Project Description AND Scope of Work For Revamping of Fire Water Network of Ongc Residential Colony of Ankleshwar Asset
Project Description AND Scope of Work For Revamping of Fire Water Network of Ongc Residential Colony of Ankleshwar Asset
Project Description AND Scope of Work For Revamping of Fire Water Network of Ongc Residential Colony of Ankleshwar Asset
PROJECT DESCRIPTION
AND
SCOPE OF WORK
FOR REVAMPING OF FIRE WATER NETWORK OF ONGC
RESIDENTIAL COLONY OF ANKLESHWAR ASSET
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Project description and Scope of Work
TABLE OF CONTENTS
S. No. DESCRIPTION SHEET NO.
1. INTRODUCTION
2. DEFINITION
3. INSTRUCTIONS TO BIDDERS
7. MATERIALS
8. ORDER OF PRECEDENCE
9. MANDATORY REQUIREMENTS
10. INSPECTION
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Project description and Scope of Work
1.0 INTRODUCTION
ONGC intends to revamp the fire water network of its residential colony at Ankleshwar. on Lump Sum
Turn Key (LSTK) Basis.
ONGC shall appoint a TPI agency for stage-wise / final inspection of all bought out items and supervise
the site activities.
2.0 DEFINITION
The CONTRACTOR / BIDDER / VENDOR is the company awarded the contract to carry out the
entire part of designing, engineering, manufacturing, site fabrication, inspection, testing, painting,
and other allied works as per the scope of supply for ONGC Ankleshwar residential colony
fire water network.
CONTRACT shall mean a written CONTRACT signed between ONGC and the BIDDER
(successful bidder) including subsequent amendments to the CONTRACT in writing thereto.
OWNER / CLIENT/ COMPANY shall mean, OIL & NATURAL GAS CORPORATION LIMITED,
ANKLESHWAR and includes its representatives, successors in title and permitted assignees.
The SITE shall mean the place in which the operations / services are to be carried out or places
approved by the ONGC for the purposes of the contract together with any other places designated
in the contract as forming part of the site.
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Project description and Scope of Work
- Guarantees
- List of recommended spare parts with unit prices.
(1) Erection and commissioning period
(2) Two years operational spares
- List of special tools, equipment fixtures material etc required.
- Quality assurance and control (general presentation)
- Name of sub Bidders, indicating nature of sub-contract and list of proposed suppliers for vendor item.
Purchaser’s approved vendor list will be made available and vendor selection shall be made out of this list.
- Power consumption.
- Process description and system design basis along with P&I Diagram.
- Layout of the network.
- Plant air requirement.
- Utilities requirement.
- Design and engineering of complete network.
- Pressure drop across the line between pump discharge flange and final discharge point.
- Details of fire water pumps..
3.2 DATA TO BE FURNISHED BY THE BIDDER AFTER THE AWARD OF CONTRACT
1. List of drawings and documents to be submitted for review, approval and information with scheduled
submission dates.
2. Quality Assurance Plan (QAP).
3. Flow diagram showing major control loops, battery limit stream flow rates, operating & design
conditions, compositions & properties.
5. Process & Mechanical Datasheets for all equipment.
6. Sizing calculations for system components.
7. Detailed P&I diagram showing clearly the scope of supply of equipment, piping with line sizes and
material specifications, valves, specialities, instrumentation and control and all the accessories. All
equipment, lines, valves, specialities and instruments shall be tagged as per the ONGC procedure to be
given to the successful BIDDER. All terminal points shall be clearly identified. All design data and other
information furnished in data sheets shall be covered either in this drawing or other relevant drawings or
documents mentioned below.
8. Detailed equipment list and bill of materials of all items in the bidder’s scope.
09. Mechanical design calculations for fire network system components.
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Project description and Scope of Work
10. Dimensioned to-scale equipment layout drawing showing all equipment, accessories, relevant external
dimensions, location and elevation of terminal points, details of piping and electrical connections to be
made by the PURCHASER, clearances required for erection, dismantling, operation and maintenance.
11. Dimensioned cross-section drawings of flare stack and other proprietary items with part list and
materials of construction.
12. Detailed fabrication drawings.
13. Line designation schedule for all lines.
14. Dimensioned to-scale piping layout drawing for piping in the Supplier’s scope with allowable forces and
moments on the piping nozzles and displacement of the nozzles.
15. Overall foundation plan, base frame drawing for each equipment, static and dynamic loads on each of
the anchor bolts and dimensional details of pockets and anchor bolts.
16. Motor datasheets & vendor drawings.
17. Earthing & Lightning Protection Layout.
18. Electrical control wiring diagrams with all interlocks.
19. Electrical Heat Tracing Drawings.
20. Erection, start-up, operation and maintenance manual complete with lubrication schedule,
consumables etc.
21. Documents for statutory approval.
22. Detailed plan of inspection, testing and performance testing of equipment at works and the assembled
package at site.
23. Final Load List
24. Lighting Layout
25. Quality Assurance Plan for Electrical Equipment.
26. As built drawings
27. Type Test Certificates for the electrical equipment
28. Routing Test Certificates after inspection of the electrical equipment
4.0 SITE DATA / DETAILS
Collection of data, if required any, prior to detail engineering is in Bidders’ scope. Bidder shall collect any
relevant and necessary information required for detail engineering during site survey at his own cost
without any cost and / or time implication.
5.0 MAJOR FACILITIES UNDER SCOPE OF WORK FOR REVAMPING OF FIRE WATER
NETWORK OF ONGC RESIDENTIAL COLONY OF ANKLESHWAR ASSET.
List of major facilities to be installed are as below:
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Project description and Scope of Work
Multi Story Tower Complex: Multi Story Residential Tower i.e. Gandhar, Narmada and Malviya
Tower has common fire water network. The existing pump house is having one Diesel, one Electrical
and one Jockey Pump which are common for all the three towers. Each building has a riser with
isolation valve and Hose Reel at each floor level. In addition to this, each Tower has a Terrace Fire
Water Tank of 5000 litres capacity and an Electrical driven Terrace Booster Fire Pump at Terrace
level of each tower.
In addition to this, Yard Hydrant System at ground floor are provided with coverage to all Towers.
Surya Auditorium: Standalone Fire Water Network for Auditorium is provided for Auditorium having
Riser up to first floor, Hydrant surrounding all around the Auditorium/ building. The network is
extended to cover ONGC club and Ashok Rangmanch as well. System is having a one Electrical
Driven Fire Water Pump along with one Jockey Pump.
Scope of work:
5.1 Fire Pump Houses for Multi-storeyed building of ONGC Residential Complex,
Ankleshwar:
a) Construction of new pump house for housing one diesel engine driven pump, associated
diesel tank and its associated MCC panel, instrumentation and piping etc. along with
electrical wiring & other accessories as per the direction of EIC.
b) Construction of civil foundation for one nos of pump.
c) Installation of one no of new pump along with its suction and discharge pipes, valves , NRV,
instruments, Air Release / Breather Valve, & Air Release Vessel etc.
d) All Pressure Switches and Pressure Gauge should be mounted on branch line with proper
bend.
e) Removal of existing old terrace water tanks, pumps, pipe lines etc. Terrace is covered with
GI sheets, for removal of old terrace water tanks & installation of new one may require
removal of these GI sheets. Removal & reinstallation of GI sheets (if required) on terrace of
multi story buildings will also be in contractor scope.
f) Construction of foundation for new terrace pumps, tanks along with associated piping &
valves and its installation in line with NBC requirement. MOC for piping- GI, MOC of Valves-
SS
g) Replacement of CS Gate Valve & NRV of 6” size near 4- Way Fire Brigade Connection in all
three Towers at ground floor level.
h) Replacement of CS Gate Valve & NRV of 6” size in the Riser 6” size of all three Tower at
ground floor level.
i) Hydrants are to be provided by ONGC as free issue material however Flanges of size 4”, 150
class for these hydrants along with installation will be in contractor scope.
j) Piping, for HSD supply & return, shall be of GI.
k) Laying of Fire Water Network of 6” size pipeline from new pump house to Heli Pad & Public
gathering Area/ Stage.
l) Supply and installation of 03 nos. Hydrant points of Type- B, 4-Way Fire Brigade Connection
with Gate Valve & NRV of 6” size and 01 no. Point for Water cum Foam Monitor of 500 GPM
capacity in the helipad area
m) Interconnection of both the existing Fire Water Networks of High Rise Towers and Surya
Auditorium through the 4” pipeline and provide gate valve on both the interconnected side of
Fire Water Network.
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Project description and Scope of Work
n) Laying of pipeline from multistoried building to guest house and connect it with network at
Surya auditorium. Install 02 nos. Hydrant point of Type- B in front of guest house.
o) Air release valve is to be installed at highest point of riser of High rise building/ Surya
Auditorium. No air vessel required with riser line. Air Vessel with air release valve is to be
installed / provided with Jockey pump at auditorium only. MOC for Air Vessel MS / SS.
p) Capacity of each new terrace water tank will be 5000 liters, multiple tanks may be considered
for each terrace totaling to 5000 liters provided all are interconnected and meet pump flow
MOC of
requirement. MOC of tanks
tanks will
will be
be PVC.
HDPE with ISI Mark / Similar to existing tank.
5.2 Fire Pump Houses Surya Auditorium of ONGC Residential Complex, Ankleshwar: -
a) Construction of new pump house to install one no of new diesel engine driven pump along
with electrical wiring & other accessories as per the direction of EIC..
b) Construction of civil foundation for new pump.
c) Installation of one no of new pump along with its suction and discharge pipes, valves , NRV,
instruments, Air Release / Breather Valve & Air Release Vessel etc.
d) Pressure Switches and Pressure Gauge should be mounted on branch line with proper bend.
e) Installation of new Air Vessel (300 MM Diameter & Length: 1.2 Meter) with Air Release /
Breather Valve.
f) Replacement of all existing suction, discharge valves and NRVs.
g) Installation of Rubber Expansion Bellow in the Discharge Line of all Fire Pumps (i.e. Diesel
Engine Driven Pump, Jockey Pump & Main Electrical Pump) below NRV.
h) AUTO starting system of all the pumps is to be installed in the pump house.
i) Modification of existing MCC panel, if required, to start the jockey pump in AUTO mode.
j) All the three pumps should start in AUTO mode in the sequence of jockey > diesel > motor.
An Electronic Fire detection along with Alarm System is to be installed in ONGC club house
along with installation of smoke detector, hooter, cables, controller etc.
Layout of ground floor of officer’s club is attached. At first floor, there is only one room whose
size is same as the multipurpose hall at ground level however bidder to visit the site before
bidding for better clarity.
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Project description and Scope of Work
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Project description and Scope of Work
42 Hose Box- Double Door: Material- Mild Steel of 18 SWG CRC Sheet, 06 Nos.
Suitable for Two Delivery Hose of Type- B, Colour- Fire Red along with Free Issue
Mild Steel Stand
43 Delivery Hose- RRL- IS: 636, Type- B, Size: 63 MM, Instantaneous 01 lot
Couplings- Gun Metal. Free Issue
44 Hand Controlled Branch- Material: Aluminum Alloy Hard Anodised, 01 lot
Pattern: Jet & Fog Free Issue
45 Manually operated Electronic Fire Alarm System i.e. MOEFAS (with Detectors-
detection) along with all accessories like: Manual Call Point (MCP) with 60
reset facility, Electrical cable: 1.5 Sq. MM 2 Core FRLS Steel Wire MCP-15
Armored, Hooter with Flasher, Smoke & Heat Detector, & Addressable Cable-
Panel etc. 1000
meters
However final quantity will be decided at the design engineering stage. (Approx.)
Hooters-
15 Nos.
46 Orifice plate: To reduce pressure to operating pressure (3.5 to 4.5 Kg/cm2) 30 Nos.
47 Pump House (RCC roof) for multi-storeyed building for 01 nos of diesel 01
driven main pump and associated accessories
48 Approach Road (Bitumin) from nearest existing bitumen road to Water tank LS
at multi Storied Building old Pump House Approx 20 mtrs
49 Construction of new Pump House (RCC roof) for new fire water pump at 01 Nos.
Surya auditorium
50 Flanges of size 4”, 150 class for Hydrant Valve Type- B (Helipad Area- 03 05 Nos.
Nos., Guest House & VVIP Guest House- 02 Nos. and ONGC Club House-
01 no)
Notes:
a) Above mentioned quantity in Bill of Material is tentative only, bidder to visit the site before
bidding for better clarity.
b) Bidder / Contractor to ensure that the entire work meets/complied with all the statutory
requirements
c) Road cuttings for the project work to be restored to original condition.
d) Minimum Class 150 pipes are to be used in fire water network.
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Project description and Scope of Work
Connection from the existing fire water network for filling the terrace tanks is to be provided
along with associated valves, NRV etc.
The Pump shall be run for a period of 04 (four) hours non-stop delivering the rated output. During
the test all parameter like cooling system, temperature of the engine, oil temperature shall match as
per manufacturer’s recommendation.
This Section includes Process, Civil, Building, Structural Steel, Mechanical, Piping, Electrical,
Instrument and Painting work for revamping jobs.
General Requirements
6.1 The project is to be executed on LSTK basis with single point responsibility as per scope of work.
The bidder shall submit a lumpsum quote in Price Schedule enclosed with bid document. The
data given in the tender document is indicative only. Bidder to note that the contract being of
turn-key nature, Bidder’s responsibility shall also include scope of any such works and supplies
whether specifically included in this bid or not, but required to complete the job for safe, smooth
and successful operation of the complete fire water network as per scope of work, design criteria,
drawings, data sheets, job specifications, technical specifications etc. and directions of the
ONGC.
6.2 The Bidder shall perform the construction and supply all labor, supervision, materials, laboratory
services including consumables, equipment, tools, testing devices, supplies, services and each
and every item of expense necessary for the work such as fabrication, transportation, field
erection, installation, construction, assembly, testing, warehousing, handling, hauling, unloading,
each and every item of receiving, evaluation, quality assurance, and services with workmanlike
execution of the Work as set forth in the tender documents.
6.3 Transportation of all equipment & Material to site include Loading and unloading, storage,
Maintenance, construction, installation, obtaining all necessary statutory approvals from
concerned Government authorities as applicable. Pre-commissioning, Commissioning,
Performance Guarantee Test runs Including Total Project Management and Handing over of
storage and Handling Facilities on Single Point Responsibility basis.
6.4 Bidder shall be responsible for proper installation of vendor supplied materials in accordance
with such vendor’ installation specifications. Bidder shall be responsible for checking the
completeness and adequacy of such data and informing ONGC of any discrepancy.
6.5 The scope of work and supply also includes co-ordination of engineering related activities for
incorporation in his works, monitoring of the progress, inspection and expediting, transit
insurance, transportation, handling and safe storage at site, assistance in commissioning and
successful run of the complete system.
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Project description and Scope of Work
6.6 Bidder shall comply with Quality Assurance requirements and submit its Quality Assurance Plan (QAP) for
Company‘s review and approval. For Inspection and test Plan (ITP), Bidder shall comply with the
requirement of Inspection & Quality Assurance Methodology.
6.7 Bidder shall also arrange the services of the package suppliers / vendor specialists at site during erection,
testing, start-up and commissioning, or as and when required and advised by the Company.
6.8 Bidder shall be fully responsible for all the equipment / items/ materials etc delivered / received at site till
issue of Completion Certificate.
6.9 Construction Plant and Equipment :-
Bidder shall supply at site all the necessary construction plant and equipment, tools, consumables, fuels
and supplies required for the execution of the job. If such plant and equipment brought to site is not
sufficient to keep the schedule and/or performance as planned, in the opinion of Company, Bidder shall
add, at his own expense such additional plant and equipment as deems necessary.
6.10 Bidder shall submit the list of construction equipment, he proposes to deploy for the subject work along
with recourses based network which shall be revised time to time to meet the requirement of updated
PERT/CPM. Please note that no equipment will be supplied by the Company.
6.11 In providing for the above, the bidder shall recognize and comply with the detailed requirements of any
National Codes of Practice of Nation or any other statutory requirements described in Scope of Work,
Specifications and Drawings attached with, and mentioned in this documents and related Standards.
6.12 Arrangements of all tool / tackles, hydras, cranes, welding equipment, NDT equipment, Testing equipment
etc., deployment of skilled / semi-skilled manpower, supervisors, safety officers etc. to complete the job
within stipulated time frame as indicated in the tender.
6.13 The bidder shall deploy adequate equipment and tools and tackles at site and augment the same
depending on exigencies of work to suit the project schedule.
6.14 The Bidder shall carryout preparatory work to obtain hot / cold work permit before taking up the job. Any
spilled sludge and oil, oily grass, etc. in the vicinity of the construction area has to be removed by the
Bidder to avoid fire hazard. Necessary hot work permits for starting the hot works will be issued only after
clearance by the Company
6.15 Detailed scope of work shall be as mentioned in detailed technical specifications of related disciplines and
in tender drawings. The broad scope of work shall include but not limited to the;
i. Pre-engineering,
ii. Project management,
iii. Residual, basic design and detailed engineering,
iv. Barricading works,
v. Site levelling,
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Project description and Scope of Work
vi. Procurement, supply, receipt, storage, conservation, preservation and handling of material at site
of all metallic and non-metallic materials and consumables required for work
vii. Manufacture, fabrication
viii. Preparation of all fabrication drawing / schemes / layouts etc.
ix. Review/approval of document from appropriate authorities
x. Documentation,
xi. Inspection & Testing,
xii. Coating/ painting
xiii. Transportation of all material to site.
xiv. Site fabrication/ construction / erection/ Installation
xv. Assembly
xvi. Welding
xvii. Hydro testing,
xviii. Coating & Painting works
xix. Insulation works , if required.
xx. Complete piping,
xxi. Transfer pumps, equipment & machinery,
xxii. Necessary civil works such as Sand bed, Hard stand, soil strengthening, tunnel / trenches,
foundation works, pipe rack, road, culverts & piling works etc.
xxiii. Complete supply of instrumentation and field erection,
xxiv. Electrical works including supply and erection
xxv. Providing all temporary works and equipment for completion
xxvi. Pre-commissioning / commissioning
xxvii. Supply of all mandatory and commissioning spares
xxviii. Final hook-up with owner facilities
xxix. Obtaining applicable statutory approvals
xxx. Deploying suitable staff, labour, all tools and tackles etc.
xxxi. Guarantee of systems to the entire satisfaction of inspecting authority and engineer-in-charge.
xxxii. Other Allied works
6.16 Completing all the work in all respects on turn-key basis within the battery limits as defined in the P&IDs,
layout drawing, engineering drawings, specifications / standards etc. and detailed scope of work and
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Project description and Scope of Work
supply defined in different sections of bidding documents and its attachments. in strict compliance as
stipulated under various clauses, sections, chapters and volumes of bid document including addendums,
amendments, corrigendum, clarifications & revisions, and specifications, applicable code, relevant
drawings and documents enclosed along with the tender.
6.17 Bidder shall, at his own expense, furnish all materials, labor, construction equipment, tools, supplies,
and/or services to furnish the Work as described in the tender, and shall carry out all scope of work &
supplies, obligations, duties, and responsibilities mentioned teherein. It includes but not limited to the
followings:
A. PROCESS (SCOPE OF WORKS AND SUPPLY)
1. Fire water network is to be revamped on LSTK basis. The supply shall be complete in all respect to
complete the scope of work. However, it should be noted that the scope of supply as indicated on these
documents, shall only be considered the minimum required. Any additional material / item required to
complete the fire water network, ensure good construction, trouble free reliable operation, smooth start-up
and operation during normal course and emergencies shall be included in the supply. The scope of supply
shall be as follows:
2. All the pipelines are to be laid as per the standard practices / standards applicable for the residential
colony fire water system.
3. Bidder scope shall also involve work of installing 4 nos x 5000 ltrs syntax tank on the roofs
4. Supply, Erection, Testing of all Piping items like Pipes, Valves, and Flanges required for complete fire
water network including the piping from PSV discharges, Control Valve Discharges etc. to main header
shall be in the scope of LSTK Bidder.
5. Erection of platforms for operation and maintenance of elevated PSV’s, Control Valve, valves etc as
required as per site requirement shall be in the scope of LSTK Bidder.
6. Supply and installation of fire water pumps.
7. All necessary Instrumentation and control required for the complete fire water network.
8. The scope of work shall include complete design, engineering, procurement, manufacture, supply,
inspection and testing, installation and commissioning as per enclosed specification but not limited to the
followings:
i. UL listed / EN Standard fire water pumps.
ii. All the interconnecting piping, valves, fittings and flanges etc for complete network
iii. Cables (both power and control) as required.
iv. Spares for commissioning and two years operation.
v. Technical Documentation.
vi. Approval of statutory authorities (if required).
vii. Packing, Marking and Despatch.
viii. Battery limit connections having same specifications, thickness and weld profile as that of purchaser.
ix. The Bidder shall take into consideration all required safety aspects while erection. Also, the Bidder
shall delineate clearly the safety aspects considered while erection in the erection procedure to be
submitted by the Bidder.
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Project description and Scope of Work
x. The Bidder shall furnish design, engineering and construction documents as per Clause No. 8.0 and
furnish detailed fabrication drawings “GOOD FOR CONSTRUCTION” along with erection manual for
taking up fabrication and supply cum erection including painting by the bidder.
xi. Bidder shall also submit within 4 weeks from the Letter of Intent the step wise procedure for carrying out
installation taking into consideration existing network, safety concerns, site condition. The procedure
shall be backed by document supporting safety radiation limits for working and as required for safety
while erection.
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Project description and Scope of Work
15. Laying areas of concrete paving including sub-base, mesh reinforcement and joint materials
16. All excavation works as per civil drawings and specifications. Excavation for foundation including
hand digging, protection of existing services and stockpiling of suitable material for re-use as
general fill.
17. Backfilling and compaction
18. Installation of pipe sleeves, cable ducts and concrete surrounds to road crossings
19. Installation of any temporary drainage works which may be required during construction works
20. Pre-survey, removal and relocation of all existing underground obstructions and live cables
21. Protection of existing facilities inside the colony from heavy traffic and heavy lifts
22. Laying of blinding concrete, concrete protection membranes and etc. under foundations, floor slabs
and paving. Laying of concrete foundations, plinths, bases, columns, beams, ground beams, ground
slabs to buildings and paving
23. Installation of anchor bolts, sleeves and templates. Grouting of base plates for all steelwork and
equipment
24. Backfilling and compaction of foundations with selected excavated or imported material
25. Removal of unsuitable material or surplus excavated materials to designated disposal area as
directed by the Company.
26. Foundations’ work.
27. Building works and Material Supply (brick, block, cement mortar, insulation accessories etc.).
28. Waterproofing works
29. All works for Checkered Plate, Grating, Steel Handrail and Ladder, Steel Staircase, Roof Drain,
Down Pipe, Gutter etc.
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Project description and Scope of Work
g. Springs, Expansion joint/ Bellows (All types specialty item like sample coolers, steam traps
strainers, air traps, hoses, etc.
5. Shop & field fabrication, and erection of piping in accordance with documents listed including
erection of piping materials enumerated above. Fabrication, lifting, erection & installation, pre-
heating & post weld heat treatment, inspection & pressure testing of piping installations. Fabrication,
supply, installation and commissioning of pipe supports, guide anchors, and spring supports, as
required
6. Fabrication and erection of pipe supports like shoes, stiffener rings, corrosion pads, saddles, guides,
stops anchors, clips, cradles. Hangers, turn buckles. Supporting fixtures brackets cantilevers, struts,
and tee-posts, including erection of spring supports and sway braces. Fabrications of piping
specials like special radius bends, reducers, miters, etc. Fabrication of plain and threaded nipples
from pipes as required during erection. Fabrication of swage nipples as and when required.
Fabrication of angle elbows like 60 deg., 30 deg. Or any other angle from 90- deg./45 deg. Elbows
as and when required. Fabrication of flanges, reducing flanges, blind flanges, spectacle blinds as
and when required. Fabrication of stub in connections with or without reinforcement and
reinforcement pads, etc.
7. Installation of all valves and other miscellaneous in/off line items
8. Grinding of edges of pipes, fittings, flanges, etc. to match mating edges of uneven/different
thickness of valves, etc. as and when required.
9. Preparation of Isometrics & bill of materials for all lines including instruments purging vents and
drains. Supporting details of all Non-IBR lines up to and including 1-1/2” and lines specified as field
routed within the battery, limit including subsequent approval from Engineer-in-Charge as and when
required.
10. Obtaining approval for drawing prepared by Bidder from statutory authority if required.
11. 10 % Radiography, 100% dye penetration etc. as per the specification
12. Construction of concrete pedestals and fabrication and erection of small structures for pipe supports
including supply of necessary materials.
13. Providing insert plates in concrete structures / paved floors and repair of platform gratings around
pipe openings. Fabrication & erection of pipe supports, loop supports on pipe racks, etc.
14. Protection of joining surfaces or open ends of piping with plastic caps
15. Flushing and testing of all piping systems of fire water network as per standard specifications for
inspection, flushing and testing. The accessories required for blinding the line like flange, blind
flange, gaskets & stud-bolts, etc. shall be arranged by Bidder. After testing, the flange shall be cut
and pipe ends shall be prepared as per piping specification. Testing and flushing for every unit will
be done based on same philosophy. A spool piece of approx. 1-4m (as per field condition) shall be
welded to complete the line and both the welds shall be 100% radiographed.
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Project description and Scope of Work
16. Providing coating & wrapping for pipes, pipe sleeves crossing or roads/ dykes as per approved
drawings and specification.
17. The scope shall include any other works and specifically not mentioned above, but required
completing the work-in all respects as per direction of Company.
18. Removal of miscellaneous items e.g. control valves, in-line instruments, relief valves, probes,
meters and etc. for any test, flushing and etc.
19. Coating and wrapping of field welding joint and small size piping components for underground
piping
20. Compliance with the Mechanical Completion requirements
21. Installation of any blind to isolate lines as necessary for the works
22. Working in live facilities, obtaining of permits and scheduling of such work in accordance with
agreements made with Company.
23. Live tie-ins to existing piping during shutdown period
24. Demolition of existing piping
25. Tie-ins to existing equipment. Hook up with existing facilities including storage inlet and outlet lines,
discharge headers, utilities, control systems etc. shall be bidder’s responsibility.
26. Complete fire water network as per applicable standard.
ELECTRICAL (SCOPE OF WORKS AND SUPPLY)
1. PMCC
2. MLDB
3. Cables
4. Complete Illumination system with Lighting Fixtures in the pump house.
5. Earthing and lightning protection system including any buried cable requirements which shall
include trenching, excavation, trial excavation, back-filling, marking, tiling, sand filling & disposal of
excavated soil etc;
6. Electric heat tracing system, if required;
7. Sockets, switches, fuses, pushbuttons, etc.;
8. Distribution boards and panels;
9. Installation of accessories such as terminal lugs, labels, cable markers, ties, etc.;
10. Cable trenches, Cable trays, rack and ladders (including marking and supports) with fittings
11. Up-stands, mounting plates and brackets required for any equipment item;
12. Sealing for cable entrance hole.
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Project description and Scope of Work
1. Supply of all type of paints, thinners, other painting materials for carrying out complete scope of
work as per the technical specifications and drawings provided with tender.
2. Preparation of all surfaces, apply paint, etc., to steelwork, SYNTEX Tanks, piping and other
equipment or building inside and out as per the Project Specification and vendor’s recommendation
3. Marking / painting on safe working loads on runway beams and lifting points
4. Provision of labels to instruments, valves, cabinets, junction boxes, equipment, doors, covers, etc
5. Provision of painted signs / notices / directions as may be required on the Site
6. Marking/painting of equipment no , line Nos. on the surface of line /equipment as per the Project
Specification
Any other works specified elsewhere in the bid document. Bidder to note that the contract being of turn-key
nature, Bidder’s responsibility shall also include scope of any such works and supplies whether specifically
included in this bid or not, but required to complete the job for safe, smooth and successful operation of the
complete system as per scope of work, design criteria, drawings, data sheets, job specifications, technical
specifications etc. and directions of Company’s representative. Such works and supplies shall be
performed by Bidder without any cost and / or time impact to the Company.
7.0 MATERIALS
7.1 Procurement and supply at appropriate stages of all metallic and non-metallic materials, equipment,
consumables and all other items including commissioning spares, ocean freight / air freight, customs
clearance, insurance, inland transportation, receipt, accounting, storing and preservation of materials etc.
all complete as per scope of supply/work detailed in various sections of bidding document, drawing,
specifications, other documents is in the scope of Bidder.
7.2 All materials whatsoever required for the fabrication, supply of equipment along with associated piping,
instrumentation, structural platforms, ladders/stairs, supports etc. within the specified battery limits and
installation of the complete system at site shall be in Bidder’s scope of supply.
7.3 All the materials in Bidder’s scope of supply shall be new and of first quality and shall be supported with
test certificates.
7.4 Any material or equipment procured and supplied by Bidder to the Company, the Bidder shall continue to
remain responsible in all respects for conformity of materials and equipment supplied to the contractual
specifications and purpose of the work, the Bidder shall not be absolved of his responsibility to properly
execute, perform and complete the work.
7.5 All the surplus materials and equipment shall be removed after final acceptance job/work by the Company.
8.0 ORDER OF PRECEDENCE
8.1 The detailed scope of work for individual works like civil, structural, mechanical, piping, electrical,
instrumentation etc. is defined in the bid document. Efforts have been made to avoid any contradiction /
mismatch in scope of work, design basis, P&IDs, data sheets, job specifications, standard specifications,
codes, standards etc. appearing in respective engineering disciplines in the bid document.
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Project description and Scope of Work
8.2 Bidders are advised to go through the complete bid document thoroughly and obtain all clarifications at the
time of pre-bid conference. Notwithstanding the above, in case, any conflict still remains unresolved, the
order of precedence as given elsewhere in this bid document shall be followed. Client / Consultant’s
decision shall be final & binding on the bidder / Bidder in accomplishing the above tasks.
10.1 Notwithstanding the sub-division of the document into these separate sections and volumes, every part of
each shall be deemed to be supplementary of every other part and shall be read with and into the Contract
so far as it may be practicable to do so.
8.3 The materials, design & workmanship shall satisfy the applicable relevant Indian Standards, the job
specifications contained herein & codes referred to. Where the job specifications stipulate requirements in
addition to those contained in the standard codes and specifications, these additional requirements shall
also be satisfied. In the absence of any Standard / Specifications / Codes of practice for detailed
specifications covering any part of the work covered in this bidding document, the instructions / directions
of Engineer-in-Charge will be binding upon the Bidder.
8.4 The bidder shall take total responsibility of executing the project in accordance with the bid document
(including and if required any clarifications issued in the form of corrigendum / addendum) including
supplying of all material and consumable (unless otherwise indicated elsewhere in the bid document),
construction equipment, labour etc. and shall adhere to bid document instructions and requirements in
respect of all matters related to this project.
8.5 In case of contradiction between relevant Indian standards, GCC, Special Conditions of Contract,
Specifications, Drawings and Schedule of Rates, the following shall prevail in order of precedence.
i) Approved Drawings/ Data Sheets
ii) Scope of Work
iii) Special Conditions of Contract
iv) Standard Specifications
v) Relevant Indian Standards/ Specifications
vi) Purchase Order along with Statement of Agreed Variations, if any, and its enclosures
vii) Schedule of Rates with Quantities
viii) Fax of Intent (FOI)/Letter of Intent(LOI)
ix) General Conditions of Contract
9.0 MANDATORY REQUIREMENTS
EXECUTION OF WORK
9.1 All the works shall be executed in strict conformity with the provisions of the contract documents and with
such explanatory details, drawings, specifications and instructions as may be furnished from time to time to
the Bidder by the Engineer-in-Charge/ Site-in-Charge, whether mentioned in the Contract or not. The
Bidder shall be responsible for ensuring that works throughout are executed in the most proper and
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Project description and Scope of Work
workman- like manner with the quality of material and workmanship in strict accordance with the
specifications and to the entire satisfaction of the Engineer-in-Charge/Site-in-Charge.
9.2 The accuracy / correctness of all design, detailed engineering and drawings shall be the sole responsibility
of Bidder and any delay / loss / damage due to any mistake / discrepancy / anomaly in such design and
drawings shall be entirely rectified / borne by Bidder.
9.3 Any defect observed during construction / testing / commissioning or till the defect liability period of work,
shall be rectified and removed by the Bidder without any cost and / or time implication to the Company
irrespective of the fact whether the same has been reviewed and approved by Company or not. Bidder
shall also carry out whatever modification or reconstruction as needed for the purpose of completion of
scope to the entire satisfaction of Company without any extra cost and / or time implication to Company.
9.4 The completion of work may entail working in monsoon also. The Bidder must maintain the necessary
work force as may be required during monsoon and plan to execute the job in such a way the entire project
is completed within the contracted time schedule. No extra charges shall be payable for such work during
monsoon. It shall be the responsibility of the Bidder to keep the construction work site free from water
during and off the monsoon period at his own cost and expenses.
9.5 For working on Sundays/Holidays, the Bidder shall obtain the necessary permission from Engineer In
charge/Site In charge in advance. The Bidder shall be permitted to work beyond the normal hours with
prior approval of Engineer-In-Charge/Site-In-Charge and the Bidders quoted rate is inclusive of all such
extended hours of working and no extra amount shall be payable by the owner on this account.
SITE CLEANING
9.6 The Bidder shall clean and keep clean the work site from time to time to the satisfaction of the Engineer-
in-Charge for easy access to work site and to ensure safe passage, movement and working. All dismantled
material shall be shifted /removed by BIDDER at his own cost to designated place.
9.7 If the work involves dismantling of any existing structure in whole or part , any RCC foundation, paved area
care shall be taken to limit the dismantling up to the exact point and/ or lines as directed by the Engineer-
in-Charge and any damage caused to the existing structure beyond the said line or point shall be repaired
and restored to the original condition at the cost and risk of Bidder to the satisfaction of the Engineer-in-
Charge, whose decision shall be final and binding upon the Bidder.
9.8 The Bidder shall dispose off the unserviceable materials, debris etc. within the site and into the designated
area as directed by Engineer-in-Charge. The quoted Rates shall be inclusive of the above activities also.
The Bidder shall sort out, clear and stack the serviceable materials obtained from the dismantling/ renewal
at places as directed by the Engineer-in-charge.
9.9 No extra payment-shall be paid on this account. The rates quoted are deemed to be inclusive of all the
costs towards all the above activities as well.
9.10 The Bidder shall be the custodian of the dismantled materials till the Engineer-in-Charge takes charge
thereof.
STATUTORY APPROVALS
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Project description and Scope of Work
9.11 Obtaining statutory approvals shall be the responsibility of the Bidder. Bidder shall arrange the inspection
of the works by the authorities and necessary co-ordination and liaison work in this respect. The
application on behalf of the Employer for submission to relevant authorities along with copies of required
certificates complete in all respects shall be prepared and submitted by the Bidder well ahead of time so
that the actual construction/ commissioning of the work is not delayed for want of the approval/inspection
by concerned authorities.
9.12 Statutory fees paid, if any, for all such inspections and approvals by authorities shall be deemed to be
included in the quoted prices, if not specified otherwise.
9.13 Any change/ addition required to be made to meet the requirements of the statutory authorities shall be
carried out by the Bidder free of charge. The inspection and acceptance of the work by statutory authorities
shall however, not absolve the Bidder from any of his responsibilities under this contract.
9.14 All statutory approvals other than specified above shall be obtained by Employer and provided to the
Bidder.
CONSTRUCTION POWER AND WATER
9.15 Water required for the works shall be arranged by the Bidder. The Bidder has to make all necessary
arrangement for drawing water including making temporary storage, pumping etc.
RESPONSIBILITY OF BIDDER
9.16 It shall be the responsibility of the Bidder to obtain the approval for any revision and/or modifications
decided by the Bidder from the Company before implementation. Also such revisions and /or modifications
if accepted / approved by the Company shall be carried out at no extra cost to the owner. Any change
required during functional requirements or for efficient running of system, keeping the basic parameters
unchanged and which has not been indicated by the Bidder in the data / drawings furnished along with the
offer shall be carried out by the Bidder at no extra cost to the owner.
9.17 All expenses towards mobilization at site and demobilization including bringing in equipment, work force,
materials, dismantling the 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.
9.18 It shall be entirely the Bidder’s responsibility to provide, operate and maintain all necessary construction
equipment, steel scaffoldings and safety gadgets, cranes and other lifting tackles, tools and appliances to
perform the work in a workman like and efficient manner and complete all the jobs as per time schedule.
9.19 Preparing approaches and working area for the movement of his men and machinery. The procurement
and supply in sequences and at the appropriate time of all materials, and consumables shall be entirely the
Bidder’s responsibility and his rates for execution of work will be inclusive of supply of all these items.
10.0 INSPECTION
10.1 Unless otherwise specified, all the equipment and site activities shall be subjected to stage-wise
inspection and testing (to be witnessed) at vendor’s / manufacturer’s works / site by a third party
inspection agency (TPIA). Bidder shall submit an Inspection & Test Plan (ITP) / Quality Assurance (QA)
plan before commencement of fabrication / manufacturing / production / site activities.
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Project description and Scope of Work
The inspection / monitoring methodology including QAPs of equipment is enclosed elsewhere in the bid
document. Wherever QAPs are not available, same shall be prepared by Bidder and submitted to Client /
Consultant for review / approval. Approved QA plan shall form the basis for inspection.
The responsibility for co-ordination with TPIA shall be that of Bidder.
The TPI agency for stage-wise inspection and testing (to be witnessed) at vendor’s / manufacturer’s
works shall be appointed separately by ONGC.
The various minimum inspections required are given in the respective data sheets, job specifications and
standard specifications. Whether highlighted or not, heat treatment, destructive and non-destructive
testing shall be carried out as per requirement of National / International codes & standards.
10.2 Tests shall be carried out as specified in the data sheets / standard specifications / job specifications and
elsewhere (if any). However, Client / Consultant reserve the right to witness all hydrostatic, mechanical
and performance tests.
10.3 Inspection shall also include dimensional check of the equipment, its driver and auxiliaries (if any) duly
mounted on the base plate and check for direction of rotation of the assembly in accordance with
approved General Assembly drawings.
10.4 Until inspection is completed, no part of the equipment / material shall be painted.
10.5 At least 15 days’ notice prior to commencement of testing shall be given.
10.6 Bidder shall notify his sub-vendor for inspection and testing requirements.
10.7 Acceptance of shop test shall not relieve Bidder and vendor from any of their responsibilities in any way,
whatsoever.
10.8 All equipment / pressure containing parts shall be hydro tested with potable water at a pressure to be
determined as per the stipulations of applicable code for a minimum period as per code.
10.9 All instrumentation controls and safety devices shall be calibrated and tested for satisfactory operation
and settings. All the arrangement for shop testing and calibration of equipment/ instrument shall be
carried out by the Bidder.
10.10 Company representative shall have access to Bidder’s / manufacturer’s shop at all times during
manufacturing of the equipment and vendor / manufacturer shall provide all requisite facilities including
necessary monitoring and measuring devices to the Company representative for carrying out satisfactory
inspection and witnessing the test.
10.11 Bidder shall furnish schedules for all inspections and tests to be conducted on all the equipment and
auxiliaries in his scope of supply in a single document titled ‘Inspection & Test Plan’ within four weeks of
placement of purchase order / letter of intent for Client / Consultant 's review and approval. The extent of
Client / Consultant 's participation and schedule of submission of inspection and test procedures as
specified in inquiry / order shall also be reflected in 'Inspection and Test Plan' / ‘QA Plan’.
10.12 Motors shall be tested at the manufacturer's premises. Manufacturer's test certificate shall be submitted
for review / acceptance of the inspector.
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Project description and Scope of Work
11 Performance Guarantees
Bidder shall guarantee satisfactory operation of the complete fire water system for trouble free operation
for one year from the date of handing over the revamped system to the Company. Specifically the bidder
shall guarantee that there shall be no surges / cavitation in operating the pumps. Company / DEC’s
approval of the equipment’s design shall not relieve Bidder and equipment vendor of their responsibilities
to ensure satisfactory performance of the items supplied.
11.1 Bidder shall warrant that all materials used are new, satisfactorily passed through acceptance procedure
and is acceptable in quality, form and appearance.
11.2 The Bidder shall be responsible for hydraulic, mechanical and overall performance of the equipment. If any
defect or mal-performance occurs during the guarantee period, Bidder and equipment vendor shall make
all necessary alteration, repairs, and replacements free of charge.
12 SUGGESTED VENDOR LIST
12.1 Bidder is required to follow the Suggested Vendors List enclosed in the bidding document for
procurement of materials and equipment.
13 DOCUMENT AND DRAWING SCHEDULE AND SUBMISSION
13.1 GENERAL
These details are about various drawings and documents to be generated at various stages during the
course of execution of the project by the BIDDER for different project activities. An effort has been made to
distinctly categorize each document and the purpose for which they are required by either agency.
The BIDDER recognizes that efficient handling of drawings and documents to be prepared by him under
the contract is the key to the timely completion of the plant. The BIDDER undertakes to ensure that all
drawings and documents to be submitted by him to the Company shall be of professional quality and
conforming to the contractual requirements. BIDDER also undertakes to institute a formal drawing control
system, which will be documented and submitted to the Company / DEC for review or approval.
Compliance of this section on drawings and documents is mandatory and is non-negotiable.
13.2 The drawings/documents as generated by BIDDER at various stages of the project will be in the category
of Approval/Review/information. The drawings and documents required under different categories are
enclosed elsewhere. However, this will in no way relieve the BIDDER of responsibility to conform to
drawings, standards, specification, codes and contractual requirements.
13.3 Successful Bidder is required to submit the drawings and documents as mentioned in technical
specifications to Company / DEC for review / approval / information during detail engineering. The number
of copies shall be as indicated elsewhere in the tender documents.
13.4 Bidder shall prepare a detailed list of documents and drawings for all the disciplines and activities covered
in the scope of work, design basis and functional / standard specifications and shall furnish to Client /
Consultant as soon as possible (first issue along with the kick-off-meeting for the project, which shall be
within 15 days of the award of Contract), a complete list of all such documents and drawings to be
generated in the form of DCI / DDS (Document Control Index / Document & Document Schedule) for
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Project description and Scope of Work
Company / DEC’s approval. The aforesaid list shall include all the documents and drawings along with
document / drawing number, job number, document / drawing identification code, size of drawing, Sl. no.,
Revision. No., issue date etc.
13.5 Preparation of design, drawings, P&IDs/ GADs, data sheets, specifications & other related documents for
review/approval from Company / DEC and issue of As –Built Drawings is in Bidder’s scope.
13.6 Drawing index shall be prepared for each item giving serial number, description of drawings, drawing
number and revision number. Updated index shall be forwarded along with each submission.
13.7 Bidder shall submit complete documents as indicated elsewhere in the bid document but not limited to
drawings like piping GA drawings, isometric drawings, design calculations, data sheets etc. for review and
/ or information / record. A comprehensive list of such documents shall be submitted by Bidder for
Company / DEC‘s approval prior to the start of detail engineering. The list shall be continuously updated /
revised during the course of detailed engineering and submitted to Client / Consultant‘s review /
information.
13.8 English language and metric unit shall be used in all documents. Drawings shall be prepared in prescribed
sizes as standardized by BUREAU OF INDIAN STANDARDS (BIS) and shall be preferably in the sizes
such as 210 X 297, 297X 420, 420 X 597, 597 X 841, 841 X 1189mm. All Bidder drawings shall be folded
to A4 size and visible title block.
13.9 All documents before forwarding to Company / DEC will have to be vetted in detail by BIDDER. Document
received without vetting will be returned without review. Also any inaccuracies/mistakes found will not only
be rectified by the BIDDER. Delay owing to these shall be to the account of BIDDER.
13.10 All Bidders’ drawings submitted to ONGC shall be based on tender and shall bear reference number and
revision of the corresponding ONGC drawings. In addition, it shall indicate item number, client name,
project name, Bidder’s name, purchase order number, tender number, discipline / craft number, drawing
number, revision number, etc. all in the lower right hand corner. All revisions shall be clearly marked by
encircling with revision marks.
13.11 The approval/review by the Company / DEC shall not be construed by the BIDDER as limiting any of his
responsibilities and liabilities for mistakes and deviations from the requirements, specified under these
specifications and drawings.
13.12 For drawing, data sheet and all graphic works AUTOCAD latest versions and for all texts MS Word 2000
shall only be used.
13.13 Each drawing submitted by the BIDDER shall be clearly marked with the name of the Owner, the unit
designation, the specifications, title, the specification number and the name of the Project with revision No.
and date. If standards, catalogue pages are submitted the applicable items shall be indicated therein. All
titles, noting, markings and writings on the drawings shall be in English.
13.14 All the dimensions should be in metric units. Upon receiving comments on Drawings/Documents by the
BIDDER, the subsequent submission should give compliance report, separately on each of the comments,
document-wise.
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Project description and Scope of Work
13.15 Comments given by Company / DEC shall be discussed, if required, and finalized within agreed schedule.
13.16 The schedule of submission of Drawings/Documents shall be in accordance with project plans only. The
detailed list under different category, document-wise, shall be prepared by BIDDER for approval/review of
Company / DEC.
13.17 Sequence of submission of drawing is essential for proper review of documents and timely completion of
the project and is to be strictly adhered to. In case sequence is not maintained, the documents submitted
will not be reviewed by Company / DEC and responsibility of timely execution of plant/unit shall be to
BIDDER’S accounts.
13.18 The BIDDER shall maintain up-to-date record of drawings & document status and make regular issue of
drawing/documents index discipline wise, on monthly basis, as agreed, with copies to Company / DEC
indicating schedule date of submission, submission date of various revisions and date of review with code.
13.19 Category of Documents and Cycle Time
The handling of documents by Company/Bidder shall be as follows:
Company’s/DEC's Review
Code 1: Approved
Approval is mandatory and BIDDER cannot proceed without obtaining Company / DEC’s approval.
Code 2: Approved for Construction, Revised drawing required.
Code 3: Not approved, new drawing / Doc. required.
Drawings under code-3 are summarily rejected. Bidder shall not proceed based on code 3 drawings.
Bidder shall revise the code 3 drawings and obtain its approval from PDIL across the table.
13.20 Company/DEC shall comment / Approve within 07 working days. However, if major deviation to contract
specification for any design deficiency is detected in the course of review after stipulated period, it shall be
the responsibility of the Bidder to see that such deviations and deficiencies are corrected to ensure
compliance to contract without any cost and time implication to the company.
13.21 Drawings for -Information/Records
The information category document will be retained for records only. It is BIDDER’S responsibility to
correct the deviation, if any, to the stipulation in the bid document, without any cost or time implication to
Owner. BIDDER shall submit documents for Company/DEC’s information and proceed with the work.
Company comments, if any, which relates any cost and time implication to the owner due to
inadequacies/inaccuracies may be brought to the attention of BIDDER at any stage for incorporation
without any cost or time impact to owner.
13.22 The documents falling under approval/review category shall in general, except for drawings requiring multi-
disciplinary review, be returned with comments within 15 working days. 15 working days shall be reckoned
from the date of receiving the documents at Company/DEC. Receiving date shall be considered as date
entered by DEC. However, documents like equipment layout etc. where multi-disciplinary activity is
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Project description and Scope of Work
involved, the BIDDER, after submission for Company/DEC’s review, shall visit Company/DEC for
discussion for expeditious review of documents.
13.23 Documents submitted without meeting pre-requisite requirements will be returned without review.
BIDDER’S Review
13.24 BIDDER shall revert on unacceptable comment, if any, within 02 days from the date of release of
documents by Company/DEC. In absence of any rebuttal by BIDDER all comments will be deemed as
acceptable to BIDDER.
13.25 Review of Bid Evaluation Report
BIDDER shall ensure that all equipment in this package are ordered on vendors who are capable of
supplying equipment, meeting all requirements of the Project Specifications.
BIDDER shall submit a comprehensive bid evaluation report and recommendation for procurement of
major equipment to Company prior to award of purchase order.
Details of major Equipment will be finalized during Detail Engineering.
The report shall incorporate, but is not limited to:
Names and addresses of the companies invited to quote or bid.
Recommended supplier.
Reason for selection.
Evaluation of Vendor quality system.
Scheduled award date.
Quoted delivery date.
Reason(s) for rejecting unsuccessful bidders whether it is technical, commercial, delivery, etc.
13.26 Review of Purchase Requisition
BIDDER shall forward for specific equipment, Purchase Requisition together with attached documentation,
without pricing details, to Company/DEC for review prior to award of the Purchase Order. Such review by
Company shall not relieve BIDDER of any of his obligations under the Contract.
13.27 Details of Documents to be submitted for approval are covered in Bid document discipline-wise.
13.28 All subsequent changes to purchase requisition following review of the original shall be subject to prior
APPROVAL. Where requisitions specify a particular make or brand of equipment to be used followed by
the statement “or PURCHASER approved equal”, any such “equal” proposed by the suppliers shall be
submitted for APPROVAL of Company.
13.29 Control and Monitoring of documents review and submission
For Company’s review
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Project description and Scope of Work
Bidder is to develop a website for submission of drawing, documents, monthly report etc and give access
to company to download, upload the reviewed documents, view the progress reports etc. Bidder is to
update the status of the project in this website.
13.30 Drawing schedule shall indicate the following:
Schedule/Actual submission to Owner
Category of submission
Receipt of comments from Owner
Category of return status from Owner
Issue date for Construction
13.31 This updated schedule shall be issued on fortnightly/monthly basis, as agreed, and compared with
company’s log.
13.32 Detailed listing of documents (discipline wise) which are scheduled to be submitted or resubmitted
incorporating Company’s comments shall be provided by BIDDER in the weekly meetings. Bidder may
ensure that drawings / documents are submitted as per the agreed schedule only. Bunching of documents
/ out of sequence submissions and consequential delay of documents and approval there of shall be
exclusively attributable to BIDDER.
13.33 Detailed manufacturing schedules of fabricated/manufactured items shall be submitted within fortnight of
ordering, Status report for all the items in detail, will be submitted once in a month.
13.34 Documents to statutory authorities shall be submitted on getting the documents reviewed by Company. To
any other agencies, documents shall be submitted under intimation to Company.
13.35 Revision of any design / drawing / detailing shall not be permitted unless the same is necessitated due to
comments on review of such documents by the Company. Such revisions shall be restricted to
incorporation of Company’s comments only and no new details shall be added in the drawings unless
called for by comments during review. All revisions shall be clearly marked and clouded for easy
identification. It is expressly made clear that subsequent review of all revised documents shall be limited to
revisions as clouded only and any changes made by Bidder without such clouding shall be treated by
Company as null and void. Further, any new entry(ies) / detail(s) that become necessary based upon
vendors’ information or any other reason thereof shall be to Bidder’s account only and Company shall not
be liable for cost and / or time impact thereof.
As-Built Drawings/Documents:
13.36 As built drawings and documents will be generated within one month of completion of activities on
respective items of work.
13.37 BIDDER shall furnish reproducible and electronic files of all the drawings under their scope to Company
certified as "As Built Issue."
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Project description and Scope of Work
13.38 Upon completion of identifiable units or components of the fabrication, construction and installation phase
of the project, the BIDDER will complete all the related plans to the "as built" stage including all Vendor
drawings and furnish Company with the following :
a. 2 complete sets of full size prints of the drawings and 2 sets of reduced size prints.
b. 2 complete bound sets of Manufacturer’s specifications including design calculations.
c. As Built drawings generated specifically for this job in electronic media (AutoCAD latest version).
d. All vendor drawings & documents either in AutoCAD or in scanned images stored in electronic
media.
e. All operating & maintenance instructions in electronic media or in scanned images converted in
electronic media.
f. 4 complete sets in hard binders of the Manufacturer’s data book including certified prints and data
for all items including test reports. Data Book shall be complete with index as tag numbers
associated with Manufacturer’s data shown. Equipment data shall include as a minimum
requirement the principal and description of operation, drawings and dimensions, spare parts lists
and un- priced purchase orders and bill of materials.
g. 4 bound copies each of the Spare Parts data book and the Lubricants inventory schedule.
h. 4 complete sets of field records shall be signed by the BIDDER’S and Owner’s representatives at the
site.
i. Original approvals and related drawings and documents from the statutory authority.
j. Copies of correspondence with the statutory authorities.
k. Following documents shall be submitted in hard binder in three sets (one original):
l. Welding Procedure Qualification Report.
m. Welder Qualification Report
n. Radiographic Procedure Qualification
o. Radiographic Reports along with Radiographs ( Radiographs only with originals)
p. Heat treatment charts
q. Material test certificates
r. Hydrostatic and other test results and reports
s. Pre-commissioning and commissioning check list.
t. All other requirement as specified in the respective specifications.
Pre-Requisites Needed from Bidder
13.39 At the Kick-off meeting, the BIDDER must submit discipline wise list of documents and drawings index.
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Project description and Scope of Work
13.40 The Drawing Index (discipline wise) shall include description of drawings / documents, category of
drawings, scheduled date of submission, actual date of submission, approval/review code received with
dates. This shall be updated fortnightly/monthly, as agreed by BIDDER and copies issued to DEC as well
as Company. Drawings submitted before finalization of drawing index shall be rejected.
13.41 BIDDER shall separately submit list of drawings/documents involving multidisciplinary reviews, considering
their departmental activities furnished in the contract during the kick off meeting itself. They are also
highlighted in the discipline-wise document list.
13.42 Critical and typical drawings/documents having impact on schedule and quality should only be identified for
such timely reviews. This shall be adopted after receipt of drawings/documents indexes from the BIDDER
at the kick-off meeting with mutual understanding of the BIDDER/ Company.
13.43 All requirements specified in the Bid Package/contract is with the intent of providing a safe, user-friendly
plant conforming to all applicable codes, standards, regulations, etc. It is BIDDER’S responsibility to
comply with the bid package. To monitor the same, Company shall select a few critical
documents/drawings for approval/review and leave the rest as Information/Record Category.
13.44 Any deviation on such Information/Record category drawings/documents and on approval/review category
drawings observed later or in execution at site during site visit / technical review by Company/DEC shall be
taken seriously. Bidder shall rectify the same at his own cost and time.
13.45 BIDDER shall plan submission progressively so that no bunching takes place in any discipline.
13.46 Review period shall be reckoned from the “Date of Receipt” of documents/drawings in ONGC OPMAC
portal to the “Date of Receiving” the reviewed documents by the BIDDER. BIDDER shall monitor
submission and receipt.
13.47 Documents/drawings received prior to holiday/week end shall be accounted as received on the following
working day and the review period committed shall include only working days.
13.48 Quality of drawings/documents is essence for a timely review. If major comments/deviations to the agreed
design basis are noticed, the drawing shall be rejected in Code-3. (BIDDER cannot proceed with
construction with Code-3 approval/review).
13.49 Sequence of submission of drawings is essential for proper review of documents and timely completion of
the project and the same is to be adhered to. In case sequence is not maintained, the documents
submitted shall not be approved/ reviewed by Company and the responsibility of timely execution of the
plant shall remain to BIDDER’S accounts.
13.50 Piping/Instrument & other engineering drawings/documents shall be issued only after the corresponding
P&IDs & Process documents coming under approval/ review category are first approved/ reviewed by the
concerned department in code- 2 as a minimum.
13.51 In principle BIDDER is not expected to revise drawings/ documents already reviewed in Code-1.
13.52 If it is of utmost necessity to revise or add some minor details in Code-1 drawings, BIDDER shall highlight
such revisions by marking “CLOUD” to such additions/alterations. BIDDER is also needed to provide a
“BLOCK” in the drawing indicating reasons of such changes and to insert another “Approval/Review
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Project description and Scope of Work
Block”. DEC shall put relevant code for such revisions only “Code marking given by PDIL on such revisions
shall not change the category of drawing.
13.53 Any major change in Code-1 drawing shall call for preparation of new drawing.
13.54 Based on the confidence gained on BIDDER’S quality of drawings/documents already submitted,
“Approval/Review Category” drawings could be retained as Information/Records and vice versa at the
discretion of Company. This however, does not change the category of drawings.
13.55 Once a document is already reviewed in Code-2, subsequent submission due to non-incorporation of
comments shall not be accounted for any contractual commitment of approval/review period from DEC.
BIDDER is expected to comply with Company’s comments in the next revision after Code-2 and is required
to submit a compliance report accordingly.
13.56 Deviation permit, submitted for seeking deviation, shall be separately identified and shall not be considered
as a document for timely approval/review.
13.57 When Company deploys engineers at the BIDDER’S work centre following shall be satisfied:
Reviews limited to identified long delivery/schedule critical items only.
Readiness of documents/drawings shall be ensured by the BIDDER.
Presence of lead engineers of all disciplines of the BIDDER.
13.58 If Company highlights any necessary rectifications required in the construction at the time of Technical
Review/Audit, construction executed based on I-category drawings not complying with Bid requirement,
BIDDER shall rectify without any impact of time and cost to Company.
13.59 BIDDER shall submit designs drawings for review only after the corresponding GA/Equipment data sheets
etc. have been co-coordinated in his office and reviewed by Company engineers at least in Code 2. Such
Company reviewed drawings shall be furnished along with drawings/designs for timely review.
Approved for Construction Drawings
13.60 Drawings approved/reviewed under Code 2 & Code 1 required for execution at site shall be decided by
BIDDER and copies need to be sent to Company, BIDDER’S RCM and ONGC (site).
13.61 “Approved for Construction” stamped/sticker drawings shall be issued by BIDDER for execution.
13.62 “Approved for Construction” stamp/sticker separately on the reviewed print and not on the Title block.
13.63 Without changing Revision Number, BIDDER to arrange adequate number of prints of documents and
drawings to BIDDER’S RCM and one copy to Company (site) with transmittal.
13.64 Copies of only reviewed or final documents like design calculations, design basis etc. shall be sent to
Company site for records.
13.65 Copy of such transmittal shall be sent to Company for records.
13.66 Operation and Maintenance Manual
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Project description and Scope of Work
Bidder shall submit an ‘Operation and Maintenance Manual’ of the facilities to company for approval. It
shall include as a minimum but not limited to the following:
Design Basis
Process Description
Start-up Procedure
Operating Procedures & Maintenance
Trouble Shooting Operations
Equipment Maintenance Manuals
On approval, Bidder shall submit hard copies of the ‘Operation and Maintenance Manual’ along with soft
copies . The number of tracings / reproducible and soft copies shall be as per relevant clauses.
Page 35
Project description and Scope of Work
Page 36
Project description and Scope of Work
TABLE OF CONTENTS
Page 37
Project description and Scope of Work
1.1 The location of the Project site is within residential colony of Ankleshwar assets
of ONGC, which is in Gujarat State.
2.2 The entire work is to be completed as per the Project time schedule. The
programme of the work in details shall be submitted by the Bidder before
commencement of the work. The detailed programmes prepared by the Bidder
shall conform to the targets set forth in the Time Schedule and will be subject to
the approval of the COMPANYs/COMPANY’s representative. All the work shall
be carried out in such a manner that the work of other agencies operating at site
is not hampered due to any action of the Bidder.
3.0 REPORTING:
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Project description and Scope of Work
Before finally leaving site, all the Bidder's huts, plant, tools and rubbish must be
removed and the site left clean and tidy. Necessary site clearance certificate
shall have to be obtained from COMPANY/COMPANY’s representative.
5.2 The Bidder will observe all statutory and legal requirements by Central and State
Governments applying to the work as well as any local regulations applying to
the site issued by the COMPANY’s representative or any other authority.
5.3 The Bidder should have a documented HSE policy to cover commitment of
their organization to ensure health, safety and environment aspects in their
line of operations.
5.4 Bidder shall be fully responsible for planning and implementing HSE
requirements applicable for residential colony. Bidder as a minimum
requirement shall designate / deploy the following to co-ordinate the above :
5.5 The Bidder shall ensure that the Health, Safety and Environment (HSE)
requirements are clearly understood & faithfully implemented at all levels at
site.
iii) Compliance with statutory requirements for inspection and test of all lifting
appliances and auxiliary lifting gear.
5.7 Staircases, doors and gangways must not be obstructed in any way that will
interfere with means of access or escape.
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Project description and Scope of Work
railed off at all times, or completely breaded over and properly marked during
the hours of darkness by red warning lamps, using flameproof warning lamps in
non-smoking areas. Debris or material which cannot be immediately removed
must be heaped in such a way as to leave adequate passage way. Any finds
such as relic or antiques, coins or fossils, etc. shall be promptly handed over to
the COMPANY.
5.9 The Bidder will notify the COMPANY of his intention to bring on the site any
equipment, such as space heating or welding apparatus or any container holding
liquid or gaseous fuel or other substance which might create a hazard. The
COMPANY/COMPANY’s representative will have a right to prohibit the use of
such equipment or to prescribe the conditions under which such equipment may
be used. The COMPANY’s representative will have the right to inspect any
construction plant, and to forbid its use if in his opinion it is unsuitable or unsafe.
No claim arising there from shall be made by the Bidder. The Bidder or any one
acting on his instructions will not bring on to the site any radio-active substance
or any apparatus using such substances or any X-ray apparatus until written
permission and direction regarding the use of such equipment has been
received from the COMPANY’s representative/COMPANY.
5.10 The Bidder will meet all requirements, and act on the instructions of the
COMPANY/COMPANY’s representative where it is necessary to operate a
`permit-to-work' system.
5.12 The Bidder shall have his own fire fighting extinguishers and equipment.
5.13 The Bidder shall be responsible for the provision of all safety notices and safety
equipment required by both the relevant legislation and such as the
COMPANY/COMPANY’s representative may deem necessary.
5.14 The Bidder shall be responsible for the safe storage of the radio-graphic sources
or those of his sub- Bidders.
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Project description and Scope of Work
6.1 PURPOSE :
To ensure safe control over Bidder working on site & safe working condition
for execution of job.
To safeguard against the mishaps & damage to the material, man machine &
environment carrying out work in premises of ONGC, Ankleshwar Assets.
6.2 SCOPE :-
Bidder’s Safety Officer will make safe job procedure considering hazard at the
site and will get approved from Project Cell and ONGC Safety Department.
Site Engineer /Supervisors of Bidder should always present on the job & liaise
with ONGC Plant Control Room, Project Engineer & Safety officer.
The Bidder must adhere to the safety code & safety procedures to ensure
safe job execution. This code covers only basic safety requirements. Detailed
job safety instructions will be issued to the Bidder by concerned Engineer- in
–charge before commencement of the work by the Bidder.
Valid Third party inspection & testing certificates of the lifting machines, tools
& tackles shall be submitted to Safety Department.
Housekeeping is daily and compulsory activity for every job site. Scrap will be
removed every day.
All Hot work, height & Excavation job need Safety Permit, all care shall be
confirmed to avoid falls, burns, cuts, soil sliding, slippery area. Dewatering
need to be carried out as per drain capacity, in view to avoid overflow.
All the PPE, Power tools, welding machine, cutting set &their connections etc
will be checked & examined by ONGC Project Engineer & Safety officer to
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Project description and Scope of Work
ensure that all equipment & machines are in good conditions. Cutting &
grinding wheels to be used shall be having valid period for use.
Every workman at the working site must wear Boiler Suit, Safety Shoes,
Safety Helmet, Safety hand gloves compulsorily. Special PPEs such as full
body harness with life line face shield, Ear plug shall be recommended as per
requirement of the job.
Child labour is not allowed at ONGC, ANKLESHWAR sites & age should be
more than 18 years.
For each job, Job Hazard Analysis & Safe job Procedure should be prepared
by Bidder’s Engineer and Safety Officer. Every day in morning while starting
of such job, Safety Preparation & Readiness Talk should be given to the
workers.
Every job will be done with issue of Safety Work Permit either class-I or
Class-II or Vessel Entry as per nature of the job.
Any violation of such safety rules & regulations, a safety Advisory note will be
issued against concerned Bidder.
Do:-
Do use safety work permit for all hot work, cutting/welding, Vessel Entry &
Height job more than 3 meter.
Do confirm availability & proper working of ELCB for electrical hand tools.
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Project description and Scope of Work
Don’t:-
Don’t obstruct road traffic & walk to the side of the road.
Don’t keep materials on the roads and keep them clear during emergencies.
Don’t work in hurry & in speed .Don‘t use short cut methods.
Doesn’t allow horse play during work & avoid un-attention, mischief activities.
Don’t smoke in the plant or light/allow any naked fire etc in the plant area.
6.4 Health:
Bidder should submit Health fitness certificate of his workers to ensure fitness
at worksite. Workers shall be mentally and physically fit.
Worker shall not come on duty under intoxication, if found anybody will be
removed from site with severe penalty.
First aid box and name of the first aider shall be displayed at Site office.
Injuries to the workmen will be taken effective care by prompt first aid and
medical treatment. All injuries will be investigated and recommendations
shall be implemented in view to avoid recurrence.
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Project description and Scope of Work
7.1 In no circumstances will the Bidder interfere with fuses and electrical equipment
belonging to the COMPANY or other Bidders.
7.2 Before the Bidder connects any electrical appliances to any plug or socket
belonging to the other Bidder or COMPANY, he will -
7.4 The voltage for all portable equipment e.g. drilling machines, temporary lighting
etc. will not exceed 240 volts.
7.5 No work shall be carried out on any live equipment. The equipment must be
made safe and a `permit-to-work' issued before any work is carried out.
7.6 Bidder shall employ authorised electrician to maintain his temporary electrical
installation.
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Project description and Scope of Work
IS 3844
IS 13039
IS 15301
NBC 2016
IS 1648
Page 45
Project description and Scope of Work
CONSTRUCTION SUPERVISION
AND MANAGEMENT
Page 46
Project description and Scope of Work
TABLE OF CONTENTS
Page 47
Project description and Scope of Work
4.7 Review approval of the activities by COMPANY shall not however dilute the responsibility of the BIDDER
for maintaining quality.
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Project description and Scope of Work
c. Usage of stand jacks for heavy equipment erection to reduce space requirements for cranes and its
movements
The details of such methods proposed to be used by the BIDDER should form a part of the construction
management/execution plan.
5.5 BIDDER shall deploy portable alloy analyzer with print out facility and carryout “Positive Material
Identification (PMI)” of materials and welds after erection/ installation but prior to hydro testing. Any non-
conformance detected shall be removed and replaced prior to final testing.
5.6 BIDDER shall be responsible for provision of adequate radiography sources to meet the NDT
requirements.
5.7 BIDDER shall be responsible for arranging all facilities for torque tightening / tensioning of bolts/ fasteners
as specified in the bid document. BIDDER shall ensure that stud bolts are ordered extra long by one
diameter to facilitate tensioning.
5.8 BIDDER shall carryout the route survey for transportation of over dimensioned consignments including
water ways from source of manufacturing/supply to site, well in advance of placement of order to ensure
unhindered transportation of the same to construction site. BIDDER shall arrange cranes/strand jacks of
suitable capacities to match with the erection requirements and inform the source and COMPANY ship of
the same.
5.9 For efficient working and maintenance of construction aids, BIDDER shall establish and maintain crane
yard/workshop equipped with regular maintenance facilities for various construction aids for routine field
maintenance during performance of the contract. Weekly/fortnightly maintenance’s shall be planned in
such a way that the same does not hamper the erection schedule.
5.10 BIDDER shall ensure timely augmentation of equipment and machinery depending upon the exigencies of
the work to meet the overall project schedule and as per instructions of Engineer-in-Charge/COMPANY.
5.11 During the execution of the work, BIDDER must ensure that structures, materials and equipments are
adequately braced with Guys, Struts or any other means as deemed fit and approved by Engineer-in-
Charge. Such means shall be supplied and installed by the BIDDER as required till the erection works are
satisfactorily completed. Such guys shoring, bracing, strutting, planking supports etc, shall not interfere
with the work of other agencies and shall not damage or cause distortion to works executed by other
agencies. All lifting tools, tackles and cranes shall be tested periodically by statutory/competent authorities
for their load carrying capacity. Such relevant valid/test certificates shall be submitted to COMPANY for
review before actual use of tools, tackles, lifting devices and cranes.
5.12 BIDDER shall submit the construction equipment deployment schedule. Daily construction equipment
deployment report shall also be submitted by the BIDDER to COMPANY in the Performa approved by the
Engineer-in-Charge.
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SPARES PHILOSOPHY.
Revamping of fire water network of ONGC residential
colony of Ankleshwar Asset
Engineering Services, Ankleshwar
SPARES PHILOSOPHY
Page 55
SPARES PHILOSOPHY.
Revamping of fire water network of ONGC residential
colony of Ankleshwar Asset
Engineering Services, Ankleshwar
CONTENTS
1.0 GENERAL REQUIREMENTS ...................................................................................... 3
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SPARES PHILOSOPHY.
Revamping of fire water network of ONGC residential
colony of Ankleshwar Asset
Engineering Services, Ankleshwar
Page 57
SPARES PHILOSOPHY.
Revamping of fire water network of ONGC residential
colony of Ankleshwar Asset
Engineering Services, Ankleshwar
4.1 Besides the mandatory spare parts specified in the Bid document, Bidder shall provide a list of
recommended operation and maintenance spares for a two-year period required for all equipment. The
offer for supply of 2 years operation maintenance spares shall be valid for a period of one year after
mechanical completion of the project. These spares may be ordered on the Bidder by Company.
4.2 Bidder shall provide procurement services for these operation and maintenance spare parts and quote
separately for the same.
4.3 All spare parts shall be new, of acceptable quality and in unused condition with relevant warranties and
guarantees provided. The spare parts shall be identical in Design, specification to the original equipment
component.
4.4 Bidder can offer spares over and above those indicated in this enquiry specifications, if considered
essential for satisfactory operation and shall indicate item wise prices for each spares.
4.4.1 Static equipments (for 2 years operations)
Gaskets - Four sets of Gaskets.
Bolts, Nuts & Washers - Two pieces for each flange/cover connection.
- 20% internal bolts and nuts (min. 5 pieces each), if required.
Other spares - 30% spares for sight and protector glasses plus 100% gaskets for equipment
with sight glasses.
4.4.2 Static equipments (for Erection and Commissioning)
Gaskets - One set of gasket
Bolts, nuts and washers - Two pieces for each flange / cover connection.
4.4.3 Instruments:-
5.1 Bidder shall supply Company all special tools and test equipment (including test rings / test flanges /
dummy shells) required for operation and maintenance of all the equipment, as part of the work and their
cost shall be included in the Lump sum Price. Bidder shall ensure that all such items are clearly identified
as to the equipment item for which that is required and indicated in the bid.
5.2 Any special tools required for equipment, package items and those mentioned in the respective scope of
work and job specifications shall be included in the lump sum price.
5.3 All special tools shall be in new condition with warranties and guarantees provided.
5.4 All special tools shall be handed over to Company warehouse prior to the issuance of the Provisional
Acceptance Certificate for the Facilities
5.5 In the event Bidder may need to use the special tools during installation, pre-commissioning and
commissioning, Company may authorise Bidder to utilise the special tools with understanding that Bidder
shall promptly replace the special tools, if damaged.
6.0 CONSUMABLES, CHEMICALS AND PACKING
6.1 Bidder shall provide initial charge of all the lubricants, chemicals, packing and consumables for all
equipment within battery limit of the units covered in the lump-sum price and for a period of 6 months
normal consumption. This excludes requirement of inert balls, which are required to be filled along with the
catalyst as per specifications and quantities indicated in process package are in Bidder scope of supply.
6.2 Further, since the storage life of chemicals may also be subject to an expiry time due to deterioration,
stage deliveries of these products are required to be considered by Bidder. Bidder shall summarise all
chemicals and consumables requirements showing;
Initial fill or charge (unit of measure)
Annual indicated rate of consumption (attrition rates)
Quantity for initial purchase (and required date)
Quantities required for process guarantees
Method of handling with appropriate precautions
Quantity recommended for operating and back-up supplies
Method of delivery
Required date for first operating inventory delivery
Specifications
Expiration date for use effectiveness, special storage instructions and environment conditions hazard to be
encountered and any other special remarks.
6.3 In preparing the list, Bidder shall identify chemicals, lubricants and consumables, furnished by Sub-Bidder
as part of equipment (i.e. packaged units).
6.4 As part of the WORK, Bidder shall provide all services related to the delivery and handling at worksite of all
chemicals, consumables. Such services shall be included in the Lump sum price.
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SPARES PHILOSOPHY.
Revamping of fire water network of ONGC residential
colony of Ankleshwar Asset
Engineering Services, Ankleshwar
7.0 OPERATING OILS, LUBRICANTS, PROTECTIVE COATINGS AND OTHER OPERATING SUPPLIES
AND CONSUMABLES
7.1 Bidder shall provide initial charge of all fuels, operating oils, lubricants, transformer and switchgear oil,
protective coatings, consumables and other such operating supplies as required for the mechanical
completion of the facilities for a period of 6 months normal consumption and one replacement fill as part of
the Lump sum price. As far as is reasonably possible Bidder shall ensure commonality of all oils /
lubricants, etc to minimize inventory.
7.2 As part of the work, Bidder shall provide all services for the engineering, procurement, inspection,
expediting delivery to and handling at worksite of all such operating supplies. Costs for this shall be
included within the Lump sum price.
7.3 Bidder shall furnish a complete lubrication schedule listing of all equipment requiring lubrication by item
number and indicating the type, grade and quantity of lubricant specified for each equipment item. This
schedule shall be submitted to Company / COMPANY’S REPRESENTATIVE at least (6) six months prior
to the date of mechanical completion.
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Project description and Scope of Work
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Project description and Scope of Work
1.0 INTRODUCTION
This specification establishes the Quality Assurance requirements to be met by BIDDER.
In case of any conflict between this specification and other provisions of the contract / purchase order, the
same shall be brought to the notice of COMPANY at the stage of bidding and shall be resolved with prior
to the placement of order. COMPANY shall also appoint a TPI agency for stage-wise and final inspection
of all bought out items at Manufacturer’s premises and at site
2.0 DEFINITION
BIDDER for the purpose of this specification, the work “BIDDER” means the person(s), firm, COMPANY or
organization that is under the process of being contracted by COMPANY for delivery of some products
(including service). The word is considered synonymous to supplier, contractor or vendor.
Correction is Action taken to eliminate the detected non-conformity. Refers to repair, rework of adjustment
and relates to the disposition of an existing non-conformity.
Preventive Action is Action taken to eliminate the causes of a potential nonconformity, defect or other
undesirable situation in order to prevent occurrence.
Process is Set of inter-related resources and activities which transform inputs into outputs.
3.2 After award of work the BIDDER may review augmentation of manpower and resources deployment chart
(submitted earlier), detail it out, if so consented by COMPANY and resubmit the same as “Issued for
implementation”.
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Project description and Scope of Work
3.3 The BIDDER shall plan the contract scope of work on quality plan form at such that no major variation is
expected during delivery of contract scope of work. This quality plan shall be made on enclosed form at
complete in all respect. The quality plan shall be assumed to be detailing BIDDER’s understanding and
planning for the contract / offered scope of work. The BIDDER shall plan the type of resources including
various work methodology which he agrees to utilize for delivery of contract scope of work.
3.4 The BIDDER is required to review the contract at all appropriate stages to evaluate his capabilities with
respect to timely and quality completion of all activities pertaining to contracted scope of work and shall
report to COMPANY of constraints, if any.
3.5 The design activities, if any, performed during delivery of contract scope of work shall be so controlled that
the output is reliable enough. It is expected that during development of design, the BIDDER shall take
recourse to detailed checking, interdepartmental reviews and documented verification methods.
3.6 For all documents which the BIDDER is likely to utilise for delivery of contract scope of work, a system
must exist which assures that latest / required version(s) of the document(s) is available at all location /
point of use.
3.7 In case the BIDDER decides to sub – contract any part / full of the contract scope of work (without
prejudice to main contract condition), the BIDDER shall:
-Evaluate the technical and financial capabilities and past performance of the sub-contractor(s) and their
products and/or services before awarding them with the subcontracted scope of work. Selection of a sub-
contractor should meet COMPANY approval in documented form.
-Requirement of this specification shall be enforced on sub-contracted agency also. The BIDDER shall
choose subcontractor based on their capability to meet requirements of this specification also.
NOTE: It may so happen that, in a given situation, a subcontractor may not have a system meeting the
requirements of this specification. In all such eventualities, BIDDER may lend his system to sub-contractor
for the contract such that sub–contractor effectively meets the requirements of this specification. In all such
cases COMPANY shall be duly informed.
3.8 BIDDER shall establish methodology such that the materials supplied by the COMPANY shall be suitably
identified in such a manner that either through identification or some other means, sufficient traceability is
maintained which permits effective resolution of any problem reported in the outputs.
3.9 Critical activities shall be identified and the BIDDER is required to have documented methodologies which
he is going to utilize for carrying out such activities under the contract scope of work. Wherever it is difficult
All rights reserved
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Project description and Scope of Work
to fully inspect or verify the output (special process) BIDDER shall pre-qualify, the performers and
methodologies.
3.10 All inspections carried out by the BIDDER’s surveillance inspection staff shall be in conformity to quality
plans and / or inspection and test plans. All inspection results shall be duly documented on controlled /
agreed form s such that results can be co-related to specific product that was inspected / tested.
3.11 All inspection, measuring & test equipments (IMTEs) shall be duly calibrated as per National/ International
standards / codes and only, calibrated and certified IMTEs shall be utilized for delivery of contract scope of
work.
3.12 All outputs / products delivered against contract scope of work shall be duly marked such that their
inspection status is clearly evident during all stages / period of the contract.
3.13 All non-conformities (NCs) found by the contractor’s inspection / COMPANY surveillance staff shall be duly
recorded, including their disposal action. The deficiencies observed during stage of the product, shall be
recorded and resolved suitably. Effective corrective and preventive action shall be implemented by the
BIDDER for all repetitive N Cs, including deficiencies.
3.14 All deficiencies noticed by COMPANY’s representative(s) shall be recorded on a controlled form such
deficiencies shall be analyzed by the BIDDER and effective and appropriate correction, corrective and
preventive actions shall be implemented. BIDDER shall intimate COMPANY of all such corrective and
preventive action implemented by him.
3.15 BIDDER shall establish appropriate methodologies for safe and effective handling, storage, preservation of
various materials / inputs encountered during delivery of contract scope of work.
3.16 BIDDER shall prepare sufficient records for various processes carried out by him for delivery of contract
scope of work such that requirements of this specification are objectively demonstrate. In case COMPANY
find that enough objective evidence / recording is not available for any particular process, BIDDER shall be
obliged to make additional records so as to provide sufficient objective evidence. The decision of
COMPANY shall be final and binding on such issues.
3.17 The BIDDER shall arrange internal quality audits at quarterly intervals, to independently assess the
conformance by various performers to the requirements of this specification. The findings of such
assessment shall be duly recorded and a copy shall be sent to COMPANY for review.
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Project description and Scope of Work
3.18 For all special processes, BIDDER shall deploy only qualified performers. Wherever COMPANY observes
any deficiency, the BIDDER shall arrange the adequate training to the performer(s) before any further
delivery of work.
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QUALITY PLAN - FIELD INSTRUMENTS
Page 66
QUALITY ASSURANCE PLAN (QAP) FOR MECHANICAL ERECTION WORKS
TYPE OF QUANTUM REF. / ACCEPTANCE
ITEM CHARACTERISTICS REMARKS AGENCY
CHECK OF CHECK NORMS
A. UNDER GROUND PIPING
MATERIAL
Appearance, surface IS: 2062, In case of lamination, cracks are
defect free from pitting, Free from pitting, scaling, suspected; such items shall be check by
OWNER/OWNER’S
1. Plates scaling, distortion, rolling Visual 100% distortions, laminations & ultrasonic test. REPRESENTATIVE
defects like lamination, cracks. Composition of plates
cracks for heat no. of plates with T.C.
Bend test If T.Cs are To confirm to IS:2062
To be tested in Govt. Approved test
Tensile test not available, requirement
house for physical & chemical
each lot of OWNER/OWNER’S
properties
Physical plates to be REPRESENTATIVE
tested.
Chemical test -Do- -Do- OWNER/OWNER’S
Chemical composition REPRESENTATIVE
2. Pipes Check of cutting Cutting diagram,
Cutting diagram for each OWNER/OWNER’S
Page 67
fabricated from scheme of 100% Calculation sheet to meet the REPRESENTATIVE
size of pipe
plates plates requirement of parameters
Physical measurement In case T.Cs are not available, pipe to
of length, thickness, Visual, Physical be tested in approved lab for
ASTM A106 Gr.B/IS1239
3. CS/MS roundness, test measurement & physical/chemical properties to meet the OWNER/OWNER’S
100% Heavy or Tech.SP of the REPRESENTATIVE
pipes certificates containing review of test requirements of code/tech.SP of
contract/P.O
physical properties certificates contract/P.O
chemical composition
Not to be accepted without T.C.
OWNER/OWNER’S
4. Fittings -Do- -Do- -Do- -Do- REPRESENTATIVE
Manufacturers Batch certificate to be reviewed.
OWNER/OWNER’S
5. Electrodes Physical Visual 100% specifications, Flux to remain intact. REPRESENTATIVE
As approved brand
As per the norms of Production test certificate for the
IS:10221 batch. no to be checked & reviewed OWNER/OWNER’S
6. Asphaltic Physical & Chemical Visual 100% REPRESENTATIVE
QUALITY ASSURANCE PLAN (QAP) FOR MECHANICAL ERECTION WORKS
TYPE OF QUANTUM REF. / ACCEPTANCE
ITEM CHARACTERISTICS REMARKS AGENCY
CHECK OF CHECK NORMS
7. Asphaltic OWNER/OWNER’S
-Do- -Do- -Do- -Do- -Do- REPRESENTATIVE
enamel type - A
OWNER/OWNER’S
8. Glass cloth -Do- -Do- -Do- -Do- -Do- REPRESENTATIVE
OWNER/OWNER’S
9. White wash -Do- -Do- -Do- AWWA standard C-203-78 -Do- REPRESENTATIVE
10. Coal tar OWNER/OWNER’S
-Do- -Do- -Do- IS:10221 -Do- REPRESENTATIVE
primer
11. Coal tar OWNER/OWNER’S
-Do- -Do- -Do- -Do- -Do- REPRESENTATIVE
enamel type - II
12. Tissue OWNER/OWNER’S
-Do- -Do- -Do- -Do- -Do- REPRESENTATIVE
paper
As per TS
Measurement
Length, Diameter, Length = +3mm OWNER/OWNER’S
Fabrication through tape & 100% REPRESENTATIVE
Roundness ovality Dia max – Dia min X 100
template
= Nominal dia < 1%
OWNER/OWNER’S
Welding WPS Review 100% WPS as per ASME Sec-IX REPRESENTATIVE
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Radiography As per TS
OWNER/OWNER’S
PQR tensile & 2 tests 100% ASME B31.3 REPRESENTATIVE
Bend-1 test
As per TS OWNER/OWNER’S
WPQ Radiography 100% REPRESENTATIVE
ASME B31.3
Inspection of
Visual + 100% visual OWNER/OWNER’S
pipe after Welding ASME B 31.3 REPRESENTATIVE
Radiography radiography
welding
Hydro test of Pressure test at 60% of Visual & STD. As per contract SP. OWNER/OWNER’S
100% visual REPRESENTATIVE
spools YP of plate material Films WOR 60% of Y.P.
SA-21/2 in case of shot/grit
Protective In case of OWNER/OWNER’S
Surface cleaning 100% blasting REPRESENTATIVE
coating shot/grit blasting
SA-3 for wire brush
Visual + Elco 100% OWNER/OWNER’S
Primer thickness Tech. SP of the contract REPRESENTATIVE
meter Random
Visual + Slice
Thickness of coating OWNER/OWNER’S
cutting test of Random Tech. SP of the contract REPRESENTATIVE
after final layer
adherence
QUALITY ASSURANCE PLAN (QAP) FOR MECHANICAL ERECTION WORKS
TYPE OF QUANTUM REF. / ACCEPTANCE
ITEM CHARACTERISTICS REMARKS AGENCY
CHECK OF CHECK NORMS
TRENCH CUTTING
Survey of routs + Measurement by
Underground piping layout OWNER/OWNER’S
Layout marking of bench mark + tape + Dumpy 100% REPRESENTATIVE
Plant elev.
co-ordinates level
Fox holes to be made after proper
Measurement of level OWNER/OWNER’S
Excavation -Do- -Do- -Do- marking of co-ordinates for making fox REPRESENTATIVE
after cutting
holes for field weld
Sand bed For providing cushion to Contract document OWNER/OWNER’S
-Do- -Do- REPRESENTATIVE
marking pipe specification
Erection at right co- Measurement OWNER/OWNER’S
Laying of pipe -Do- Layout drg. REPRESENTATIVE
ordinates dumpy level
Weld profile + Visual + Upto 30” Pipe X-Ray – 100% OWNER/OWNER’S
Field Weld -Do- PQR >30” – 50% (Bottom half) REPRESENTATIVE
reinforcement Radiography
All characteristic -
Wrapping mentioned for wrapping OWNER/OWNER’S
- - - REPRESENTATIVE
coating coating of pipe after
Page 69
shop test
Back filling spec. Back filling to be done with soil free
Compactness for dry from stones in layer not exceeding OWNER/OWNER’S
Back filling Compaction test Random 95% of D.O.T. at optimum REPRESENTATIVE
density of soil 150mm
moisture conta.
Safety against dropping
Closing of Round blanks OWNER/OWNER’S
of solid particles in the 100% Tack welding REPRESENTATIVE
risers tapping tack welding
pipe
B. ABOVE GROUND PIPING MATERIAL
a. Pipes Use on job to be permitted on receipt of
Reference code as specified inspection report and test certificate
b. Elbows
in the construction. (T.C.)
c. Tees OWNER/OWNER’S
Physical & chemical Visual & T.C. 100% Inspection Report T.C. and REPRESENTATIVE
d. Reducers
comparison of T.C. with
e. Valves
applicable SP. Of P.O.
f. Specials
Batch certificate.
Free from moisture & flux to OWNER/OWNER’S
g. Electrodes Visual 100% REPRESENTATIVE
remain intact and approved
brand
QUALITY ASSURANCE PLAN (QAP) FOR MECHANICAL ERECTION WORKS
TYPE OF QUANTUM REF. / ACCEPTANCE
ITEM CHARACTERISTICS REMARKS AGENCY
CHECK OF CHECK NORMS
ASME SEC IX For each type of material where
WPS Review X-Ray, electrode specification changes,
Relevant code for piping as OWNER/OWNER’S
Welding PQR Tensile test, 100% separate WPS, PQR and WPQ are REPRESENTATIVE
per ASME B 31.3
WPQ Bend test. required to be established
As per specification of
OWNER/OWNER’S
Pre - Fab Dimensional Measuring tape 100% contract REPRESENTATIVE
Dimensional & Measuring tape OWNER/OWNER’S
Erection -Do- -Do- REPRESENTATIVE
Alignment & Visual
OWNER/OWNER’S
Filed Welding Gap, Edge preparation Measurement -Do- -Do- REPRESENTATIVE
D.P.T. / M.P.T. / As per the
As per the norms allowed in OWNER/OWNER’S
N.D.T. Radiography, Ultrasonic Visual requirement REPRESENTATIVE
the code
testing & Stress relieving of code
Measurement As per drawing & support OWNER/OWNER’S
Supporting Type, Location etc. 100% REPRESENTATIVE
Visual schedule
Page 70
Leakage & Pressure Line list OWNER/OWNER’S
Hydro testing Visual 100% REPRESENTATIVE
drop. As per Piping specification
C.
MACHINERY
PUMPS, Physical inspection & Tech. Specification
OWNER/OWNER’S
COPRESSOR Review of inspection Visual 100% P.O. specification & relevant REPRESENTATIVE
S, FANS, reports code.
BLOWERS,
TURBINES
Measurement by
Heights, Level, flatness, OWNER/OWNER’S
Foundation tape & Dumpy 100% Equipment lay – out drawing REPRESENTATIVE
surface finish
level
Levelling & Concentricity, Level, Dial gauge, Filler Installation manual of vendor, OWNER/OWNER’S
100% REPRESENTATIVE
Alignment. parallel, station gauge, Visual Vendors Recommendation
D. STATIC Physical inspection & Drawing + code
OWNER/OWNER’S
EQUPMENT, Review of inspection Visual 100% Approved fabrication drawing REPRESENTATIVE
HEAT report & applicable code
QUALITY ASSURANCE PLAN (QAP) FOR MECHANICAL ERECTION WORKS
TYPE OF QUANTUM REF. / ACCEPTANCE
ITEM CHARACTERISTICS REMARKS AGENCY
CHECK OF CHECK NORMS
EXCHANGERS
, FURNACE
TOWERS
Equipment layout drawing +
OWNER/OWNER’S
Foundation Level, Co-ordinates etc. Measurement 100% 5mm from reference bench REPRESENTATIVE
mark
Erection Review of Erection scheme as Erection scheme showing crane position OWNER/OWNER’S
Safe erection 100% & type of crane, capacity to be prepared REPRESENTATIVE
scheme Erection scheme submitted by erector
Orientation, Verticality & Visual + OWNER/OWNER’S
Erection 100% As per applicable code REPRESENTATIVE
Alignment Measurement
E. PAINTING Physical + chemical Manufacturer OWNER/OWNER’S
100% Relevant code REPRESENTATIVE
MATERIALS colour batch certificate
Measurement by Spot in every OWNER/OWNER’S
Application Finish, D.F.T Relevant tech Sp. Of contract REPRESENTATIVE
Elco meter meter
Page 71
Sl. Characteristics Type of Check Quantum of Check Acceptable Reference Agency Remarks
No. Item Norm Document
A. Civil Works
1. Site survey & a) Site grade level Theodolite 100% As per Drg. Grade level Perform by
establishment of b) Co-ordinate & levelling record & grid Contractor &
grid pillars level of grid pillars instrument & pillar record approved by Client
measuring
tape(steel)
2. Establishment a) Mix proportion Lab Test 100% As per Spec. IS: 10262 - do- Redesigning of mix will be
concrete mix cement: F.A.: C.A. resorted to for change of source
design b) W:C ratio Lab Test of material
c) Slump Slump Cone
d) Compressive Lab Test
Strength
3. Construction
Material Test
a) Cement a) Free from lumps Visual 100% Free from IS: 269 Controller of Test Certificate of manufacturer
and solids Moisture, Stores for each consignment is required
lumps/solids
b) Compressive Test for i) Three Samples 7 days / 28 days Contract Client Engineer Whenever cement is stored for
Strength Compressive for each strength as per Document more than 3 months, compressive
Strength ii) One Sample grade specified IS:269 strength test will be re-performed
for each batch before major concreting
Page 72
c) Initial & Final Lab Test i) Three Samples As per IS Spec. Relevant IS Client Engineer Manufacturer’s Test Certificate to
Setting Time for each of Type of Codes be obtained and verified
ii) One Sample Cement
for each batch
b) Fine a) Proper Gradings Sieve Analysis Silt 3 Samples shall Finer particles IS: 383 Client Engineer Sands from sea shores, river
Aggregate b) Free from Content test be tested for passing through banks and creeks not to be used.
excessive silt Bulking test to each new source 150 micron sieve
c) Free from determine of supply or as not to be exceed
excessive moisture moisture content per Tech. Spec. 10% IS:516
d) Free from Visual At Random Within ± 5% % IS:2386 Client Engineer Bulking Test & sieve analysis to
vegetation and age existing in be done every time major
other organic design mix concreting is to be done.
impurities
e) Quantitative 3 sample shall be i) Once every As per contract IS:383 Client Engineer
check for design prepared month document
mix whenever mix is
designed or when ii) Whenever
any of the inputs major concreting
i.e. cement, water is done
or aggregate’s
changed
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No. Item Norm Document
c. Coarse a) Hard, rough, Sieve Analysis 3 Samples for Contract IS:383 Client Engineer
aggregate sound and graded each new source. Specification &
3 Tests for each IS:383
design mix
b) Heavy Specific Gravity At Random Specific Gravity Client Engineer
>2.6
c) Abrasion Lab Test At Random As per Tech. IS Codes Client Engineer
Spec
d) Crushing/Impact Lab Test At Random As per Tech. IS Codes Client Engineer
value Spec.
d. Earth Work a) Free from Visual At Random Client Engineer
organic materials
b) Properly Proper density/ i) Every time As per Contract IS Codes Client Engineer i) Filling below floors and
compacted Dry Density & earth is taken Specification. foundations shall be in layers as
CBR value test from new source per Tech. Spec.
ii) Every major ii) Filling for roads in layers to 300
compaction done mm
below floors &
load bearing
walls
iii) One sample iii) Over excavation shall be filled
Page 73
every 100 meters with lean concrete as per Tech.
of road sub grade Spec.
e. Bricks a) Well burnt Visual For each struck Regular shape, IS Codes Controller of Every now & then a site rough test
uniform shape and neither over-burnt Stores will be performed by putting tow
colour nor un-burnt brick, one above the other at right
angles making a + & dropping
both together from a height of 1
metre on earthen ground. None of
the bricks should break.
b) Minimum water Dry & soaked 3 Samples for Within limit IS Codes Client Engineer
absorption each new source specified in the
and two samples contract
for each 1,00,000
bricks of
subsequent
supply
c) Compression weighing test for -do- -do-
Strength compressive
strength
d) Proper levels & Measurement At Random True to levels Contract Client Engineer Coarses to be roughly horizontal
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No. Item Norm Document
verticality within ± 15 mm. Document Thick Joints to be avoided
Truly Vertical
Local depression
/ protruding Not
more than 3 mm
f. Reinforcement a) Uniform shape. Visual 100% Uniform. No Contract Controller of
No Cracks Cracks or Document Stores
No rusting excessively rusty
b) Strength as per Mechanical Tests 3 Samples for As per contract IS: 432 Client Engineer i) Deformed bars shall confirm to
Spec. each initial supply Specification IS: 1786.
ii) Quality Engineer shall check
shape, dimension, length of
splices
c) Correct length Dimensional 100% As per drawing Contract Client Engineer
bending/cranking Document
as per bending
schedule
g. Shuttering Tube Levels & i) Level 100% Level as per Drg Drg./Spec. of Client Engineer Materials used, shape dimension,
forms ± 5 mm Spec. the Contract lines, levels and surface finish
shall be checked by Client
Engineer.
Page 74
ii) Shape/ Vertically <1 mm
Horizontal per metre max.
10 mm
iii) Strength of Ballies/Pole Adequacy of ties/brackings/
support support Shoring shall be checked by
sufficiently strong Client Engineer, before allowing
to withstand load the reinforcement to be laid. After
laying of reinforcement shall be
cleared once again by Client
Engineer.
h) Embedments a) Dimension/Size Physical 100% As per Drawing One Pour Card Client Engineer -do-
b) Number Physical
c) Type Physical
i) Concreting Before starting of major Concreting
a) Proper quality a) Fine aggregate As per 1,2 & 3 Client Engineer i) Grade V aggregate shall not be
check of input b) Coarse above used for concreting.
material aggregate ii) Water proofing compound
c) Cement and where specified shall conform to
IS:2645. Any other additives
If potable water is not available & natural water is proposed to be used, the required to be added shall
same shall be approved by client engineer considering following before conform to IS:9103.
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No. Item Norm Document
resorting to design mix. iii) Hand mixing will be resorted to
a) Free from oil IS: 3025/ only with prior approval of Client’s
IS: 254 Quality Engineers & by addition
b) Free from 10% extra cement over the design
Alkalies/Acid mix cement content.
c) PH Value < 6 iv) In case concreting is done on
rock, the rock shall be kept moist
for 2 days and applied cement
slurry before hand.
ii) Design Mix To be done with approve inputs according to required IS: 10262
strength & approved by Client’s Engineer.
Redesigning of Mix will be resorted to whenever source of
any material is changed
During Concreting
i) Water Cement ratio to be adjusted to get required
workability depending upon the place where concreting is
being done i.e. narrow places like columns or heavily
reinforced places, wide areas like slabs etc.
ii) Cone Test will be done to achieve required slump as per
IS: 10262
iii) Hand ramming and / or suitable (flat based) mechanical
Page 75
vibrating shall be resorted to for slabs etc. Needle vibrators
shall be used for narrow places like column beams etc.
iv) Excessive vibrating, resulting in loss of water shall be
avoided.
v) 6 standard cubes shall be taken for every 200 cum of
concreting for subsequent testing.
After Concreting
Dense/Uniform Visual for porosity/ 100% Uniform finish Contract Client Engineer
without honey hollows Small honey Document
combs comb
< 10 mm and in
< 10 x 100 mm
area of 1 sq. m
may be accepted
Hammer Test At Random Sound of strong Contract Client Engineer In case of less comp strength
concrete Document than required suitable tests as
specified in IS:456 should be
conducted on affected concrete
and result recorded for final
decision.
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No. Item Norm Document
Strong Concrete Compressive As per Tech. 7 days / 28 days i) Contract
capable of strength test Spec. / IS Code strength as per Specification
withstanding requirement ii) IS: 456
designed loads and specified in the iii) Determining
weather conditions contract Compressive
Strength as per
IS:4031
j) Brick Work a) Soaking of Brick Physical Random As per Drg. Inspection Contractor &
b) Plumpness Physical Record Client to witness
c) Mortar Physical
k) Plastering Smooth Visual 100% Smooth IS Codes Client Engineer
True to Shape Client Engineer
Verticality Check by Plumb At Random Local Undulation
<3 mm
Specified Measurement One sample Thickness not to Contract Client Engineer One sample would mean
Thickness check every 100 vary +5 mm–1mm Document measuring thickness of plaster of
sq. m. by Client’s 3 different places by piercing nail
Engineer etc.
One sample
check every 500
sq. m by Client’s
Page 76
Quality Engineer
Strength Checking of Mix of Surprise Check Mix as specified Contract Client Engineer
Volume at Random in the Contract Document will conduct
surprise checks at
Random
l) Finishing Work a) Surface Physical -do- -do- -do- -do-
like white preparation
washing/colour b) No. of Coats Physical
washing etc. c) Shade Uniformity Physical
Note: 1. All testing / measuring equipments should have valid calibration record certificate based on which tests should be
performed.
2. All standard and codes shall be referred as in drg / technical specification.
m) Road Work Earth work, excavation/filling/compaction shall be same
as per earth work specified above.
Correct level & Dimensional At Random Longitudinal Client Engineer i) Rolling will be done from edge
Layout Sub grade+/- 25mm towards centre of road
Sub base+/- 20mm
Base + / - 15 mm
Wearing Coat +/-10 Client Engineer ii) In curved roads, where super
mm elevation is provided, rolling shall
Horizontal be started from concave edge
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No. Item Norm Document
Edge of the towards convex edge.
carriage +/- 25 mm
In any 300 M
length, variation of
level will not be
more than 15-25
mm
B.
STRUCTURAL
WORKS
MATERIALS
1) Structural
Steel
a) Plate Appearance Visual Inspection 100% Free from pitting IS:2062 & other Client Engineer In case any lamination or cracks
/Surface defect scaling relevant IS are suspected, such items shall
Free from pitting distortions, codes be checked by Ultrasonic Test
scaling, distortions, lamination and and results submitted to Client’s
rolling. cracks Quality Engineer.
b) Beams defects such as -do- -do- -do- -do- -do- -do-
lamination and
Page 77
cracks etc
c) Channels Physical Bend Test 10% of each lot To conform to IS -do- Tested from Manufacturers here mean main
or 2 sample Code or Approved producers like RINL, SAIL, TISCO
where equivalent foreign Laboratory, Quality or other well known
Tensile Test manufacturer’s code Engineer of Client manufacturers.
test reports are to accept
not available.
d) Angles Chemical Chemical Test One Samples per -do- -do- -do-
Composition lot where
manufacturer’s
test reports are
not available
e) Round/Flats -do- -do- -do- -do- -do- -do-
2) Clad Steel
a) Tiscral Plate Appearance 100% Free from Client Engineer NDT to be performed wherever in
lamination/cracks doubt
b) Stainless Physical/Chemical Mechanical/ To accept To conform Client Engineer NDT to be performed whenever in
Steel Properties Chemical Test material only if AISI-304 or doubt.
manufacturer’s AISI 312 or
test reports are AISI 316 etc as
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No. Item Norm Document
available per contract
requirement
3) Electrodes
Electrodes Physical Visual 100% a) Approved Client Engineer List of electrodes to be approved
Brand by client considering the metals to
b) Flux coating to be welded & weather conditions.
be sound and
intact
c) Polythene
cover and outside
Cartons to be
intact
d) ISI marking on
each packet
e) Date of
manufacturer &
shelf life to be
checked
f) Free from
Moisture
Weldability a) Tensile Test One Test on IS:814 IS: 814 Quality Engineer
Page 78
b) Bend Test each type of of Client
c) Welding electrode from IS: 823 IS: 823 -do-
Procedure each lot
Quality of Visual 100% Surface to be IS: 800 Quality Engineer
Weldment free from IS: 9595 of Client
overrun, below
holes, slag
inclusions, cracks
under cutting &
porosity
4. Fasteners
a) M.S.Bolts Visual 10 Samples from Regular shape, IS: 1363 Client Engineer
Nuts Washers each size clean,
lubricated, sharp
threads, without
burrs
b) High Tensile Dimensional Measurement 10 Samples from Dia +0-1% IS: 1364 -do- For (b) and (c) Test Certificate
Precision/Semi each box Length + Upto 1 IS: 1367 from reputed manufacturer must
Precision Bolts/ mm-0
Nuts/Washers
c) High strength Mechanical & Bend and 5% if test IS: 3757/4000 Approved Test Test Certificate to be checked by
All rights reserved
Sl. Characteristics Type of Check Quantum of Check Acceptable Reference Agency Remarks
No. Item Norm Document
structural Technical Flattering Test certificates are for Bolts IS: House Client’s Quality Engineer
bolts/nuts/ properties not available. 1% 6623 for Nuts
Washers if test certificates IS: 6649 for
are available Washers
IS:1148 for
normal rivets &
1149 for high
tensile rivets
d) Rivets Visual UTS 10 sample from
each batch if Test
Certificate is not
available
5) Paints a) Certification Marking on Tin to All tins / packing Relevant IS as Client Engineer 1) Manufacturer’s names to be
be hacked for 100% to be fully & per Contract approved by Client / PDIL before
a) Manufacturer properly marked Document hand.
from reputed / 2) Primers shall conform to IS:
Approved 2074 & Synthetic Enamel to IS:
Manufacturer 2932 unless specified otherwise.
only accepted
b) Date of Shelf life to be Client Engineer
Manufacturer checked as per
Page 79
manufacturer’s
Very old stock not
be accepted.
Shelf life to be
checked as per
manufacturers’
pamphlet
c) IS No. To conform to
respective IS
Code
b) Chemical 3) Testing of Paints essential,
shall be done as per IS-101
c) Viscosity Physical Each time when No solidification Engineer/Client’s
tin is opened Quality Engineer
Storage System
1) Structural Stacked properly to Visual 100% a) To be stacked
Steel avoid unnecessary separately,
stresses and Quality wise, Size
distortions wise
b) Ground to be
roughly level
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No. Item Norm Document
c) Area to be well
drained
d) Long items to
be on dunnage 6-
8 inches high
e) Flat products
not used within 3-
4 weeks to be on
dunnage.
f) Identification
placards to be put
2) Electrodes Stored Properly to Visual 100% a) To be stacked Client Material
avoid damage to on racks/shelves. Officer
packing etc. & Easy Bottom shelf to
Identification be at least 12”
above ground
b) Stacked
separately quality
wise/size wise
c) Identification
placards to be
Page 80
provided
d) Shelf life to be
checked
periodically
e) To be
protected from
moisture
3) Fastener Properly stacked Visual 100% To be stored Client Material
for easy quality wise/size Officer
identification wise with
identification
placards.
4) Paints -do- Visual 100% a) To be stored Client Material
quality wise with Officer
identification
placards
b) Protect from
excessive heat
c) Stored away
from fire hazards
Fabrication
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Sl. Characteristics Type of Check Quantum of Check Acceptable Reference Agency Remarks
No. Item Norm Document
1) Setting out/ Measurements 100% a) A level Contract Client Engineer
Layout/Marking plastered document &
platform to be Approved Drgs.
made for layout
of all critical items
b) Full scale
layout to be made
for trusses
/bracings/gussets
c) Portions joining
different
structural item to
be marked to full
scale
d) Members
required to be
assembled.
Should be
marked at joining
ends before
despatch to
erection site.
Page 81
e) Dimensions to
be checked on
full scale layout
before cutting
individual
members for all
important
components.
2) Cutting Dimensional 100% Length of Approved Client Engineer
Conformity members Drawing
upto 2 M-+ / -3
upto 5 M-+/ -4
above 5 M -+ /-5
mm
Diagonals of
rectangular plates
upto 5M long +3
mm
Above 5 M up to
10 M +5 mm
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No. Item Norm Document
Above 10M + 7
mm
3) Drilling Holes Dimensional 100% Diameter of holes Approved Client Engineer
Conformity Dia + 1.5 mm up Drawing
to 25 mm dia
Bolts
DIa + 2 mm for
Bolts above 25
mm dia
Variation in dia of
Hole -0 + 2 mm
Variation in Approved Client Engineer
distance between Drawing
extreme holes
Upto 5 M – 2 mm
> 5< 10M-3 mm
>10 M-4 mm
Variation of Approved Client Engineer
spacing in Drawing
adjacent holes
not more than 1
Page 82
mm
4) Tack Dimensional 100% Conformity Variation Approved Wherever load is designed to be
Assembly before Dimensions Drawing transferred through direct bearing,
clearing or final <2 M-1 mm end-milling shall be done.
Welding >2< 5 M-2 mm
>5< 10 M-4 mm
>10-7 MM Client Engineer
Variation
between group of
drilled holes after
assembly
< 2 M – 1 mm
> 2 M<5 M -
1.5mm
> 5M<10 M- 2 mm
> 10 M-2.5 mm
Overall length of
column upto 10 M
-+/-8 mm > 10 M
<30 M +/- 15 mm
> 30 M – 25 mm
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No. Item Norm Document
Overall length of Approved Client Engineer
C.G. Upto 6 M – Drawing
3 mm > 6 M – 5
mm
Depth of C.G. -+/-
3 mm
Level of CG
Seating Plate of
column from
designated level
+/- 5 mm
Curvature of
assembled parts
-1 mm / M length
max. 10 mm
5) Final Welding Welding Test for Two Test for IS Codes IS Codes Client Inspection Drying Oven shall be provided in
Electrodes & each brand Engineer the store. All welders shall be
parent metal provided with carry ovens
specially in monsoon & winter
months.
Welder’s All Welders IS Codes IS Codes -do-
Page 83
Qualification
Welding Procedure IS Codes IS Codes Client Engineer /
Client Insp.Engr.
Preheating/Post +/- 100 of Contract Client Engineer
Heating where specified Agreement
specified/required temperature min.
considering the 1200
materials and
weather conditions
Fillet Welds Visual Profile 100% Regular Ripples, IS: 3658 Client Engineer
Convex shape,
No under cuts,
No cracks, Free
from surface
cracks
Dye Penetration Crane girders-100% Free from cracks IS: 3658 Client Engineer
Columns -100%
Other – 20%
Butts Weld Dye Penetration 20% Free from Cracks Contract Client Engineer For all important Butt Welds
for root after / discontinuity Agreement extended test pieces will be
gouging provided which shall be later on
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No. Item Norm Document
subjected to destructive testing
Tensile Zone Radiography IS: 1182 IS: 1182 Client Quality
100% Engineer
Compression 20% Radiography IS: 3664 IS: 3664
Zones Balance 80%
Ultrasonic Test
Transportation
1) Loading/ Safe transportation 100% for heavy Safe Transportation Safety of Heavy Client Engineer Erection Engineer shall inspect
Unloading/ & of heavy items Items Items Tractor, Trailer including leaf
Carriage springs, tyres, connecting hinges
and loading platform each time a
heavy item is loaded on it for
transportation to erection site.
Due weight-age should be given
to weight and dimension of
structural item to be transported
and the capacity of prime mover
and trailer. The items shall be
securely tied to avoid
displacement/ damage to items
during transportation.
Page 84
Experienced rigger to pilot the
trailer.
2) Cranage Safe Transportation 100% for heavy Safe Transportation Client Engineer Erection Engineer will check
items of Heavy items a) Crane capacity before loading/
unloading
b) S.W.L. of hook
c) Strands of wire rope slings,
Sling will be rejected if more than
5% of its wires are broken.
d) Ground to be sound
considering the load of crane &
similar item.
3) Stacking 100% Safety of a) Fabricated Structures will be
Structures & stacked as near the Erection site
works as possible.
b) The ground should be well-
drained and generally level
c) Stacking should be horizontal
d) Stacking items one above the
other shall be avoided
e) Care shall be taken that no
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No. Item Norm Document
undue stress is created in any
member and that there is no
distortion in any member.
Erection
1) Columns To be vertical to Column axis with
transfer load to respect to
foundations, theoretical axis
without buckling
Deviation in 100% ± 5 mm Approved Client’s Inspection
longitudinal Drawing Engineer
direction
Deviation in lateral ± 5 mm
direction
Level of ± 5 mm
foundation with
respect to
theoretical level
Verticality of 100% 1 mm per meter Approved Client’s Quality
column is height of column Drawing Engineer
measured at top subjected to max.
of 25 mm for
Page 85
columns upto 30
metres height &
35 mm max for
longer columns
Transverse 1 mm per metre -do- -do-
buckling at any length of column
point along the subjected to max
height of column of 10 mm
Distance between +10 mm from
two adjacent distance shown
columns on drawing
2) Trusses Vertically of Truss
Shift of top chord 100% + 1 of height Approved Client’s Quality
at centre of span 250 of truss at Drawing Engineer
centre of span
Lateral shift of top + 1 of span Approved Client Engineer
chord at centre of 1500 subjected to Drawing/Spec.
span max of + 10 mm
Distance between 100% +7.5 mm from -do- -do-
two adjacent theoretical
trusses distance
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No. Item Norm Document
Level at the 100% 1 mm per metre -do- -do-
bearing level height of bearing
level subject to
max of 20 mm
3) Crane Girders Level at bearing 100% 1 mm per metre
surface height of bearing
surface subject to
max of 10 mm
Alignment of 100% ± 5 mm
centre line
Distance between 100% ± 5 mm for spans
opposite crane upto 15 m & ± 7.5
girders for spans > 15 M
upto 25M -+ 10
mm for large
spans
4) Crane Rails Shift of Centre line 100% ± 2 mm
of 2 adjacent
crane girders
Bend Width 100% ± 2 mm Approved Drg. Client Engineer
Flange Width ± 2 mm
Page 86
Web Thickness ± 2 mm
Head Thickness - 1 mm
Height of Rail ± 3% of
theoretical height
Weight 10% + 2% of designated Approved Drg. Client Engineer
- 1% weight/metre
Camber Not more than
2% of length
Difference in 100% + 15 mm
levels between rail
tracks at supports
Difference in 100% ± 20 mm
levels between rail
tracks at supports
Mix Span
Shift of crane rails 100% ± 5 mm Approved Drg. Client Quality Rail joints and crane girder joints
axis with respect Engineer to be staggered at least 600 mm
to theoretical
Distance between ± 3 mm for spans
opposite rails upto 10 M ± 5
(span) mm upto 15 M
All rights reserved
Sl. Characteristics Type of Check Quantum of Check Acceptable Reference Agency Remarks
No. Item Norm Document
span
Shift of Centre line 100% ± 2 MM
of Crane rail with
respect to centre
line of web of C.C.
Relative shift of 100% ± 1 MM
crane rails at joint (Surface can be
ground if the
height of the
adjacent rails is
not matching)
Page 87
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for pipes (except CS pipes)
Extent Of Specification / Ref. /
Characteristic Type of Check Records Manufacturer Vendor TPI
Check Acceptance norms
RAW MATERIAL MTCs / PO
Laddle Analysis / Chemical Analysis /
IDENTIFICATION IS : 1239 (Pt.-1) / requirements
Mechanical Mechanical Each Coil P&W R R
(Review of Test IS : 3589 Gr.410 Correlation
properties properties
Certificate) with M.T.C.
Product analysis Chemical Analysis / As per relevant IS : 1239(Pt.-1) / Test reports/ P&W R R
product analysis standard IS : 3589 Gr.410 Certificate
FINISHED PIPES Mechanical Mechanical
(Tensile, properties As per relevant IS : 1239(Pt.-1) / Test reports/ P&W W W
flattening / Bend (per heat / per size) standard IS : 3589 Gr.410 Certificate
test, etc.)
Page 88
NDT As per applicable 10% W
Radiography RT of welded pipes 100% NDT Reports P&W W
(If Applicable) Standard Balance-R
Visual /
IS : 1239 (Pt.-1) /
FINAL VISUAL / Dimensional / As per relevant 10% W
Measurement IS : 3589 Gr.410 Final Report P&W W
DIMENSIONAL Straightness / standard Balance-R
As per PO
Ovality
GALVANIZING
Thk. of Galvanizing
TESTING IS: 4736 IS: 4736 Test Report P&W R R
to be checked
(if applicable)
HYDROSTATIC IS : 1239(Pt.-1) / Test 10% W
Hydro test Leakage 100% P&W W
TEST IS : 3589 Gr.410 certificate Balance-R
As per relevant
MARKING Visual Visual 100%
standard
Final Report P&W R R
All relevant
CERTIFICATES Review 100% As per PO R R R
Certificates
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Legend W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party
Spec: Specification P.O.: Purchase Order TC: Test Certification
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
2. Each Pipe shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY in original.
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by COMPANY / COMPANY’s approved agencies.
Page 89
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for CS Fittings.
Specification / Ref. / Manufa
Type of Check Quantity Records Vendor TPI
Acceptance norms cturer
RAW MATERIAL
IDENTIFICATION Chemical & As per applicable ASTM MTCs / PO requirements
100% W R R
(Review of Test physical properties Standard/ IS:1239 (Part-2) Correlation with M.T.C.
Certificate)
HEAT TREATMENT As per applicable ASTM
Process / Charts 100% Charts / Certificate P&W R R
(as applicable) Standard/ IS:1239 (Part-2)
Chemical / Product analysis 1 No. per each heat As per applicable ASTM Test / Analysis Report /PO P&W R R
FINISHED Standard/ IS:1239 (Part-2)
FITTINGS Mechanical -do- -do- -do- P&W W W
(Tensile, hardness )
Page 90
RT for Welded fittings
UT for Seamless Fittings
MPI at But weld end
NDT THK ≥ 6mm 100% As per applicable ASTM Standard NDT Reports P&W W 10% W
D.P. at But weld end
THK < 6 mm
UT for wrought / forged
fittings
FINAL VISUAL
(including Surface
Visual / Dimensional 100% As per PO / Drawing Final Report P&W W 10% W
finish) /
DIMENSIONAL
GALVANIZING
Thk. of Galvanizing to be Randomly check
TESTING IS: 4736 Test Report P&W R R
checked (10%)
(if applicable)
MARKING Visual 100% As per applicable ASTM Standard Final Report P&W R R
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Specification / Ref. / Manufa
Type of Check Quantity Records Vendor TPI
Acceptance norms cturer
CERTIFICATES Review 100% As per PO / Drawings All relevant Certificates R R R
Legend W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party
Spec: Specification P.O.: Purchase Order TC: Test Certification
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
Page 91
2. Each Fitting shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY/COMPANY’s representative in original.
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by M/S COMPANY/COMPANY’s representative approved agencies.
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for CS Flanges
Specification / Ref. /
Type of Check Quantity Records Manufacturer Vendor TPI
Acceptance norms
RAW MATERIAL
IDENTIFICATION Chemical & MTCs / PO requirements
100% As per applicable ASTM Standard W R R
(Review of Test physical properties Correlation with M.T.C.
Certificate)
HEAT
TREATMENT Process / Charts 100% As per applicable ASTM Standard Charts / Certificate P&W R R
(as applicable)
1. Chemical per heat / per size As per applicable ASTM Standard Test / Analysis Report /PO P&W R R
FINISHED
FLANGES 2. Mechanical -do- -do- -do- P&W W W
(Tensile, hardness )
Page 92
UT (before machining) 100% As per applicable ASTM Standard NDT Reports P&W W 10% W
NDT
D.P. (after machining) 100% -do- -do- P&W W 10% W
FINAL VISUAL
(including Surface
Visual / Dimensional 100% As per PO / Drawing Final Report P&W W 10% W
finish) /
DIMENSIONAL
GALVANIZING
Thk. of Galvanizing to Randomly check
TESTING IS: 4736 Test Report P&W R R
be checked (10%)
(if applicable)
MARKING Visual 100% As per applicable ASTM Standard Final Report P&W R R
CERTIFICATES Review 100% As per PO / Drawings All relevant Certificates R R R
Legend W: Witness P: Perform R: Review
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
2. Each Flange shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY / COMPANY’s representative in original.
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by COMPANY / COMPANY’s representative approved agencies.
Page 93
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for CS Ball valves.
Component & Quantum of Reference Acceptance
Type of Check Format of Record M V TPI
Operation Check Documents Norms
RAW MATERIAL
Pouring of casting 100%
Chemical test Drawing Drawing Foundry TC’s
Per Heat
Physical test
BODY & SIDE P/W R R
Visual 100% Drawing MSS-SP-55 Incoming GRN / IIR
Impact test Per Heat ASTM A 370.12a ASTM A 370.12a Foundry TC’s
Radiography 100% ASME B 16.34 ASME B 16.34 R.T. Report & Films
Chemical test
Per Heat Drawing Drawing Foundry TC’s
Page 94
BALL Physical test P/W R R
Visual & Dimension 100% Drawing MSS-SP-55 Incoming GRN / IIR
Chemical test
STEM Per R. bar / Heat Drawing Drawing Lab / Supplier TC P/W R R
Physical test
BROUGHTOUT ITEMS
Chemical test
Per Lot Drawing Drawing Supplier TC /
FASTENERS Physical test P/W R R
Inspection Report
Impact test (above 12 mm) Per Lot ASTM A 370.12a ASTM A 370.12a
INPROCESS INSPECTION
Transfer of Heat No. 100% - - Inspection Report P/W - -
BODY & S/P
Dimensions 100% Drawing Drawing Drawing P/W - -
BALL Dimensions 100% Drawing Drawing Drawing P/W - -
STEM Dimensions 100% Drawing Drawing Drawing P/W - -
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Component & Quantum of Reference Acceptance
Type of Check Format of Record M V TPI
Operation Check Documents Norms
FINAL INSPECTION
Visual
Dimensions
Hydro test Body
Product Drawing, Product Drawing,
Hydro test Seat 100% Inspection Report P W W
P.O. Spec. P.O. Spec.
Pneumatic test Seat
Functional test
Antistatic test
Page 95
Fire safe test
Fire safe test Type Test API 6FA/ API 607 API 6FA/ API 607 R R R
certificate
Calibration
Calibration of Inspection 100% API 6D API 6D P R R
Certificate
SURFACE
PREPARATION Physical Random Painting Spec. Painting Spec. Report P/W R -
& PAINTING
FINAL DOCUMENT Review Verification QAP, PO QAP, PO Reports R R R
Legend W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party
Spec: Specification P.O.: Purchase Order TC: Test Certification
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
2. Each Valve shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY / COMPANY’s representative in original.
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by COMPANY / COMPANY’s representative approved agencies.
Page 96
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for strainer.
Component & Type / Method of Extend of REF Acceptance Format of
Characteristics M V TPI
Operation Check Check Documents Norms Record
MATERIAL CONTROL
Physical & Physical & Drawing / Drawing /
Body 1/Heat/Batch Lab Report / MTC P/W R R
Chemical Properties Chemical Analysis Tech. Spec. Tech. Spec.
Physical & Physical & Drawing / Drawing /
Flanges 1/Heat/Batch Lab Report / MTC P/W R R
Chemical Properties Chemical Analysis Tech. Spec. Tech. Spec.
1/ Sheet Drawing / Drawing /
Mesh Chemical Properties Chemical Analysis Lab Report / MTC P/W R R
100% Tech. Spec. Tech. Spec.
Physical & Physical & Drawing / Drawing /
Perforated Sheet 1/Heat/Batch Lab Report / MTC P/W R R
Chemical Properties Chemical Analysis Tech. Spec. Tech. Spec.
IN PROCESS CONTROL
Page 97
Workmanship. Visual Examination Internal
All Components 100% Mfg. Drawing Mfg. Drawing P/W P/W -
Finish Dimensions Measurement Inspection Report
100 % on Fillet ASME SEC. VIII
DPT Welding 100% ASME SEC. V DP Report P/W P/W W
Welds DIV.I
ASSEMBLY CONTROL
Drawing / Drawing /
Clng. & Deburing Visual 100% Internal Report P/W P/W R
Tech. Spec. Tech. Spec.
Drawing / Drawing /
Complete Strainer Over all Dimensions Measurement 100 % Dimension Report P/W P/W W
Tech. Spec. Tech. Spec.
Leak Tightness for Drawing / Drawing /
Hydro Test 100 % Dimension Report P/W P/W W
15 Minutes Tech. Spec. Tech. Spec.
Surface Preparation DFT & Visual
Visual Random Painting Spec. Painting Spec. Report P/W R -
& Painting measurement
Compliance to QAP,
FINAL DOCUMENT Review Verification QAP, PO QAP, PO Reports R R R
PO
All rights reserved
Legend W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party
Spec: Specification P.O.: Purchase Order TC: Test Certification
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
2. Each Strainer shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY / COMPANY’s representative in original.
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by COMPANY / COMPANY’s representative approved agencies.
Page 98
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for Gaskets.
ACTIVITY ACCEPTANCE Reference Method of EXTENT OF Format of Scope of inspection
CHARACTERISTICS
DESCRIPTION CRITERIA Documents inspection INSPECTION record M V TPI
RAW MATERIAL STAGE
SPIRAL WOUND GASKET
NABL Lab
WINDING MATERIAL
Physical & Chemical ASTM A240 ASTM A240 Testing Per heat/Batch TC/Inspection P R R
SS316 (0.2mm)
report
NABL Lab
Outer ring material
Physical & Chemical IS 1079 Gr. D IS 1079 Gr. D Testing Per heat/Batch TC/Inspection P R R
carbon steel
report
NABL Lab
Inner ring material
Chemical SS 316 SS316 Testing Per heat/Batch TC/Inspection P R R
SS316
report
NABL Lab
Filler Material
Page 99
Chemical MFG,S STD MFG,S STD Testing Per heat/Batch TC/Inspection P R R
Graphite
report
CNAF GASKET
IS2712.GR.W/3 , IS2712.GR..W/3 , IS2712.GR..W/3 , Visual Mfg`s Test
Physical Per heat/Batch P R R
IS2712.GR.A/1 GR.A/1 GR.A/1 Measurement Certificate
INPROCESS INSPECTION
Inspection
Visual examination Visual PO/SPEC PO/SPEC Visual 100% P/W
report
Dimension Inspection
Dimension PO/SPEC PO/SPEC Measurement 100% P/W
Measurement report
Compression & Inspection
Testing PO/SPEC PO/SPEC Testing One per size P/W
Recovery test report
MARKING
Identification Spiral Inspection
As per Standard ASME B16.20 ASME B16.20 Visual Visual P/W W RW
wound gasket report
FINAL INSPECTION
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
ACTIVITY ACCEPTANCE Reference Method of EXTENT OF Format of Scope of inspection
CHARACTERISTICS
DESCRIPTION CRITERIA Documents inspection INSPECTION record M V TPI
Inspection
Visual examination Visual PO/SPEC PO/SPEC Visual 10% P/W W RW
report
Dimension Inspection
Dimension PO/SPEC PO/SPEC Measurement 10% P/W W W
Measurement report
Compression & Inspection
Testing PO/SPEC PO/SPEC Testing Random P/W W W
Recovery test report
PMI Test For SS/AS 10% Random Inspection
Chemical A-240 A-240 Testing P W W
Material witnessed report
PACKING LABLE
Page 100
Tagging with
Identification Tag PO.NO./SIZE/QTY/MA PO/SPEC PO/SPEC 100% Visual TAGS P/W R
TL/MFG`S NAME
DOCUMENTATION
Final Documentation
(Issue of IRN and PO/SPEC/QAP PO/SPEC/QAP PO/SPEC/QAP 100% PO/SPEC IRN R W/R
Endorsement)
Legend W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party
Spec: Specification P.O.: Purchase Order TC: Test Certification RW: Random witness
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
2. Each Gasket shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY / COMPANY’s representative in original.
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
5. TPI shall be carried out by COMPANY / COMPANY’s representative approved agencies.
Page 101
All rights reserved
QAP FOR STUD & NUTS
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Engineering Services, Ankleshwar
ITEM: STUD
Reference Format of Scope of
Stage Inspection Inspection parameter Method of inspection Documents Sample record inspection
vendor TPI
As per One sample per
Raw Material Raw material Testing Chemical composition Spectro RMTC P R
specification heat
In process Heat Treatment HEAT cycle (Hardening & Tempering Temperature) MTC P R
Universal tensile
Page 102
TL, YS, %E1, %RA
machine
As per One sample per Inspection
Final stage Mechanical testing IMPECT (if applicable) IMPACT MACHINE P W
specification heat report
HARDNESS Hardness tester
Major Dia
Thread Length ASME Randomly Inspection
Final stage dimensions Vernier P RW
B 1.1 selected sample report
Total Length
Inspection
Final stage PMI Cr. %, Mo % PMI Machine P RW
report
As per
specification Galvanising
Marking & galvanising Randomly
Final stage UFL, B7 , 2H Visual report/MTC P/R R
report selected sample
Inspection
Final stage Assembly Fitment Checking Fitment NA
report
P RW
QAP FOR STUD & NUTS
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Engineering Services, Ankleshwar
ITEM: NUTS
Reference Sample Format of Scope of
Method of
Stage Inspection Inspection parameter Documents record inspection
inspection
vendor TPI
As per One sample per
Raw Material Raw material Testing Chemical composition Spectro RMTC P R
specification heat
Universal tensile
As per One sample per Inspection
Final stage Mechanical testing Proof load machine P W
Page 103
specification heat report
Across Flat
Across Corner As per Inspection
Final stage Final Inspection Digital Vernier 5% P W
specification report
Head Thickness
As per Inspection
Final stage Marking UFL Visual Visual P W
specification report
Legend W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party Inspection
Spec: Specification P.O.: Purchase Order RW: Random witnessed MTC: Material test certificate RMTC: Raw material test certificates
Note:
All rights reserved
QAP FOR STUD & NUTS
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Engineering Services, Ankleshwar
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT Level-II qualified
personnel.
2. Each studs nuts shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY / COMPANY’s in original.
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by COMPANY / COMPANY’s approved agencies.
Page 104
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for CS Globe, Gate, check valves.
Type of Quantum of Acceptance Format of
Component & Operation Characteristics REF Documents M V TPI
Check Check Norms Record
Forged Carbon Steel body, Dimensions Measurement 100% Drawing Drawing Inspection Report P/W R R
Bonnet / Cover / Disc /
Wedge & Seal Surface Finish Visual 100% Drawing MSS-SP-55 Inspection Report P/W R R
Chemical & Mechanical
Cast, Forged Carbon Steel Review of ASTM-STD / PO ASTM-STD / PO
Properties, Radiography All Heats Foundry TC’s P/W P/W R
Body, Bonnet / Cover Vendor TC’s & Specification & Specification
casting,
Annealing / Normalising & Review of HT ASTM-STD / PO ASTM-STD / PO Review of HT
HEAT TREATMENT 100% R P R
tempering Charts & Specification & Specification Charts
Page 105
Review of Lab
All Heats / ASTM-STD / PO ASTM-STD / PO
TRIM / DISC SEALS Chemical Analysis / Vendor TC Lab / Vendor TC P/W R R
Batches & Specification & Specification
Review
As per
Visual
Dimensions Sampling IS-1364 IS-1364 Inspection Report P/W R R
Measurement
Plan
FASTENERS
(Pressure containing parts)
Chemical & Mech. Review of ASTM-STD / PO ASTM-STD / PO Supplier
All Heats P/W P/W R
Properties Vendor TC’s & Specification & Specification Certificate
Dimensional
MACHINING (In process) Dimensions 100% Drawing Drawing Inspection Report P/W P/W -
Inspection
Body/Bonnet Radiography Review of
100% as per ASME B 16.34 Radiography /
NDT Examination DPT of Disc Radiography ASME B 16.34 P/W P/W R
Specs. Annex B DPT Report
Seals Films
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
Type of Quantum of Acceptance Format of
Component & Operation Characteristics REF Documents M V TPI
Check Check Norms Record
1. Shell Test Gate/ Globe/
Hydro test
Check
2. Back Seat Gate/ Globe Hydro
TESTING Product Drawing, Product Drawing,
100% Test Report P/W P/W W
(FINISHED VALVE) PO Specification PO Specification
3. Seat test ( Check / Gate
Hydro
/ Globe )
4. Seat test (Gate / Globe ) Air
Measurement/
Page 106
DIMENSION OF VALVES Certified Dimensions / Valve/Size/Tag- Applicable Applicable 10%
final Visual Report PW P/W
(FINISHED VALVE) Marking Details 100% Drawing Drawing W
Examination
SURFACE
PREPARATION Paint Shade / DFT Physical Random Painting Spec. Painting Spec. Report P/W R -
& PAINTING
FINAL DOCUMENT Compliance to QAP, PO Review Verification QAP, PO QAP, PO Reports R R R
Legend W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party
Spec: Specification P.O.: Purchase Order TC: Test Certification
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
2. Each Valve shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY/COMPANY’s representative in original.
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by M/S COMPANY/COMPANY’s representative approved agencies.
Page 107
All rights reserved
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
QAP for CS Pipes.
Specification / Ref. /
Type of Check Quantity Records Manufacturer Vendor TPI
Acceptance norms
RAW MATERIAL
IDENTIFICATION Chemical & MTCs / PO requirements
100% As per applicable ASTM Standard P&W R R
(Review of Test physical properties Correlation with M.T.C.
Certificate)
HEAT TREATMENT
Process / Charts 100% As per applicable ASTM Standard Charts / Certificate P&W R R
(as applicable)
Chemical Sampling as per As per applicable ASTM Standard Test / Analysis Report/ PO P&W R R
FINISHED PIPES
applicable ASTM
Standard
(per heat / per size)
Page 108
Mechanical
(Tensile, flattening / -do- -do- -do- P&W W W
Bend test, etc.)
UT for Seamless Pipes 100% As per applicable ASTM Standard NDT Reports P&W W 10% W
NDT
Balance-R
RT of welded pipes 100% -do- -do- Film Film
P&W
Review Review
FINAL VISUAL / Visual / Dimensional / 10% W
100% As per PO Final Report P&W W
DIMENSIONAL Straightness / Ovality Balance-R
HYDROSTATIC 10% W
Hydro test 100% As per applicable ASTM Standard Test certificate P&W W
TEST Balance-R
MARKING Visual 100% As per applicable ASTM Standard Final Report P&W R R
0 24.10.2017 24.10.2017 SK PD JS
REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD
Project description and Scope of Work
Revamping of fire water network of ONGC residential colony of Ankleshwar Asset
CERTIFICATES Review 100% As per PO All relevant Certificates R R R
Legend: W: Witness P: Perform R: Review M: Manufacturer V: Vendor TPI: Third Party
Spec: Specification P.O.: Purchase Order TC: Test Certification
Notes:
1. Testing by suitable method shall be done at NABL certified laboratories only. The NDT Reports shall be certified and approved by minimum ASNT/ISNT
Level-II qualified personnel.
2. Each Pipe shall be clearly marked with TPI stamping in addition to the other information as per Standard / Specification.
3. All the Reports reviewed / certified by TPI shall be submitted to COMPANY / COMPANY’s representative in original.
Page 109
4. Stage-wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage.
5. TPI shall be carried out by COMPANY / COMPANY’s representative approved agencies.
110 Page
PROPOSED FIRE WATER NETWORK
Page 111