PART-II

GENERAL RULES AND DIRECTIONS FOR THE GUIDANCE OF THE

TENDERERS AND FORM OF AGREEMENT

Item Rate Tender and Contract for Works

(Central PWD Code Paragraph-95)

2.0 General Rules and Directions:

2.1 All works proposed for execution by contract will be notified in a form of invitation
to Tender signed by The Director, Reactor Design & Technology Group. This form
will state the work to be carried out as well as the date for submitting and opening
Tenders, and the time allowed for carrying out the work, also the amount of earnest
money to be deposited with the Tender, and the amount of security deposit to be
deposited by the successful Tenderer and percentage, if any, to be deducted from
bills. Copies of specifications, design and drawings for the purpose of identification
shall also be open for inspection by the Contractor at the office of the Engineer
during office hours.

2. 2 In the event of the Tender being submitted by the firm, it must be signed separately
by each member thereof. In the event of absence of any partner, it must be signed
on his behalf by a person holding power of attorney authorizing him to do so; such
power of attorney shall be produced with the Tender, and it must disclose that the
firm is registered under Indian Partnership Act.

2.3 Receipts for payments made on account of works when executed by a firm must
also be signed by the several partners except where the Contractors are described in
their Tender as a firm, in which case the receipt must be signed in the name of the
firm by one of the partners, or some other person having authority to give effectual
receipts for the firm.

2.4 Any person who submits the Tender must fill up the prescribed form stating the sum
of money for which he is willing to undertake the work. The Tenders which propose
any alteration in the work specified in the said form of invitation to Tender or in the
time allowed for carrying out the work or which contain any other condition of any
sort, will be liable for rejection.

2.5 The rate(s) or amount(s) must be quoted in Indian Rupees both in words and figures
& it shall be inclusive of all taxes including GST.

2.6 Director, Reactor Design & Technology Group or his duly authorized representative
will open the Tenders individually, in the presence of the respective Tenderer or his
representative who may be present at the time stated in the notice. The earnest money
deposit paid by the successful Tenderer will be treated as part of security deposit. The
balance amount of security deposit will be paid by the Contractor on acceptance of the
Tender. The security deposit will be accepted in cash or in Government Securities and
fixed deposit receipt and guarantee bonds of Scheduled Banks and State Bank of
India. In the event of the tender being rejected the earnest money forwarded with such
unaccepted Tenders shall thereupon be returned to respective Contractors

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2.7 The officer inviting Tender shall have the right of rejecting all or any of the Tenders
and will not be bound to accept the lowest Tender.

2.8 The receipt of an accountant or clerk for any money paid by the Contractor will not
be considered as an acknowledgement of payment to the Engineer and the
Contractor shall be responsible for ensuring that he procures a receipt signed by the
Engineer or by the Accounts Officer or duly authorized Cashier.

2.9 The memorandum of the work Tendered shall be filled and completed in the Office
of the Engineer before the Tender form is issued. If a form is issued to the Tenderer
without having been so filled in and completed, he shall request the Office to have
this done before he completes and delivers his Tender.

FORM OF AGREEMENT (DECLARATIONS)

2.11 I/We, the undersigned, do hereby declare that the Tenderer is:

2.11.1 * A Company duly incorporated under the laws of

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(insert to authorized jurisdiction).

2.11.2 *A Partnership, joint venture or consortium carrying on business under the firm
name and style above stated, the names, addresses and places of incorporation, if
any, of all the partners or members of the firm being the following:

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----------

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(* Strike out sub-section 2.8.1 or 2.8.2 whichever is not applicable).
2.12 We have examined all the Sections / Parts of these Tender Documents and are fully informed as to the nature and scope of the
work and the conditions related to its performance. I/We, have also visited the site of work and considered the site conditions
in full in relation to the performance of the work.

24
 2.13 Offer:

2.13.1 I/We, hereby tender for execution for the President of India the work specified in
the underwritten memorandum at the rates specified herein and in accordance in all
respects with the specifications, designs, drawings and instructions in writing
referred to in the Tender Documents and as per Clause-11 of General Conditions of
Contract (Part-IV).

MEMORANDUM:

a) Name of the work :

b) Place of the work :

c) Earnest Money :
Deposit
d) Security Deposit :

e) Time Allowed : SIX MONTHS

2.13.2 Should this tender be accepted in whole or part, I/We hereby agree to :

(i) Abide and fulfill all the terms and provisions of the said conditions annexed
hereto and all the terms and provisions contained in the notice inviting tender as far
as applicable, and/or in default thereof to forfeit and pay to the President of India or
his successor in the office; the sum of the money mentioned in the said condition. A
sum of Rs.________________ is hereby forwarded as Deposit at Call Receipt of
a Scheduled Bank or Nationalized Bank / Demand Draft as Earnest Money. If,
I/We fail to commence the work from the date specified in the above memorandum,
I/We agree that the said President or Successor in Office, shall without prejudice to
any other rights or remedy be at liberty to forfeit the said earnest money that shall
be retained by him towards deposit mentioned against Clause (C) of the above
mentioned memorandum.

(ii) Execute all the work referred in the Tender Documents upon the terms and
conditions contained or referred to therein and to carryout such deviations as may be
ordered at the rates quoted in the Tender Document, for respective items of the work
so long as the entire total cost of the work executed by us under this Contract is
within the limits of (+) 25% and (-) 25% of the Contract amount entered into the
agreement at the rates quoted in the Tender Document and those in excess of that
limit at the rates to be determined in accordance with the provisions contained in the
Clause 12-A of Section-IV of General Conditions of the Contract.

2.13.3 I/We, agree to keep this offer open for a period of ninety days (90) days from the
date of opening of the Tender).

2.14 I/We do hereby quote for the works as mentioned in Parts V & VI.

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 2.15 I/We give the unit prices in Section-VI in the appropriate columns of the forms
supplied by you. These prices include cost of the materials as applicable, field
fabrication, assembly including all labour, supervision, consumables, materials,
inspection, insurance, site erection, taxes, duties, overheads and profits etc.
2.16 I/We do agree to the terms of payment as specified in Part-III, Special Conditions of
Contract.

2.17 I/We agree to carry out the work according to the scope of work and technical
specification and shall strictly adhere to schedule given in the Tender.

2.18 Data to be supplied with Tender (IN TRIPLICATE)

I/We enclose herewith following appendices giving the additional information to
our Tender:
2.18.1 Appendix- 1 : List of manpower whom we are going to be engage
exclusively for this Contract at site

Appendix- 2 : Details of manpower and their experience

Appendix- 3 : List of deviations from specification referring to specification

number and Clause number of specification in Part V.
Appendix- 4 : Proof of ability: This shall be as per PROFORMA-I attached to this
Part of tender document giving the particulars of similar works carried out.

2.18.2 Sub-Contractors:
I/We propose to employ following Sub-Contractors for the work and give the details
of the work to be undertaken by each of them and details of work of similar nature
previously carried out by each; no other Sub-Contractors shall be allowed later.

Name of Sub-Contractor Work to be Sub-Contracted Previous Experience

of the Sub-Contractor

ii)
ii)
iii)

2.18.3 I/We have acquainted ourselves with the site conditions.

Date:_______________

Signature of the Tenderer : _________________________________

Address :

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 Occupation : _________________________________

The above Tender is hereby accepted by me on behalf of the President of India

Signature of the Officer

Date :_______________ by whom accepted

PROFORMA-I
APPENDIX-5 : PROOF OF ABILITY FOR TENDERERS

(Use one form for each work carried out and number as Va, Vb, Vc etc., for each work
carried out)

1.0 Name of work executed :

1.1 Name of Firm/Project for whom work :

done

1.2 Address for reference :

1.3 Value of total work carried out :

1.4 Value of work of contract, if it is a

composite one

1.5 Date of commencement :

1.6 Name of Sub-Contractors employed, if :

any

1.7 Has the work been completed and final

payment made :

1.8 Was there any arbitration :

1.9 Nature of arbitration, if any :

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Date:_________________ Signature of
tenderer_____________________

(Proof of having established and carrying out work away from Registered Office/Works is
also required for outstation bidders. Those who have not carried out fabrication and erection
of SS piping and components in major contracts will not be considered).

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 PART- III

SPECIAL CONDITIONS OF CONTRACT

III.1 Location:
The proposed site for this work is at IGCAR, Kalpakkam near Sadhurangapattinam.
This site is accessible by road from Chennai via Chengalpattu, Thirukkalikundram
and also via Mahabalipuram.

III.2 Site Investigation:

The Contractor acknowledges that he has satisfied himself as to the nature and
location of the work, the general and local conditions, particularly those bearing
upon transportation, disposal, handling and storage of materials, availability of
labour, water, electric power, roads and uncertainties of weather, or similar physical
conditions of the site. Any failure of the Contractor to acquaint himself with all the
available information concerning these conditions will not relieve him from
responsibility for estimating properly the difficulty or cost of successfully
performing the work. Non-familiarity with the site conditions will not be considered
a reason either for extra claims or for not carrying out the work in strict conformity
with drawings and specifications. The Contractor shall note that if any clarifications
regarding Specifications, Conditions of Contract, Schedule of Quantities, Scope of
Work etc. are required, he should contact the office of the Engineer. No claim on
account of ambiguity in any respect will be entertained.

III.3 Security Rules:

The Contractor shall follow at site all Security Rules as may be framed by the
department from time to time regarding removal of materials from site, issue of
Identity Cards, Control of Entry of Personnel and all similar matters. The Contractor
and his personnel shall abide by all security measures imposed by the Engineer or
his duly authorised representative from time to time.

III.4 Accommodation, Transport, Medical Facilities:

IGCAR will not provide accommodation, transport and medical facilities to
Contractors’ personnel. The Contractor shall at his cost make his own arrangement
for accommodation, transport and medical aid / treatment for his staff and workers
engaged by him on this Contract.

III.5 Government Labour Laws:

The Contractors have to follow strictly the Government labour acts which are in
force at present including any amendments or additions that may be made by the
Government during the entire period covering the date of publication of this Tender
Notice till the completion of the work covered by the Contract and all necessary
arrangements for labour will have to be made by the Contractor.

III.6 Withdrawal of Tender:

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 Should the Contractor modify or withdraw his Tender within a period of SIX
months from the date of opening of the Tender, his earnest money will be forfeited.

III.7 Compensation for Loss/Damage:

During the execution of the Contract and until Completion Certificate is issued, the
Contractor will be fully liable to compensate all concerned for any loss, damage or
destruction of works, structures, plant and machinery, persons, property etc.
including third party risk arising due to causes attributable to the Contractor as may
be decided by the Engineer whose decision in this regard will be final. No claim
shall be made against Government on this account.

III.8 The Contractor shall take necessary precautions to ensure safety of his crew,
materials, equipment and the works during the period of the Contract. No claim
from the Contractor for loss of or damage to equipment, materials, crew or the
works during the course of the work due to natural causes like cyclones, gales,
floods, rains or other cause or combination of causes will be entertained by
Government. The Contractor shall be fully liable to compensate Government for
any loss or damage to works till the time of taking over of the work by Government.

III.9 Transportation of Materials:

The Contractor shall make his own arrangements for the transportation of the
materials to be used by the contractor for the maintenance work to the Work Site.

III.10 Assistance for Taking Measurements:

The Contractor shall provide necessary labour and assistance to the Engineer for
assessment of work completed by them at no extra cost to the Government.

III.11 Schedule of Quantities and Rates:

The Schedule of Quantities is to be read in conjunction with this Special Conditions,
General Conditions of Contract, Tech. Specifications.

Each Tender should contain not only the rates but also the value of each item of
work entered in a separate column and all the items should be totalled up in order to
show the aggregate value of the entire Tender. All corrections in the Tender
schedule shall be duly attested by the dated initials of the Tenderer. Corrections,
which are not attested, may entail the rejection of the Tender. The Tender Document
should be signed and returned without, detaching any part of the document.

III.12 Employees:
It is to be ensured that all the employees and workers employed by the Contractor
are law abiding citizens, with clean record. Anti-social elements, rowdies and
persons with adverse police records should not be employed on the works at
Kalpakkam. It is to be ensured by the Contractor that the correct personal particulars
and addresses of all the employees and workers employed by the Contractors are
available.

III.13 Emergency Preparedness:

It may be noted that the Government as a part of the emergency preparedness for
any eventual site emergency civil defence which would require the entire or part of
the Contractors personnel and labour to be evacuated from the site without any

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 advance notice as and when deemed necessary. This may result in temporary
stoppages of work with possible loss of time and productivity not likely to exceed 1
day. This aspect shall be taken into account while quoting their rates and the
department will not entertain any claim/compensation on this account. However, the
department may grant suitable extension of time only.

III.14 Tender Clarification:

The Tenderer should note that if any clarifications regarding Specifications,
Conditions of Contract, Schedule of Quantities or Scope of Work are required he
should Director, RD&TG, IGCAR, Kalpakkam-603102. No claim on account of
any ambiguity in any respect will be entertained. The decision of Director, RD&TG
is final in case of any ambiguities between different portions of Tender and
drawings.

III.15 All prices quoted shall remain firm throughout the period of the contract and shall
not be subjected to any escalation for changes in the cost of labour and material and
any other cost.

III.16 Confidential Report from Bank:

The name of the bank (the branch or branches) with which Contractor has dealings
and who can certify the Contractor’s financial status should be given. The
Contractor should arrange for a Confidential Report to be sent by one of their
bankers directly to:

DIRECTOR
REACTOR DESIGN & TECHNOLOGY GROUP
INDIRA GANDHI CENTRE FOR ATOMIC RESEARCH
KALPAKKAM -603102

so as to reach him before the date fixed for opening the Tender. The Contractor
shall also send the latest available copies of the balance sheet and profit and loss
account of the firm.

III.17 The Contractor shall take up the maintenance work as per priority indicated by the
Engineer-in-Charge.

III18 Medical Facilities:

The Contractor shall arrange adequate facilities for medical aid and treatment of his
workers engaged in his works. Only the first aid facility available at site may be
extended to Contractor’s workers.

III.19 Liabilities of the Contractor:

During execution of the Contract and until the completion certificates issued the
Contractor shall be fully liable to compensate all concerned for, any loss, damage or
destruction of any of departments plant and machinery, persons, building, property
including third party risks attributable to the Contractor as may be decided by the
Engineer whose decision in this regard shall be final.

III.20 Co-ordination of Works:

The Contractor shall plan his site works so as to avoid interference with other works
going on at site.

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III.21 Sub-Contractors:
The Contractor shall not sub-contract the whole or any part of the work without the
written permission of Director, RD &TG. The main Contractor shall be responsible
for all work of Sub-Contractors. Sub-Contractors shall be bound to the Contractor
by the same terms of drawings and specifications, the obligations and
responsibilities, the Contractor assumes towards the Engineer. The offer of a
Contractor is liable for rejection if it entails sub-contracting of large portions of
work.

III.22 The Contractor may be allowed to work in shifts/holidays with prior approval of the
Engineer.

III.23 Final Agreement:

The Contractor has to sign a Final Agreement to execute this Tender as per specifications given in

this Tender Document, if the tender work is decided to be awarded to him.

III.24 Payment:
Payment will be made bimonthly based on the quantum of work carried out and
assessed by the Engineer-in-charge.

Important Note:
No advance is payable against this Tender.

III.25 The entire Contract work should be carried out by a single Contractor who should
have the capacity to carry out all the works. However, DIRECTOR, RD&TG
reserves the right to give any part of the work to any bidder. The bidder shall thus
be willing to carry out part of the work at the price quoted by him.

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 PART III A

ADDITIONAL SAFETY RULES

IIIA 1.0 The Contractor shall follow the Safety regulations as prescribed in the Tender and
Indian Standards. He shall provide necessary safety appliances to his employees
depending upon the nature of work as instructed by the Engineer-in-Charge/Safety
Officer deputed by the Project Engineer.

IIIA 2.0 In case of an accident resulting in any rest or disability to the workmen the same
should be immediately reported to the Safety Officer.

IIIA 2.1 Any person found under the influence of alcohol or any intoxicating drugs on duty
is unfit for duty and should not be allowed to work. His work permit should be
confiscated and he should be sent out of the premises of the work.

IIIA 2.2 Drums or other make shifts must not be used in place of ladders or work benches
or supports on any job.

IIIA 2.3 First aid kits or boxes and stretchers should be readily available at all times with
the Contractor.

IIIA 2.4 For all work that cannot be done from the ground level or from part of any
permanent structure or from other available means of support, soundly constructed
scaffoldings of adequate strength shall be used as a safe means of access to places
of work.

IIIA 2.5 All scaffolding shall be securely supported or suspended and wherever necessary
be properly braced to ensure stability.

IIIA 2.6 Defective scaffolding or ‘make shift’ must never be provided. All scaffolds must
be inspected by a competent person in-charge before commencement of work.

IIIA 2.7 Chains, ropes or other lifting materials used for the suspension of scaffolding must
be of adequate strength and suitable quality and shall be of tested quality.

IIIA 2.8 The platforms of suspended scaffoldings shall be sufficiently wide. Suspended
scaffolding shall have hand rail of about 1 metre height from the floor of the
platform. Such scaffolding or staging shall be fastened to prevent it from swaying
away from the structure.

IIIA 2.9 All sides of the platform from which a person is liable to fall shall be provided
with guard rails to a height of at least 1 metre with the toe boards of at least 15
cms high so placed as to prevent the fall of materials and tools from the platform.

IIIA 2.10 Every ladder shall be securely fixed at top and bottom. A ladder more than 5
metres long shall have a prop.

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IIIA 2.11 Spacing between the side rails of the ladder shall not be less than 45 cms. Uniform
step spacing shall not exceed 30 cms.

IIIA 2.12 Whenever it is necessary to work at elevated places not adequately protected by
railing, safety belts with life lines securely tied to some firm structure or other
support which is independent of the equipment on which the person is working,
must be worn.

IIIA 2.13 Nobody should be allowed to work at elevated places without wearing safety
belts. As an additional precaution, safety nets made of coir rope or nylon or any
other suitable material should be hung at suitable elevation to prevent people and
equipment falling below.

IIIA 2.14 Dropping or throwing materials from roof structures or other elevated position is
prohibited.

IIIA 2.15 Where work is going overhead, the area below should be cordoned. If it is not
possible to cordon the area, place caution sign ‘CAUTION-MEN WORKING
ABOVE’ or depute responsible person to warn passer-by.

IIIA 2.16 Helmets (made of fibre glass or any other suitable material) must be used by all
employees working in shuttering or staging jobs, material handling jobs or where
the chances of falling objects are present or where there is a possibility of person
striking against projecting objects etc.

IIIA 2.17 All necessary personnel safety equipment such as face masks, safety helmets,
safety boots, safety belts, gloves, safety goggles etc. as considered adequate by the
Engineer-in-charge have to be kept available for the use of persons employed at
the site of work and maintained in condition suitable for immediate use and
Contractor shall take steps to ensure proper use of equipment by the workers.

IIIA 2.18 The Contractor shall furnish along with the Tender the type of staging, formwork,
type of access for men, materials and the construction technique he proposes to
use for the work.

IIIA 2.19 The Contractor shall use only tubular steel for scaffolding for all heights more
than 5 metre height as approved by the Engineer.

IIIA 2.20 The areas where painting work is being done shall be kept adequately ventilated
by the agency executing the work and shall meet the approval of the Engineer.

IIIA 2.21 The safety code as specified in Annexure-1 of Part-V of this Tender Document
are also applicable.

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 PART III B

PROCEDURE FOR REPORTING ACCIDENTS OCCURRING TO

CONTRACTOR’S WORKMEN, PROVIDING MEDICAL FACILITIES AND
PAYMENT OF COMPENSATION

IIIB 1.0 The accident reporting procedures shall be followed promptly, in all cases of
accidents to workmen.

IIIB 2.0 As per Section-10 of the Workmen’s Compensation Act 1923, the Contractor shall
within 7 days of the death or serious bodily injury of a workman send a report to the
Commissioner giving the circumstances attending the death or serious bodily injury.
(Serious bodily injury’ means an injury which involves or in all probability will
involve, the permanent loss of the use of, or permanent injury to, any limb, or the
permanent loss of or injury to the sight or hearing, or the fracture of any limb, or the
enforced absence of the injured person from work for a period exceeding 20 days).

IIIB 3.0 The Contractor shall be aware of the provisions of the Workmen’s Compensation
Act 1923, and shall report cases of death/serious bodily injuries to the
Commissioner for Workmen’s Compensation Act as well as Chief Administrative
Officer and Safety Engineer. The Contractor shall deposit the compensation
amount, if any, payable to the workman with the Commissioner.

IIIB 4.0 The Contractor shall take all steps for the treatment of the injured to the satisfaction
of the Principal Employer.

IIIB 5.0 The Contractor shall send a report periodically about the status of the injured.

IIIB 6.0 In the cases of injuries which have been cured, the Site Engineer will obtain from
the workman concerned, in person, in the presence of the Contractor, a statement to
the effect that he/she has been cured and is free from any disability for which
compensation is payable and no claim is pending from the Contractor on account of
the accident.

IIIB 7.0 If any claim from the Contractor’s workman is pending for settlement, the payment
due to the Contractor from the Department shall be withheld by the Accounts
Officer on the advice of the Site Engineer executing the Contract. The copy of this
advice shall be sent to the Chief Administrative Officer and Safety Engineer.

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 PART IV

GENERAL CONDITIONS OF CONTRACT

 
 
 
The applicable provisions of GENERAL CONDITIONS OF CONTRACT for this work were
made available to me by Engineer in Charge and I have understood the same & I will abide
the same..
 
 
 
 
 
Signature of the Contractor :

 
 
Name of the Contractor      :

 
 
Address of the Firm          :
 

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 TECHNICAL SPECIFICATON FOR FABRICATION AND ERECTION OF
SELF SUPPORTED STEEL CHIMNEY IN SGTF.

1.0 DESCRIPTION
At SGTF,IGCAR,Kalpakkam, there is a Boiler House which has a fire tube Boiler
with one number of Chimney. This Chimney is the last integral part of the boiler system for
maintaining its efficiency, draft and also for minimizing the atmospheric pollution.The above
self-supporting chimney has a dimension of 1.5m inner diameter at base level tapering
through three stages to 0.5 meter straight cylindrical portion with conical hood at top most
elevation of 30.5m. The wall thickness is 12mm at the base and 6mm at the top. The chimney
stack is divided into different section with different sizes. Flanges provided at end of chimney
sections enable sections to connect together.(Details are as per the drawing attached with this
tender document).Total weight of the chimney is approx. 11 Tonnes.
Two structural steel platforms are provided on the stack, which can be accessed from
the ground by means of a ladder with safety cage and safety tie on. In addition, aircraft lights
were located on top of platforms, and a lightning arrester system with one lightning rods and
a ground wire attached to the stack.

2.0 SCOPE OF WORK

The work involves Fabrication of a new Boiler Chimney using IS 2062 Plates along
with accessories like Ladder, platform, Earthing strip as per the drawing attached with this
tender, Painting of newly fabricated Chimney as per painting schedule, Transportation of
newly fabricated chimney after getting inspection clearance from IGCAR inspection
authorities at the expense of Contractor along with the required insurance documents,
Dismantling of existing corroded Boiler chimney in SGTF/IGCAR using required lifting
machines, scaffolding etc... after obtaining necessary safety clearance. Purchase of required
material/paint/fasteners for fabrication is within the scope of this contract. No additional
material / lifting equipment/scaffolding would be provided by IGCAR.
This specification together with the drawing is for supply of One (1) number of M S
chimney along with the following accessories.
a) Ladder
b) Earthing strip with 3Mtr extra length
c) Lightning arrestor
d) Clean out and inspection doors Self-supported chimney:
e) Platforms at various elevations
f) Cone hood
g) Aviation lamps
h) Base plate and supports
i) All other accessories exactly as shown in drawing.

2.1 Material Procurement: Purchasing of Material required for fabrication of new

Chimney after site measurement and as per the material specified in the drawing and subject
to the inspection and approval of test certificates by IGCAR. Test certificates of materials/
Paints/ fasteners purchased should be submitted to IGCAR / testing agency of IGCAR.

2.2 Chimney fabrication: Fabrication of a new chimney as per the drawing attached and
to match the site conditions and foundation bolts of existing Chimney. The newly fabricated
Chimney has to match the site condition and orientation requirements. Wherever there’s a

37
conflict between Site measured data vs Drawing the fabrication should be as per site
measurement or the size of the component should be modified to suit the site conditions at the
expense of the contractor. Bidder has to assure this by visiting the site and checking the site
condition and constraints. The Chimney is located inside plant area surrounded by Air
conditioning plant, DM water plant, Boiler house and SGTF building. The proposed repair
work is to be carried out without creating any damage/trouble/hindrance to the
operation/surrounding equipments. After fabrication, newly fabricated Chimney need to be
safly transported to SGTF site, and necessary transit insurance coverage is within the scope
of the Contractor. No special amount would be awarded for the same.

2.3 Dismantling of the old chimney: Safe dismantling of the existing corroded chimney
having weight of Approximately 11 Tonnes, debris removal and transporting of dismantled
steel Chimney portions from the site of chimney to the scrap yard at IGCAR stores (around
1km distance). All necessary Double tubular scaffolding, lifting arrangements, tools and
tackles, Crane, winches etc...are to be arranged by the contractor at his own expense. No
special amount would be awarded for the same.

2.4 Erection of new chimney at site: Erection of newly fabricated chimney in place of
existing Chimney following necessary Safety precautions. The scaffolding, lifting
arrangements, lifting equipments like crane, tools, tackles etc… is to be arranged by
Contractor at his own expense. No special amount would be awarded for the same.

2.5 Hookup with the existing flue gas exhuast duct: The newly erected chimney need
to be Hooked up with the existing exhaust duct. After this, with Boiler in operation, trial run
of the Stack without any Flue gas leak need to be ensured. If any leak occurs, repair of the
same to be carried out on free of cost which is also in the scope of this contract. No special
amount would be awarded for the same.

2.6 Painting:Painting work of entire outer surfaces of newly fabricated chimney for
protection from environment corrosion by application of one coat of Epoxy zinc Silicate
primer and 2 coats of Heat resistant synthetic medium based two packs Aluminium paint
with surface preparation by air blast method cleaning with abrasives. Paint has to be
purchased by the manufacturer as per specification of IGCAR.

2.7 Trial run of the newly erected chimney along with all the required accessories like
manhole, platforms, ladders, aviation lamps, conical hood, safety cages etc… to ensure a
minimum stack exit flue gas temperature of 175˚C.

2.8 Lighting Conductor: The supplier shall provide 50 Sq mm standard Cu conductor to

be laid down along the chimney and air terminal to provide 300mm above chimney top. At
least 3 meter long conductor shall be left after foundation and will be further connected by
the user.

The scope of work is to be read in conjunction with the Annexures-1 to 6 attached with this
specification.

a) Annexure-1: Materials and Consumables.

b) Annexure-2: Fabrication of Boiler MS Chimney shell and its components.
c) Annexure-3: Dismantling of existing corroded Boiler Chimney
d) Annexure-4: Erection of Boiler MS Chimney shell and its components.

38
e) Annexure-5: Painting Work of Boiler MS Chimney.
f) Annexure-6: Hookup with existing exhaust duct from Package Boiler
g) Annexure-7: Indemnity Clause
3.0 APPLICABLE CODES & STANDARDS
The following specifications, standards and codes are made a part of this
specification. All standards, specifications, codes of practice referred to herein shall be the
latest edition including all applicable official amendments and revisions. In case of
discrepancy between this specification and those referred to herein, this specification shall
govern.
a) Material
(i) IS:814 Covered Electrodes for manual arc welding of Carbon and Carbon Manganese
Steel.
(ii) IS:1030 Carbon Steel Castings for General Engineering Purposes
(iii) IS:1239 Mild steel tubes, tubulars and other wrought steel fittings. Part 1 - Mild Steel
Tubes Part 2- Mild Steel Tubulars and Other Wrought Steel Fittings
(iv) IS:1363 Hexagon head bolts,screws and nuts of product grade C (Size range M5 to M64 )
Parts 1,2 and 3
(v) IS:1367 Technical supply conditions to Threaded Steel Fastners ( All Parts )
(vi) IS:2062 Steel for General Structural Purposes
(vii) IS:2266 Steel Wire ropes for general Engineering purposes
(viii) IS:2315 Thimbles for wire ropes.
(ix) IS:2361 Bull dog grips.
(x) IS:2485 Drop forged sockets for wire ropes for General Engineering Purposes.
(xi) IS:3121 Rigging Screws and stretching screws.
(xii) IS:3150 Hexagonal wire netting for General Purposes.
(xiii) IS:5624 Foundation bolts.
(xiv) IS:8183 Bonded mineral wool.
(xv) IS:13183 Aluminium paint - Heat resistant.
b) Code of Practice
(i) IS:800 Code of practice for general construction in steel
(ii) IS:816 Code of practice for use of metal arc welding for general construction in mild steel
(iii) IS:822 Code of practice for inspection of welds
(iv) IS:875 Code of practice for design loads (other than earthquake) for buildings structures
(Part 1 to Part 5).
(v) IS:1893 Criteria for earthquake resistant design of structures.
(vi) IS:6533 Code of practice for design and construction of steel chimney Part 2 Structural
Aspects
(vii) IS:9595 Recommendations for metal arc welding of carbon and carbon manganese steel.
4.0 SAFETY REQUIREMENTS
Staff on site should undergo competence and health cum safety training on the
following areas:
a) Height pass training and Safe work at heights;
b) Hot work permit
3.1 Hoardings & Notices: the contractor will be required to install “DANGER” warning
signs at all accesses to the site and suitable safety hoarding are to be erected to all site
perimeters.
3.2 Scrap Metal: Generated from dismantling of chimneys and other. Scrap metal shall be
cut into manageable components on-site, transported by a contractor to the SGTF’s Scrap
yard which is hardly a km distance apart.

39
3.3 As the Machineries are working underneath Roof, work is to be carried out at utmost
care without damaging site property. In case of any damage, cost will be recovered from the
contractor.
3.4 At the end of each working day, the contractor needs to ensure that all elements of the
boiler chimney that remain in place are adequately secured to prevent the collapse of free
standing elements during silent hours.
3.5 Electrical Isolation: Before commencement of works, the contractor shall identify the
equipment and cables to be isolated.
3.6 All work must be carried out in accordance with the requirement of safety guidelines
of ATOMIC ENERGY REGULATORY BOARD or equivalent Indian standard and all most
HSE regulations applicable. Prior to commencement of any works the contractor will need to
supply a site specific method statement for the works and will be required to meet the
Engineer In-charge on site.
5.0 SITE FACILITIES PROVIDED BY IGCAR
a) Electric power will be made available free of charge at a single point near work site.
The contractor shall arrange for further connections if required by him. The contractor shall
indicate approximate power requirement (capacity in KW) while quoting. All statutory
regulations are to be observed.
b) Single point water free supply will be made available near the work area.
Accommodation / transport of workmen and supervisors of the contractor shall be the
responsibility of the contractor.
c) Only open area at work site at SGTF , where fabrication work is to be executed will
be allocated to the contractor. The contractor shall make his own arrangement for shed for
carrying out his fabrication activities. Contractor also has to ensure safe storage of his tools
and engineering materials issued from stores for fabrication.
6.0 SAFETY RULES

a. The Contractor shall follow the Safety regulations as prescribed in the Indian
Standards. He shall provide necessary safety appliances to his employees depending upon the
nature of work as instructed by the Engineer-in-Charge/Safety Officer deputed by the Project
Engineer.

b. In case of an accident resulting in any rest or disability to the workmen the same should be
immediately reported to the Engineer-in-Charge/Safety Officer.

c. During the execution of the Contract and until Completion Certificate is issued, the
Contractor will be fully liable to compensate all concerned for any loss, damage or
destruction of works, structures, plant and machinery, persons, property etc. including third
party risk arising due to causes attributable to the Contractor as may be decided by the
Engineer whose decision in this regard will be final. No claim shall be made against
Government on this account.

d. The Contractor shall take necessary precautions to ensure safety of his crew, materials,
equipment and the works during the period of the Contract. No claim from the Contractor for
loss of or damage to equipment, materials, crew or the works during the course of the work
due to natural causes like cyclones, gales, floods, rains or other cause or combination of
causes will be entertained by Government. The Contractor shall be fully liable to compensate
Government for any loss or damage to works till the time of taking over of the work by
Government.

40
e. Any person found under the influence of alcohol or any intoxicating drugs on duty is unfit
for duty and should not be allowed to work. His work permit should be confiscated and he
should be sent out of the premises of the work.

f. Drums or other make shifts must not be used in place of ladders or work benches or
supports on any job.

g. First aid kits or boxes and stretchers should be readily available at all times with the
Contractor.

h. For all work that cannot be done from the ground level or from part of any permanent
structure or from other available means of support, soundly constructed scaffoldings of
adequate strength shall be used as a safe means of access to places of work.

i. All scaffolding shall be securely supported or suspended and wherever necessary be

properly braced to ensure stability.

j. Defective scaffolding or ‘make shift’ must never be provided. All scaffolds must be
inspected by a competent person in-charge before commencement of work.

k. Chains, ropes or other lifting materials used for the suspension of scaffolding must be of
adequate strength and suitable quality and shall be of tested quality.

l. The platforms of suspended scaffoldings shall be sufficiently wide. Suspended scaffolding

shall have hand rail of about 1 metre height from the floor of the platform. Such scaffolding
or staging shall be fastened to prevent it from swaying away from the structure.

m. All sides of the platform from which a person is liable to fall shall be provided with guard
rails to a height of at least 1 metre with the toe boards of at least 15 cms high so placed as to
prevent the fall of materials and tools from the platform.

n. Every ladder shall be securely fixed at top and bottom. A ladder more than 5 metres long
shall have a prop.

o. Spacing between the side rails of the ladder shall not be less than 45 cms. Uniform step
spacing shall not exceed 30 cms.

p. Whenever it is necessary to work at elevated places not adequately protected by railing,

safety belts with life lines securely tied to some firm structure or other support which is
independent of the equipment on which the person is working, must be worn.

q. Nobody should be allowed to work at elevated places without wearing safety belts. As an
additional precaution, safety nets made of coir rope or nylon or any other suitable material
should be hung at suitable elevation to prevent people and equipment falling below.

r. Dropping or throwing materials from roof structures or other elevated position is

prohibited.

41
s. Where work is going overhead, the area below should be cordoned. If it is not possible to
cordon the area, place caution sign ‘CAUTION-MEN WORKING ABOVE’ or depute
responsible person to warn passer-by.

t. Helmets (made of fiber glass or any other suitable material) must be used by all
employees working in shuttering or staging jobs, material handling jobs or where the chances
of falling objects are present or where there is a possibility of person striking against
projecting objects etc.

u. All necessary personnel safety equipment such as face masks, safety helmets, safety boots,
safety belts, gloves, safety goggles etc. as considered adequate by the Engineer-in-charge
have to be kept available for the use of persons employed at the site of work and maintained
in condition suitable for immediate use and Contractor shall take steps to ensure proper use of
equipment by the workers.

v. The Contractor shall furnish along with the Tender the type of staging, formwork, and
type of access for men, materials and the construction technique he proposes to use for the
work.

w. The Contractor shall use only tubular steel for scaffolding for all heights more than 5
meter height as approved by the Engineer.

x. The areas where painting work is being done shall be kept adequately ventilated by the
agency executing the work and shall meet the approval of the Engineer.

7. OTHER TERMS AND CONDITIONS

1. The contractor should deploy sufficient number of personnel at site to meet the above
mentioned service requirements failing which recovery will be made from your bills.
2. No accommodation, medical facilities or transport will be provided to the contractor’s
personnel. It is the sole responsibility of the contractor.
3. The contractor shall arrange for the entry passes for the site following the procedures
existing at site.
4. The contractor shall ensure the safety of his personnel by providing the required safety
devices.
5. The Contractors have to follow strictly the Government labour acts which are in force at
present including any amendments or additions that may be made by the Government
during the entire period covering the date of publication of this Tender Notice till the
completion of the work covered by the Contract and all necessary arrangements for
labour will have to be made by the Contractor.
6. During the execution of the Contract and until Completion Certificate is issued, the
Contractor will be fully liable to compensate all concerned for any loss, damage or
destruction of works, structures, plant and machinery, persons, property etc. including
third party risk arising due to causes attributable to the Contractor as may be decided by
the Engineer whose decision in this regard will be final. No claim shall be made against
Government on this account
7. The Drawing attached is to be read in conjunction with other terms and conditions,
General Conditions, Tech. Specifications.

42
8. It may be noted that the Government as a part of the emergency preparedness for any
eventual site emergency civil defence which would require the entire or part of the
Contractors personnel and labour to be evacuated from the site without any advance
notice as and when deemed necessary. This may result in temporary stoppages of work
with possible loss of time and productivity not likely to exceed 1 day. This aspect shall be
taken into account while quoting their rates and the department will not entertain any
claim/compensation on this account. However, the department may grant suitable
extension of time only.
9. All prices quoted shall remain firm throughout the period of the contract and shall not be
subjected to any escalation for changes in the cost of labour and material and any other
cost.
10. The Tenderer should note that if any clarifications regarding Specifications, Conditions of
Contract, Schedule of Quantities or Scope of Work are required he should consult
Director, RD&TG,Kalpakkam-603102. No claim on account of any ambiguity in any
respect will be entertained. The decision of Director, RD&TG is final in case of any
ambiguities between different portions of Tender and drawings.
11. During execution of the Contract and until the completion certificates issued the
Contractor shall be fully liable to compensate all concerned for, any loss, damage or
destruction of any of departments plant and machinery, persons, building, property
including third party risks attributable to the Contractor as may be decided by the
Engineer whose decision in this regard shall be final.
12. Transportation of materials, required platform and material handling are in the scope of
the contractor. Safety items like shoes, goggles and safety belts etc. required for the
work are in the scope of the contractor. Daily cleaning of the work area is very much
essential and is in the scope of the contractor. After erection of the structural material,
roofing sheets and the tank, work area should be cleaned. All temporary arrangement
should be removed by the contractor.
13. The Engineer In-charge reserves the exclusive right to decide, giving no reason
whatsoever, the suitability of the field personnel deputed by the Contractor. The
Engineer also reserves the right to ask the Contractor to withdraw any personnel from the
site who, according to the Engineer, is not suitable for the proper supervision of erection
of the work, non following safety rules and ask for replacement and/or additional
supervisory staff for proper execution of the Contract according to the requirement of the
drawings, specifications and field instructions within the scheduled construction period

(Radhakrishnan
Unni.K.G,TO/D)
SGTF OS

43
 Annexure-1
Materials and Consumables.
Responsibilities of the contractor includes, but not limited to the following.
1.0 Purchasing of all materials and consumable like Structural Steel, Pipes, welding
electrode, Bolts, and Gasket of Standard make & paints required for complete work as per
drawing and as per scope of work shall be in bidder’s scope. The quantity is indicative only.
In case any item of material is insufficient to carry out the job as per the drawing and site
conditions, the Contractor will have to bring additional quantity for completion of work. No
separate payment for such expenditure will be made under any conditions.
a) Structural steel: confirming to IS226 /IS 2062 (Make: From reputed Indian
manufacturing firms like TATASTEEL /SAIL/MSL/JINDAL/JSW etc.,).
b) Bolts & Nut: IS: 1363-1992.
c) Welding Electrode: IS: 814-1991.
2.0 The material shall strictly confirm to the specifications / make given by
IGCAR/SGTF.
2.1 Unloading of the material/ fabricated Chimney shall be done with your own
arrangement.
2.2 All consumables like welding electrodes, gas, grinding wheel, for surface preparation
shall be of approved make.
2.3 Arranging all tested tools and tackles, safety items, ladders, scaffolding etc. required
for the completion of the job.
Only tested material shall be used. The contractor shall submit Manufacturer’s valid
approved test certificate to IGCAR. If test certificate for the material is not available from
main producer, the following tests shall be carried out at the discretion of IGCAR and should
be certified by a NABL accredited lab.: a. chemical composition, b. mechanical properties c.
weldability test. Cost towards this testing need to be borne by the contractor only.
2.4 The contractor has to arrange all tools, tackles, safety equipment, Crane and other
lfting equipments required for dismantling, erection of Chimney, welding equipments, Gas
cutting tools, grinding tool, gas cylinders and material handling equipment on their own.
IGCAR will not extend any of the above facilities / services under any circumstances. No
balance material / scrap shall be allowed to be taken outside the plant on completion of work
2.5 All material procured by the supplier including weld materials if any shall be tested as
required by material designation standard. Proof in the form of mill certificates will be
acceptable, but if these are not available the supplier shall perform these tests. The purchaser
reserves the right to cross check the material. Samples will be drawn by the purchaser for
chemical analysis and Mechanical properties.Plate material shall be free from any defects like
cracks, inclusion laminations, surface distonion while handling etc. UST for plates sizes
above 6 mm to be as per the ASTM A435. Reg. defect standard for angle beam shall be 5 %
deep notch & for straight beam 1.5 mm dia. flat bottom hole as per latest ASTM specification
and mill test certificates shall be approved.
2.6 Marking / Material Identification: Each plate / pipe shall bear clear identifiable
marking / stamping with respect to material heat number, plate No., grade, size marking. The
material Identification markings for fabrication of these equipment shall remain
distinguishable until fabrication is completed. The identification scheme shall be evolved in
consultation with the purchase.

44
 Annexure-2
Fabrication of Boiler MS Chimney shell and its components.
1. Responsibilities of the contractor includes, but not limited to the following.
1.0 Fabrication of M.S. Chimney top shells and components as per existing design and
dimension and as per tender drawing,
2.0 Cold straightening of section and plates, whenever they are bent and kinked.
3.0 Control, assembly of steel structural components at site/shop, whenever required.
4.0 Loading, transporting from fabrication workshop to site of erection and unloading of
all steel structural components/unit/assemblies.
5.0 All the items are to be cut as per requirement of drawing. If joints are to be provided
in any item in order to meet the requirement of size and shape, cutting plan showing location
of joints shall be prepared for consideration of SGTF.
6.0 Rolling and cutting tolerances shall be as per IS: 1852-1985.
7.0 Cut edges shall be finished smooth by grinding or machining whenever necessary.
Sufficient allowance (3mm to 5mm) should be kept in the items in case machining is
necessary.
8.0 Cutting may be effected by gas cutting, shearing, cropping or sawing. Straightening
and bending shall be done in cold condition as far as practicable. If required, straightening
and bending may be done by application of heat between 900°C and 1100°C. Cooling down
of the heated item shall be done slowly.
9.0 Drilling and punching of holes for bolts shall be done as per clause no.11.2.4 of IS:
800-1984.
10.0 Fabrication of all steelwork shall be accordance with IS: 800-1984 and in conforming
to various clauses of the specification, unless otherwise specified in the drawing.
Requirements of IS code of practice is IS 6533 part 1, 1989, (reaffirmed 1998) and IS 6533
part 2 1989.
11.0 Permissible deviation from designed (true) geometrical form of the despatch elements
shall be accordance with IS: 7215-1974.
12.0 The contractor shall work out welding procedure for SGTF’s approval, considering
the following factors: a. specification and thickness of steel, b. specification of electrode or
and base wire, welding procedure, c. sequence of welding, d. weather condition, e. inspector
procedure to be followed, f. design requirement of the joints.
13.0 All metal arc welding shall be carried out as per IS: 9595-1980. Welding Electrode
conforms: IS: 814-1991. Specification of Welding Electrode: AWS: A5.1: E7018, Make:
Esab/D&H/Ador/Modi/Sudo only. All inspection of welds shall conform to IS 822
14.0 The extent of quality control in respect of welds for structural elements shall be as
follows and shall be conducted by the contractor at his own cost:
a) Visual examination- all welds shall be 100% visually inspected to check the
following: a. presence of undercuts, b. visually identifiable surface cracks in both, welds and
base metals.
b) Dye penetration test (DPT) - this shall be carried out for all important fillet welds and
groove welds to check the following: a. surface cracks, b. surface porosity.
c) Cleaner, penetrant, developer, DP testing etc..are in the scope of the Contractor. No
additional amount would be sanctioned for carrying out the same.
d) Record of all the welding inspection report and other associated documents
related to fabrication need to be mainatined by the contractor and a copy of complete

45
set of these documents or part of these documents need to be handed over to the
purchaser as and when demanded by the purchaser.

2. FABRICATION
CONTRACTOR shall post an experienced and qualified ENGINEER to supervise the
fabrication work. All workmanship and finish shall be of the best quality and shall conform to
approved method of fabrication. All holes and edges shall be free of burrs. All shell plates
shall have a smooth curvature without faults or kinks.
The edges of shell plates to be welded may be prepared by shearing, machining or
machine-operated flame cutting. Shearing shall be limited to 10mm thickness of plates. When
edges are flame cut, the resulting surface shall be uniform and smooth and free of scale and
slag accumulations.
All shell plates shall be rolled accurately to the proper curvature so as to obtain a true
cylindrical or conical shell as required
Welding shall conform in all respects to IS:816 and IS:9595. All joints shall be butt-
welded joints with suitable edge preparation to obtain penetration to the full thickness of the
plates.
3. INSPECTION
All materials and fabrication covered by this specification shall be subject to
inspection by ENGINEER/OWNER or his authorised representative. They shall have access
to all parts of the shop while material is being prepared, and shall be provided by
CONTRACTOR with all inspection services and facilities.
CONTRACTOR shall give due notice to ENGINEER/OWNER in advance of
materials or workmanship getting ready for inspection. All rejected material shall be
promptly removed from the shop and replaced with new material for ENGINEER/OWNER's
approval/Inspection. Approval of material/workmanship shall not relieve CONTRACTOR
from his responsibility for furnishing material conforming to requirements of these
specification or invalidate any claim which OWNER may make for defective or
unsatisfactory- material or workmanship. No materials shall be painted or despatched to site
without the inspection and approved by OWNER/ENGINEER, unless such inspection is
waived in writing by ENGINEER. Adjacent shell strakes be shop assembled and match
marked to ensure satisfactory matching at site.
OWNER's/ENGINEER's inspector shall also have free access to all parts of the job
during erection. The erection and installation methods employed such as welding, bolting etc.
All inspection of welds shall conform to IS 822. Material test certificates of Plates and
fasteners used should be handed over to OWNER/ENGINEER at the time of inspection.
4. TOLERANCE ON OVALITY, VERTICALITY ETC...
1. The difference between the maximum and minimum internal diameter of shells
measured at any one cross section shall not exceed 1% of the nominal diameter or 25
mm whichever is lower. There should be no flats at seams and any local deviations
from circularity shall be gradual.
2. After erection, the departure of the stack from the vertical at any level, shall not
exceed 1/1000 of the height, at that particular section
3. When fitted together before bolting any gap between the flanges should not exceed
1.5mm
5. DIMENSIONAL CHECKS / INSPECTION:
1. Maximum misalignment permitted 10 % of nominal plate thickness up to 100
mm.1mm misalignment for longitudinal joints.

46
2. Maximum misalignment permitted 10 % of nominal thickness +1 mm with maximum
overall limit of 4 mm for circumferential joint.
3. Maximum misalignment permitted for circumferential tolerance + 0.25 %.
4. Maximum misalignment permitted for roundness difference of maximum diameter at
any cross section of a shell welded longitudinal shall not be done mote than 1 % of
ID. with a maximum of (D1 -1250)/200.Maximum misalignment permitted out of
straightness of shell not more than 0.3 % both of total cylindrical length in any 5
meter length.
6. Liquid Penetrate tests: All welds shall be fully DP for all passes (layer by layer) as per
ASTM E 15. All defects shall be repaired and retested.

47
 Annexure-3
Dismantling of Existing Boiler Chimney.
Carefully dismantling the free standing boiler chimney using suitable Platforms,
safety equipments,, heavy lift crane, guide lines and cutting equipment down to ground level.
Lower the sections safely to ground and dismantle by mechanical means and cart away to
SGTF’s scrap yard following safety procedures. Contractor should ensure that dismantling of
damaged portion of chimney is undertaken in such a way so that the safety of boiler house,
DM plant, AC Plant building and pipe lines situated adjacent to the boiler chimney is not
compromised. Necessary double tubular scaffolding with suitable jally, pipe sections, fixtures
etc.. should be provided by the contractor for safe dismantling of the stack without affecting
the nearby structures/plant/office buildings.
1.0 DISMANTLING TECHNIQUE: Top- down segmenting of the boiler chimney in
horizontal slices or pieces:
a) Top-down segmenting comprises cutting the boiler chimney into large but
manageably sized sections and lifting and lowering these sections to ground level. This
approach includes three main activities:
- Establishing safe working platforms.
- Cutting operations.
- Lifting operations.
b) Working platforms are required for workers to safely cut through the stack and to
sling the section being released. Safe working platforms can be provided by several means,
including scaffolding, mobile platforms (independent or attached to or suspended from the
boiler chimney) and crane suspended cages.
c) Cutting operations are required to separate a section of the boiler chimney from the
main structure. Appropriate techniques depend upon the type of stack construction. Cutting
techniques generally use established construction industry methods, including: Mechanical
saws, shears, nibblers, etc., Flame or plasma cutting. All the tools required for cutting,
shearing, dismantling, lifting etc… are in the scope of the contractor. IGCAR would provide
only free electricity and water.
d) The segmenting will be carried out by specialized workers suspended by cables.
2.0 Chimney dismantling methodology: a heavy lifting mobile crane will be utilised for
dismantling of damaged portion of boiler chimney. Contractor needs to atatch equipment
technical data and performance sheet with tender as per Annexure-C. If any other method to
dismantling is envisaged the same is to be discussed with Engineer In charge and a mutual
consensus has to be reached.
a) Position the mobile heavy lifting equipment (Crane) at predetermined site, ensuring
stability safety and secure foundation (positioning site, to be inspected for any possible
instability by way of inferior, damaged, and worn or poor quality road/surface covering).
b) Once the suitable crane has been securely positioned in place, together with the help
of another mobile heavy duty crane, metal basket and operated by skilled and fully qualified
personnel in the art of dismantling; utilising a type of choker system, chain, grips and cables
will used to establish a safe working platform and securing first suitable length of the
chimney to be lowered to the ground.
c) Once inspected and confirmed the first suitable length of the stack is firmly secured,
ready for cutting and lowering to the ground, two (2) operator will be climbed up in safe

48
working platform attached to the boiler stack; equipped with oxy settling cutting equipment
will proceed to cut right round the stack just above the joint of the second suitable length of
chimney and the attached access ladder.
d) Before cutting the final section, the crane operator will be communicated with, via
walkie-talkie, to ascertain the correct aplomb of the crane.
e) Dismantling of damaged/tilted top portion of chimney with wire rope sling net for
avoiding free fall of damaged metal of top portion.
f) This process will be repeated exactly until the final level of damaged portion of
chimney is finally dismantled.
g) However, if any other material discovered not attached to damaged portion of
chimney, it will be allowed to drop down the inside of chimney to be collected at the
disposed of the end.
3. Scaffolding
Double tubular scaffolding should be provided for safe and secure dismantling of the
various sections of Boiler Chimney. The safety of double tubular scaffolding would be
assessed by the staff concerned and the staff concerned should be taken in confidence
regarding the utility and safety of the scaffolding. No additional payment would be given for
erection and dismantling of scaffolding. Required safety nets, drop area markings, required
hollow pipe sections , fixtures, platform jally etc.. are in the scope of the contractor. The
contractor has to ensure the workers are following safe working practices like wearing of
safety belts, helmets etc..and if any erroneous practice is found the staff concerned would
take action against the errant contract employee. Necessary safety training / obtaining height
permit/ height pass/hot work permit etc… to be obtained , staff have to undergo safety
training and the staff at erection site may have to undergo medical examination at the
expense of the contractor. It is the responsibility of the contractor to meet the safety standards
of IGCAR Safety sections and if any violations of safety rules are observed the safety officers
concerned may issue stop memo and it’s completely upon the contractor to get necessary
clearance for starting the work. Any request for noncompliance of safety rule, temporary
unsafe arrangements , additional payment etc… would not be entertained.
4. Caution during Dismantling.
The Foundation bolts of the existing chimney should not be damaged while
dismantling the bottom portion of the Boiler Chimney. The same is to be used for the
new chimney also. Sizing of the foundation of bolt and it’s orientation is to be matched
with the new Steel Chimney which is being fabricated by this contract. Contractor / his
representative have to visit site and match the base plate template to the site condition.
All expenses for this should be anticipated during quoting. This Chimney is to be erected
inside a running plant surrounded by different equipments, machinery, plant structures. The
work should be planned carefully so as not to damage any surrounding equipment. All
necessary departmental safety permits like height work permit, hot work permit to be
obtained by the contractor.

49
 Annexure-4:
Erection of Chimney shells and its components.
Erection of Chimney
Erection of chimney involves, but not limited to
1) Installation of newly fabricated pieces of the chimney on the existing foundation
matching with the existing foundation bolts.
2) Installation of the Lightening Arrestor (LA) & Aviation lights (02 nos) on the top
portion of new installation.
3) Connection of earthing strip with new LA & laying and fixing of same on the newly
fabricated chimney pieces.
4) Connection of earthing strip to existing old earthing strips of the existing installation
and checking & proving of the continuity of the complete strip
5) Installation of the new platforms with railing on newly fabricated chimney as per
existing installation.
6) Installation of the monkey ladder with cage for complete newly fabricated chimney
pieces.
7) Painting of complete new installation as detailed in the Annexure 5.
8) Electrical connection of the aviation lights with the cable and power supply at the
bottom of chimney.
9) Submission of actual (as built) GA drawing of complete chimney after erection &
commissioning
10) Trial run of the chimney .
11. In addition to provision of erection and transport equipment, the scope of work
includes supply of tools and tackles, consumables, material, labour and supervision
and shall cover the following:
12. Storing &unloading of all fabricated steel components/units/assemblies at site storage
yards.
13. Transportation of steel components from storage yard to site of erection, including
multiple handling, if required. Handling and storage of materials shall be as per IS:
7969-1975.
14. All minor rectification/modification of steel components as per instruction of
Engineer-In-charge.
15. Erection of steel components including making connection by bolts/welding as
required.
16. Alignment of all steel chimney components true in line, level plump and dimensions
within specified limits of tolerance.
17. Erection shall be carried out accordance with IS: 800-1984 and conforming to the
requirements of is code of practice is 6533 part 1, 1989, (reaffirmed 1998) and is 6533
part 2 1989, other relevant standards referred to therein.
18. For safe and accurate erection of steel work, staging, temporary support, false work
etc. shall be erected as required. The fabricated material received at erection site shall
be verified with respect of marking on key plan/marking plan.
19. The approved erection drawings and any approved arrangement drg., specification or
instruction accompanying them shall be followed in erecting chimney components.
20. Erection work shall be taken up after receipt of clearance from SGTF.

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21. For safety requirement during erection, provision in IS: 7205-974, IS: 7969- 1975 and
other relevant Indian standards shall be followed.
22. Erection shall be carried out with the help of suitable crane and maximum
mechanization possible.
23. Prior to commencement of erection, all the erection equipment, tools, tackles, ropes
etc. shall be tested for their load carrying capacity. Such tests may be repeated at
intermediate stages also if considered necessary and frequent visual inspection shall
be done of all vulnerable areas and components to detect damages or distress in the
erection equipment, if any.
24. Erected members shall be held securely in place by bolts to take care of dead load,
wind load and erection load.
25. No final bolting or welding of joints shall be done until the structure has been
properly aligned.
26. Checking of correctness of initial setting out of steel components of chimney and
adjustment of alignment shall be carried out in sequence and at different stages as
required. The final levelling and alignment shall be carried out immediately after
completion of each section.
27. The contractor shall design, manufacture, erect and provide false work; staging
temporary support etc. required for safe and accurate erection of chimney components
steelwork and shall be fully responsible for the adequacy of the same.
28 The contractor shall also provide facilities such as adequate temporary access ladders,
gangways, tools & tackles, instruments, etc. to SGTF for his inspection at any stage
during erection.
29. Caution before Lifting: At each new job site prior to hoisting personnel, the personnel
lift platform, rigging, and hook block shall be proof-tested by a qualified inspector to
125 percent of the personnel platform's rated capacity by holding it suspended for 5
minutes with the test load suitably distributed on the personnel platform.
30. After proof-testing, any deficiencies revealed by inspection, or by the proof test, are
corrected and another proof-test conducted. Any modification to the personnel lift
platform or rigging requires retesting. Test reports are kept on file and be readily
available to appointed personnel.
31. A meeting, with the qualified operator, signaler, persons to be lifted, and the person
responsible for overall worksite safety to plan is held prior to the trial lift to review
the procedure.
32. The crane before lifting shall be uniformly level within 1 percent of level grade and
firm footing exist under both crawler tracks or under each outrigger float. Cribbing
mats under tracks or blocks under outrigger floats are used as necessary to provide a
firm and substantial footing. Cranes equipped with outriggers have outriggers
extended in accordance with the manufacturer’s instructions
33. Crane systems, controls, operator aids, and safety devices are activated and
functioning properly.
34. The total weight of the loaded personnel lift platform (including personnel) and
related rigging does not exceed 50 percent of the crane rating under the planned
conditions of use.
35. The personnel lift platform is not loaded in excess of its rated load capacity.
36. The number of employees occupying the platform does not exceed the number
required for the work being performed.
37. Trial Lift:
Before each lift, personnel initially enter the personnel lift platform, the operator and
signaler shall conduct a trial lift. The trial lifts shall include:

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(i) Loading the unoccupied personnel platform to at least the maximum anticipated load.
Materials and tools to be used during the actual lift, if secured to prevent
displacement, can be in the platform for the trial lift.
(ii) Making the trial lift from the location where personnel will enter the platform to each
location where the platform will be hoisted and positioned. It is acceptable to perform
a single trial lift on each shift for all locations to be reached from a single setup
position.
b) The trial lift shall be repeated whenever:
(i) The crane (mobile) is moved and setup in a new location or returned to a previously
used location.
38. CONTRACTOR shall post an experienced and qualified ENGINEER who shall be in
full time charge of the erection job.
39. CONTRACTOR shall complete all preliminary works at site well before the arrival of
fabricated materials such as establishment of office, labour quarters if any, electrical
connections, electrical winches, gin poles, compressors, cranes, all tools and tackles,
rivet guns, welding sets, staging etc. as a part of his contract and any other work that
may be necessary so as to start erection immediately after arrival of fabricated
material at site.
40. CONTRACTOR shall furnish at his own expense, the necessary non inflammable
staging and hoisting materials or equipment required for the erection work and shall
remove and take them away after the completion of the job. CONTRACTOR shall
also provide necessary protection for all equipment and works, necessary passage
ways, fences, safety bolts, helmets, lights and other fittings to the satisfaction of
OWNER/ENGINEER and to meet the rules of local authorities and for protection to
his men and materials. A licenced electrician shall be kept on the job for the entire
duration of the work to maintain CONTRACTOR's electrical equipment and
connections.
41. CONTRACTOR shall protect all existing plant structures, piping, conduits,
equipment and facilities against damage during erection. CONTRACTOR shall
perform his work in a manner which in no way will endanger any of the existing
facilities.
42. CONTRACTOR shall carefully check the location and layout of anchor bolts
embedded or foundations constructed to ensure that the stack can be properly erected.
Any discrepancy in the anchor bolts/foundations shall be reported to ENGINEER.
CONTRACTOR shall carry out erection as required by ENGINEER/OWNER. The
method of erection shall be modified whenever required by ENGINEER/OWNER.
The vertical seams in adjacent stack strakes shall be staggered by atleast 15°.
43. In case of faulty erection all consequent dismantling re-erection required will be at
CONTRACTOR's cost.
44. All shim stock required to maintain the specified thickness of grout as well as for
levelling of the structure during erection shall be of good M.S. plates and shall be
supplied by CONTRACTOR at his cost.
45. A certain amount of cleaning of foundation and preparing the area is considered
normal and shall be carried out by CONTRACTOR at no extra cost.
46. The holding down bolts shall be adequately tightened and shall be provided with a
nut and a lock nut. Grouting of the base plate will be carried out by CONTRACTOR
to match site conditions. Quick setting grout for this to be supplied by
CONTRACTOR .
47. Anchor bolt straightening or bending by heating is prohibited.

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 Annexure-5
Painting Work of Boiler MS Chimney.
Surface preparation for painting
1. Procedure for Surface Preparation :
Near white metal Blast cleaning to near white metal cleanliness, until at least 95% of
each element of surface area is free of all visible residues with desired surface profile.
2. Method: Air Blast cleaning with abrasives
The surfaces shall be blast cleaned using one of the abrasives like angular chilled cast
iron or steel grit, copper slag or Nickel slag, Al2O3 particles at pressure of 7kg/cm2 at an
appropriate distance and angle depending of nozzle size maintaining constant velocity and
pressure.
Chilled cast iron or steel shall be in the form of shot or grit of size in the range of G16
– G42 conforming to SSPC AB1 and S250 grade size of steel shots (maximum) to obtain a
desired surface profile of 35-50 microns trough to peak. For all other abrasives, size shall be
in the range of G16 – G24. The combination of steel grits and shots shall be normally in the
ratio of 3:1. The quality of abrasives shall be free from contaminants and impurities and shall
meet the requirements of SSPC AB1. Compressed air shall be free from moisture and oil. The
blasting nozzles should be venturi style with tungsten carbide or boron carbide as the
materials for liners. Nozzles orifice may vary from 3/16” to ¾”. On completion of blasting
operation, the blasted surface shall be clean and free from any scale or rust and must show a
grey white metallic luster.
3. Primer/first coat of paint shall be applied within 4 hours of surface preparation. Blast
cleaning shall not be done outdoors in bad weather without adequate protection or when there
is dew on the metal, which is to be cleaned. Surface profile shall be uniform to provide good
key to the paint adhesion (i.e. 35 to 50 microns). If possible vacuum collector shall be
installed for collecting the abrasives and recycling.
4. PAINT MATERIALS: All the paint materials shall be of first quality, should not be
of beyond expiry date and conform to the following general characteristics as per the table-1.

Table-1
Sl.No Description Heat resistant Two pack self Two
Silicone curing solvent component
aluminium based Acrylic
paint suitable Inorganic Zinc Polyurethane
up to 500C dry silicate Primer Finish paint
temperature
1 Type & composition Single pack Ethyl A two
silicone resin silicate/Metallic component
based medium Zinc acrylic
with Aluminium polyurethane
flakes finish giving
excellent
durability and
long term
recoatability

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 2 Volume of solids 20% 40±3 57±3
(approx.)
3 DFT per coat (Approx.) 20-25 65-75 50-75
4 Theoretical covering 8-10 8-9.2 11.40
capacity, M2/coat/Ltr
5 Weight per liter (Kg/litre) 1.1 - 1.2
6 Touch dry at 300C 30 mts. 30 mts 90 mts
7 Hard dry at 300C 24 hrs Overnight 6 hrs
8 Overcoating interval Min 16 hrs, Min. Overnight 6 hrs
Max Unlimited Max. Indefinite
9 Pot life at 300C for two Not applicable 4-6 Hrs 2 hrs
component paints
10 Temperature resistance 500C
5. Painting
a. Painting system for the boiler chimney covering surface preparation, application of
primer coats and final coats to develop the required minimum dry film thickness on steel
surface is as per Table-2. The same will be assessed by Engineer in Charge of Inspection.
Elcometer for ascertaining DFT shall be arranged by the contractor.

b. Application of paint be by spraying or brushing as per IS: 487-1985 and in uniform

layers of 50% overlapping strokes. Painting shall not be done when the temperature is
less than 5°C or relative humidity more than 85% unless manufacturer’s
recommendations permit. Also painting shall not be done in frosty or foggy weather.
During application, paint agitation must be provided whenever such agitation is
recommended by the manufacturer.Areas which become inaccessible after assembly of
steel components shall be painted before assembly, after cleaning the surface as
specified. Edges, corners, crevices, depression, joints and welds shall receive special
attention to ensure that they receive painting coats of the required thickness.

TABLE-2
Sl.N Item Primer Finish Total DFT 
o
1 Stack External 1x65  DFT 2x20  DFT 105
Inorganic Zinc Heat resistant
Silicate Primer Silicone
Aluminium
Paint
2 Stack Top Aviation colour 3x25 DFT 130 (Including
band Aviation colour DFT of Primer)
bands of 3 Red
bands & 2
white bands of
400mm height
each from Top
3 Platform brackets, Platform 1x65  DFT 2x100  DFT 305
members & Cleats etc. Inorganic Zinc High build
Silicate Primer epoxy paint,
1x40  DFT

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 Acrylic
Polyurethane
finish paint
4 Ladders, Handrails, Misc. 1x65  DFT 2x100  DFT 305
Structurals etc.. Inorganic Zinc High build
Silicate Primer epoxy paint,
1x40  DFT
Acrylic
Polyurethane
finish paint
5 Stack Internal Painting 2x30  DFT
Red Oxide Zinc
chromate primer

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 Annexure – 6
Technical Specification of Heavy mobile Crane:
(Contractor shall submit the certified current load chart of crane with following information).
(i) Model:

(ii) Make:

(iii) Machine description:

(iv) Maximum tested lifting capacity: ……………………ton at 20m radius.

(v) Boom extension:

(vi) Lattice jib:

(vii) Carrier engine output: kW.

(viii) Crane Engine output: kW.

(ix) Operational weight: ton.

(x) Total Counterweight: ton.

(xi) Renter Name & Address:

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 Annexure-7
Indemnity Clause

The Steel Chimney is located inside plant area surrounded by Air conditioning plant,
DM water plant, Boiler house and SGTF building. The proposed repair work is to be carried
out without creating any damage/trouble/hindrance to the operation/surrounding equipments.
In the event of any damage to the surrounding equipments/ building/ structures, the
contractor has to pay the compensation for repairing of equipment / purchasing new
equipment/ building new structure as the case may be as per the discretion of Engineer In
charge.
No relaxation for this would be allowed even on grounds like genuine oversight. The
contractor has to sign this clause and plan the work accordingly with utmost discretion and
care not to damage any structure/ machinery/component/cable tray etc...

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 SCHEDULE OF RATE
Rate
SL.N Qty- Including
ITEM Total ₹
O Number GST and all
taxes in ₹
Fabrication & erection of Stack: The work involves
Procurement of Materials required for Fabrication of a
Self supported Steel stack of 11Tonnes made from IS
2062, and supporting structures like Platforms, safety
ladder, safety cage and safety tie on, lightning arrestor
system with one lightning rods and a ground wire,
aviation lamps, intermediate platforms, Cone hood at
top of the stack etc...and fabrication of Stack as per the
drawing attached, Painting of the stack as per Painting
schedule mentioned in the Technical Specification,
1 1
Transportation of the prefabricated parts to the site at
the expense of the contractor, including the necessary
transit insurance coverage borne by the contractor, and
safe storage of the Prefabricated Stack in site as directed
by the Engineer In charge and Erection of the stack .
Double tubular scaffolding required for the erection of
the Stack and Crane, tools, tackles, scaffolding items,
lifting arrangements etc...are in the scope of contractor.
(ref.attached drawing and spec for details).

Dismantling of existing Steel Stack . The work

involves safe dismantling of existing Steel stack of 11
Tonnes from site following safe dismantling procedure
using necessary Double tubular scaffolding, safety nets,
by using necessary heavy equipment lifting tools, crane,
winches, tackles etc... after obtaining necessary height
2 1
pass, work permits and safety clearance as required in
IGCAR, without affecting the safety of nearby
equipments, persons and buildings and storage of the
dismantled parts in the designated locations as directed
by Engineer in charge.

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