HINDUSTAN ORGANIC CHEMICALS LIMITED(A Govt. of India Enterprise)

KOCHI UNIT, AMBALAMUGAL, PH: No. 0484 2720911, FAX NO-0484 2720893

NOTICE INVITING TENDER

No: HOC/ELECT/279 A 25.06.2010

Dear Sirs,

1) Sealed quotations are invited by CHIEF ENGINEER (ELECTRICAL), Hindustan Organic Chemicals Ltd., Ambalamugal for the works as detailed below. A set of tender document is enclosed for submitting your quotation.

2) Name of Work

SUPPLY, ERECTION AND COMMISSIONING OF 30 M HIGH MAST LIGHTING SYSTEM. A brief description of the scope of works is attached herewith.

3) Last Date of Receipt of Quotations

Tenders will be received at the office of Deputy General Manager (P&A), Hindustan Organic Chemicals Ltd., Ambalamugal - 682 302 on or before 28/07/10 upto 15.00 hrs. Bids received after the due date will not be considered.

4) Earnest Money Deposit

Quotation shall accompany an EMD of Rs.12,000/- (Rupees Twelve Thousand only) paid by crossed demand draft of State Bank of India drawn in favour of M/s. Hindustan Organic Chemicals Ltd., payable at Ambalamedu branch of SBI. Quotations not accompanied with EMD, are liable to be rejected.

5) Time of Completion

The time of completion of the work will be 6 Months from the date of issue of work order or issue of instructions to start the work, which ever is earlier.

6) Submission of Quotations

a) Bidders shall submit their offer in two separate sealed envelopes. Envelop No. 1 is to be addressed and superscribed as un priced bid and the name and address of the bidder and to contain the Earnest Money and signed in all pages of the offer and details asked for, for pre qualification along with a forwarding letter containing all schemes with all technical details and technical and commercial deviations if any.

b) Envelop No. 2 to be addressed and subscribed (PRICED BID) and the name and address of the bidder and to contain price alone and signed in all pages.

Both envelopes No. 1 & 2 shall be put together in one envelop duly sealed and shall be superscribed with Enquiry no. and offer for “SUPPLY, ERECTION AND COMMISSSIONING OF 30 M HIGH MAST LIGHTING SYSTEM” Due date 28/07/10 and shall be submitted DEPUTY GENERAL MANAGER (P&A), HINDUSTAN ORGANIC CHEMICALS LTD., AMBALAMUGAL - 682 302 by post or deposited in the TENDER BOX kept in our Administrative Building. Bidders shall print their address on all envelopes.

7) BIDDERS shall go through all documents attached to the quotation and fill in the blank spaces provided for and submit the same duly signed and dated. Quotation should be complete in all respects and in accordance with the various terms and conditions specified in the enquiry document. Incomplete quotations are liable to be rejected.

8) There will be public opening of quotations for the subject work.

9) Taxes and duties: Rate quoted for supply portion shall be inclusive of all taxes and duties. The extent of central excise duty included in the price for which HOCL can avail of CENVAT credit shall be indicated separately. KVAT on works ( For Installation) will be deducted at the applicable rate. Service tax on erection part if any shall be charged extra as applicable .

10) Security / Safety Regulations : The contractor shall strictly follow all the security and safety regulations and other relevant rules of HOC Ltd. The work in the plant and other restricted specified areas shall be done only after obtaining necessary

safety permit/ work permit from competent authority. Contractors shall inform the concerned department, the location of work, nature of work etc. and obtain clearance before entering into the work. Contractor shall strictly abide by the ‘ SAFETY REGULATIONS’ under Article-9 of General Conditions of Contract.

a) The contractor shall strictly abide by the article 8 ‘Labour laws’ of General Conditions of Contract and 8.6 “ Employees State Insurance Act”, in particular.

b) A separate PF Code No. under the Employees PF act 1952’ and also furnish details of CPF contribution payment made with the Regional Commissioner.

11) Defect Liability Period : The defect Liability Period for this work shall be twelve (12) months.

12) Security Deposit : Security deposit shall be 10% of the order value. This shall be deposit initially at 2.5% (two and half percent) of order value referred as initial security deposit within ten days of the receipt by the party of the notification of acceptance of the tender.

Balance 7.5% (seven and half percent) shall be recovered through deductions at the rate of 10% (ten percent) of the value of each running account bill till the total security deposit amount is collected, after which no further deductions shall be made on this account. In case of only one bill the balance 7.5% (seven and half percent) shall be ducted from the bill.

The contractor can furnish the initial or total security deposit amount through bank guarantee from any scheduled or nationalized bank in the prescribed form in favor of HOCL.

13) Payment Terms :

a) Supply : 75% against delivery of all items, 15% after erection and commissioning. Balance 10% of value of supply shall be retained as security deposit.

b) Erection and Commissioning: 90% after erection & commissioning, 10% shall be retained as security deposit. After the completion of work security deposit shall be refunded on submission of Performance Bank Guaranty (PBG) valid for the defect liability period for equal amount.

14) Validity of Offer : The Offer shall be valid for a period of 120 Days from the date of receipt of tender. The successful tenderer

shall sign the ‘Form of rate list’ or execute an agreement in non- judicial stamp paper of appropriate value (to be borne by the contractor) within 10 days from the date of issue of letter of acceptance.

15) The tender notice may be read in conjunction with standard General Conditions of Contract, Special Conditions of Contract, Technical Specification, Drawings and other documents forming part of this enquiry (GCC is available in our web site www.hoclkochi.com.

16) Unless otherwise stated all clauses of General Conditions of Contract and Special Conditions of Contract shall generally be applicable to this contract.

17) Hindustan Organic Chemicals Ltd. reserves the right to accept other than the lowest quotations, reject any or all quotations at the discretion without assigning any reason thereof.

18) Quotations from vendors in our approved list shall alone be considered, others may respond for enlistment.

19) Date, Time & Venue of Public Opening of the Tender.

Date : 28/07/10Time : 4.00 p.m.Venue : Tender Room in Training Centre of HOCL,

Ambalamugal

Following documents are enclosed.

1. Scope of work /Technical specification for the high mast lighting2. Technical Data Sheet for 30 M High Mast with Integral Power3. Schedule of Rates for supply of 30 M High Mast lighting System.4. Schedule of Rates for Erection and commissioning of 30 M High

Mast5. GCC

G.VENUGOPALCHIEF ENGINEER (ELECTRICAL)

TECHNICAL SPECIFICATION FOR THE HIGH MAST LIGHTING

Scope of work

1.0 SCOPE

The scope of this specification covers the design manufacture, transport, testing and commissioning of the complete lighting system, using Raising and Lowering type of High Mast Towers, including the Civil Foundation Works for civil foundation work cement, steel, sand, stones etc has to be good quality as per IS standard. For mast no.1, 10 nos. 2 x 400W luminaries has to be arranged asymmetrically in 1800 degree orientation and for mast no.2, 14 nos. 2 x 400W luminaries has to be arranged asymmetrically in 2700 degree orientation. The owner will only provide the supply point and the feeder cable of the required size, up to the bottom of the high mast. However, all items required for the safe and efficient operation and maintenance of the lighting system, including the high mast, whether explicitly stated in the following pages or not, shall be included by the contractor.It is the responsibility of the bidder to supply and erect all items and all labour that are included and necessary for the completion of the work whether specifically mentioned or not.

2.0 APPLICABLE STANDARDS

The following shall be the Reference Standards for the loading of High Mast:

Code No. Title

a) T.R. No.7 High Masts for Lighting and CCTV (2000 edition)

of ILE, U.Kb) IS 875 Part – 3 Wind Loadingc) BS EN 10025:1993 High Tensile Steel Sheetsd) IS 2062 Mild Steele) BS EN ISO 1461 Galvanizationf) IS 3459 / 2266 Stainless steel Wire ropeg) IS 9968 Part – 1 Trailing Cableh) IS 325 Motor

3.0 HIGH MAST

3.01 Structure

The High mast shall be of continuously tapered, polygonal cross section, at least 20 sided, presenting a good and pleasing appearance and shall be based on proven In-Tension design conforming to the standards referred to the above, to give an assured performance, and reliable service. The structure shall be suitable for wind loading as per IS 875 part III 1987.

3.02 Construction

The mast shall be manufactured using special steel plates, conforming to BS-EN10-025 and shall be delivered in multiple sections of effective length 10 metres. Thus a 30 m mast shall be delivered in three sections to site. Each section shall be fabricated out of single plate duly folded and welded. There shall be only one longitudinal seam weld per section. Section with more than one weld, circumferential or longitudinal, shall not be accepted. At site the sections shall be joined together by slip-stressed-fit method. No site welding or bolted joint shall be done on the mast. The minimum overlap distance shall be 1.5 times the diameter at penetration. The minimum top diameter shall be 150mm. Bottom diameter and plate thickness shall be as per the structural requirements. Detailed design calculation of the mast shall be submitted for verification.

The mast shall be provided with fully penetrated flange, which shall be free from any lamination or incursion. The welded connection of the base flange shall be fully developed to the strength of the entire section. The base flange shall be provided with supplementary gussets between the blowholes to ensure of helical stress concentration. For the environmental protection of the mast, the entire fabricated mast shall be hot dip galvanized, internally and externally, having a uniform average thickness of 86 microns for plate more than 5 mm and 70 microns for less than 5 mm. Galvanizing shall be done in single dipping method for better adhesion and life.

3.02. 1. Door Opening

An adequate door opening shall be provided at the base of the mast and the opening shall be such that it permits clear access to equipment like winches, cables, plug and socket, etc. and also facilitate easy removal of the winch. The door opening shall be complete with a close fitting, vandal resistant, weatherproof door, provided with a heavy-duty double internal lock with special paddle key.The door opening shall be carefully designed and reinforced with welded steel section, so that the mast section at the base shall be unaffected and undue buckling of the cut portion is prevented. Size of door opening

shall not be more than 1200 X 250 mm. to avoid buckling of the mast section under heavy wind conditions.

3.03 Dynamic Loading for the Mast: The mast structure shall be suitable to sustain an assumed maximum reaction arising from a wind speed as per IS 185 (three second gust), and shall be measured at a height of 10 metres above ground level. The design life of the mast shall be 25 years.

3.04 Lantern Carriage

3.04.1 Fabrication

A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fittings and control gear boxes. The Lantern Carriage shall be of special design and shall be steel tube construction, the tubes acting as conduits for wires, with holes fully protected by grommets. The Lantern Carriage shall be so designed and fabricated to hold the required number of flood light fittings and the control gear boxes and also have a perfect self balance. The Lantern Carriage shall be fabricated in two halves and joined by bolted flanges with stainless steel bolts and nylon type stainless steel nuts to enable easy installation or removal from the erected mast. The inner lining of the carriage shall be provided with protective PVC arrangement, so that no damage is caused to the surface of the mast during the raising and lowering operation of the carriage. The entire Lantern Carriage shall be hot dip galvanized after fabrication.

3.04. 2 Junction Box

Weather proof junction box, made of Cast Aluminum shall be provided on the Carriage Assembly as required, from which the inter-connections to the designed number of the flood light luminaries and associated control gears fixed on the carriage shall be made.

3.05.1 Raising and lowering machanism

For the installation and maintenance of the luminaries and lamps, it will be necessary to lower and raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement shall be provided, with the winch fixed at the base of the mast and the specially designed head frame assembly at the top. The lantern carriage assembly shall reach 1 M from the base of the mast for easy access. There shall be provision to disconnect the main towing cable going to Lantern carriage before starting to lowering mechanism.

3.05. 2 Winch

The winch shall be of completely self-sustaining type, without the need for brake shoe, springs or clutches. Each driving spindle of the winch shall be positively locked when not in use, gravity activated PAWLS. Individual drum also should be operated for fine adjustment of lantern carriage. The capacity, operating speed, safe working load, recommended lubrication and serial number of the winch shall be clearly marked on each winch.

The gear ratio of the winch shall be 53 : 1. However the minimum working load shall be not less than 750 kg. The winch shall be self-lubricating type by means of an oil bath and the oil shall be readily available grades of reputed producers.

The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay, with no chances of rope slippage. The rope termination in the winch shall be such that distortion or twisting is eliminated and at least 5 to 6 turns or rope remains on the drum even when the lantern carriage is fully lowered and rested on the rest pads. It should be possible to operate the winch manually by a suitable handle or by an integral power tool. It shall be possible to remove the double drum after dismantling, through the door opening provided at the base of the mast. A test certificate shall be furnished by the Contractor from the original equipment manufacturer, for each winch in support of the maximum load operated by the winch.

3.05. 3. Head Frame

The head frame which is to be designed as a capping unit of the mast, shall be of welded steel construction, galvanized both internally and externally after assembly. The top pulley shall be of appropriate diameter, large enough to accommodate the stainless steel wire ropes and the multi-core electric cable. The pulley block shall be made of non-corrodable material, and shall be of die cast Aluminum Alloy (LM-6). Pulley made of synthetic materials such as Plastic or PVC are not acceptable. Self-lubricating bearings and stainless steel shaft shall be provided to facilitate smooth and maintenance free operation for a long period. The pulley assembly shall be fully protected by a canopy galvanized internally and externally.

Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not dislodged from their respective positions in the grooves. The head frame shall be provided with guides and stops with PVC buffer for docking the lantern carriage.

3.05.4. Stainless Steel Wire Ropes

The suspension system shall essentially be without any intermediate joint and shall consist of only non-corrodable stainless steel of AISI 316 grade.

The stainless wire ropes shall be of 7/19 construction, the central core being of the same material. The overall diameter of the rope shall not be less than 6 mm. The breaking load of each rope shall not be less than 2350 kg. giving a factor of safety of over 5 for the system at full load as per the TR-7 referred to in the beginning of this specification. The end constructions of ropes to the winch drum shall be fitted with talurit. The thimbles shall be secured on ropes by compression splices. Two continuous length of stainless wire ropes shall be used in the system and no intermediate joints are acceptable in view of the required safety. No Intermediate joints/terminations, either bolted or else, shall be provided on the wire ropes between winch and lantern carriage.

3.06 Electrical System, Cable and Cable Connections

A suitable terminal box shall be provided as part of the contract at the base compartment of the high mast for terminating the incoming cable. The electrical connections from the bottom to the top shall be made by special trailing cable. The cable shall be EPR insulated and PCP sheathed to get flexibility and endurance. Size of the cable shall be minimum 5 core 4 sq mm copper. There shall be two cables per mast, one for essential supply and the other for non-essential supply. The cable shall be of reputed make. At the top there shall be two weather proof junction boxes to terminate the trailing cable. Connections from the top junction box to the individual luminaires shall be made by using 3 core 1.5 sq. mm. flexible PVC cables of required make.Also, suitable provision shall be made at the base compartment of the mast to facilitate the operation of internally mounted, electrically operated power tool for raising and lowering of the lantern carriage assembly. The trailing cables of the lantern carriage shall be terminated by means of specially designed, metal clad, multi pin plug and socket provided in the base compartment to enable easy disconnection when required.

3.07 Power Tool for the winch

A suitable, high-powered, electrically driven, internally mounted power tool, with manual over ride shall be supplied for the raising and lowering of the lantern carriage maintenance purposes. The speed of the power tool shall be to suit the system. The power tool shall be single speed, provided with a motor of the required rating. The power tool shall be supplied complete with suitable control. The capacity and speed of the electric motor used in the power tool shall be suitable for the lifting of the design load installed on the lantern carriage.

The power tool mounting shall be so designed that it will be not only self-supporting but also aligns the power tool perfectly with respect to the winch spindle during the operations. Also, a handle for the manual operation of the winches in case of problems with the electrically operated tool, shall be provided and shall incorporate a torque limiting device.

The power tool operation shall always be through a separate torque-limiting device to protect the wire ropes from over stretching. It shall be mechanical with suitable load adjusting device. The torque limiter shall trip the load when it exceeds the adjusted limits. There shall be suitable provision for warning the operator once the load is tripped off. The torque limiter is a requirement as per the relevant standards in view of the over all safety of the system. Each mast shall have its own power tool motor. The motor shall have over load relay and fuse protection

3.08 Lightning Finial

One number heavy duty hot dip galvanised lightning finial shall be provided for each mast. The lightning finial shall be minimum 1.2 M in length and shall be provided at the Centre of the head frame. It shall be bolted solidly to the head frame to get a direct conducting path to the earth through the mast. The lightning finial shall not be provided on the lantern carriage under any circumstances in view of safety of the system.

3.09 Aviation Obstruction Lights:

Suitable Aviation Obstruction Lights or reliable design and reputed manufacturer shall be provided on top of mast.

3.10 Earthing Terminals :

Suitable earth terminal using 12mm diameter stainless steel bolts shall be provided at a convenient location on the base of the Mast, for lightning and electrical earthing of the mast.

3.11 Feeder Pillar

Each mast shall be provided with a feeder pillar fabricated out of 14 SWG CRCA sheet and finished with two coats of red oxide primer and gray enamel paint of shade 631 of IS-5. The feeder pillar shall comprise of two compartments, one for essential supply and the other for non-essential supply. Switchgears shall be to suit the power loading. The motor shall also house control contractors for the power tool motor.

3.12. Incoming Power Cable

A cable of size 4 X 16 sq.mm. Aluminum conductor, Armoured cable for power supply and 4 X 1.5 sq.mm. Copper conductor Armoured cable for

motor supply shall be provided to the base compartment of the highmast. Cable shall be taken to the base compartment of the highmast through the provision made in the foundation.

Power cable of suitable size upto the supply point shall be provided by purchaser.

4.0 LUMINAIRES

Luminaries shall be specially designed with cast aluminium housing suitable lamp housing and control gears for 400 W HPSV lamps. The luminaries shall be tested as per Indian standards and test reports shall be submitted along with the materials. The luminaries shall be suitable for installation on high masts.

Make of luminaries shall be BAJAJ/PHILIPS/CROMPTON only

TECHNICAL DATA SHEET FOR 30 MTR HIGH MAST WITH INTEGRAL POWER

TOOL AND COMPONENTS

HIGHMAST SYSTEM

a) Height of mast : b) No. of Sections : c) Make of high mast : d) Material construction : e) Thickness of sections : f) No. of longitudinal welds/section : g) No. of circumferential welds/sectionh) Make of luminaire/lamp :

i) Cross section of Mast : j) Base dia. And top diameter A/F :

k) Type of joints : l) Length of overlap : m) Metal protection treatment for :

n) Method of hot dipping : o) Average thickness of galvanisation : p) Size of opening and door at base : q) Type of locking arrangement : r) Details of slack board inside the base :

Compartment. : s) Provision for cable termination : t) Diameter of base plate : u) Thickness of base plate : v) Size of anchor plate and thickness : w) Details of template : x) Weight of 30 mtr. Mast : (without accessories)y) Lightning Protection finial :

2. DYNAMIC LOADING AS PREVAILING AT SITE

a) Max. wind speed : b) Max. gust speed time : c) Height above ground level these two :

Factors are measuredd) Factor of safety for wind load : e) Factor of safety for other load :

3. FOUNDATION DETAILS

a) Type of foundation : b) Size of foundation : c) Soil bearing capacity at site : d) Design Safety factor :

: e) Considered wind pressure (Kg/Mt2) : f) Depth of foundation : g) Number of foundation bolts : h) PCD of foundation bolts : i) Type of foundation bolts : j) Bolt diameter :

4. LANTERN CARRIAGE

a) Material of construction : b) Diameter of carriage ring (mm) : c) Construction : d) Number of joints : e) Buffer between carriage and masts : f) Load carrying capacity : g) Total weight of assembly with fittings : h) Number of fittings : i) Type of fittings/fixture :

5. CABLE

a) Type : b) Material : c) Current carrying capacity : d) Conductor size : e) No. of cores : f) No. of circuits :

6. WINCH

a) Make of winch : b) Number of drums/winch : c) Gear Ratio : d) Capacity : e) Method of operation : f) Lubrication arrangement : g) Type of lubricant :

7. STAINLESS STEEL WIRE ROPE

a) Make : b) Grade : c) Number of ropes : d) Construction : e) Centre core material : f) Diameter (mm) : g) Thimbles & Talurit : h) Braking load capacity : i) Factor of Safety :

8. POWER TOOLa) Model : b) Input Supply : c) Wattage/HP : d) Number of speeds : e) Operating speed (Average) :

9. TORQUE LIMITERa) Lifting capacity : b) Adjustable/Non- adjustable : c) Tripping device :

SCHEDULE OF RATES FOR SUPPLY OF 30 M HIGH MAST LIGHTING SYSTEM

Sl.No.

DESCRIPTION OF EQUIPMENT/ACTIVITY

UNIT QTYUNIT RATE (Rs.)

AMOUNT

(Rs.)

1.0

1.1

SUPPLY OF ITEMS

Supply of 30 M high mast system totally hot dip galvanized and suitable for 45mt/s wind velocity. The mast shafts shall be in three sections with no circumferential weld on each sections with integral power tool. Accessories for 30 M High mast including head frame, steel wire rope 6mm dia (7/19 construction) double drum winch, Galvanized Lantern carriage arrangement suitable for 10 luminaries and 14 luminaries asymmetrically arranged for 2 mast respectively and its control gear boxes and lighting finial.

No. 2

1.2Supply of foundation bolts manufactured from special steel along with nuts, washers, anchor plates and templates

No. 2

1.3

Supply of specially designed Non integral flood light luminaire type BGENF 22 R or equivalent with two nos 400 W SON T/HPSV lamps and its control gear boxes.

No. 24

1.4

Supply of Control panel housing suitable timer contractor circuit for Automatic switch ON and switch OFF of the mast at a pre-set time

No. 2

1.5Supply of LED type single twin aviation obstruction light ( BENOY/BAJAJ/CG/PHILIPS make)

No. 2

SCHEDULE OF RATES FOR ERECTION & COMMISSIONING OF 30 M HIGH MAST

2.0

2.1

ERECTION AND COMMISSIONING

Erection and commissioning of the High Mast with the help of suitable equipment

No. 2

2.2Design and casting of suitable foundation for the high mast considering the safe soil bearing capacity at site .

No. 2

2.3Pipe earthing station for high mast (2 per mast is mandatory, 1 for lightning and one for electrical) as per IS standard

No. 4

2.4 Installation of the above panel on suitable foundation No. 2