Scope of Works
Scope of Works
Scope of Works
1.2 Design Submission and Completion Period for the Whole Works
The Contractor shall submit the Preliminary Design for approval latest by Twenty One (21) Days from the
Start Date. Upon discussion with the Employer, the Contractor shall submit the Final design for approval
within Thirty (30) Days from the Start Date of the Contract.
The contract completion time shall be Six (6) months from the date of contract agreement. The following
milestones of the contract are set for monitoring the progress of the contract.
Milestone1: completion of survey and submission of design works within One (1) months from date
of signing of Contract Agreement.
Milestone 2: completion of all physical works within 5 months from date of design approval period.
Milestone 3: Completion of whole works within Six (6) months.
Note: For more storage capacity design, the above milestones are to be reviewed and determined
during Contract Agreement.
The successful tenderer within 10 days of issuance of work order, name an engineer (Bachelor’s Degree
in Mechanical Engineering or equivalent with at least 3 years of general working experience in projects
of similar nature) responsible for the job at site on behalf of the contractor. Bidder should give in writing
to NOC, the name of his authorized and qualified engineer who will supervise the work and shall remain
at the site during execution of the job.
2. Site Assessment before Bidding
The bidder shall be deemed before bidding to have undertaken a thorough study of the proposed work, the job
site(s) involved, the site conditions, soil conditions, the terrain, the climatic conditions, the labor, power,
material and equipment availability and transport and communication facilities, the availability of transport,
the availability of land for right of way and temporary office and accommodations, quarters, and all other facts
and facilities necessary or relevant for the formulation of the tender, supply of materials and the performance
of the work. Without prejudice to the foregoing, the tenderer may be allowed access to any information
regarding the site of the work, the investigations conducted relative thereto, such as soil investigation etc. But,
these shall be only indicative in nature and the tenderer are expected to collect their
own data for preparation and submission of their tender.
Any claim at a later date based on either incorrectness or inadequacy of the information/data made
available by the OWNER/tenderer to a tenderer shall not be entertained. The OWNER/tenderer shall be
fully absolved of any and all liabilities in this regard. Since the location is a licensed premises, handling
with petroleum products, where the safety is of at most importance; the Contractor needs to adhere to the
working hours of the facility. No one from the Contractor’s side will be allowed to stay at the location
beyond working hours unless specific permit/permission is given.
3. Contractor’s Scope of Supply
3.1 Supply of Materials:
All materials including cement, reinforcement, structural steel, steel plates, consumables, testing
appliances, tools and tackles, and all materials necessary for completing the work shall be supplied by the
Contractor at his own cost. No claim/ delay on this account will be entertained by NOC.
NOC reserves the right in selection of best makes of materials to be procured by the contractors &
contractor shall procure the same only up on the approval by site in charge. Make of material to be used
at site should conform to the list of approved makes as per the instructions of Engineer-in-Charge.
3.2 Water Supply:
The contractor shall arrange water/procure water required for the work at his own cost for all leads and
lifts. NOC shall not be responsible for supplying water and Contractor shall ensure timely and adequate
supply of water to meet the schedule.
3.3 Power Supply:
NOC will make arrangements for power required for the work. DG set of suitable capacity may be
installed and operated by the contractor at his cost. NOC shall not be responsible for DG power supply
and contractor shall ensure proper supply of electricity to meet the schedule. The electrical works shall be
carried out through Licensed Electrical personal only.
4. Audits
This project is subjected to inspection by various audit / vigilance agencies of NOC, the Government of
Nepal or any outside agency. If any inspection of works is carried by such agencies, Contractor shall
extend his full co-operation to these agencies in examining records, works etc. On inspection by such
agencies, in their inspection report, if it is pointed out that Contractor has not carried out work according
to guideline laid down in this tender document and also if any recoveries in some items is pointed out
therein, same shall be recovered from Contractor’s RA bills / final bills. The items under dispute shall not
be paid in full till inspection agency gives their No Objection report.
4. Meetings
The partners or Directors of the Contractor shall meet the officers of the NOC at the site of works or
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their respective offices whenever requested to do so. Weekly site co-ordination meetings shall be
attended by the Contractors working on site & proper intimation should be given to NOC in order to
monitor the project more efficient way. The relative decision for the execution of tender items shall be
given in these meetings by NOC by producing working drawings / handmade sketches if any.
6. Removal of Debris and Site Clearing
Contractor shall arrange to dispose off debris, wood shaving and any other waste product created while
carrying out the work, inside/outside NOC’s premises as instructed by NOC. The Contractor shall take
due care while disposing of such waste materials and ensure that any rules / regulations lay down by
Local Authorities, NOC or any other statutory body are not violated. The Contractor shall be responsible
and answerable to any complaint arising out of improper disposal of wastage. Quoted rate shall include
the cost of same and no extra payment shall be made towards this account. The Contractor shall take care
for clearing the working site from time to time for easy access to work site and also from safety point of
view. Working site should be always kept cleared up to the entire satisfaction of the Engineer- in-Charge.
Before handing over any work to owner, the contractor in addition to other formalities to be observed as
detailed in the document shall clear the site to the entire satisfaction of Engineer-in-Charge.
7. Protection of Work Done
During inclement weather the Contractor shall suspend concreting and plastering for such time as NOC may
direct and shall protect from injury all works in the course of erection. Should the work be suspended by
reason of rain, strike, lockouts or other cause the Contractor shall take all precautions necessary for the
protection of the work at his own expense shall make good any damages arising from any of this cause.
8. Work Performed at Contractor’s Risk
The Contractor shall take all precautions necessary and shall be responsible for the safety of the work and
shall maintain all safeguards, including providing for guards, proper lights, signs, temporary passages, or
other protection necessary for the purpose. All work shall be done at the Contractor’s risk, and if any loss
or damage shall result from fire or from other cause, the Contractor shall promptly repair or replace such
loss or damage free from all expenses to the NOC. The Contractor shall be responsible for any loss or
damage to materials, tools or other articles used or held for use in connection with the work. The work
shall be carried on and completed without damage to any work or property of the NOC or of others and
without interference with the operation of existing machinery or equipment, if any.
9. Site Drainage
All water, which may accumulate on the site during the progress of the work or in trenches and
excavations from other than expected risk should be removed from the site to the satisfaction of NOC at
the Contractor’s
expense. All soil, filth or other matter of an offensive nature taken out of any trench, sewer, drain,
cesspool, or other place shall not be deposited on the surface, but shall be at once carried away by the
Contractor disposed of as per the rules and regulations of the Local Authorities concerned.
10. Miscellaneous Requirements
All expenses towards mobilization & demobilization including bringing in equipment, clearing the site
etc. shall be deemed to be included in the prices quoted and no separate payments on account of such
expenses shall be entertained. It shall be entirely Contractor’s responsibility to provide, operate &
maintain necessary construction equipment, scaffoldings and safety gadgets, cranes and other lifting
tackles, tools and appliances to perform the work in a workman like and efficient manner & complete all
jobs as per time schedules.
Preparing approaches and working area for movement and operation of the cranes, leveling the areas for
assembly and erection shall also be the responsibility of the Contractor. The Contractor shall acquaint
himself with access availability, local labor etc. to provide suitable allowances in his quotation. The
Contractor, at his own cost, may have to build temporary access roads to aid his own work that shall also
be taken care while quoting for the work. The procurement and supply in sequence and at the appropriate
time of all materials & consumables shall be entirely the Contractor’s responsibility. Rates for execution
of work will be inclusive of supply of all these items.
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Notes:
a. The above documents cover the minimum requirements and shall be supplemented with other
requirements listed in the specification, if any. Any other documents required to understand and
maintain the system, as felt necessary till handing over of the project, shall be supplied by the vendor.
b. All documents shall be supplied in English language as per following.
i. - Approval/ Information - 4 sets
ii. - Final -4 sets
c. One set of final detailed termination wiring interconnection diagram shall be kept inside each cabinet
and equipment.
d. Name and address of subsystem vendors with name and telephone no. of contact persons.
e. As built drawings shall be laminated and properly bound with index sheet for preservation and future
reference.
f. All drawing which are submitted for approval, shall be submitted on CD as a final document (after
approval).
g. For diagrams of cable layout, power distribution, earthing etc., the existing diagrams will be provided
to the vendor. The proposed new layout will have to be approved and the final comprehensive
documents have to be submitted.
h. The submission of drawings applies only for the equipment being supplied by the vendor.
17. Safety Precautions & Hot Work
Contractor shall have to take all safety precaution for carrying out hot work in the premises after obtaining
hot work permit from location in charge at his own cost as directed by the Engineer-In-Charge. Necessary
safety equipment such as safety belts, helmets and other equipment are to be positioned by the contractor
and use as per requirement. Safety distance as per CCE Rules and Oil Industry Safety Directorate shall be
maintained strictly. Any casualty or damage caused to property or person by any untoward incidents while
executing this contract will be at the contractor’s risk and cost. The contractor shall also abide by hot
work permits to be taken on day-to-day basis from the location as per policy of the Corporation.
18.1 DOs
a. Before commencement of work give sufficient input to the workers on safety requirement of the job.
b. Use personal protective equipment (safety belt, safety shoes, safety helmet etc.) at construction.
Safety belts (ISI approved) must be used when working at heights above 3 m height.
c. Keep the site clean from all unwanted materials and properly store the equipment for easy access.
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d. Keep the visitors away from the construction site.
e. Use safety net whenever required.
f. Keep firefighting equipment handy at site.
g. Keep the escape route clear
h. Provide adequate lighting at site.
i. Use electrical hand tools with double insulation or fitted with ELCB protection.
j. Maintain safe angle of repose while excavating pit exceeding 1.5M depth.(45).
k. Suitable bench of 0.5 M width at every 1.5 M depth of excavation in all soils to be provided expect in
case of hard rock or proper shuttering and shoring.
l. Necessary steps to be provided for escape.
m. Protect the neighboring structure from collapse where excavation is planned.
n. Take adequate precaution for underground utility lines (cables, sewers) before carrying out excavation.
o. Make necessary arrangement for de-watering of the pit.
p. Ensure Mechanized excavator is operated by well-trained experienced operator.
q. Ensure the wheel / belt of the excavator are suitably jammed to prevent accidental movement.
r. Ensure use of metallic scaffolding designed for their maximum load.
s. Check for any overhead electric wire running over the construction site. If exist, ensure the same is
de-energized.
t. Cordon off the excavated pit with proper red and white band / caution board.
u. Provide suitable rubber mat around electrical panels/switches.
v. Provide First Aid kit with proper medicine at the site.
w. Openings of manholes etc. should be kept in close condition.
x. Cordon off the area where field radiography is carried out.
y. Ensure all electrical connections, water connections etc. have been cut off before start of demolition.
z. Use 24 Volt FLP lamp fitting only for illumination inside confined space.
18.2 DONTs
a. Do not start any work without presence of contractor’s skilled supervisor.
b. Do not wear loose clothing while working near rotating machine or working at height
c. Do not keep inflammable material, waste and debris near the construction site.
d. Do not carry out hot work where inflammable materials are present and also while carrying out
painting job.
e. Do not keep the excavated earth within 1M of the edge of the pit.
f. Do not allow vehicles within 2 M distance from the edge of the pit.
g. Do not allow personnel to come within 1 M of extreme reach of the mechanical shovel.
h. Do not exceed safe working load marked on lifting equipment.
i. Do not use unamored electric cable in construction site.
j. Do not allow electrician without license for carrying out electrical job
k. Do not use bare wire ends in the socket.
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67. IS: 8142-Indian Standard Specification for Determining Setting time of Concrete by Penetration
Resistance
68. IS: 8989-Safety Code for Erection of Concrete Framed Structures
69. IS: 9013-Indian Standard Specification for Method of Making, Curing and Determining Compressive
Strength of Accelerated-cured Concrete Test Specimens
70. IS: 9103-Indian Standard Specification for Admixtures for Concrete
71. IS: 10262-Recommended Guidelines for Concrete Mix Design
72. IS: 226: Structural Steel (Standard Quality)
73. IS: 800: Code of Practice for use of structural steel in general building construction
74. IS: 806: Code of practice for use of steel tubes in general building construction.
75. IS: 808: Rolled steel beams, channels and angle sections
76. IS: 813: Scheme of symbols for welding
77. IS: 814: Covered electrodes for metal arc welding of structural steel
78. IS: 815: Classification and coding of covered electrodes for metal arc welding of mild steel and low
alloy high tensile steel
79. IS: 816: Code of practice for use of metal arc welding for general construction in mild steel
80. IS: 817: Code of practice for training and testing metal arc welders
81. IS: 818: Code of practice for safety and health requirements in electric and gas welding and cutting
operations
82. IS: 822: Code of practice for inspection of welds
83. IS: 9595: Recommendations for metal arc welding of carbon and carbon manganese steels.
84. IS: 919: Recommendations for limits and fits for Engineering
85. IS: 961: Structural Steel (High Tensile)
86. IS: 1148: Rivet bars for structural purposes
87. IS: 114: High tensile rivet bars for structural purposes
88. IS: 1161: Steel Tubes for structural purposes
89. IS: 1200: Method of measurement of steel work and ironwork (Part 8)
90. IS: 1239: Mild Steel Tubes
91. IS: 1363: Black hexagon bolts, nuts and lock nuts (dia. 6 to 30 mm) and black hexagon screws (Dia 6
to 24 mm)
92. IS: 1364: Precision and semi-precision hexagon bolts, screws, nuts and lock nuts/dia. range 6 to 39
mm).
93. IS: 1367: Technical supply conditions for threaded fasteners
94. IS: 1442: Covered electrodes for the metal arc welding of high tensile structural steel
95. IS: 1608: Method for tensile testing of steel products other than sheet strip, wire and tube.
96. IS: 1730: Dimensions for steel plate, sheet and strip for structural and General Engineering purposes.
97. IS: 1731: Dimensions for steel flats for structural and general engineering purposes
98. IS: 1852: Rolling and cutting tolerances for hot-rolled steel products
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99. IS: 1977: Structural steel (Ordinary quality) St-42-0
100. IS: 2062: Structural steel (fusion welding quality)
101. IS: 2074: Ready mixed paint, red oxide zinc chromate priming
102. IS: 2629: Recommended practice for Hot-Dip Galvanizing of Iron and Steel
103. IS: 2633: Method for testing uniformity of coating on Zinc coated Articles
104. IS: 3757: High Tensile Friction Grip bolts
IS: 4759: Specifications for Hot-Dip Zinc Coatings on Structural Steel and other Allied
products
105. IS: 7215: Tolerances for fabrication of steel structures
II: Specifications for General Civil Works
2. Materials
a. IS: 269 - Specification for 33 Grade Ordinary Portland Cement (If Specially Intended To Be Used
As Per Drawings/Specifications)
b. IS:455 - Specification for Portland slag cement.
c. IS:1489 - Specification for Portland-Pozzolana cement.
d. IS:8112 - Specification for 43 grade ordinary Portland cement.
e. IS:12330- Specification for Sulfate resisting Portland Cement
f. IS:383 - Specification for coarse and fine aggregates from natural sources for concrete.
g. IS:432(Parts I & II) - Specification for mild steel and medium tensile steel bars and hard- drawn
steel wires for concrete reinforcement.
h. IS:1786 - Specification for high strength deformed steel bars and wires for concrete reinforcement.
i. IS:1566 - Specification for hard-drawn steel wire fabric for concrete reinforcement.
j. IS: 2062 – Steel for general structural purposes.
k. IS:9103 - Specification for admixtures for concrete.
l. IS:2645 - Specification for integral cement water proofing compounds.
m. IS:4990 - Specification for plywood for concrete shuttering work.
2. Material Testing
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a. IS:4031(Part 1 to 13) - Methods of physical tests for hydraulic cement.
b. IS:4032 - Method of chemical analysis of hydraulic cement
c. IS:650 - Specification for standard sand for testing of cement.
d. IS:2430 - Methods for sampling of aggregates for concrete.
e. IS:2386(Part 1 to 8) - Methods of test for aggregates for concrete.
f. IS:3025 - Methods of sampling and test (physical and chemical) water used in industry.
g. IS:6925 - Methods of test for determination of water soluble chlorides in concrete, admixtures.
4. Material Storage
a. IS: 4082 - Recommendations On Stacking And Storing Of Construction Materials At Site.
5. Concrete Mix Design
a. IS:10262 - Recommended guidelines for concrete mix design.
b. SP:23(S&T) - Handbook on Concrete Mixes.
6. Concrete Testing
a. IS:1199 - Method of sampling and analysis of concrete.
b. IS:516 - Method of test for strength of concrete
c. IS:9013 - Method of making, curing and determining compressive strength of accelerated cured
concrete test specimens.
d. IS:8142 - Method of test for determining setting time of concrete by Penetration resistance.
e. IS:9284 - Method of test for abrasion resistance of concrete
f. IS:2770 - Methods of testing bond in reinforced concrete.
7. Equipment
a. IS:1791 - Specification for batch type concrete mixers.
b. IS:2438 - Specification for roller pan mixer.
c. IS:4925 - Specification for concrete batching and mixing plant.
d. IS:5892 - Specification for concrete transit mixer and agitator.
e. IS:7242 - Specification for concrete spreaders.
f. IS:2505 - General Requirements for concrete vibrators: Immersion type.
g. IS: 2506 - General Requirements for sereed board concrete vibrators.
h. IS:2514 - Specification for concrete vibrating tables.
i. IS:3366 - Specification or pan vibrators.
j. IS:4656 - Specification for form vibrators for concrete.
k. IS:11993- Code of practice for use of screed board concrete vibrators
l. IS:7251 - Specification for concrete finishers.
m. IS:2750 - Specification for steel scaffolding.
8. Codes of Practice
a. IS:456 - Code of practice for plain and reinforced concrete.
b. IS:3370(Parts I TO IV) - Code of practice for concrete structures for storage of Liquids.
c. IS:3935 - Code of practice for composite construction.
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d. IS:2502 - Code of practice for bending and fixing of bars for concrete reinforcement.
e. IS:5525 - Recommendation for detailing of reinforcement in reinforced concrete works.
f. IS:2751 - Code of practice for welding of mild steel plain and deformed bars used for reinforced
concrete construction.
g. IS:9417 - Specification for welding cold worked bars for reinforced concrete construction.
h. IS:3558 - Code of practice for use of immersion vibrators for consolidating concrete.
i. IS:3414 - Code of practice for design and installation of joints in Buildings.
j. IS:4326 - Code of practice for earthquake resistant construction of building.
k. IS: 13920 – Code of Practice for ductile detailing of reinforced concrete structures subjected to
seismic forces.
l. IS:4014(Parts I & II) - Code of practice for steel tubular scaffolding.
m. IS:2571 - Code of practice for laying in-situ cement concrete flooring.
n. IS:7861 - Code of practice for extreme weather concreting.
o. Part-I Recommended practice for hot weather concreting. Part-II Recommended practice for cold
weather concreting.
9. Construction Safety
a. IS:3696(Parts I & II) - Safety code for scaffolds and ladders.
b. IS:7969 - Safety code for handling and storage of building materials.
c. IS:8989 - Safety code for erection of concrete framed structures.
10. Measurements
a. IS:1200 (Part 2, 5 & 23) - Method of measurement of building and engineering works
1. General
This specification covers design, manufacture, testing and supply of forged carbon steel seamless welded
pipe fittings like LR bends, concentric/ eccentric reducers, equal/unequal tees and cross bar tee suitable
for use in Petroleum Product service. The type, size, working pressure and quantity of fittings required as
per Schedule of Rates of Tender Document. The following temperatures shall form the basis of design of
these fittings.
a. Maximum temperature : +55°C
b. Minimum temperature : +5°C
Fittings shall be designed and manufacturing tolerances shall be as ANSI31.4.
2. Product Piping
SIZE
DESCRIPTION RANGE SPECIFICATION
NB(MM)
Pipes 15-20 SCH 160 Ι Seamless Ι ASTM 106 Gr.B Ι ASME B36.10
25-50 SCH 80 Ι Seamless Ι ASTM 106 Gr.B Ι ASME B36.10
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80-100 4.78 THK Ι ERW Ι API 5L Ι ASME B36.10
Fittings 15-20 6000# Ι Socket Weld Ι ASTM A105 Ι ASME B16.11
(R=1.5Dfor 25-40 3000# Ι Socket Weld Ι ASTM A105 Ι ASME B16.11
Elbows)
50 SCH 80 Ι Butt Weld Ι ASTM A234 Gr. WPB Ι Seamless Ι
ASME B16.9
80-150 4.78 (80 & 100 mm) /6.35 (150 mm) THK Ι Butt Weld Ι
ASTM A234 Gr. WPB Ι Seamless Ι ASME B16.9
200-450 6.35 THK Ι Butt Weld Ι ASTM A234 Gr. WPB-W Ι ASME
B16.9
500-600 7.14 THK Ι Butt Weld Ι ASTM A234 Gr. WPB-W Ι ASME
B16.9
SIZE
DESCRIPTION RANGE SPECIFICATION
NB(MM)
Flanges 15-600 150# Ι Weld Neck Ι Raised Face Ι 125 AARH Ι ASTM A105 Ι
ASME B16.5 Ι Bore to suit pipes, which are as follows:
15-20 NB : ASTM A106 Gr.B SCH 160
25-50 NB : ASTM A106 Gr.B SCH 80
80-100 NB : API 5L Gr BX 4.78 THK
150-450 NB : API 5L Gr BX 6.35 THK
500-600 NB : API 5L Gr B X 7.14 THK
Blinds 15-600 150# Ι Raised Face Ι 125 AARH Ι ASTM A105 Ι ASME
B16.5
Flanges 100 150# Ι Raised Face Ι 125 AARH Ι ASTM A105 Ι ASME
B16.48
Gaskets All sizes 150# Ι Spiral Wound SS316 + Grafoil Ι ASME B16.20/ASME
B16.5 (Glass Filled Teflon For Ethanol Service)
Note: Thickness of Gasket shall be 2mm upto 300NB and
3mm for sizes above 300NB.
Studs/Nuts/ All Studs and Nuts shall conform to ASTM A193 Gr. B7 and
ASTM A194 Gr. 2h respectively.
Washers
Washers shall conform to IS 2016 (Punched washers ‘A’
with 2mm minimum thickness)
Gate Valves 20-25 800# Ι Rising Stem Ι Outside Screw & Yoke Ι Bolted Bonnet
Ι Solid Wedge Ι Renewable Seat Ring Ι Hand Wheel
Operated Ι Body & Bonnet ASTM A105 Ι Trim Stellited Ι
Stem 13 Cr Steel Ι Mfg. Std. API 602 Ι Testing Std. API 598
Note: To be supplied with 100mm long ASTM A 106 Gr.B
Sch 80 seamless pipes with ASME B16.5 Weld neck Flanged
at one end and welded to each end of the valve.
50 150# Ι Rising Stem Ι Outside Screw & Yoke Ι Bolted
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Bonnet Ι Solid Wedge Ι Renewable Seat Ring Ι Body &
Bonnet ASTM A216 Gr.WCB Ι Trim Stellited Ι Stem 13 Cr
Steel Ι Raised Face Flanged Ι Mfg. Std. API 600 Ι Testing
Std. API 598
Ball Valves 15- 50 150# Ι Single Piece Ι Full Bore Ι Fire Safe to API 607 Ι Anti
Static Ι Anti Blow Out Stem Ι Lever Operated Body ASTM
A216 Gr.WCB Ι Ball & Stem SS316L Ι Seat RPTFE Ι Raised
Face Flanged Ι Mfg. Std. BS 5351 Ι Testing Std. BS 6577
NonReturn 50- 250 150# Ι Swing Type Ι Body & Cover ASTM A216 Gr.WCB Ι
Valves Disc ASTM A216 Gr.WCB With 13% Cr SS Facing Ι Raised
Face Flanged Ι Mfg. Std. BS 1868 Ι Testing Std. BS 5146
3. Structural Sections
would not be included for measurement in pipeline.Maximum wastage of 1.5% shall be allowed in
pipeline fabrication for all diameters of pipes.
2. Scope
This specification covers the minimum requirements for erection, flushing, pressure testing, draining,
drying and reinstatement of piping systems.
3. Requirement of Drawings
General Layout accompanying the tender document are indicative of scope of work and issued for
tendering purpose only. Detail piping drawings, P & IDs diagram, will be submitted by successful
bidder for carrying out the work.
The contractor shall prepare the isometric drawings for product piping and calculate the actual
requirement of various items/fittings like bends, flanges etc. The complete set of drawings shall be
submitted for approval before commencement of the work. No fabrication will start without the
approval of NOC. The construction drawings shall include:
a. Location of all weld seams, weld sizes and details of weld etc.
b. Material to be used.
c. Welding procedures and radiographic inspection.
d. Edge preparation and method employed.
e. Tolerances
f. Quality, brand and gauge of electrodes to be used.
g. Details of welding reinforcement
h. Details of brackets for supporting pipes, platforms, etc.
i. Complete bill of materials with item wise quantities for materials to be supplied by NOC and the
contractor.
j. Any correction or modifications suggested by NOC while approving the drawings.
The drawings shall be prepared on computer and one USB Flask disk of as built drawings shall be
submitted after completion of work. All drawings are to be prepared on Auto-CAD.
4. Inspection
Engineer-in-Charge or his authorized representative or third party appointed by NOC shall have free
access at all reasonable time to inspect those parts at the manufacturer's works which are connected
with the fabrication of the steel work and shall be provided with all reasonable facilities for satisfying
himself that the fabrication is being undertaken in accordance with the provision of this contract.
Inspection shall be made at site/ at the place of manufacture prior to dispatch of the fittings. The
inspection shall be conducted so as not to interfere unnecessarily with the operation of work.
Should any structure or part of a structure be found not to comply with any of the drawings and
specifications, it shall be rejected. No structure or part of the structure once rejected shall be re-
submitted for test except in case where the corporation considers the defects as rectifiable. Defects
which may appear during fabrication shall be made good by the contractor.
The suitability and capacity of all plants &equipment used for erection shall be to the satisfaction of
the engineer.
5. Fabrication
Fabrication, installation/erection and assembly shall be done as indicated in P & IDs and piping layout
drawings. Contractor shall promptly notify Engineer-in-charge of any defective or damaged material,
materials that are not as per specification and materials that differ in any manner from the
designations in the drawings.
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Pipe to pipe jointing for CS & SS materials
Bends, reducers, expanders, tees and end blinds provided shall be factory made forged irrespective of
diameter of pipeline .Such fittings shall have approximately the similar material composition as that
of pipeline under fabrication. Use of miter bends/reducers are not permitted.
Carbon steel pipes shall be cut by mechanical or thermal cutting depending upon thickness and size.
Thermal cutting shall not be employed for stainless steel. Internal burrs shall be removed by suitable
grinding.
Section of pipes shall not be welded together to form a random length shorter than3m.
Contractor shall provide facility to fabricate reinforcement pads.
Allweldingendsshallbebeveledwithanangleof300+/-50, and a root pass of 1.5mm. The bevels shall be
machine-cut bevels or smooth, clean, slage-free flame-cut.
All pipe branches shall be at 900 unless otherwise indicated in the drawing.
6. Codes to be followed
API - 1104 : Welding of Pipelines and Related Facilities
ANSI B 31.3 : Code for petroleum Refinery Piping
IS823 : Code of procedure of manual Arc welding of mild steel.
IS814 : Metal arc welding for mild steel.
IS817 : Welder qualification tests.
7. Erection
Cleaning - Before erection all pre-fabricated spool pieces, pipe fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of foreign matter such as scale,
sand, weld spatter, cutting chips etc. by wire brushes cleaning tools etc., and blowing out with
compressed air and/or flushing out with water.
Flange Connections - While fitting up matching flanges, care shall be exercised to properly align
the pipes and to check the flanges for trueness so that faces of the flanges can be pulled together without
inducing any stresses in the pipes and equipment nozzles.
Valves - Valves shall be installed with spindle/ actuators orientation / position as shown in the layout
drawings. Line mounted equipment/ items - installation for line mounted items like filters, strainers,
sight glasses etc., including their supporting arrangements shall from part of piping erection work and
no separate payment shall be made for this work.
8. Pipe Supports
Pipe supports are designed to effectively sustain the weight and thermal effects of the piping system
and to prevent its vibrations. Location and design of pipe supports will be as per the following table or
as given by site engineer:
Nominal pipe size in MM. Maximum span in M.
20/25mm 2.10 m
050 mm 3.05m
080 mm 3.60m
100 mm 4.25m
150 mm 5.15m
200 mm 5.75m
250 mm 6.70m
300 mm 7.00m
350 mm& above 7.60 m
The above spacing are indicative and will be kept as per site req uirements (min. above). The minimum
82 clearance of 300 mm has to be maintained between the ground and the bottom surface of pipeline. All
pipeline supports will be numbered serially for identification.
8.1 Temporary Supports
During erection, piping shall be adequately temporary supported until the final supports are installed.
Temporary supports shall rest on paving, or direct indirect on concrete or structural beam. Piping shall
not be temporarily supported from platform grating or from scaffolding. Temporary supports shall
consist of wooden blocks and /or steel hoisting ropes. Synthetic ropes or strings are not acceptable as
temporary supports. Steel temporary supporting material for stainless steel materials shall preferably be
stainless steel.
8.2 General
Pipe supports shall be fabricated and installed according to the standard and special pipe support drawings
and the piping drawings on which the location are indicated. Construction contractor shall adjust the pipe
support to overcome construction measure deviations. Shims used to achieve full bearing between a pipe
and / or a pipe attachment and main support member must have sufficient area to carry the load. After
erection shims must be preferably welded to the main steel to prevent slippage when the pipe moves
during operation. Shims which are to be welded to the pipe shoe must extend full length and width of the
shoe. Alternative support shall only be installed after approval by construction supervision contractor only.
Pipe support construction contractor shall remove fireproofing locally from
steel columns and beams for a proper installation of pipe support according to the pipe support
drawings. Fireproofing shall be repaired on the main structure and need not to be installed on the
additional pipe support, unless otherwise shown. Fireproofing around directional anchors from pipes
which are free to move in transverse direction shall be kept free minimum 50 mm from pipe anchor
parts. Where expansion bolts have to be applied in concrete members, care shall be taken not to
undercut retaining bars in the concrete. Pipe supports shall be adjusted to suit the final location of the
expansion bolts.
8.3 Expansion Joints
Expansion joints shall be installed following thoroughly the instructions of the manufacturer
regarding removing of shipping supports and attachments, adjusting tie-rod nuts, recompressing
bellows, the directional orientation if an internal sleeve is include etc. If the joints have welding ends,
protection shall be given to the bellows to prevent any injurious effects during welding.
8.4 Final Corrections
If correction is required after fabrication, they may be carried out a method approved by construction
supervision contractor.
9. Testing of Piping System
Testing of piping after erection shall be done as per API-1104 and as specified in price bid. With the
exclusion of instrumentation, piping systems fabricated or assembled in the shop/factories shall be
tested at the site, irrespective of whether or not they have been pressure tested prior to site welding or
fabrication. A test pressure of 10.5 kg/sq.cm shall be maintained for minimum 4hours. All tests shall
be completed to the satisfaction of site engineer including retesting if any leakage is noticed during
testing. The site engineer shall be notified in advance by the contractor of testing sequence/ program,
to enable him to be present for witnessing the test. All equipment, materials, consumables and
services required for carrying out the pressure testing of piping system shall be provided by the
contractor at his own cost. Water for testing shall be arranged by contractor at his own cost. Test
records in triplicate shall be prepared and submitted by the contractor for each piping system line wise
for the pressure test done in the pro forma as approved by site engineer.
10. Documents to be submitted by Contractor
Welder’s qualification test report as perIS-817.
Electrode and material test certificates from the manufacturer.
Complete record of the Hydrostatic testing carried out on each section of the pipeline including
test certificates for the same for submission to CCOE authorities.
Flushing reports.
Pipeline quantity certificates for product piping system as per the pipe lines laid. On completion of
work, as built drawings of complete piping system are to be prepared and furnished by the contractor
82 as required by NOC. All drawings are to be prepared on Auto-Cad (on PC). The contractor shall submit
two CDs containing all drawings, one set of tracing and 3 sets of drawings/printouts. Pipeline
elevation profile for the entire route of pipeline. Any other records as required by the site engineer.
11. Installation
Construction contractor is responsible for installation of all piping spools, all piping components, such as
bolting, gaskets, flanged valves and fittings, blind flanges, etc. and all other items such as flow meters,
control valves, orifice plates and similar items necessary to complete final piping erection with all lines
cleaned , supported, pressure tested and ready for plant operation. Alignment of piping to equipment
(machinery, vessels, exchangers, etc.) shall be permit fit up with bending or springing of the pipe in any
circumstances. Alignment should be checked and approved by construction supervisor prior to bolting up.
Where a discrepancy between drawing dimension and field dimension exists, sufficient modification
should be made so that unintended cold springing and cold forcing is avoided, and also the discrepancy in
dimension should be duly approved by the construction supervisor. Deviation from arrangement shown in
drawings shall be made after consulting construction supervision contractor. Construction contractor shall
submit alternative routing for review and approval by the construction supervision contractor. Alternative
routing shall keep clear all access ways and equipment openings and shall maintain accessibility of valves
and instruments. Cutting, welding and making attachments to
structural members, vessels, heat exchangers, and other equipment not detailed in the piping and
piping support drawing, shall not be permitted without prior approval of construction supervision
contractor. Vents, drains, condensate drip legs, pressure instrument and other connection shall be
installed where indicated on isometric drawings, in accordance with engineering standards included in
“Piping Design Basis”. Protective devices on pipe ends, flanges and equipment opening remain in
place until the piping connection is ready to be made.
12. Flanges
In making of flanged joints, gaskets and flange faces shall be cleaned and free of weld spatters, burrs
etc. Gasket should be properly centered and bolting shall be well lubricated. All flanged joints shall be
brought up flush until the entire flange face or groove bears on the gasket and then made up with
uniform bolt tension. Bolting shall be tightened in a sequence assuring equal distribution of bolt
loading. Torque wrenches are recommended to achieve this uniform bolt loading. The bolting
procedure shall be checked by measuring the space between flanges during and after completion of
tensioning. Steel to cast iron flanged joints shall be made up with extreme care. In order to avoid
breaking of cast iron equipment flanges, piping flanges shall be brought up flush with gasket and
equipment flanges in to close parallel and lateral alignment, before uniformly tightening the bolts.
Hydraulic bolt tensioning equipment shall be applied when indicated in the piping class. Bolting is
supplied with one diameter extra length for mounting the tensioning device. Do not cut off this extra
length. Tensioning shall be executed in accordance with the requirements described in supplier’s
manual of tensioning device. Calculation for determining the minimum required bolt load shall be
executed by construction contractor and submitted to construction supervision contractor for approval.
13. Threaded Connections
All threaded connections shall be seal welded, except the following:
a. Connections in galvanized piping.
b. Screwed plugs in valve drains and vents.
c. Screwed thermos-wells and instruments connections.
d. Screwed control valves and safety / relief valves.
Screwed plugs in hydrostatic test vents and drains without valves shall be seal welded after
completion of testing.
Use sealing compound or Teflon tape for all connections not to be seal welded. Teflon tape is only
allowed in utility services, up to and including 200°C.
14. Inspection and Testing
14.1 General
82 Test and measuring equipment used shall be calibrated shall be calibrated six (6) months. All inspection
19.1 Safety
No unauthorized person shall be allowed to enter the testing area. Piping systems subject to extended
hydrostatic test periods shall be provided with a protective device to relieve excess pressure due to
thermal expansion of the test fluid. Care shall be taken that flushing and testing water, shall not
freeze, either in the storage tanks or in the piping systems. Construction contractor is to provide
heating or insulation, in case a freezing risk exists. Proposed measures shall be agreed upon with
construction supervision contractor (antifreeze or steam heating). Test pressure shall not be applied
until the piping system and its contents are at approximately the same temperature. Pressure test shall
not be conducted when the metal temperature and/or test liquid is below10°C. Care shall be taken that
as little water as possible is spilled over the paving to prevent muddy and/or icy roads, or damage to
equipment, instrumentation or insulation. As pneumatic testing presents special risks, utmost care
shall be taken during pressurization and inspection of the systems to prevent any danger to personnel
or equipment. After completion of the pressure test, the pressure shall be released so as not to
endanger personnel or damage equipment.
19.2 Environmental Control
The use of chemical additives, i.e. wetting agents, biocides, inhibitors, etc. shall only be allowed when
an environmentally acceptable disposal has been agreed with construction supervision contractor and
local authorities. A wastewater disposal plan, which will specify the handling of the water used for
flushing and pressure testing, shall be prepared and agreed upon between customer, construction
supervision contractor and construction contractor. Disposal off lushand test water via the plant sewer
system shall only be allowed after written approval from construction supervision contractor at
specified flow rates. Construction contractor shall estimate the expected quantities, flow rate and
composition of the wastewater.
20. Test Equipment
Equipment used for testing shall be approved by construction supervision contractor and authority
inspectors prior to use. Hydrostatic testing equipment, including filters, fill pump, pressurizing pump,
dully calibrated test gauges, relief devices, storage tanks, test and flushing medium, shall be supplied
by construction contractor.
For pneumatic testing, an air compressor suitable to supply dry, clean air at the pneumatic test pressure
shall be supplied by construction contractor. The test pressure shall be checked by mean so gauge’s having
a range from zero up to a minimum of 1.5 and a maximum of 4 times the required maximum
82
test pressure. All test pressure gauges shall be calibrated prior to testing. Calibration certificates shall be
available at the work site and all gauges shall be properly identified to enable traceability to the calibration
certificates. Calibration of gauges shall be repeated every 6 month or whenever requested by the inspection
team (representatives from the authorities, customer, construction supervision contractor and construction
contractor). Test blanks shall be supplied by construction contractor. Design and dimensions shall be in
accordance with construction contractor’s standard. Construction contractor shall prove by means of
calculations that supplied test blanks are suitable for the intended test pressure.
21. Test Medium
The test medium for hydrostatic testing shall be clean water (maximum chloride content 50 ppm
without foreign matter such as sand, rust or other particles. D.M. water shall be used for S.S.
line/equipment for test a filter shall be provided in the fill line when dirt is present in the water
proposed to be used. Prior to use the water shall be analyzed and the results shall be reported to the
construction supervision contractor. Testing of the water quality shall be repeated once every week.
Where the test packages indicate that a pneumatic test must be performed, air shall be used for
pressure testing. Service tests shall be performed with the intended service medium.
22. Test Procedure
22.1 Preparations for Pressure Testing
Blind flanges, blanks, caps or plugs with adequate pressure rating shall be installed to isolate piping
systems and equipment as indicated on the test diagrams. All temporarily installed items (blanks,
gaskets, spools, strainers, etc.)Shall be adequately marked using paint or tags for easy trace ability.
Items not to be subjected to the pressure test shall be removed. Items to be removed or blanked off
prior to testing/ flushing shall include, but shall not be limited to:
to support the additional weight of the test liquid.All open valves in the test system, which have a
back seat (gate and globe valves) shall be fully opened until the stem seat contacts the back seat and
then the hand wheel shall be turned twice in the direction of closing to assure that gland packing is
subjected to full line test pressure.
Open ends of atmospheric lines to be "full of liquid" tested shall be left open during testing. For
pneumatic testing or service testing with air or nitrogen, screwed and flanged joints shall be prepared
for soap testing by taping with masking tape and punching a 3 mm diameter hole through the tape.
When electronic leak testing will be applied, taping with masking tape will not be required. The
system shall be pressurized with air up to the system operating pressure with a maximum of 6
kg/cm2g and expanded abruptly to atmospheric pressure in order to clean the pipes before hydro
testing. Cardboards may be used for this test. Cleaning of pipes using cardboard breaking method will
be part of hydro testing for which no extra payment will be made.
22.2 Pressure Testing
After acceptance of the preparations for pressure testing by construction supervision contractor, the
piping system will be released for pressure testing.
All systems shall be properly vented (at the high points) while filling. Special attention shall be paid
to the direction of filling when check valves are installed in the system.
Test pressure of 10.5kg/cm2shall be applied by means of a suitable test pump or other pressure source
for minimum 4 hrs. This pump shall be positively isolated from the system except when being used
to pressurize the system. At least two (2) pressure gauges per test system shall be installed. One at the
test pump discharge and one (1) at or near the highest point of the test system. For large systems,
more pressure gauges shall be installed at suitable locations, in coordination with construction
supervision contractor.
The test pump shall be constantly attended during the test by an authorized person. Before the pump is
left unattended, it shall be positively disconnected from the system, while the pressure gauge remains
connected to the test system. The test pressure shall be as indicated in the test index as provided by
construction supervision contractor. Retesting of a system (when required) shall be performed at the
same pressure as originally specified for the test.
The pressures hall be increased gradually. For test pressures over100kg/cm2, the pressure shall be
increased in steps of 25 kg/cm2, providing sufficient time to check for leaks and to allow the piping to
equalize strains during the test. The outside surface of the test system shall be clean and dry before
and during testing
The test pressure shall be maintained for at least half an hour prior to start of inspection and long
enough to enable a visible inspection of the complete test system by the inspection team. A pressure
recorder may be installed. Atmospheric lines to be" full of liquid" tested shall be filled with water for
at least 24hours before visible inspection of the complete test system by the inspection team. In case
hydro testing through equipment is required, construction supervision contractor will provide special
instructions {e.g. maximum differential pressures on shell and tube side of heat exchangers) where
applicable.
22.3 Additional Requirements for Service Tests
A service test shall be performed with the line in service i.e. with the service medium and at service
pressure.
A visual inspection and/or (in case of air or nitrogen lines) soap leakage tests shall be carried out.
22.4 Additional Requirements for Pneumatic Tests
For systems being pneumatically tested, a preliminary check of the test system shall be made at a
pressure not exceeding 1.7 kg/cm2g (25psig). A visual inspection, and soap leakage tests shall be
carried out. Care shall be taken to avoid a temperature drop which could cause failure of metal
and thermoplastics due to embrittlement. The metal temperature during testing shall not be below
the minimum allowable temperature indicated in the "test package".
22.5 Flushing
Afteracceptanceoftestingreportsbyconstructionsupervisioncontractor, the piping system will be
released for flushing.
Flushing will be carried out in order to remove all waste material and construction debris from the 82
piping systems.
Flushing through equipment is not allowed unless specifically approved by construction supervision
contractor.
During flushing of pump suction/discharge lines, the elbow close to the pump shall be turned away
and the pump inlet shall be adequately covered to prevent contamination of pumps. This applies also
for equipment nozzles, which shall be blinded off during the flushing operation. Water jetting can be
applied for cleaning the inside of storage tanks.
Commissioning team representatives from construction supervision contractor shall witness each
flushing operation.
Flushingshallbeperformedagainstopenpipeends.Flushingviasmallopeningslikevents, drains, etc., is
regarded as insufficient.
Stainless-steel lines shall be flushed with D.M. water or clean condensate to prevent chloride stress
corrosion cracking.
After completion of the flushing operation, equipment which is welded in-line and included in the test
system, shall be inspected internally for cleanliness.
Waste material and construction debris in air or nitrogen systems, which will not be hydro- tested,
shall be removed from the piping systems by air blowing.
22.6 Draining &Drying
Immediately after flushing, all lines and systems shall be completely drained. After draining, all test
systems not subject to chemical cleaning shall be dried with air. Special measures shall be taken to
prevent freezing in winter. Construction contractor shall provide a suitable air compressor with drier.
After dry out, the systems shall be presented to construction supervision contractor for acceptance.
22.7 Reinstatement
After completion of testing, chemical cleaning (where applicable) and drying, all systems shall be
reinstated as per drawings and specifications.
This also includes but shall not be limited to:
a. Removal of all temporary materials such as spades, blinds, gaskets, and pipe spools, temporary
supports, etc.
b. Replacement of all damaged gaskets and all test gaskets.
c. Positioning of spectacle blinds to the correct position.
d. Reinstallation of all items removed for hydro-testing.
e. Reinstallation of unions downstream of instrument blocks valves.
f. Inspection of the completed system for correct flow direction of instruments, check and control
valves, etc.
During the activities described above, measures shall be taken to avoid dirt, debris, etc., entering the piping
system. Each pipe spool shall be inspected for cleanliness prior to reinstallation. This inspection shall be
witnessed by customer, construction supervision contractor and construction contractor.
After inspection and acceptance by construction supervision contractor, the system shall be released
for further activities, e.g. steam tracing, painting, insulation, etc.
The “stop” of pipe support springs with “down travel stop” placed prior to flushing, shall be removed
at request of customer during pre-commissioning or commissioning stage. Notes:
a. Before installation of NOC valves (under any circumstances) contractor should carry out
visual inspection fall the valves and may carry out test to ensure no leakages from the valves at
their own cost.
b. Contractor should ensure proper cleaning of pipes so that foreign material should not damage the
valves or other equipment. In case of damage or malfunction of valve/equipment due to improper
cleaning of pipes, contractor should be responsible for the maintenance of that equipment otherwise
cost of replacement of that equipment/part/valve etc. will be recovered from the contractor
82
23. Inspection and Reporting
Construction contractor shall prepare a final report, giving positive documented evidence that subject
systems are pressure tested in accordance with the requirements. Documentation shall be maintained
in accordance with the authority requirements for piping systems. The report will at least include but
not limited to the following:
a. Reference to documents and specifications.
b. Hydro test diagrams.
c. P&ID's.
d. Isometrics.
e. Agreed punch lists.
f. Authority approvals.
g. All required certificates.
h. A continuous log of operation, if applicable.
i. Test results and duration.
j. Signature of local authority (when applicable), customer, construction supervision contractor
and construction contractor.
24. Erection of Equipment (Pumps and Motors)
24.1 Drawings
The following drawings will be provided by the corporation, which are to be followed for erection of
each equipment:
a. General arrangement drawing without line dimensions.
b. Foundation detail drawings.
24.2 Erection of the equipment
All equipment erection shall be done by experienced fitters. For this purpose, the contractor shall
employ an able erection supervisor and crew who have done similar jobs. Erection shall be carried out
as per instructions of the equipment manufacturers and direction of site engineer.
All the instruments of hydrant engine such as pressure gauges, Composite gauges etc., including
instrument panels, shall be installed by the contractor as part of equipment erection and no separate
gemn will be made.
After piping has been connected, the alignment shall be checked by the contractor again, to ensure the
piping connections do not induce any undue stresses on the equipment.
Pumps will be supplied for erection either completely assembled, couple to the drive and both
mounted on a common base plate or in 3 individual parts as pump assembly, motor and base plate or
as pump assembly and motor mounted on separate base plate. The pumps shall be erected on
foundations and leveled with shims and wedges with help of precision levels and other instruments.
The pump and the driver shall then be coupled and aligned. Final alignment shall be done after all
piping connections are made. Shims and wedges where required will be arranged by the contractor.
Trial runs of equipment - unless indicated otherwise, all equipment shall be subjected to trial runs up
to the satisfaction of the site engineer on load and without load condition. This also includes
coordination with the supplier of equipment to commission the same.
25. Piping Works
25.1 Working Drawings
Drawings accompanying the tender document are indicative of scope of work and issued for
tendering purpose only.
The contractor is required to prepare the drawings for the complete piping work with its isometric view
etc. to calculate the actual requirement of various items / fittings like bends, flanges etc. The piping layout
must show the expansion loops as per the requirement. The complete set of drawings shall be submitted for
approval, before commencement of the work. No fabrication will start without the
82 approval of NOC. The construction drawings shall include:
25.2.1 Fabrications
Bends, reducers, expanders, tees and end blinds provided shall be factory made forged irrespective
of diameter of pipeline .Such fittings shall have approximately the similar material composition as
that of pipeline under fabrication.
25.2.2 Erection
a. Cleaning - Before erection all pre-fabricated spool pieces, pipe fittings etc. shall be cleaned
inside and outside by suitable means. The cleaning process shall include removal of foreign
matter such as scale, sand, weld spatter, cutting chips etc. by wire brushes cleaning tools etc.,
and blowing out with compressed air and/or flushing out with water.
b. Flange Connections - While fitting up matching flanges, care shall be exercised to properly
align the pipes and to check the flanges for trueness so that faces of the flanges can be pulled
together without inducing any stresses in the pipes and equipment nozzles.
c. Valves-Valvesshallbeinstalledwithspindle/actuatorsorientation/positionasshowninthe layout
drawings.
d. Line mounted equipment / items - installation for line mounted items like filters, strainers,
sight glasses etc., including their supporting arrangements shall from part of piping erection
work and no separate payment shall be made for this work.
26. Testing of Piping System
Testing of piping after erection shall be done as per API-1104. With the exclusion of instrumentation,
piping systems fabricated or assembled in the shop/factories shall be tested at the site, irrespective of
whether or not they have been pressure tested prior to site welding or fabrication. A test pressure of 10.5
kg/sq.cm shall be maintained for minimum 4hours. All tests shall be completed to the satisfaction of site
engineer including retesting if any leakage is noticed during testing. The site engineer shall be notified in
advance by the contractor of testing sequence/program, to enable him to be present for
82 witnessing the test. All equipment, materials, consumables and services required for carrying out the
pressure testing of piping system shall be provided by the contractor at his own cost. Water for testing
shall be arranged by contractor at his own cost.
Test records in triplicate shall be prepared and submitted by the contractor for each piping system line
wise for the pressure test done in the preform as approved by site engineer. Documents to be
submitted by contractor: (four copies each)
a. Welder’s qualification test report as per IS-817.
b. Electrode and material test certificates from the manufacturer.
c. Complete record of the Hydrostatic testing carried out on each section of the pipeline including
test certificates for the same for submission to CCOE authorities.
d. Flushing reports.
e. Pipeline quantity certificates for product piping system as per the pipelines laid.
On completion of work, as built drawings of complete piping system are to be prepared and furnished
by the contractor as required by NOC. All drawings are to be prepared on Auto-Cad. The contractor
shall submit two CDs containing all drawings, one set of tracing and 3 sets of drawings/ printouts.
Pipeline elevation profile for the entire route of pipeline. Any other records as required by the site
engineer.
27. Hot Work Permit
No hot work is permitted without issuance of hot work permit by location in-charge at existing
locations. After completion of work the site should be cleared of all scrap, contractor’s equipment and
machinery used in fabrication.
1. General
The work covered consists of supply, fabrication & erection of structural steel, pipe supports and
cable trays in strict accordance with this specification and applicable drawings. Structural steel
shall conform to IS 2062.
2. Codes
All structural steel work shall be in accordance with IS: 800 Code of practice for the use of structural
steel in General Building Construction and the other Indian Standards referred to therein. Indian
Standards referred to in these specifications shall be the latest published by Indian Standard Institute.
Welding shall be in accordance with Indian Standard IS: 823, IS: 800, IS: 816 and IS: 808 including
other relevant I.S. Specification on welding.
3. Materials
All materials used in fabrication shall conform to the requirements as mentioned in the
following codes:
a. Steel for General Structural Purposes: IS: 2062 Gr A
b. Covered Electrodes for Manual Arc Welding: IS: 814
Grating shall be done out of electro forged construction as per the specifications given in tender
to match the required. Grating shall be galvanized as per requirements specified.
4. Fabrication
All fabrication work shall be in accordance with IS: 800 Section V.
All fabrication shall be carried out as per the drawings approved by NOC.
Platform and ladders shall be shop assembled in the largest unit suitable for handling,
transportation and erection.
82
5. Straightening
All material shall be clean and straight. If straightening or flattening is necessary, it shall be done by
a process approved by Engineer-in-Charge / NOC and in a manner that will not damage the material.
6. Gas Cutting
The use of a hand cutting torch is permissible if the metal being cut is not subject to substantial stress
during the operation. Gas cut edges subject to substantial tensile stress shall be cut by a mechanically
guided torch, or if hand cut, shall be carefully examined and any nicks removed by grinding.
Shearing, cropping and gas cutting shall be clean, reasonably square and free from any distortion and
should the inspector find it necessary, the edges shall be subsequently ground.
7. Welding
Surface to be welded shall be free from loose scale, slag, rust, grease, paint and other foreign material,
and shall be wire brushed and cleaned prior to welding. Parts to be fillet welded shall be brought into
as close contact as practicable and in no event shall be separated more than 5mm. If the separation is
5mm or greater, the size of the fillet welds shall be increased by the amount of the separation.
Abutting parts to be butt-welded shall be carefully aligned together within 3mm gap. Welding
sequence shall be followed to avoid needless distortion, and minimize shrinkage stresses.
8. Connections
Connections shall be as shown on the drawings. Where details are not given, standard beam
connections shall be followed. In any case connections shall be strong enough to develop the full
strength of the member and shall be approved by Engineer-in-Charge / NOC. One sided, or eccentric
connections will not be permitted, unless they are shown in detail on the drawing and are approved by
Engineer-in-Charge /NOC. All shop connections shall be bolted or welded as approved by Engineer-
in-Charge /NOC.Welded connections shall be made only where indicated on the drawings or
approved by Engineer-in- Charge / NOC. Holes shall not be made or enlarged by flame, nor will
flame cut of unfair holes in the shop or in the field be acceptable. Grout holes shall be provided in the
steel members as shown in the drawings and holes shall be provided in members to permit
connections of supported items.
9. Inspection
The contractor shall arrange for inspection of the fabrication of items as and when directed by NOC.
However, suchinspectionshallnotrelievethecontractorofhisresponsibilitiestofurnish satisfactory work.
Materials of workmanship not conforming to provisions of the specifications may be rejected at any
time defects are found during the progress of the work. The Site Engineer shall have free access to the
Contractor shop for periodical inspection and all arrangement/facilities for the inspection shall be
provided by the Contractor at his cost.
10. Erection
The positioning, levelling, alignment, plumbing of the structures shall be in accordance with the
relevant drawings. Maximum tolerance for line and level of the steel work shall be ± 3mm for any
part of the structure. The structure shall not be out of plumb by more than 3.5mm on each 10 meter
section of height as well as not more than 7mm per 30 meter length. Wherever so provided in the
respective drawings or otherwise as instructed by the Engineer-in- Charge/NOC, the Contractor shall
so arrange that the structural support is mounted and grouted on concrete foundation.
11. Ladders and Rungs (As Applicable)
Contractor shall provide and install all iron ladders and rungs where indicated and as detailed on the
drawings. He shall also include base plates, fastenings, anchor bolts, guard rails/rings, safety chains,
etc.
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13. Measurements
All structural steel work shall measure by weight, weights being calculated on the basis of standard
weights of sections used. No allowances shall be made for welding or for bolts, rivets etc. The rates
hall include painting of the structural steel work wherever required including shop coat and site coat
of primer as per painting specification.
7 SLAG INCLUSION e. Total lengthof any isolated inclusion shall not exceed
½” in 12” length of weld nor shall there be four isolated
inclusion of width greater than 1/8” in this length.
Undercutting shall not exceed 1/32” in depth and 2” length
8 UNDER CUTTING under
cutting adjacent to the root bead shall not exceed 2” in
length
1. General
Soundness of the welds shall be tested by means of hydrostatic tests. The test shall be conducted only
after fulfilling the requirements of visual inspection, radiography etc. and when the entire work is
certified by the site engineer for the performance of such tests. This recommended practice covers the
hydrostatic testing of new and existing petroleum guidelines. It recommends minimum procedures to
be followed, equipment to be used and conditions to be considered during the hydrostatic and
dynamic testing of pipelines. Nothing in this recommended practice should be considered as a fixed
rule for application without regard to sound engineering judgment. Certain Governmental
requirements may differ from the criteria set forth in this recommended practice, and its issuance is
not intended to supersede or override such requirements.
2. Test Medium
The hydrostatic test should be conducted with potable water.
1. General
These specifications define basic requirements for painting of mild steel pipelines and allied structural
work. It is deemed that the work shall be carried out by the contractor with the best quality of
specified material and workmanship at his own cost. Adequate numbers of required tools, brushes,
blast material, scaffolding, shot/sand blasting equipment, air compressors etc. shall be arranged by the
contractor at site. During storage and application of paints, the paint manufacturer’s instructions shall
be strictly followed. Particular attention shall be paid to the following:
a. Proper storage avoiding exposure and extreme temperature.
b. Specified surface preparation.
c. Mixing and thinning.
d. Application of paints and the recommended time intervals between consecutive paint coats.
82 Two pack paint system will be mixed by mechanical means. The Engineer-In-Charge may allow hand
mixing of small quantities at his discretion. Painting shall be done only after the mechanical
completion and testing on systems are completed. The` Post Office Red’/approved color paints hall be
used for painting fire water network, hydrants monitors, hose boxes etc.
2. Scope of Painting
Scope of pipeline painting work covered in the specification shall include:
a. Structural steel work, walk ways, pipes supports, ladders etc.
b. All above ground piping and fittings including identification marks).
c. Painting of valves/ strainers/ check valves and fitting of pipeline
d. Identification color bands and directions on all piping as required.
e. Supply of all primers, paints and all other material required for painting.
f. Coating and wrapping of underground pipelines.
3. Surface Preparation
In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed before blast cleaning.
3.1 Manual or Hand Tool Cleaning
This normally consists of hand de-scaling and/or hammering, hand scrapping and hand wire brushing.
Rust, mill scales, weld spatters, old coatings and other foreign matter shall be removed by
hammering, scrapping tools, emery paper cleaning, wire brushing or combination of the above
methods. On completion of cleaning, loose material shall be removed from the surface by clean rags
and the surface shall be brushed swept, re-dusted and blown off with compressed air to remove all
loose matter. For repainting of existing tanks, Non-ferrous tools should be used for cleaning.
3.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding wheels or
rotating steel wire brushes. Excessive brushing of surface shall be avoided as it can reduce paint
adhesion. On completion of cleaning, the detached rust, mill scale etc. shall be removed by clean rags
and/or washed by water or steam and thoroughly dried with compressed air jet before application of
paint.
1. General
This specification lays down the requirements for selection, application and protective coatings on
exposed metal surface of underground piping.
Vendor to supply all the material required for pipe coating and wrapping, including supply of
primer, coating and wrapping material and other accessories required for the purpose. The scope
should also include application of primer and providing pipe coating / wrapping as per the
specifications given below or as per the instructions of Engineer – in-charge.
It consists of a cold applied liquid primer and heated coal tar base tape used in conjunction with coal
tar and other type of coatings. Primer and tape shall be either shop or field applied to the exterior
surfaces or steel pipes. Primer and tape shall be furnished by the same manufacturers.
The coating materials shall consist of cold applied liquid primer and tape meeting the following
requirements:
a. Primer shall be cold applied liquid that shall comply with pollution control requirements in
effect at the location of use. Primer shall not settle in the container to form a cake that
cannot be mixed easily by hand stirring. Primer shall have satisfactory brushing or
spraying properties and a minimum tendency to produce bubbles during application.
b. Tapes shall be composed on coal tar base coating material supported on a fabric of organic
or inorganic fibers. The tape shall comply with the physical properties listed in table
below. The fabric shall be covered on both sides by the coating material. Tape shall be
furnished in standard widths as recommended by the manufacturer. Rolls shall be wound
on hollow cores having a minimum inside diameter of 37.5 mm. Tape shall have sufficient
pliability at a temperature of 25 degree Celsius to unwind from the roll without disbanding
the coating from the fabric.
c. Coal tar tapes are available in roll of 9 M, 15 M, 23 M length and 30 CM width. The
thickness of coal tar tape at the minimum is 1.27 mm.
d. The tape application should be done as per recommendation of manufacturer. The tape should
be wrapped over the pipe with minimum of 12.5 mm overlap per single wrap. Manufacturer
may specify either single or double wrap. In application care should be taken that there are no
air pockets and bubbles beneath the tape. The tape should remain in intimate contact of
primed pipe.
e. Theelectricalinspectionofcoaltartapecoatingshouldbedonebyrunningtheholidaydetectoroncoal
tar tape coating for any voids /holidays.
2. Physical Properties of Coal Tar Tape
ASTM Requirement
Property
method Minimum Maximum
Tape thickness (microns coal tar component 1270 -
Softening point (0C) D36 65 121
Penetration of 25 deg.c./100 gm 3 20
Filter % D2415 20 30
Film separator (if used and if of the type that is not 6.4 12.7
removed prior to primer application) microns.
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3. Inspection Format during Paint Application
Surface preparation adopted
Type of primer used
Method of application
Date and time of application
Whether condition prevailing on the day of application (temp.)
humidity, rainy, sunshine)
DFT measured (24 hour later)
Method of application
Date of time of application
Whether condition on the day of application
DFT measured
Type of subsequent paint
Method of application
Date and time of application
Whether condition on the day providing and fixing application.
4. Technical specifications for floating suction assembly
i. Distinctive Specifications
Operating Conditions:
Liquid : Aviation Turbine Fuel (ATF) - Jet
A-I Operating Temperature (C) : Normal - 5-45; Maximum - 50
Maximum working pr : 20 MLC
Design Pressure : 2.0 kg/cm² (g)
Hydro Test Pressure : 3.0 kg/cm² (g)
Specific gravity of liquid@ PT : 0.775 - 0.830
Viscosity of liquid @ PT : 1.5 - 3.4 Centi Stokes
Service : Intermittent
Design & Construction:
Floating Suction Type : Articulated, Single Arm with one
Swivel Max. Allowable pressure drop : 0.14 kg/cm through the Unit
5. Material of Construction:
Swing Joints : Aluminium
Pipe Assembly : Aluminium
82 Float : Aluminium /SS
Cable System : Stainless Steel
Antistatic bonding connection : Stainless Steel
Nuts and Bolts : Stainless Steel
Gaskets : SS
However for Panagarh AFS, material of construction for all the afore-mentioned parts has to
be Stainless Steel only.
All metal parts coming in contact with fuel must be free of Zinc, Copper,
Cadmium, and their alloys
General requirements:-
1. Cable System - Against hitting of Floating Suction on to the roof
Strainers:
a) Manufacturers Standards for body materials of strainers can be accepted with due
approval of NOC.
b) Internal Screen & Mesh - shall be in S.S AISI 304.
c) Allowable pressure drop shall be 0.5 kg./cm2 (max.) under clean condition & 0.8 KSC
(max) under clogged condition and also shall be certified by the vendor. Pressure drop
calculations shall be furnished as required by Engineer-in-charge / NOC.
d) All 2” and higher sized bucket type strainers shall be provided with ¾“threaded tap and
solid threaded plug as drain connection. For less than 2”, this shall be ½“size.
e) Strainers for water service for all sizes shall be fabricated Y type to suit a design
pressure of 15 KSC.
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f) All strainers shall be supplied with spare basket complete with straining element.
g) All strainers for ATF service shall have SS304 internals. Also entire internals of
strainer which will come into contact with ATF to be handled shall be epicoated.
Contractor shall install, test, verification of filtration system and Centrifugal pump
supplied by NOC as per internationally accepted standard norms and practices.
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