL CLEANING:

All the metallic surfaces with scales and newly welded surfaces shall be cleaned by

scrubbing with stainless steel metallic wire brush.

5.6.2 PICKLING:

This is done to remove rust and scale. This is done by cleaning with water, followed

by pickling with a solution containing Hydro-fluoric acid (HF) and Nitric acid

(HNO3).

The composition of the pickling solution and duration are adjusted after trial test on a

sample piece to remove uniformly less than 25 micron thick material. Mostly the

composition is

HF : 5% (by mass)

HNO3 : 15 to 20 %

Water : Remainder

This is followed by rinsing with water.

5.6.3 PASSIVATION:

It is done with a solution of the following composition

HNO3 : 25% (by volume)

Water : 75 %

Duration : 2 hours (minimum)

This is followed by rinsing with clean water. The supply of clean water is under the

scope of the Department. The litmus paper required for checking the PH of rinsed-out

water is also under the scope of Contractor.

5.7 RETRIEVAL OF PRE-WELDED FITTINGS AND FLOW COMPONENTS

The work shall involve removing the weldment by grinding between the pipes, fittings

and flow components from the dismantled segment of the pipeline assembly and

retrieving the fittings and flow components to re-usable state. The price to be agreed

under this heading shall be per “inch-diameter joint” of the pre-welded fittings and

components retrieved, but irrespective of the schedule number

16

5.8 DISMANTLING OF PIPELINE ASSEMBLIES

Due to changes brought in the Engineer-in-charge of the facility, it may be required to

dismantle pipeline assemblies installed either by the same contractor or by some other

contractor. The work shall involve cutting the specified segment of the pipeline

assembly, removing U-clamps from supports and shifting to the store of the work site.

The work shall also include removal of cladding and PUF insulation in case of

insulated pipelines. The prices to be agreed upon under this heading shall be per

“inch-metre” length of the segment of the pipeline assembly dismantled.

5.9 STRUCTURAL WORKS

5.10.1 Structural Works Including Supply Of Structural Materials

(Supply of Structural Materials under the Scope of Contractor)

The rates shall be quoted per tonne of fabricated structure. The structural steel

materials supplied shall conform to IS 2062 Material grade. The work under this item

cover design, fabrication, assembly, installation and painting of all types and sizes of

structures like pipe supports, templates and any other type of structure as may be

required by the Department. The work shall include supply of the structural materials

such as angles, channels, I-beams, chequered plates, U-clamps, bolts, nuts, washers,

etc. The contractor shall get approval for the design and drawings from the

Department. Handling, fabrication, cutting, drilling, machining, welding, assembly,

installation and adjustment of the structures according to their specifications and

drawings at specified locations are also included in the scope of work. There shall be

no limitation on the number of welds or drillings to be carried out per tonne of the

structural works. The payment will be made based on the weight of the fabricated

structure painted with 2 coats of zinc chromate primer and 2 coats grey colour

chlorinated Rubberised paint over it. The contractor shall obtain necessary approval

before selecting the colour shade and brand of the paint. If the painting on the

structural members constructed by the department is removed or scratched off due to

mounting and installation works carried out by the contractor, then such materials

shall be painted properly with the same colour by the contractor. The cost quoted

under this item shall take into account the fabrication losses of material. The weight

will be calculated based on geometry of the structure and density of the steel used.

5.10.2 Structural Works Excluding Supply Of Structural Materials

(Supply of Structural Materials under the Scope of Department)

The rates shall be quoted per tonne of fabricated structure. The required structural

steel materials shall be supplied by Department. The work under this item cover

design, fabrication, assembly, installation and painting of all types and sizes of

structures like pipe supports, templates and any other type of structure as may be

required by the Department. The contractor shall get approval for the design and

drawings from the Department. Handling, fabrication, cutting, drilling, machining,

welding, assembly, installation and adjustment of the structures according to their

specifications and drawings at specified locations are also included in the scope of

work. There shall be no limitation on the number of welds or drillings to be carried

out per tonne of the structural works.

The payment will be made based on the weight of the fabricated structure painted with

2 coats of zinc chromate primer and 2 coats grey colour chlorinated Rubberised paint

over it. The contractor shall obtain necessary approval before selecting the colour

17

shade and brand of the paint. If the painting on the structural members constructed by

the department is removed or scratched off due to mounting and installation works

carried out by the contractor, then such materials shall be painted properly with the

same colour by the contractor. The cost quoted under this item shall take into account

the fabrication losses of material. The weight will be calculated based on geometry of

the structure and density of the steel used.

5.11 PAINTING

The work shall include supply of reputed brand Chlorinated Rubberised (CR) Paint,

Zinc chromate primer and arrangement of necessary scaffolding, spray gun, paint

brush, abrasive paper, etc. The painting shall be carried out on flat and curved surface

on following 4 modes. The rate shall be quoted per Sq.Mtr. of painted surface for

applying 2 coats of Primer and 2 coats of paint

Painting Procedure

The surfaces to be painted shall be thoroughly cleaned (using metal brush,

abrasive paper, etc.) dried and shall be free from oil & grease.

Painting shall be carried out in compliance with the specifications given in the

drawings.

Chlorinated Rubberised (CR) Paint and Zinc chromate primer of reputed brand

such as “Berger” make shall only be used.

The primer should be applied within 2 hours after preparation of the surface.

Painting shall be done only after the primer has completely dried.

5.12.1 LETTER WRITING

Marking of all pipelines and flow components with their identification remarks like

tag number, name plate details, etc. Stencils shall be used for painting alpha-numeric

characters. Prior to painting, the surfaces shall be prepared in compliances with IS 147

Part I and II. The requirements of this standard shall be considered the minimum

acceptable criterion.

Letter shall be written over the painted surface. The rate shall be quoted “per letter”

for a Letter Height ≤ 50 mm, and for letter height more than 50 mm the rate shall be

quoted for diff. range of size (height)

The scope of work under this item includes surface preparation, supply of primers,

paints, painting brushes, thinners, etc and painting (writing of letters). All the surfaces

shall be initially painted with 2 coats of Zinc chromate primer.

The surfaces shall be finally painted with 2 coats of chlorinated rubber paint over

which the letters shall be painted (written). The surface preparation and painting shall

be performed to the satisfaction of the Department. The colour scheme will be

provided during the execution of work.

18

5.13 MINOR CIVIL WORKS

The rates shall be quoted in cubic meters separately for excavation and laying of Plain

cement concrete (PCC), Re-enforced cement concrete (RCC) and Brick masonry. The

typical works under this heading include, but not limited to the following:

Excavation

Breaking and making holes across the wall for laying pipelines,

excavation of RCC/PCC concrete floor, pavements, and ground

wherever required for laying the pipelines and providing pipe supports.

Laying

Providing foundation and pedestals for equipments, as required by the

Department.

Grouting of pipe supports or other structural works.

The scope of work includes supply of torr-steel reinforcement rods,

binding wires, cement, sand, pebble stone, gravels etc., and masonry

work & plastering and white washing (2 coats) of concrete & plastered

surfaces. The composition of concrete shall be as follows:

PCC :: cement: Sand: gravels = 1:5:10

RCC :: cement: Sand: gravels = 1:2:3

Brick masonry.

Plastering : Cement : Sand = 1: 6

6.0 WORK SITE CONDITIONS

6.1 SITE ESTABLISHMENT

The contractor shall provide sheds, stores, tarpaulins and other covers for the

accommodation of his workmen and materials. All materials likely to deteriorate in

the open area shall be stored under suitable cover. The contractor shall mention in his

bid the site requirements, which shall include the office, covered storage, open

storage, fabrication yard, dark room, etc. Space shall be allotted to the contractor for

erection of his sheds and storage of materials, but he will not be permitted to make use

of any other space without the prior written permission/ approval of the department.

The sanitary conditions of the ground in and around such areas shall be maintained by

the contractor.

Security of the contractor’s equipments and materials is his own responsibility.

The contractor shall ascertain what security arrangements are made available on

site by the department and make his own arrangements for additional security as

he may think necessary. The department accepts no liability for loss or damage

to the contractor’s materials.

19

The material issued to the contractor by the department will remain under the custody

of the contractor. The contractor will be responsible for loss or damage of such

materials and shall preserve them in a good working condition as required for the

contract and good construction practices till such time that they are erected, aligned,

fully installed in position and handed over to the department.

In case, the department feels that the arrangements made by the contractor are not

adequate, department shall so advice the contractor and the contractor promptly take

corrective action. In case contractor fails to take corrective steps within reasonable

time, then the department will take corrective action, and recover the cost thereof

from the contractor‟s bills.

The contractor shall provide all necessary equipments, tools, tackles, etc,

necessary to complete the works under the contract. Such materials shall not be

removed from the site till completion of the work. A gate pass must be obtained

from the department in order to remove from site any tools, materials and

equipment.

All employees of the contractor shall comply with the rules of conduct,

established by the department. Failure to do so will be sufficient cause for

removal of such person from the site.

It is the responsibility of the contractor for safe un-loading and storage of his

own materials and also for safe transportation of free-issue material from the

department’s store and its proper storage at the work area.

6.2 ELECTRICITY

Free supply of electricity will be made available at one point on the site. Any further

distribution will be the responsibility of the contractor.

The contractor shall arrange for his own power distribution board with switch-cum-

fuse unit and calibrated energy meter. Necessary power cabling from the

department‟s power isolator (terminal point) to the contractor‟s utility points shall be

provided by the contractor. The joints on the cable shall be properly insulated. All

temporary cabling must comply with local regulations and subject to the department‟s

satisfaction before giving power supply.

6.3 WATER

Free supply of water will be made available at one point on the site. Any further

distribution will be the responsibility of the contractor.

6.4 MESSING & ACCOMMODATION

The contractor shall make his own arrangements for messing, accommodation and

food for his employees.

6.5 FIRST AID

The contractor may have access to the purchasers‟ qualified first aid personnel and

ambulance in case of accidents, subject to the availability of the same. However, the

20

contractor shall make his own medical and transport arrangements to take care of his

employees in case of accident. The contractor shall provide a first aid kit at the work

site to meet the requirements of minor injuries. The contractor shall arrange necessary

arrangements for the insurance.

6.6 SUPERVISION OF WORK

The contractor shall submit to the department a resume of his Site – in – charge /

supervisor(s) for approval, prior to commencement of the work. Once approved,

contractor shall not remove his Site – in – charge / supervisor(s) without prior

concurrence of the contract Manager of department.

6.7 EMPLOYMENT OF LABOURS

The contractor will be expected to employ, on the work, only his regular skilled

employees with experience of this particular work. No female labour shall be

employed after normal working hours. No person below the age of 18 years shall be

employed.

The contractor shall pay to each person, wages not less than those paid for similar

work in the neighbourhood. The employees / labour, for carrying out all the site works

shall be identified well in advance by the contractor and necessary approval shall be

obtained from the department for entry to the work site. The contractor shall be liable

to comply with all relevant laws of the land with respect to all the labours deployed

for the work either permanently, temporarily or contracted.

The Contractor shall identify the different categories of personnel with their names

and designations, who shall be deployed by him for the site work. The Contractor

shall indicate against each name of the personnel, the duration for which the presence

of the personnel will be required at the site.

The hours of work on the site shall be decided by the department and the contractor

shall strictly adhere to it. Normal working time will be 8 hours per day. Monday

through Saturday except government holidays, permission to work on other days may

be granted at the purchasers‟ discretion, on the written request from the contractor.

It is the responsibility of the contractor to meet all the expenses including provision of

necessary transport to and from the work site, lodging, allowances and other payments

to the contractor‟s employees. All the contractor‟s employees shall wear identification

badges while working on site. All notices displayed on the site and any instructions

issued by the department must strictly adhered by the contractor‟s employees.

6.8 REPORTING

The engineer responsible for the execution of work on the part of Department shall be

designated as contract manager. The contractor must report the following information

to the contract manager by the end of every week.

a) Number of men employed, by trades

b) Progress achieved

c) Expected dates for completion of individual works

d) Any actual or likely delay in the execution of work

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6.9 WORKING AND SAFETY REGULATIONS

The contractor at his own risk shall be responsible for;

1. the safety of his men, materials, etc.

2. arranging necessary insurance coverage for his employees and labours

The contractor shall carryout the works in strict compliance with the Departments

safety norms & Instructions. The safety team of Department is authorised to stop the

work found breach of any of the safety norms & Instructions.

The contractor shall observe all statutory and legal requirements enforced by Central

and State Government applicable to the work as well as any local regulations applying

to the site issued by department or any other authority. Particular attention is drawn to

the following;

a) In case of accident, the Department shall be informed in writing

forthwith. The contractor shall strictly follow the regulations laid down

by the Factory Inspector, Central and State Government authorities in

this regard

b) Compliance with all electricity regulations

c) Compliance with statutory requirements for inspection and test of all

lifting appliances and auxiliary lifting gear

The Contractor will notify the department of his intention to bring on to the site any

equipment such as space heating or welding apparatus, or any container holdings

liquid or gaseous fuel or other substance, which might create a hazard. The

department will have the right to prohibit the use of such equipment or to prescribe

the conditions under which such equipment may be used. The department will have

the right to inspect any construction plant and to forbid its use, if in its opinion it is

unsuitable or unsafe. No claim arising there from shall be made by the contractor.

The contractor or anyone acting on his instructions will not bring on to the site any

radio-active substance or any X-ray apparatus until written permission and direction

regarding the use of such equipment has been received from the department. The

contractor shall be responsible for the safe storage of radiographic sources of those of

his sub-contractor. The contractor shall be responsible for the provision of all safety

notices and equipments required by the relevant legislation as the department may

deem necessary.

6.10 ELECTRICAL SAFETY REGULATIONS

In no circumstances will the contractor interfere with fuses and electrical equipment

belonging to the department or other contractors. Before the contractor connects any

electrical appliance to any plug or socket belonging to other contractor or department,

he will

a) Satisfy department that the appliances are in good working condition

b) Inform the department of the maximum current rating, voltage and

phase of the appliance

c) Obtain permission of the department detailing the sockets, to which

the appliance may be connected

22

The department will not grant permission to plug-in until the department is satisfied

that:

a) The appliance is in good condition and is fitted with suitable plug.

b) The appliance is fitted with suitable cable, having two earth

conductors, one of which shall be an earthed metal sheath surrounding

the cores.

No electric cable in use by the department/contractor will be disturbed without prior

permission. No weight of any description will be imposed on any such cable and no

ladder or similar equipment will rest against or be attached to it. The voltage for all

portable equipments like drilling machines, temporary lighting etc, shall be 240 ±

10% volts. No work must be carried out on any live equipment. Then equipment must

be made safe by the Department and a “permit-to-work” issued before any work is

carried out. Contractor shall employ a full time electrician to maintain his temporary

electrical installations.

7.0 GENERAL TERMS AND CONDITIONS

7.1 CONTRACT PRICE

The prices quoted shall be firm and fixed and applicable for the entire duration of

contract subject to the work variation given in section 7.2. The bidder shall include

in his bid, the cost of the following apart from those elaborated under the heading

“Description of work” given in section 3. No payment will be made under any

heading other than the ones mentioned in the contract and there fore the bidder shall

include the prices of any other material supply, services, etc to be rendered for

completion of full scope of the work of the contract in the appropriate headings.

a. Mobilization of contractor‟s equipments & materials.

b. Temporary construction of site office, stores, dark room and work shops.

c. Suitable storage facility for contractor‟s equipments & materials including

the provision of covered shed for storage of Department supplied materials.

d. Transportation of materials from the department storage yard to the work

site, loading & un-loading, etc.

e. Cost of consumables such as Industrial gases, filler wires, welding

electrodes, X-ray films, chemicals for DP test, etc. for the effective

execution of the work.

f. Statutory Insurance coverage for Contractors work force (labours) and

equipments.

g. Documentation.

7.2 VARIATION IN CONTRACT VALUE DUE TO THE VARIATION

IN THE QUANTITY OF EACH WORK COVERED UNDER THE

CONTRACT.

The break up of unit rates quoted for each work in the offer (quotation) shall remain

firm as long as the variation in the final Contract value remains with in ± 25% from

23

the total contract value. Adjustments to unit rates for variation in contract value

beyond ± 25% shall be mutually discussed and agreed. Any adjustment made shall

only apply to that portion exceeding the above mentioned ± 25%.

7.3 TERMS OF PAYMENT

The payment shall be made as follows;

a. 80% of the value of that part of work executed there of will be paid on pro-

rata basis at the end of three months from the date of commencement of

work. The value of invoice shall be certified by the Department.

b. Balance of the Contract value will be paid after satisfactory completion of

work against performance bank guarantee for 10% of the Contract value

valid for a period of 18 months from the date of completion of work.

c. The work shall be considered “Complete” after furnishing of the following

documents.

i. Issue of “work completion” certificate by the Department for the

entire work.

ii. Reconciliation of all bills of the contractor, including settlement

of deductions against the services provided by the department to

the contractor on chargeable basis.

iii. Reconciliation of all the “free issue” materials provided by the

Department.

iv. Submission of Performance bank guarantee as stated above.

7.4 SCHEDULE OF CONTRACT AND WORK EXECUTION

The effective date of contract shall be the date of awarding work order or any other

date mutually agreed upon by the Department and the Contractor. It is to be noted

that the commencement of actual work may sometimes be possible only after 4

months from the date of award of contract. The entire works under this Contract

shall be completed within 4 months from the effective date of Contract. In the total

contract period of 4 months, the work site (CE-20 HAT facility) will be made

available only for 3 months. However, the contractor has to carryout pre-fabrication

works immediately after the effective date of contract at the place nearer to the work

site identified by the department.

The Contractor shall furnish a detailed schedule of work execution within 15 days

from the date of award of Contract. The schedule of work execution will be

scrutinized and approved by Department and the approved schedule chart will be

used as a work progress monitoring tool.

The contractor shall employ necessary manpower at least not less than the number

given below in the Table;

Sl.No DESIGNATION Number

1. Supervisor Quality Assurance 1

2. Supervisor execution 1

24

3. Fitter 4

4. TIG Welder (X-Ray Quality) 4

5. Structural Welder 1

6. Rigger 4

7. Helper 6

7.5 LIQUIDATED DAMAGES FOR DELAYED COMPLETION

If the Contractor fails to complete the execution of the works within the period

stipulated in the Contract, the Department shall recover from the Contractor as

liquidated damages a sum of one–half of one percent (0.5 %) of the Contract value

for each calendar week or part thereof subject to a maximum of 10 % of the Contract

value.

7.6 SUB – CONTRACTING

The contractor shall not assign or subcontract the work or any part of the work

without the written approval of the department. The responsibility of the

performance of sub-contractor shall lie with the contractor. Any delay in carrying

out the work by the subcontractor which affects the overall schedule of the work

does not absolve the contractor from payment of compensation for the delays. All

terms and conditions applicable to the contractor shall also be applicable to the sub-

contractor.

25

7.7

CONFIDENTIALITY:

The technical information, drawings, specification, and other related documents

forming part of enquiry or contract are the property of the department and shall not be

used for any other purpose except for the execution of the contract. The technical

information, drawings, and other documents shall not be copied transcribed, traced or

reproduced in any other form or otherwise in whole and / or duplicated, modified,

divulged and / or disclosed to a third party and / or not misused in any other form

whatsoever with out the departments consent in writing except to the extent required

for the execution of the contract. These drawings, technical information, specifications

and other related documents shall be returned to the department with all approved

copies and duplicates, if any immediately after they have been used for the agreed

purpose.

7.8 WARRANTY

The Contractor shall provide warranty for the systems fabricated under this contract for

work man ship for a minimum period of 18 months from the date of final acceptance

of the systems by the Department.

7.9 PERFORMANCE BANK GUARANTEE

The Contractor shall guarantee the successful and satisfactory performance of the work

executed by them. As a performance security, the Contractor shall furnish a

performance bank guarantee for 10 % of the contract price to guarantee the workman

ship for the warranty period as specified in Section 7.8 above. On due performance,

the performance bank guarantee shall be automatically cancelled and returned to the

Contractor within 30 days after expiry of the warranty period.

7.10 CANCELLATION OF CONTRACT

The department have the right, at any time, to cancel the contract, either wholly or in

part by giving written notice. The contractor shall under take to observe the

instructions of the department as to the winding up of the contract both on his own part

and on the part of his sub – contractors. In case of cancellation of contract, all finished

/ completed work item will be taken over by department at the price specified in the

Contract.

7.11 DEPARTMENT–FURNISHED MATERIALS (“FREE ISSUE MATERIALS”)

In the event the contractor damages the Department furnished materials (above

normal fabrication loss as given below) or if the contractor work is rejected by the

Department, the contractor shall furnish, free of cost, replacement material of equal

quantity or at Departments option, the cost of damaged materials shall be deducted

from the contractor‟s invoices. Normal fabrication loss to be permitted to the

Contractor as stated above shall be as under;

26

Sl.

No Item Salvageable Un accountable

a. Pipes 3 % 0.75 %

b. Flow components , pipe

fittings, etc Nil Nil

c. Bolts & Nuts Nil 0.50 %

The Contractor shall take delivery of materials from the storage area of Department

in a systematic manner to follow sequence of erection. Indents for materials shall be

placed at least 2 days in advance, so that the department can make prior

arrangements to deliver the materials. Materials delivered shall be transported to

work site, unloaded, and stored properly by the Contractor. The Contractor will set

up an intermediate store, where they will store all the materials being issued from

the Department‟s stock for convenience and proper scheduling of erection work.

The Department reserves the right to verify, at any time, the stock of the materials

supplied as free issue to the Contractor.

7.12 INSURANCE COVERAGE FOR CONTRACTOR’S EMPLOYEES/

LABOURS

It is the responsibility of the contractor for arranging necessary insurance coverage

for their employees and labours as per statutory requirements. It is compulsory to

produce records of insurance details to the Safety division of Department for

obtaining “Safety Permit” to commence site work by the Contractor.

7.13 DOCUMENTATION

7.13.1 DEPARTMENT PROVIDED DOCUMENTS:

The technical details and drawings given in this tender document are indicative of

work to be performed under this contract and deemed to be sufficient for the bidder

to comprehend the scope of work.

In the event of the contract awarded, approved drawings for construction will be

issued to the contractor progressively during the execution of work. Work shall be

carried out strictly as per the drawings marked “good for construction” duly signed

by the departments‟ contract manager.

After completion of work, it shall be the responsibility of the contractor to prepare

and submit “as built” piping layout and isometric drawings, taking in to account of

actual dimensions after installation

7.13.2 DOCUMENTS TO BE PREPARED & SUBMITTED BY CONTRACTOR:

In the course of execution of the contract the contractor shall prepare and submit the

following document.

Procedure for welding and welder qualification tests.

27

Isometric drawings based on the piping layout supplied by the

Department

Log sheet for welding

Certificates signed by QC – CEIT of the Department for stage

inspection and clearance.

Certificates signed by QC–CEIT of the Department for testing of

pipelines and clearance.

Records for the free issue materials

The X-ray films of weld joints

As built Isometric and piping layout

The contractor shall be responsible for the preparation of all additional fabrication

drawings/sketches, which he may feel necessary to supplement the „Good for

construction‟ documentation supplied by the Department. Before completion of the

work, the contractor shall furnish 4 sets of all the drawings prepared by him of the

piping actually erected and assembled at site. The documents soft copy shall also be

provided in compact diskette (CD), besides the 4 sets of hard copies.

Any work carried out by the contractor prior to the issue of „Good for construction‟

drawings shall be at the contractor‟s risk. The contractor shall only make change to

his drawings with the prior approval of Department, which are necessary to conform

to the requirements of the contract. These shall be carried out at no additional cost to

the Department. Approval of the contractor‟s drawings shall not relieve the

contractor of any of his obligations to meet all the requirements of the contract or

the responsibility for the correctness of his drawings.

Contractor shall submit for approval his proposed weld procedures, together with

procedure qualification and shall obtain written approval from the Department

before commencing welding. Procedures shall be submitted in 4 copies. If the

procedure has been qualified and the particular electrodes used in the original

qualification are not available, then contractor shall re-qualify the procedure in the

presence of QC AIT division of the Department, who shall approve the procedure

before it is used on production welding.

The contractor shall ensure that any welder employed on the work shall be qualified

on the weld procedures being used before being permitted to weld. If welders

qualification on the procedures is more than six months old before the proposed

commencement date of this contract, he shall be re-qualified. The contractor shall

furnish to the Department 4 copies of all inspection document and test certificates

approved by QC-CEIT division of the Department. Further 4 copies of the test

certificates shall be submitted for all tests covered in the contract along with the

completion and acceptance reports.

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7.13.3 ERRORS OR OMISSIONS IN CONTRACTOR’S DOCUMENTATION

The contractor shall be responsible for and shall bear the cost of any alteration of

the work due to discrepancies. Errors or omissions in the drawings or other

particulars supplied by him, whether the drawings or particulars have been

approved by the Department or not, provided that such discrepancies, errors and

omissions are not due to inaccurate information or particulars furnished to the

contractor by the Department.

7.14 SETTLEMENT OF DISPUTES

Except as otherwise specially provided in the contract, the nature of matter

(dispute), arising under the contract shall be determined by the Department. If

amicable settlement of occurred disputes cannot be reached by the parties, then it

shall be referred to the arbitration of sole arbitrator to be appointed by the

Director, LPSC in accordance with the Arbitration and Conciliation Act 1996,

whose decision shall be final and binding on both parties.

8.0 INSTRUCTION TO BIDDERS

8.1 MAN POWER

The contractor shall employ necessary manpower at least not less than the number given

below in the Table;

Sl.

No DESIGNATION Numbers

1. Supervisor Quality Assurance 1

2. Supervisor execution 1

3. Fitter 4

4. TIG Welder (X-Ray Quality) 4

5. Structural Welder 1

6. Rigger 4

7. Helper 6

8.2 EXPERIENCE

The bidder shall have previous experience in carrying out fabrication & Installation of

high pressure pipe lines of minimum size DN 100 XXS. The bid shall necessarily be

accompanied by certificates and photographs of the works executed else where. Also the

bidder shall submit along with the quotation the resume of work of all key personnel, their

qualification and experience over the past 10 years and the number of workers by trade,

which they propose to employ during execution of work.

29

8.3 INSURANCE

It is the responsibility of the contractor for arranging necessary insurance coverage for

their employees and labours as per statutory requirements. It is compulsory to produce

records of insurance details to the Safety division of Department for obtaining “Safety

Permit” to commence site work by the Contractor.

8. 4 PRICES

The bidder shall quote firm and fixed prices valid during the currency of contract till

completion and final acceptance of the works.

The bidder shall provide the prices in the price format as in Table 8.2

8.5 PIPELINE SIZE AND DIMENSIONAL STANDARD

: Stainless Steel pipes as per ANSI B36.19

: Carbon Steel pipes as per ANSI B36.10

8.6 THE UNIT OF MEASURE “INCH-DIA” & “INCH-METRE”

INCH-DIA : 1 inch diameter. For example, if unit cost for welding is given in Inch-dia

for a varying size range, then the cost per joint of particular size within the given range is

the pipe nominal Size multiplied by the Inch-dia cost.

INCH-METRE : 1 Inch Size pipe of 1 meter length. For example, if a 4 Inch size pipeline

of 1 meter length is hydro tested then the quantity hydro tested is 4 Inch meter.

8. 7 QUOTATION (OFFER) VALIDITY

The quoted price shall be valid for a period of 6 months from the date of opening of the

quotation.

8.8 MOBILISATION CHARGES

The mobilisation charges for x-ray machine/gamma source shall be quoted separately.

8.9 PART OFFER

During the course of finalisation of contract, the Department reserves the right to award

contract either on Part offer or on full offer.

30

SPECIFICATION OF GASEOUS ARGON

Type of

impurity

Controlled purity values Rating

- Volumetric fraction of argon, % not less 99.987

Oxygen Volumetric fraction of oxygen, % not more 0.002

Nitrogen Volumetric fraction of nitrogen, % not more 0.01

Water vapor

Volumetric fraction of water vapor,% not more 0.001

Saturation temperature (dew point) at pressure of

101.3 kPa (760 Hg mm), °С not more minus 58

Carbon-containing

compounds

Volumetric fraction of sum for carbon containing

compounds in conversion for СО2, % not more 0.001

SPECIFICATION OF ISO PROPYL ALCOHOL (IPA)

Purity : 99.0 %

Moisture : 20 PPM (Max)

Non-volatile residue : 10 PPM

Balance Product : aldehydes & keytone

MAXIMUM CONTAMINATION (PARTICLES) LIMITS

Sizes of particles (µm)

2 t

o 5

5 t

o 1

0

10 t

o 2

5

25 t

o 5

0

50 t

o

100

100 t

o

200

Quantity of particles in 100±5 cm3

of solvent, not

more

Non

rate

d

125

65

8

2

absence