Technical Specifications BAMUL

TECHNICAL SPECIFICATIONS
FOR
MOUNDED STORAGE FACILITY
TECHNICAL SPECIFICATION FOR BOILER QUALITY

STEEL PLATES FOR MOUNDED BULLETS
1.
Description
40 or
: Plates Conforming to BS 1501 part I, 224, 490.LT

40 or SA537 Class I equivalent as per OISD 150
and as approved by CCOE.
: On thickness positive only
2.
Tolerance
3.
Inspection
: Lloyds / Bureau Veritas (at the works of Supplier of

BQ Plates)
4.
Impact Testing
: As per PD 5500 or equivalent
5.
Ultrasonic Testing
: As per SA 578 Level I
6.
Heat Treatment
: Normalized
7.
Maximum Tensile Stress
: 80,000 psi.
8.
The Steel shall be made to fine grain particles.
9.
Supplementary Requirement
a) The plates shall be free of scales and rolled in the direction of length specification
and shall be supplied in the normalized condition. Accelerated cooling by liquid
quenching or other means is not permitted. Plates shall be ordered with testing of
sample for mechanical properties after simulation.
b) The plates shall be supplied with gas/sheared edges with tolerance as per SA 20
latest. Manual gas cutting is not acceptable. Tolerance on thickness shall be
positive only.
c) All the plates shall be supplied in normalized condition.
d) The plates shall be free from injurious defects and shall have work-man like finish
reconditioning/ repair of plates by welding is not permitted.
e) One product analysis of each heat shall be done as per relevant BS code on the
entire surface of the plate with a square grid of 200 mm. UST shall be done after
heat treatment and results recorded in the test certificates.
f)
10.
Marking as per specification, accordingly Purchase Order No. shall be stenciled

and inspector symbol shall be die-stamped.
OTHER REQUIREMENTS
A) All Tests should be carried out in the presence of the Third Party Inspection
Agency and shall be certified and stamped on each plate ON BOTH ENDS.
B) MARKING: The plates shall be marked with the No. of relevant Standard and
approximate Grade No.
C) TEST CERTIFICATE: The material shall be duly certified by Lloyds or by Bureau

Veritas at the Steel Plate Suppliers
works. & necessary documents, test
certificates covering details given below shall be submitted to HPCL:
Heat and plate number
Chemical composition cast and product, analysis
Heat Treatment cycles
Mechanical properties viz. Tensile, Yield, Elongation, impact.
Ultrasonic test results
Results of simulation PWHT of mechanical test coupons in two conditions in
addition to the test results in as supplied condition of plates.
g) Charpy V- notch Impact Tests.
a)
b)
c)
d)
e)
f)
The Third Party Inspection at the BQ Plate suppliers Work shall be arranged
by the tenderer & the rates quoted shall be inclusive of this Inspection.
However, The TP Stampings on the Plates & material Test Certificates put at
the manufacturers works shall also be inspected by TPIA. Approved TPIA for
inspection of Steel Plates at suppliers works are M/s Lloyds / M/s Bureau
Veritas / M/s IRS.
D) Vendor to carry out FEM Analysis for the Plates supplied. This is an essential
requirement.
E) Manufacturers Test Certificate in 3 sets to be dispatched immediately after TPIA
clears the goods from their side.
F) Production Test Coupon requirement should be as follows:
i.
Number of PTC required per Vessel:
For Long Seams: One No. / Welder / procedure/heat

For Circum-seams: One No. / Welder/ procedure/heat
ii.
PTC Testing Requirement:

2 - Transverse Tensile test.
1- all weld tensile test.
4 - Bends( 2 root & 2 face) test.
Micro, Macro, Hardness & Impact ( weld, HAZ)
Note:
i.
The bidder must specify the specifications and make of the BQ steel plates
offered by him in the Unpriced Bid.
ii. The rates quoted for Supply of Steel Plate should be inclusive of all above
requirements.
Design Parameters / Material Specifications/Nozzles for Mounded

Storage:
1.0
VESSEL
1. Storage Capacity of LPG
: 10 MT each
2. Volumetric Water Capacity
: Vendor to specify considering 85% highest

filling level in the vessel.
3. Density of LPG
: 0.525 gm/cc
de
: PD 5500 Latest edition and OISD 150

5. Design Pressure (Internal)
(External)
: 14.5 Kg/cm Gauge at Top

: 1.856 kg/cm2 Gauge
6. Design Temperature
: - 27 C to + 55 C
7. Hydraulic Test Pressure
: As per code
8. Radiography
: 100% before and after PWHT
9. Corrosion Allowance
: 1.5 mm
10. Post weld Heat Treatment
: Required
11. Wet Fluorescent Magnetic Particle Testing: Required after PWHT

12. Hardness checking of HAZ
: Required after PWHT
13. Mapping of plate thickness
: Required
14. Joint efficiency
:1
15. Length of Pressure Vessel
: As per requirement.
16. Dia of Vessel
: 2900 mm (approx). Vendor to specify

optimum diameter based on lowest steel
tonnage
17. Dished Ends
: Hemispherical/ vendor to specify
Notes:
1.
All Openings will be of Flanged type with Nozzle Construction.
2.
FEM Analysis shall be conducted for the Vessel to assess the stresses in the vessel
& stiffener for various loading conditions & report shall be submitted to
TPIA/HPCL for approval.
3.
Stiffeners shall be provided as per the design requirements. The detailed design
for stiffeners shall be submitted to HPCL for prior approval.
4.
As the bottom 120 deg. Area is not accessible at hydro test, the weld joints in this
region shall be ultrasonically tested followed by DP testing after hydro test.
5.
All ASTM Pressure parts shall meet the Design Code Requirements for Impact
testing as per app. D & Cl. 2.3.2 of PD 5500 (latest edition) or equivalent. The
requirement of OISD 150 shall also be incorporated.
6.
The maximum differential settlement allowed is 25 mm. Total settlement allowed

is max 60 mm.
2.0
MATERIAL SPECIFICATIONS:
3.0
1.
Shell, Dished Ends, Stiffener : BS 1501 Part I 224 Gr.490 or equivalent

rings, Pad plates, Cleats etc.
(detailed Specs enclosed)
2.
Nozzles
: SA 333 Gr. 6
3.
Flanges
: SA 350 Gr. LF2 - ASA 300

Weld neck raised face dimensions as per
ANSI B 16.5.
4.
Couplings
: SA 350 Gr. LF2 6000 lbs.
5.
6.
Bolts/Nuts
Gaskets
: SA 320 Gr. L7 or SA 194 Gr. 4 / Gr. 7

: SS 316 Spiral Wound Asbestos filled.
Nozzles:
Following Nozzles shall be provided by the Vendor on each Pressure Vessel. A
sleeve structure made of glass reinforced epoxy or un-plasticised polyvinyl chloride
shall be provided around nozzles and manholes in line with EEMUA
recommendations. Final orientation of all Nozzles will be given by HPCL at the
time of approval of Fabrication drawings. The Liquid Inlet/Outlet Nozzle shall
extend upto 3 m from the face of vessels & shall have no flange Joint except at the
end. It shall be adequately supported & shall be stress relieved & Hydro tested.
All Nozzles should be provided with SA 350 Gr. LF2, 300 lbs. RF blind Flanges.
1.
650 mm dia Manhole with cover
: 1 no.
2.
50 mm dia Nozzle for Liquid

receipt withdrawal line at bottom
: 1 no.
3.
40 mm dia Nozzle for Liquid

Return and vapour return at Top
: 2 no.
4.
Nozzle of suitable size (2.5 NB say)

for Rochester Gauge at the top
: 2 no.
5.
1" Nozzle for Pressure Gauge

: 2 no.
/ Temperature gauge with thermo well at Top.
6.
2" / As required Nozzle for Magnetic Dip

Gauge
: 1 no.
7.
Suitable Size Nozzle for

Safety Valves on Top.
: 2 nos.
8.
50 mm NB vapour outlet / Spare
: 2 no.
(Party to design Safety Valve & Nozzle & submit calculations for the same)
9.
: 1 no.
10.
Lifting lugs suitably spaced on

the Top
12.
Cleats as required for providing

operating platforms wherever
required.
: No.of cleats to be provided

will be decided later
BSP for temperature Gauge
: 1 no
13.
4.0
50 mm dia Nozzles for High Level

Alarm with Dip pipe.
: As Required.
MISC. REQUIREMENTS:
1.
Earthing Boss and CP Connection
2. Name plate with following details

a) Manufacturer's name
b) Manufactured for
c) Designed by
d) Design code
e) Design pressure
f) Design temperature
g) Date of first hydro testing
h) Capacity & size of vessel
i) Water capacity
j) Empty weight
k) Corrosion Allowance
l) Radiography
m) Stress Relieving
n) Inspected by
o) Certificate number
p) Drawing number
q) Vessel serial number
: As required
: 1 no. per Vessel.
In addition to providing the name plate, the following details are to be punched on
the manhole flange ring.
1.
2.
Design code
Design pressure
3.
4.
5.
6.
7.
Test pressure
Date of first test
Inspected by
Certificate number
Drawing number
SPECIFICATION OF HIGH LEVEL ALARM SWITCH

Level alarm switch displacer type, Flame-proof explosion-proof weather proof construction
certified by CMRS & Chief Controller of Explosives, Nagpur. The instrument shall be
suitable for use with liquified petroleum gas (LPG) in Horton spheres/bullets. The switch
shall change contact only when the liquid level in the sphere/bullet reaches the maximum
safe filling level i.e. 85% of the volumetric capacity of the sphere/bullet. The instrument
shall be tank top mounting type and equipped with:
1.1
One no. 50 NB matching flange of material SA 350 Gr. LF2 and rating conforming
to ANSI B-16.5 Class 300 R/F.
1.2
All wetted parts like displacer, wire, spring etc. shall be made up of stainless steel
AISI 316.
1.3
Power supply
1.4
Cable glands : Explosion proof, flame proof, double compression type.
: 230 V 50 HZ
Note :
Vendor will be required to import above Level switch through their own import
license and at their own cost. No assistance in import of this item will be rendered
by HPCL to the Vendor. However, Vendor is required to indicate in their quotation as
to how Level Switch will be arranged by them.
DATA SHEET
LEVEL SWITCH-(HIGH LEVEL ALARM SWITCH)
Make
: TOKYO KEISO, JAPAN OR APPROVED EQUIVALENT
Qty.
: As per scope of supply
Specific gravity
: 0.525
Liquid
: LPG
Type
: Displacer type
Construction
& Enclosure
: Explosion proof as per IS-2148

and IP-65 weather protection
Flange
: 2" ANSI # 300 RF
Op. Temperature
: -27 to +55 deg C
Pressure
: 17 Kg./sq.cm.gauge
Test pressure
: 22.5 Kg./sq.cm.gauge
Alarm type
: H (1 point alarm)
Conduit size
: NPT 1/2 adapter
Power source
: 230 V / 50 Hz.
Transmitter
: Approved by CCOE Nagpur
Switch type
: SPDT
Accuracy
:*
* Vendor to provide the technical literature of the model being offered.

SPECIFICATIONS FOR SAFETY RELIEF VALVES FOR LPG PRESSURE VESSELS
( Supply includes supply of Safety Valves along with lock open type Gate
Valves 300# rating. ) ,
TAG NO
: WILL BE GIVEN LATER
SERVICE
: LPG VAPOUR
QUANTITY
: 2 NOS. PER LPG PR. VESSEL
FULL NOZZLE/SEMI NOZZLE
: FULL NOZZLE
CONVENTIONAL/BELLOWS
: CONVENTIONAL
BONNET OPEN/CLOSED
: STRAIGHT THROUGH DISCHARGE
SIZE-INLET/OUTLET
: VTS AS REQUIRED
FLANGE RATING - INLET/OUTLET
: 300# /150#
TYPE OF FACING
: RF SERRATED
BODY/CYLINDER
: ASTM 216 GR.WCB
SEAT DISC
: SS 316
SPRING
: CS,CD PLATED
NOZZLE/GUIDE RING
: SS 316
CAP SCREWED/BOLTED
LEVER PLAIN/PACKED
:
: NOT REQUIRED
TEST GAG
: NOT REQUIRED
CODE
: ASME SEC VIII DIV II
CALCULATION CODE
: API 520
BASIS FOR SIZING
: FGE (FIRE GAS EXPANSION) OR AS

PER CODE REQUIREMENTS.
RELIEVES TO
: ATMOSPHERE
FLUID & STATE
: LPG VAPOUR
SP.GR.AT 60 DEG F(AIR=1)
: 1.90
MOLECULAR WT
: 50.00
OPTG. PRESSURE (KG/CM2)
: 2-11(GAUGE)
SET PRESSURE (KG/CM2)
: 14.5 (GAUGE)
OPERATING TEMPERATURE
: 3-45 DEG.C
RELIEVING TEMP
: 55 DEG. C
BACK PRESSURE
: ATMOSPHERIC
ALLOWABLE OVER PRESSURE
: 21 PERCENT
CP/CV
: 1.12
VISCOCITY FACTOR
: NIL
RELIEVING CAPACITY
: VTS
SELECTED AREA
: VTS
ORIFICE DESIGN
: VTS
MISCELLANEOUS:
1. VENT PIPES
2.
GATE VALVES ( FOR Safety valve isolation )
NOTE:
: 3 MTR. HIGH PIPE VENTS WITH

RAIN WATER CAPS TO BE
PROVIDED ON ALL THE PORTS OF
EACH SRV.
: API 6FA, Fire Safe and having API
monogram.
(a)
VENDOR SHALL INDICATE THE MAKE OF THE SRV IN THE UNPRICED BID.
(b)
THE CAPACITY OF SRV SHALL NOT BE LESS THAN 30 % OF THE

CAPACITY REQUIRED FOR AN ABOVE GROUND TANK OF EQUAL
CAPACITY.
(c)
THE SRVS SHALL BE APPROVED BY CCOE.
SPECIFICATIONS FOR UPS SYSTEMS

(for the Regulated Power Supply for instrumentation & ROVs, High level alarms)
a)
Type
True, ON-LINE.
b)
Output Wave form
Pure Sine-wave
c)
Input Power Supply
230 V 30%
d)
Output
220 V 2%
e)
Input Frequency
50 Hz 5 Hz
f)
Output Frequency
50 Hz 1 Hz
g)
Backup time
30 Minutes
h)
Battery type/make
Sealed Maintenance free.

(Any reliable make such as Standard
Furukawa, Exide, Hitachi, Panasonic, CSB or
Amco Yuasa)
i)
Qty/Capacity of UPS
1 nos. 5 KVA with necessary individual

feeders as specified in the scope.
The UPS is intended for all instruments of 2 x 10 MT mounded LPG storage vessels, ROVs
& High level alarm switches.
j)
Makes :
The UPS should be of a reputed make

such as APC (American Power Conversion) or
Tata Libert (Emerson Network Power Ltd),
Siemens or Hi-Rel Electronics.
SPECIFICATIONS FOR UPS SYSTEMS

(for the Regulated Power Supply for Cathodic Protection System)
a)
Type
ON - LINE
b)
Output Wave form
Pure Sine-wave
c)
Input Power Supply
230 V 30%
d)
Output
220 V 2%
e)
Input Frequency
50 Hz 5 Hz
f)
Output Frequency
50 Hz 1 Hz
g)
Backup time
30 Minutes
h)
Battery type/make
Sealed Maintenance free.

(Any reliable make such as Standard
Furukawa, Exide, Hitachi, Panasonic, CSB or
Amco Yuasa)
i)
Qty/Capacity of UPS
As per Cathodic Protection System

requirement and vendor recommendations.
The UPS is intended for C P System of 2x 10 MT mounded LPG storage vessels.

j)
Makes
The UPS should be of a reputed make such

as APC (American Power Conversion) or Tata
Libert (Emerson Network Power Ltd),
Siemens, Hi-Rel Electronics, .
POLYURETHANE BULLET PROTECTIVE COATING

The minimum requirements for the coating materials, equipment, application, inspection,
repair, handling & other aspects of external (surface) corrosion protection of mounded
bullets (cylindrical unfired pressure vessels) are covered under these technical
specifications.
1.
SCOPE OF WORK
This specification governs the minimum requirements for materials (coating as well
as surface preparation prior to coating), equipment, coating application, inspection,
repair, handling and all other aspects of external corrosion protection of Mounded
Bullets for bulk storage of the liquifiable (hazardous) gases under pressure.
It is envisaged that the Polyurethane coating ( 100% solids, high build, elastomeric)
on the external surface of the mounded bullets shall provide a hard, tough, high
electrical resistance (for corrosion prevention in conjunction with cathodic protection
system) surface with outstanding adhesion and impact resistance to protect against
damage during the process of mounding (compaction of graded sand followed by
earth cover). The coating system shall be suitable for service temperatures between
minimum -55 C and ambient + 55 C (although these temperatures may not be
normally achieved/ encountered) in service. Also very high levels of chlorides &
sulphates, particularly in coastal installations, should be withstood by the coating
during entire design life span.
In mounded bullets, with internal pressures the unfired shell areas widen more than
the ring stiffened region. The coating system shall withstand, without damage during
the entire service life span, the constraint developed thus producing bending
moments in the mounded bullets in longitudinal direction, the maximum of which
occur/ are likely to occur in the plane of the ring stiffener.
The work to include furnishing all labour (skilled & unskilled), materials, tools &
tackles, equipment & performance of all operations and incidentals necessary for
coating handling, storing and transporting of coated bullets or part thereof. The
coating operations will have to be carried out in narrow space around the mounded
bullet prior to graded sand filling and compaction around the fabricated bullet.
The steel surface preparation prior to actual commencement of coating shall conform
to
STEEL
STRUCTURE
PAINTING
COUNCIL-:
SURFACE
PREPARATION
SPECIFICATION: SSPC-SP10
Removal of all equipment and excess materials from site, following completion of
coating operations is included in the scope of work.
Prior approval from owner/ consultant shall be obtained by the coating applicator for
any deviations from the requirements of this specification and/ or the standards
referred therein.
2.
REFERENCE DOCUMENTS:
STIP3 (STEEL BULLET INSTITUTE , USA)

NACE 6H 284 (NATIONAL ASSOCIATION OF
CORROSION ENGINEERS)
SSPC- SP1
SSPC- SP10
SIS 055900
NACE TM-01-7
NACE TM-01-75
3.
CORROSION CONTROL SYSTEMS OF

UNDERGROUND STEEL BULLETS
URETHANE TOP COATS FOR ATOMOSPHERIC
APPLICAITON (TECHNICAL COMMITTEE
REPORT)
STRUCTURAL STEEL PAINTING COUNCIL:
SOLVENT CLEANING
STRUCTURAL STEEL PAINTING COUNCIL:
NEAR WHITE BLAST CLEANING
PICTORIAL SURFACE PREPARATION
STANDARD FOR PAINTING OF STEEL
STRUCTURES
VISUAL STANDARD FOR SURFACE & NEW
STEEL AIR BLAST CLEANED SAND
ABRASIVES
VISUAL STANDARD FOR SURFACE & NEW
STEEL CENTRIFUGALLY BLAST CLEANED
WITH STEEL GRIT 7 SHOT
GENERAL REQUIREMENTS:
The applicator shall submit for owner/ consultants approval, coating procedure
including quality assurance (QA) & quality control (QC) methodology, prior to
commencement of coating of the bullets. Only duly approved methodology shall be
followed in coating application.
The applicator shall provide standard equipment for coating works, no improvised
equipment will be accepted/ allowed.
The applicator shall supply all coating materials required as per this specification &
provide test data/ reports from standard laboratories. The applicator shall also carry
out tests on applied coating for adhesion, film thickness and pinhole/ holiday
detection. The results of these tests shall be through a owner/ consultant approved
laboratory.
Considering logistical and technical aspects, coating of bullets shall be carried out in
the mound
( prior to grade sand filling & compaction) after post weld heat
treatment and hydrostatic testing.
All manpower (skilled , unskilled) shall be applicators responsibility and only
personnel skilled in the coating application shall be deployed by the applicator.
The coating shall be inspected by qualified inspectors. The qualification of inspectors
shall be verified/ approved by owner/ consultant.
The applicator shall provide access during all phases of work to the owner/
consultants and their inspectors. Any expenses incurred by the applicator due to
owner/ consultants inspectors stopping the coating work because it is not being
carried out as per these specifications, shall be borne by the applicator.
All equipment shall be subject to owner/ consultants approval and should be of good
quality, maintained in good operating condition and suitable for use to apply
materials as per this specification.
All cleaning, priming, coating machines shall be preferably equipped with rubber or
wheels overlaid with hard fiber to prevent marking or denting the external surface of
the bullet.
The owner shall provide coating schedules & engineering information including
drawings when available, showing all dimensions, obstructions and access to the
surface area to be coated as well as the calculations of area to be sprayed.
Before, bid submission, the applicators are advised to acclimatize themselves with
site working conditions and owner will permit such visits by applicators.
During surface preparation, any acceptable metal defects detected shall
be
immediately brought to the notice of owner/ consultant and the applicator shall hold
the work on such steel piece till such time as cleared for further action by the owner/
consultant.
Only plural component air less spray system shall be used as per recommendation of
the manufacturer of Primer Polyurethane.
4. SAFE PRACTICES:
High performance spray applied coatings may contain potentially toxic ingredients
and require all (local, state, central) safety regulations to be observed during coating
operations. Proper safety precautions must be observed against recognised safety
hazards even during storage of primer & coating materials at site. Applicable
(statutory, state, local) regulations governing safe handling practices, shall be
enforced.
5. MATERIAL SPECIFICATION
Sr
1
2
3
Property
Tensile Strength
Adhesion(elecometer pull off)
Recoverable Elongation
Value
15 N/ sqmm (Min)
8 N/ sqmm (Min)
50% Min. At 25 C
Test Method
ASTM-D638
ASTM-D4541
ASTM-D638
4
5
6
7
Sr
8
9
10
11
Surface Hardness (cured film)

Water vapour permeability
Operating Temperatures
Salt Spray ( 6000 hrs)
50 (Min)
0.5 gms/24hr/sqm (max.)
-55 C to +55 C
No Effect
Property
Nom. Film thickness(film build)
Value
1000 micron. (unless otherwise
specified)
2.3*105 gms. Cms (min)
Impact Resistance
13
Tear Strength
Abrasion Resistance (Taber
Abraser H-10 wheel 1000 gm
1000 cycles)
Cathodic Disbondment (-1.5 v 7075 F 30 days)
Flexibility at 25 C
14
Accelerated Weathering
12
SHORE D
ASTM-E96
ASTM-B117-73
Test Method
175 PLI (Min)

Weight loss 0.05 gm (Max.)
ASTM G-14 on
steel pipe
ASTM D-624
ASTM-D-4060
Average radius 10 mm (max)
ASTM G-8, G-95
To pass 180 C\ bend over 0.5

mandrel @ 750 microns.
Excellent Some Chalking
ASTM D 1737
ASTM G-23
PRIMER
The type of primer used shall be as per coating manufacturers specifications
a) For areas not to be cathodically protected : Polyvinyl Butryl (wash) type
b) For areas to be cathodically protected
: Aluminium filled moisture cured
Urethane Primer or two (2) component chemical cured Urethane Primer
Single package moisture-cured Urethane primers containing non-leafing Aluminium
pigmented, are fast curing, chemical & corrosion resistant and eliminate the mixing &
pot life limitation of two pack materials.
The primer shall have following characteristics;
Flash Point: 28 C TCC
Coverage:
for @ 1 Mil DFT square feet per gallon

810 - theoretical
648 - practical (assuming 10% loss factor due to over spray
etc.)
Shelf Life : Six (6) months
Drying time : at 25 C
To touch
To handle
To recant
Clean up :
Toluene (immediately)
30 mts
45 mts
4 hours
6. SURFACE PREPARATION:
Although, Elastomeric 100% solids Polyurethane coating material has excellent
Corrosion and Erosion resistant properties, it must however, be considered part of an
engineered system which includes adequate/ appropriate surface preparation. It is
axiomatic in protective coating work that the performance of most appropriately
chosen coating will be no better than the surface preparation. Accordingly, the
surface shall be blast cleaned as follows;
The external surface of bullets (or part thereof) shall be blast cleaned to SSPC-SP10
specification near white blast cleaning with 2-3 Mil anchor profile (or else conform to
SIS Gr Sa 2-1/2 Specifications)
Near white blast cleaned surface finish is defined as one from which all Oil , grease,
dirt mill scale, rust, corrosion products, oxides, paints or other foreign matter have
been completely removed from the surface.
The abrasive shall not be reused as this could be detrimental to the surface.
Dry sand blasting using compressed air blast nozzles and dry sand of a maximum
particle size not larger than that passing through a 16 mesh screen US Sieve Series
shall only be used.
Grit blasting shall be using compressed air blast nozzles & crushed grit made of cast
iron, malleable iron, steel or synthetic agents other than sand of a maximum particle
size no longer than passing through a 16 mesh screen US Sieve Series. The largest
commercial grade of metal grit permitted by this specification is SAE No. G-25
abrasive material.
Closed re-circulating nozzle blasting using compressed air, vacuum and any of the
preceding abrasive may be used.
The blasted surface shall be brushed with clean brushes made of hair, bristle or fiber
or else blown off with compressed air (from which detrimental oil & water have been
removed) or cleaned by vacuum for the purpose of removing any traces or blast
products from the surface and also for removal of abrasives from pockets & corners.
Blast cleaning operation shall be done in such a manner that no damage is done to
partially or entirely completed portions of the bullet.
If any rust is formed on Bullet (external surface) after Blast Cleaning, the surface shall
be re-blast cleaned before painting.
The blast cleaned surface shall be examined for any traces of oil, grease or smudges.
If present, these shall be removed as outlined in SSPC-SP1-63 specification.
The height of profile of the Anchor pattern product on the surface shall be 50
microns. The height of Anchor pattern to be determined by an Elcometer 123 or
equivalent surface profile gauge. The average reading from ten (10) randomly
selected areas shall constitute the height of the profile. The profile measurement to
be done on flat (with out curvature) areas only.
The blast cleaned surface should be further treated or primed preferably within 24
hours after blast cleaning but in any event before any visible or detrimental rusting
occurs.
All above operations shall be witnessed by & certified by owner/ consultants
inspector.
7. PRIMING
Measure humidity (using PSYCHROMETER) to ensure Dew Point is at aleast 3 C
below the ambient temperature. Under controlled conditions, heating steel surface
may be resorted, to eliminate the condensation problems.
Two component chemicals cure urethane primer shall be sprayed onto the cleaned
surface in a fog coat as thinly as possible (approximately 1 Mil) so as to tint but not
mask the colour of the substrate. The primer on application shall be free from runs &
drips. The primed surface shall be protected so that it will not come in contact with
rain, Mist, Dust or other foreign substances until completely hardened & the Urethane
top coat has been applied.
The Urethane top coat shall be applied before the Prime Coat has completely cured
not less than two (2) hours, nor more than five (5) days after the prime coat has been
applied. However, the Prime Coat at the time of Urethane application, should be hard
and not tacky.
8. COATING
Equipment for spray application shall be plural component Airless spray system
(Graco Hydra Cat 45:1 or equivalent)
Pressure produced at Tip
Tip Size
2200 - 3000 PSI

0.66 - 0.76 mm
Temperature
Resin
Activator
50 C - 60 C
10 C - 30 C
Standard instructions from the Manufacturer shall be followed for Spray, material
handling & storage. Always, dry nitrogen (gas) blanket over material shall be
maintained.
Nominal thickness of 100% solids elastomeric urethane shall be 40 Mils (1,000
micro) unless otherwise specified. The finished polyurethane shall be generally
smooth & free of sharp protuberances. A minor amount of sags, dimpling &
curtaining, which otherwise meets specifications requirement shall however be not
considered as cause for rejection.
Before actual coating application on the bullet surface, a test patch shall be applied &
inspected for Runs, drips & Gel time as well as Tack free time. In case of doubt,
Adhesion test shall be carried out.
Unit Repeat Area is calculated along with the Material volume in counter numbers
(counters are attached on the units that measure the volume of materials dispensed),
approximate speed and number of passes. Spray apply requisite thickness in multiple
passes in single application keeping spray gun perpendicular to the substrate. If the
surface is large enough to require more than one day for coating, the edges of the
coated area shall be feathered and roughened with a grinding tool for over spraying
and primed.
Skips, if any, holidays, detected should be repaired with 100% solids Elastomer
Urethane hand mix kit or equivalent after the edges are roughened.
9. INSPECTION
All work under this specification shall be subject to Inspection by the owner/
consultants Inspector. All part of the work shall be accessible to the owner/
consultants inspector. The applicator shall correct any defective work indicated by
the Inspector.
During coating application the wet film thickness shall be measured using Nordson or
equivalent wet film gauge as per ASTM D4414. The dry film thickness shall be
checked with a magnetic mil gauge (by De Flesko or equivalent). The coating shall be
checked for Holidays using Tinkor & Rasor (USA) Holiday detector or equivalent. Due
caution shall be taken not to use detector voltage exceeding di-electric strength of the
coating (400 V/Mil) to avoid damage to the coating.
Pull off Adhesion to steel shall be measured using Elecometer adhesion tester as per
ASTM D 4541 using a Aluminium dolly attached to the coating & a perpendicular
force applied to the dolly. Average reading from three (3) randomly selected spots
shall be at least 8 N/sqmm. Adhesion test shall be carried out on fully cured coating
(7 days at 25 C) & on flat (without curvature) test area.
Applicator shall supply certificate from the coating manufacturer that the material
used (with batch numbers) are free from manufacturing defects & will meet all
performance criteria when properly applied as given in this specifications.
All above test shall be witnessed & certified by owner/ consultants inspector.
Inspection and Testing
All painting materials including primers and thinners for application shall be procured
directly from manufacturers as per specifications and shall be accompanied by
manufacturers test certificates. Paint formulations without certificates are not
applicable.
10. QUALITY ASSURANCE
The contractor shall guarantee that the chemical and physical properties of paint
materials used are in accordance with the specifications contained herein/to be
provided
during
execution
of
work.
CATHODIC PROTECTION OF LPG TANKS

1.0
GENERAL
The cathodic protection system shall be designed as per latest specifications
and industry standards and the same shall be executed only thru expert
agencies with prior experience of design and providing of CP system for
mounded LPG storage vessels in India. The decision of HPCL with respect to the
design of the CP system shall be final and binding on the contractor.
The impressed current cathodic protection system should provide a uniform
cathodic current density to the target bullet structure in order to maintain the steel
at a potential between -0.85 V and -1.5 V relative to a Cu/CuS04 reference
electrode.
Steel potential needs to be greater than -0.85 V to avoid corrosion and less than 1.5V to avoid excessive hydrogen evolution which Induces hydrogen embitterment
of high carbon steels used in the fabrication of bullet tanks. The protected
structure thus needs to be maintained within a narrow window of 0.65V.
The type of Anode and its positioning relative to the bullet tank has a critical
influence on both achieving the uniform current density and maintaining the
potential of the structure within the -0.85 V to -1.5 V potential range. In addition,
the relative positions of the associated pipes and tanks have to be considered.
2.0
DESIGN BASIS
For designing the system, the following parameters should be considered:
1.
2.
Soil Resistivity
CP current density
3.
4.
5.
6.
LPG bullet dia

LPG Bullet length
%age bare steel
Design Life
(*)
- Min 10,000 ohm-cm (*)

- VENDOR TO DESIGN & SPECIFY
(approx. 10mA per Sq M)
- 6.0 Mtrs (apprx)
- 44 Mtrs ( appx)
- 30%
- 50 years
Exact measurements should be taken at site, of mound soil.

Based on the above design parameters, the CP contractor shall design a
suitable system taking particular care with the positioning of the ANODES and
the Cu/CuSO4 reference cells.
3.0
MONITORING
A suitable Cu/CuSO4 reference cell monitoring system shall be proposed to ensure
that the design parameters can be checked over the lifetime of the CP system.
4.0
TRANSFORMER RECTIFIER UNIT

The transformer rectifier shall be automatically controlled C.P. rectifier of rating Single Phase or 3 Phase, 415 Volts - 50 V with auto/manual override facility. The
ampere rating is a function of the type of coating used on the tank.
Control
Construction
5.0
:
:
Constant Voltage/Constant current Control

Outdoor type - IP 65 with an additional canopy.
POTENTIAL CONTROL
The C.P. system shall be provided with automatic potential control. A switch shall
be provided to switch the system between automatic and manual operation.
Automatic reference selector logic with 3 Nos. reference inputs located in the TR
unit will be capable to control the current output such that the structure to soil
potential at the connected reference cell is maintained within 10 millivolts of the
set value.
The potential measuring circuit shall be capable of working with both Cu/CuSO4
and Zinc reference cells. At any given time the system shall be either controlled by
one type of reference cell and other type shall be kept on the standby mode. The
changeover, if required, shall be effected manually at site in the TLP (Test Lead
Point).
The TR unit shall be provided with the following Visual annunciation and alarm:
Under Protection
Over Protection
All Reference Failure
Over Current
A panel-mounted meter to read the bullet-to-soil potential at the selected control reference
cell through a selector switch shall be provided.
6.0
ELECTRICAL SEPARATION
Monolithic Insulating joints of IGP or equivalent approved make shall be provided
on each tank at Manhole covers, gauges and pipe connections to each tank . The
Insulation joint shall be approved by TPIA before erection. Contractor has to get
the design approved by HPCL/TPIA.
7.0
EARTHING
The LPG bullets shall be connected to the central earthing system through two
polarisation cells.
LIST OF APPROVED CONTRACTORS / VENDORS FOR CP SYSTEM
Long Line Polymer Anodes

Transformer Rectifier Unit
Reference Electrodes Cu/Cu So4
Polarisation Cell
Raychem USA / Matcor - USA

Canara Electric Controls
Borin USA / Harco (Corrporo) USA
Kirk - USA
Monolithic Isolating Joints

Cables
Surge Arrestors
Junction Boxes
IGP / ALFA / ZUNT

Netco/ Macrotherm/Suyog/Fort Gloster
Dehn + Sohne - Germany
Flexpro / FEPL / Sudhir Electricals
FOR
MECHANICAL WORKS
TECHNICAL SPECIFICATIONS FOR TANK TRUCK UNLOADING

COMPRESSOR
Make
: CORKEN
Model
: 291
Service
: LPG Transfer
No of Stages
: Single stage
No of cylinders
: 2 Nos
Piston Displacement @ 825 rpm
: 25.4 m3/hr
Capacity
: 200 ltrs/min
Speed
: 825 rpm maximum
Maximum Discharge Pressure
: 23.1 bar
Type
: Air Cool vertical type
Drive
: Through V belt drive system

including non sparking V belt guard
Accessories
: Base plate for compressor & motor,

knock out drum, pressure gauge &
temperature gauge
Sl
No
1
2
3
4
5
6
Accessories
Size
Ball Valve
Ball Valve
Pressure Gauge(0.300 psig)
Needle Valve
POP Action Valve
4 Way Valve Indicator
40 NB
25 NB
3/8 NB
3/8 NB
NB
25 NB
Rating
minimum #
800
800
6000
6000
6000
800
Quantity
1
2
2
2
2
1
MOTOR
Type
: Flame proof, weather proof, TEFC

Squirrel cage, Induction motor
Standard followed
: IS 2148/1969 suitable for gas

group II A & B
Motor Rating
: 7.5 HP (or as required)
Motor speed
: 1440 rpm
Construction-mounting
: Horizontal foot mounting
Insulation
: B Class
Duty
: Continuous duty IP 65
CONTROLS
Local LPG Control Panel
: Required
FLP/ExP push button stations for

Operations
: Required
Tripping through ESD
: Required
Tripping in case of high level in the bullet
: Required
TECHNICAL SPECIFICATIONS FOR TANK TRUCK DECANTING PUMP

Make
: CORKEN
Type
: Positive Displacement Vane type
Model
: Z 2000
Service
: Propane/LPG
Capacity
: 12 m3/hr
NPSH Required
: NIL
Pump speed
: 600 rpm
Head
: 120 psi
Suction delivery sizes
: 50 x 50 NB
MATERIAL OF CONSTRUCTION
Case, Heads, rotor, cam, side plate
: A 536 Ductile Iron
Bearing Cap
: Gray Iron
Steel Rotor
: Carbon
Shaft
Vanes
: Steel
: Plastic
Relief Valves
: Steel
Bearing
: Cylindrical Roller
Seals
: Mechanical
Speed
: 600 rpm
MOTOR
Type
: Flame proof, weather proof, TEFC

Squirrel cage, Induction motor
Standard followed
: IS 2148/1969 suitable for gas

group II A & B
Motor Rating
: 5 HP
Motor speed
: 1440 rpm
Construction-mounting
: Horizontal foot mounting
Insulation
: B Class
Duty
: Continuous duty IP 65
Make
: Crompton Greaves/Bharat
Bijlee/Siemens
DECANTING PUMP SKID (FOR EACH PUMP)

Sl
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
Size
Pump (Corken, USA), Motor: Crompton

Push Button: Flame proof ON/OFF type
Ball Valve
Pressure gauge (0-300 psig)
Needle Valve
POP action valve
Strainer
Liquid Flow Indicator
NRV on discharge
By Pass Valve
Canopy
Operation from field/local control
FLP/ExP push button station
Tripping through ESD
Tripping in case of high level in the bullet
All of approved equivalent
Std
50 NB
3/8NB
3/8 NB
NB
50 NB
50 NB
50 NB
50 NB
Rating
Qty
1
300#
3000#
3000#
3000#
300#
300#
300#
300#
Required
Required
Required
Required
Required
3
2
2
2
1
1
1
1
TECHNICAL SPECIFICATIONS FOR LPG PRESSURE REGULATING

SYSTEM
Make
: VANAZ OR APPROVED EQUIVALENT
Inlet Pressure
: 0 -20 kg/sqcm
Outlet Pressure
: 2 kg/sqcm
Flow Rate
: 500 1500 kg/hr
Size
: As required
AUDCO Valve
: 300# rating of appropriate size
Pressure Gauge
POP OFF Valve
TECHNICAL SPECIFICATIONS FOR LPG HOSES FOR UNLOADING TANK

TRUCKS
Hose sizes
: 50 NB for liquid line, 40 NB for

vapour line
Type
: Smart Hose type
Length of hose
: 3 metres
Coupling at Hose ends
: Acme threaded suitable for the tank

truck and flanged for fill point end.
Material
: Hose material suitable for LPG

application/propane duty
Flare Line
A flare line is to be provided at the unloading point for flaring of the unloading
hose.
TECHNICAL SPECIFICATIONS FOR LPG VAPOURIZERS

Model
: GASOR 500-L/ANIL
Type
: Electrically heated water bath type
Medium
: Water
Design Criteria as follows:

DESIGN CRITERIA
Code of Manufacture
Operating Pressure
Operating Temperature
Design Pressure
Design temperature
Test Pressure
VESSEL
BIS 2825 Class 3
Atmospheric for water
30 deg C 80 deg C
5 kg/sqcm for water
100 deg C
Water
filling
7.5
kg/sqcm
COIL/LPG
For LPG ASME B 31.4
6-8 kg/sqcm(g)
30 deg C 80 deg C
14.5 kg/sqcm (g)
100 deg C
19 kg/sqcm
Approval from the CCOE, Nagpur
: Required
Capacity
: 500 kg/hr
Size LPG
: Inlet 40 NB
Connections
: Flange ASA 300#
Power requirement
: 415 V 3 Phase 60 KW (Max)
Outlet 50 NB
Coils
No
Controls
Make
Range
Size
MOC
Type
Electrical Heaters
ESCORTS
-------
------
-----
Control Panel
PROMPT
-------
15
KW
-----
------
Pressure Switch
SWITZER
CC/SS
Solenoid Valve
AVCON
0-16
kg/cm2(
g)
--------
*FLP/
EXP
*FLP/
EXP
BRASS
Pressure relief valve
GP
225 psi
50
NB
6 NB
Pressure Indicator
GLUCK
0-300
psi
10
NB
BRASS
Water level indicator
GP
Temperature sensor
GP
15
NB
SS
0-360
mm
0-120
deg C
BRASS
SS
*FLP/
EXP
POP
OFF
TYPE
BOUR
DEN
TYPE
GLASS
TYPE
THER
MOST
ATS
Qt
y
---1
1
1
1
1
1
REQUIRED
I. Water Inlet Control

II. RTD Temperature Sensor
*FLP Confirming to IS 2148. Makes are indicative. Approved Equivalent may be
used.
TECHNICAL SPECIFICATION FOR REMOTE OPERATED CONTROL VALVES

1.
The control valve shall be furnished complete with air filter

regulator set,
limit switches, solenoid valve and quick exhaust
valve which shall be mounted
on the control valve.
2.
The air filter regulator, solenoid valve and quick exhaust valve shall be pre tubed
with control valve. The connection size shall be 3/8" NPT.
3.
All electrical accessories, such as limit switch, solenoid valve should be explosion
proof suitable for (NEC) class 1 DIV 1 Group B,C,D and weather proof to IP65.
4.
The solenoid valves shall be energized under 'normal' process conditions and
suitable for operation on 230 VAC.
5.
Solenoid valves shall be of the "no-voltage-release-manual-reset" type, when

"tripped" manual latching shall not be possible until solenoid is restored to its
energized position.
6.
Cable entry sizes of solenoid valves and limit switches shall be 1/2" NPT (F).
7.
Wires from solenoid valve shall be terminated inside a flameproof terminal box.
8.
The body material of solenoid valve shall be Brass/ Aluminum alloy/ Stainless
steel.
9.
Vendor shall submit along with

quotation technical literature describing
operational features, dimensions, standard adopted and other details for
purchasers review.
10.
Instrument supplied shall be suitable for operation in an ambient temp. range 5

degree C to 55 degree C.
11.
Solenoid valves shall be of ASCO make or imported equivalent only.
12.
Filter Regulator shall be of FESTO make or Imported equivalent with Borosilicate

bowl with metal shroud for outdoor application.
13.
Closure time for the ROV shall be less than 3 seconds.
14.
Quick closing facility shall be available in manual mode also.
15.
The actuator shall be AUDCO or imported and the approved manufacturers are
BETTIS (USA), KTM (JAPAN), ROTARK (UK),
BIFFI(ITALY), HYTORQ(UK),
ELOMATIC(HOLLAND), NELES-JAMESBERY
16.
The valve shall be fire safe ball valve with API monogram.
17.
All the electrical accessories such as limit switch, solenoid valve etc., shall be flame
proof and weather proof as per IP 65 and shall have the approval of CCOE.
18. THIRD PARTY INSPECTION

Manufacturers test certificate shall be produced from the original manufacturer
for the Imported actuator.
Proof of import also shall be verified by the third party inspection agency and the
valves identified.
The total assembly shall be offered for inspection to one of the following 3 rd
party agencies.
A. EIL
B. LLOYDS
C. BV
D. RITES
E. BAX COUNSIL
F. IRS
19. SCOPE OF INSPECTION :
A. Make of components
B. Visual inspection.
C. Dimensional check.
D. Scrutiny of material test certificates.
E. Performance test for ROV/Actuator.
F. Testing of Valve
G. Fire Safe Test certificate
20.. OPERATING CONDITIONS
SERVICE
SP. GRAVITY
LPG LIQUID
LPG VAPOUR
0.525
UNITS : FLOW/PRESSURE
CU.M./HR.
KG/SQ. CM.
CLOSURE TIME
LESS THAN 3 SECONDS
INLET PRESSURE(MAX)
12KG/SQ. CM.
MAX. DP
(DIFFERENTIAL PRESSURE)
15KG/SQ.CM.
MINIMUM TEMPERATURE
(-)27 DEGREE C
MAXIMUM TEMPERATURE
55 DEGREE C
VISCOSITY AT
FLOW TEMPERATURE
PRESSURE DROP MAX/MIN
N CU.M./HR.
KG/SQ.CM.
LESS THAN 3
SECONDS
12KG/SQ.CM.
15KG/SQ.CM.
(-)27 DEGREE C
55 DEGREE C
0.5 CPS
0.5 CPS
MIN / NEGLIGIBLE
MIN / NEGLIGIBLE
20. ACTUATOR DETAILS (ADCO / IMPORTED)

MANUFACTURER
VTS
(APPROVED : AUDCO, BETTIS, KTM, ROTARK, BIFFI, EL-O-MATIC, HYTORQ)
MODEL
VTS
ACTION ON AIR FAILURE
CLOSE
OPERATOR TYPE
PISTON
SIZE
VTS
SPRING RETURN
TO CLOSE
TORQUE REQUIRED(MINIMUM TORQUE)
130% OF THE VALVE
PREDICTED SOUND LEVEL
80 dB
MIN. AIR PRESSURE REQD.(NOT MORE THAN

4 KG/SQ.CM)
LIMIT SWITCH
VTS
LIMIT SWITCH BOX
EX.PROOF (IMPORTED) WITH CCOE

APPROVAL
LIMIT SWITCH MAKE
VTS
INDICATION
OPEN/CLOSE
CONTACT RATING
5A, 230V AC
MANUAL OVERRIDE
REQUIRED
QUICK CLOSING IN MANUAL MODE
REQUIRED
FILTER & REGULATOR GAUGE
REQUIRED WITH OUTPUT
PORTS
FLP SOLENOID VALVE
3 WAY BRASS
MAKER'S SERIES NUMBER
VTS
1.
DPDT
EQUIPMENT SHALL COMPLY WITH THIS DATA SHEET. DEVIATIONS (TO BE

STATED AS SUCH) AND REMAINING INFORMATION TO BE CLEARLY SPECIFIED
BY VENDOR.
ALL THE TORQUE VALUES OF THE ACTUATOR (AIR BREAK, AIR END, SPRING
BREAK AND SPRING END) SHALL BE HIGHER THAN THE 130% TORQUE
REQUIREMENTS OF THE VALVE (VALVE BREAK TORQUE).
2.
VTS MEANS VENDOR TO SPECIFY
21. VENDOR DATA REQUIREMENTS

TYPE OF DRAWINGS & DATA REQUIRED
TO BE SUBMITTED
SCHEDULE LEAD TIME AFTER

LOI / P.O. /ALONG WITH BID
DIMENSIONED OUTLINE DRAWINGS
WITHIN 2 WEEKS FROM P.O.
INSTALLATION, MAINTENANCE &

OPERATING INSTRUCTIONS
WITH SUPPLY
PERFORMANCE TEST REPORT
WITH SUPPLY
CONTROL VALVE NOISE CALCULATIONS
ALONG WITH UNPRICED BID
RECOMMENDED SPARE PARTS (PRICED)
ALONG WITH BID
COMPLETE SPARE PARTS LIST
ALONG WITH UNPRICED BID
TYPE TEST CERTIFICATE FOR ELECTRICAL ITEM FOR

USE IN AREA CLASSIFICATION FROM UL. FM.
PTB. ETC. DEPENDING UPON COUNTRY OF ORIGIN
WITH SUPLY
22. SPECIFICATION FOR FIRE SAFE PRESSURE BALANCED BALL VALVE

A.Contruction Details
SERVICE
TYPE
LIQUIFIED PETROLEUM GAS(LPG)

BALL VALVE
1. Mfg. Standard
API 6D
2. Design
Fire safe to API 6FA
3. Stem
Blow out Proof Antistatic
4. Construction
Single orifice
5. Port
6. Ends
50mm size & above
Bi-directional
Flanged 300,raised face,serrated Finish

Flange details to ANSI B16.5
Face to face to ANSI B16.10
7. Operation
ACTUATOR
8. Position of plug
To be clearly marked
9. Min. thickness for

API 6D valves
As per ANSI B16.34
10. Gland
Bolted
11.Approved make
AUDCO / MICROFINISH/VIRGO/Imported equivalent
TESTING :
1. Standard
2. Shell Test
3. Seat Test
4. Air Test
API 6D
80 kg/cm2.(G)
58 kg/ cm2.(G)
7 kg/ cm2.(G)
NOTE :
1 . THE TORQUE VALUE FOR OPERATING THE VALVE SHALL BE CLEARLY INDICATED
WITH SUPPORTING DOCUMENTS FROM THE MANUFACTURER.
2.
VALVE SHALL HAVE API MONOGRAM.
3.
TENDERES ARE REQUESTED NOT TO DEVIATE FROM ANY OF THE TECHNICAL

REQUIREMENTS, AS ALL SUCH QUOTATIONS ARE LIABLE TO BE REJECTED.
TECHNICAL SPECIFICATIONS FOR BALL VALVES 300# (CAST CARBON STEEL)

SL
NO
DESCRIPTION
A.
1
2
3
4
5
6
7
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Stem
Construction
Port
Ends 50 mm size & above
Operation
9
10
11
B
1
Open/Close Condition
Min thickness for API 6D valves
Pressure relieving device for
body and bonnet cavity
Spring loading on body seat for
trunnion mounted ball
Gland
Back seat arrangement for
repacking under full working
pressure
MATERIALS
Body
Side/Tail piece
Ball
Stem
5
6
7
Body seat(ball sealing ring)

Body gasket
Body stud & nut
8
9
10
11
Stem(gland) packing
Back seal(stem ring)
Anti static ring
Gland nut
12
13
14
OUR REQUIREMENT
LPG
API 6 D
API 6F A
Blow out proof/Antistatic
2 piece/ 3 piece
Full bore / bi directional
Flanged
300#,
raised
face,
serrated
finish.
Flange details to ANSI B
16.5. Face to face to ANSI
B 16.10
Lever( worm gear for
150mm and above
As per ANSi B 16.34
Required
Required
Bolted
Required
Cast Carbon Steel, ASTM

A216 Gr WCB
A216 Gr WCB
ASTM
A
351
Gr
CF8M(Solid)
Stainless steel SS 316(
No casting)
PTFE
PTFE/Grafoil
Alloy Steel ASTM A193
B7/ A1942H
Grafoil
PTFE
Spring steel
Stainless steel SS 316
VENDORS
ACCEPTANCE
/REMARKS
12
13
14
C
1
2
3
4
Lever
Lock Plate
Stop pin
TESTING
Standard
Shell Test
Seat test
Pneumatic low pressure closure
test pressure
Carbon steel
Mild steel
Mild steel
API 598
79 kg/cm2(G)
57 kg/cm2(G)
7 kg/cm2(G)
TECHNICAL SPECIFICATIONS FOR BALL VALVES 800# (CAST CARBON STEEL)

SL
NO
DESCRIPTION
A.
1
2
3
4
5
6
CONSTRUCTION
Service
Design Standards
Stem
Construction
Port
8
9
10
B
1
Operation
Open/Close Condition
Pressure relieving device for
body and bonnet cavity
Gland
pressure
MATERIALS
Body
Side/Tail piece
Ball
Stem
5
6
7
Body seat(ball sealing ring)

Body gasket/seal
Body stud & nut
8
9
10
11
Stem(gland) packing
Back seal(stem ring)
Anti static ring
Gland nut
11
12
OUR REQUIREMENT
LPG
API 6 D
API 6F A
Blow out proof/Antistatic
3 piece
Full bore / bi directional,
floating ball
Socket welded to B16.11
with Sch 80 seamless pipe
extension piece 100mm
long on either side.
Lever
Required
Bolted
Required

A216 Gr WCB
A216 Gr WCB
ASTM
A
351
Gr
CF8M(Solid)
Stainless steel SS 316( No
casting)
PTFE
Grafoil
B7/ A194 2H
Grafoil
PTFE
Spring steel
Stainless steel SS 316
VENDORS
ACCEPTANC
E/REMARKS
12
13
14
C
1
2
3
4
Lever
Lock Plate
Stop pin
TESTING
Standard
Shell Test
Seat test
test pressure
Carbon steel
Mild steel
Mild steel
API 598
210 kg/cm2(G)
152 kg/cm2(G)
7 kg/cm2(G)
TECHNICAL SPECIFICATIONS FOR GATE VALVES 300# RATING (CAST

CARBON STEEL)
SL
NO
DESCRIPTION
A.
1
2
3
4
CONSTRUCTION
Service
Design Standards
Stem
6
7
13
B
1
Bonnet
Discs
Above 50mm size
50 mm & below
Seat- body
Seat disc
Seat back
Operation
pressure
Port
MATERIALS
Body
Body seat ring
Bonnet
Disc(Wedge)
Stud & Nut
8
9
10
11
12
OUR REQUIREMENT
LPG
API 600/ 6 D
API 6 FA
Rising outside screw &
yoke (OS&Y)
Flanged
300#,
raised
face,
serrated
finish.
B 16.10
Bolted
Split/Flexible wedge
Solid wedge
Renewable/integral
Renewable/integral
Renewable/integral
Hand wheel/non rising
Required
Full bore
A216 Gr WCB
ASTM A 105, Hard faced
with
Stellite
#6
or
equivalent
A216 Gr WCB
A216 Gr WCB + 13% Cr
Steel
VENDORS
ACCEPTANCE
/REMARKS
6
7
Back seat bush

Packing
8
9
10
11
Hand wheel/ Hand wheel nut

Stem
Seat surface
Wedge/Disc seating surface
12
13
Back seat
Gasket
14
15
16
17
18
C
1
2
3
4
Eye bolt
Eye bolt nut
Groove pin
Yoke sleeve(stem nut)
Grease fitting
TESTING
Standard
Shell Test
Seat test
test pressure
B7/ A194 2H
13% Cr Steel
Graphite with braided end
rings
Steel
ASTM A182 Gr F.6.a
13% Cr Steel/SS 304
ASTM A216 Gr WCB +
13% Cr Steel
13% Cr Steel/SS 316
Spirally wound SS 304
with graphite filler
Cr Mo Steel
ASTM A194 Gr 2H
Steel
ASTM A 439 Type D2
Steel
API 598
79 kg/cm2(G)
57 kg/cm2(G)
7 kg/cm2(G)

CARBON STEEL)
SL
NO
DESCRIPTION
A.
1
2
3
4
CONSTRUCTION
Service
Design Standards
Stem
6
7
Bonnet
Discs
50 mm & below
Seat- body
Seat disc
Seat back
Operation
pressure
8
9
10
11
12
OUR REQUIREMENT
LPG
API 600/ 6 D
API 6 FA
yoke (OS&Y)
Socket welded to B16.11
with Sch 80 seamless
pipe
extension
piece
100mm long on either
side.
Bolted
Solid wedge
Renewable/integral
Renewable/integral
Renewable/integral
Required
VENDORS
ACCEPTANCE
/REMARKS
13
B
1
Port
MATERIALS
Body
Body seat ring
Bonnet
Disc(Wedge)
Stud & Nut
6
7
Back seat bush

Packing
8
9
10
11
Hand wheel/ Hand wheel nut

Stem
Seat surface
Wedge/Disc seating surface
12
13
14
15
16
17
18
C
1
2
3
4
Back seat
Gasket
Eye bolt
Eye bolt nut
Groove pin
Yoke sleeve(stem nut)
Grease fitting
TESTING
Standard
Shell Test
Seat test
test pressure
Reduced bore
A216 Gr WCB
with
Stellite
#6
or
equivalent
A216 Gr WCB
Steel
B7/ A194 2H
13% Cr Steel
rings
Steel
ASTM A182 Gr F.6.a
13% Cr Steel/SS 304
ASTM A216 Gr WCB +
13% Cr Steel
13% Cr Steel/SS 316
Soft iron
13% Cr Steel
ASTM A194 Gr 2H
Steel
ASTM A 439 Type D2
Steel
API 598
210 kg/cm2(G)
152 kg/cm2(G)
7 kg/cm2(G)

CARBON STEEL
SL
NO
DESCRIPTION
A.
1
2
3
4
CONSTRUCTION
Service
Design Standards
Stem
OUR REQUIREMENT
Water
API 600
API 6 FA
yoke (OS&Y)
Flanged
150#,
raised
face,
serrated
finish.
VENDORS
ACCEPTANCE
/REMARKS
40 mm size & below

6
7
13
B
1
Bonnet
Discs
Above 50mm size
50 mm & below
Seat- body
Seat disc
Seat back
Operation
pressure
Port
MATERIALS
Body
Body seat ring
Bonnet
Disc(Wedge)
Bolts & Nut
Seat Ring
7a
Seat
7b
8
9
Back seat
Gland bush
Gland flange
10
Yoke nut
11
12
Gasket
Stem packing
13
Bonnet stud 7 nut
14
Cross bolt & nut
15
Eye bolt nut
16
17
Hand wheel
Hand wheel nut
8
9
10
11
12

B 16.10
Socket Welded to ANSI
B16.11
Bolted
Split/Flexible wedge
Solid wedge
Renewable/integral
Renewable/integral
Renewable/integral
Required
Full bore
A216 Gr WCB
with
Stellite
#6
or
equivalent
A216 Gr WCB
Steel
B7/ A194 2H
Carbon steel (vendor to
specify grade) with 13%
Cr. deposited
Stainless
steel,
AISI
4140/CA15
A 13% Cr Steel
Stainless steel, AISI 4140
Carbon Steel, AISI 4140
ASTM A105/ASTM A 216
Gr WCB
Ni resist CI/ASTM A 439
Type D2
ASTM A 308
rings
Cr Mo Steel, ASTM A193
B7/ A194 2H
B7/ A194 2H
B7/ A194 2H
Steel
Steel
18
19
C
1
2
3
4
5
6
Grease nipple
Stem
TESTING
Standard
Shell Test
Seat test
Back seat
Air test
test pressure
Steel
ASTM A 182 Gr F.6.A
API 598
32 kg/cm2(G)
22 kg/cm2(G)
21 kg/cm2(G)
7 kg/cm2(G)
API 598
TECHNICAL SPECIFICATIONS FOR NON RETURN VALVES 300# RATING

SL
NO
DESCRIPTION
A.
1
2
3
4
5
CONSTRUCTION
Service
Design Standards
Type
6
7
8
B
1
Cover
Seat- body
Seat disc
MATERIALS
Body
Body seat ring
3
4
Hinge
Disc
5
6
7
8
9
10
11
12
13
C
1
Disc seat
Disc nut
Disc nut pin
Hinge pin
Gasket
Cover
Stud & nut
Hinge pin cover
Hinge pin cover bolt
TESTING
Standard
OUR REQUIREMENT
LPG
API 600
API 6 FD
Swing
ASME B 16.5 Flanged
300#,
raised
face,
serrated finish. Flange
details to ANSI B 16.5.
Face to face to ANSI B
16.10
Bolted
Renewable/integral
Renewable/integral
A216 Gr WCB
with
Stellite
#6
or
equivalent
ASTM A216 Gr WCB
Steel
Integral
SS 304/316
13% Cr Steel
13% Cr Steel
ASTM A 308
ASTM A216 Gr WCB
ASTM A193 B7/ A194 2H
ASTM A105
ASTM A193 B7
API 598
VENDORS
ACCEPTANCE
/REMARKS
2
3
4
Shell Test
Seat test
test pressure
79 kg/cm2(G)
57 kg/cm2(G)
25% of high pressure
closure test
TECHNICAL SPECIFICATIONS FOR NON RETURN VALVES 150# RATING

SL
NO
DESCRIPTION
A.
1
2
3
4
5
CONSTRUCTION
Service
Design Standards
Type
6
7
8
B
1
Cover
Seat- body
Seat disc
MATERIALS
Body
Body seat ring
3
4
Hinge
Disc
5
6
7
8
9
10
11
12
13
C
1
2
3
4
Disc seat
Disc nut
Disc nut pin
Hinge pin
Gasket
Cover
Stud & nut
Hinge pin cover
Hinge pin cover bolt
TESTING
Standard
Shell Test
Seat test
test pressure
OUR REQUIREMENT
LPG
API 600
API 6 FD
Swing
ASME B 16.5 Flanged
300#,
raised
face,
serrated finish. Flange
details to ANSI B 16.5.
Face to face to ANSI B
16.10
Bolted
Renewable/integral
Renewable/integral
A216 Gr WCB
with
Stellite
#6
or
equivalent
ASTM A216 Gr WCB
Steel
Integral
SS 304/316
13% Cr Steel
13% Cr Steel
ASTM A 308
ASTM A216 Gr WCB
ASTM A193 B7/ A194 2H
ASTM A105
ASTM A193 B7
API 598
32 kg/cm2(G)
22 kg/cm2(G)
25% of high pressure
closure test
VENDORS
ACCEPTANCE
/REMARKS
TECHNICAL SPECIFICATIONS FOR Y TYPE STRAINERS

RATING
: AS SPECIFIED IN THE SCHEDULE OF QUANTITIES
MATERIAL
DIMENSIONS
: ANSI B 16.5
ENDS
: FLANGED TO ANSI B 16.5 RAISED FACE WITH

SERRATIONS
SCREEN
: SS 316, 80 MESH X 37 SWG
PERFORATED SHEET
: 16 GAUGE
TESTING
: 150# - WORKING PRESSURE15 KG/SQCM

HYDRAULIC TEST PRESSURE30 KG/SQCM
BODY
SA216
GR
BOLTS & NUTS SA193B7/A194 2H
WCB
300# - WORKING PRESSURE30 KG/SQCM

HYDRAULIC TEST PRESSURE60 KG/SQCM
TECHNICAL SPECIFICATIONS FOR

(WITHOUT ACTUATOR)
SL
NO
1
2
3
1
2
3
8
1
2
3
4
5
6
7
8
9
DESCRIPTION
CONSTRUCTION
Quantity Nos
Service
Line size
Area Classification
STANDARDS
Design standards
Fire safe certificate

Pressure testing
Seat disc
BODY
Type of Body
End connection & rating
Body Material
Packing material
Bonnet type
Flow Characteristics
Trim mat seal / plug
Stem / shaft material
Ball
FOUR WAY VALVES 300# RATING
OUR REQUIREMENT
1
LPG
2 (50NB)
Zone I Gr II A/ II B
Swing
As per BS 5351, full bore,
LL port, blow proof
system
API 607/6F/BS 6755 Pt2
API 598/6D/BS 6755 Pt1
Renewable/integral
Ball full bore
ANSI 300# RF
ASTM A216 Gr WCB
Teflon / Grafoil
Standard
On / Off
Soft seating /316 SSl
316 SS
Stainless Steel AISI 316 /
ASTM A 351 Gr. CF8M
(solid)
VENDORS
ACCEPTANCE
/REMARKS
10
11
12
13
C
1
2
3
4
Leakage Class
Stud & nut
Hinge pin cover
Allowable Sound level
TESTING
Standard
Body hydro Test
Seat hydro test
Seat air
V
ASTM A193 B7/ A194 2H
ASTM A105
85 DB
As per API 6 D /BS 6755
79 kg/cm2(G)
57 kg/cm2(G)
7 kg/cm2(G)
TECHNICAL SPECIFICATIONS FOR SEAMLESS PIPES

1.
Item
: Seamless Pipes
2.
Material
: Carbon Steel ASTM A 106 Gr B
3.
Dimensional Standard : ANSI B 36.10
4.
Ends
: Beveled with end protection caps (50 mm and

above). Plain with end protection caps (40 mm &
below)
5.
Length
: Single Random, 5-7 M
6.
Size
: 50 mm- 200 mm (Sch 40 ASTM A 106 Gr.B)

40 mm & below (Sch 80 ASTM A 106 Gr. B)
7.
The tube shall confirm to the following standards in their sizes and weights:
S.No. NB
(mm)
1
200
2.
150
3.
100
4.
80
5.
50
6.
40
7.
32
8.
25
9.
20
10.
15
8.
SCHEDULE
40
40
40
40
40
80
80
80
80
80
OUTER DIA
(mm)
219.1
168.3
114.3
88.9
60.3
48.3
42.2
33.4
26.7
21.3
WALL THICKNESS
WEIGHT
(mm)
(kg/m)
8.18
28.55
7.11
18.97
6.02
16.07
5.49
11.29
3.91
5.44
5.08
5.41
4.82
4.47
4.55
3.24
3.91
2.20
3.73
1.62
Scope of Third Party Inspection for Seamless pipes:
Scope of third party inspection shall be review of Manufacturers test certificate for
the following:
1.
2.
3.
4.
5.
Visual
Dimensional Check
Tensile Requirement
Chemical Analysis
Bend / Flattening Tests
: 100%
: 100%
: One sample for each size of pipe and each heat
6. Hydrotesting
NOTE:
All the pipes shall be stamped by Third party inspection agency. The TPI stamping
shall be clearly visible on all pipes and the stamping mark to be mentioned in TPI
reports.
9. Third Party Inspection Agencies:
Our approved Third Party Inspection Agencies are :(i) EIL (ii) RITES (iii) Bureau
Veritas (iv) LLOYDS (v) IRS (vi) PDIL
TECHNICAL SPECIFICATIONS FOR ERW PIPES :

1.
Item
Carbon Steel Pipes - ERW
2.
Code
3.
Dimensional
Standard
IS 1239 (Part I) Heavy Class/

IS 3589
IS 1239/IS 3589
4.
Ends
Bevelled with end protection caps
5.
Length
Single Random, 4-7 M
6.
Size &
Requirement
----------------------------------------------------------------------------------------Nominal size
IS Code
Thickness/
(NB in mm )
Class
----------------------------------------------------------------------------------------600 mm
IS 3589
12 mm
500 mm
IS 3589
10 mm
400 mm
IS 3589
8 mm
350 mm
IS 3589
8 mm
300 mm
IS 3589
7 mm
250 mm
IS 3589
7 mm
200 mm
IS 3589
6.35 mm
150 mm
IS 1239 (part I)
Heavy
100 mm
IS 1239 (part I)
Heavy
80 mm
IS 1239 (part I)
Heavy
65 mm
IS 1239 (part I)
Heavy
50 mm
IS 1239 (part I)
Heavy
40 mm
IS 1239 (part I)
Heavy
32 mm
IS 1239 (part I)
Heavy
25 mm
IS 1239 (part I)
Heavy
20 mm
IS 1239 (part I)
Heavy
15 mm
IS 1239 (part I)
Heavy
7.
Scope of Third Party Inspection for Seamless pipes:
Scope of third party inspection shall be Manufacturers test certificate for the
following:
1
2
3
4
5
6
Visual
: 100%
Dimensional (incl. wall thickness) Check
Tensile Requirement
: One sample
Chemical Analysis
: One sample
Bend / Flattening Tests
: One sample
Hydrotesting
: One sample
for
for
for
for
each
each
each
each
: 100%
size of pipe and each
heat
heat
heat
heat
NOTE:
All the pipes shall be stamped by Third party inspection agency. The TPI stamping
shall be clearly visible on all pipes and the stamping mark to be mentioned in TPI
reports.
8.
Third Party Inspection Agencies:

Our approved Third Party Inspection Agencies are :(i) EIL (ii) RITES (iii) Bureau
Veritas (iv) LLOYDS (v) IRS (vi) PDIL
TECHNICAL SPECIFICATION FOR LPG PIPING WORK

1.
All LPG piping work shall be above ground and shall be of seamless Grade A 106
Gr.B Sch 80 upto 50 mm dia NB. The vent pipe shall be of schedule 40
2.
All piping flange joints shall be provided with 40 mm wide and 5 mm thick copper
jumpers. The pipe line shall be given the color code and the flow direction to
indicate the LPG liquid and vapour and the flow direction.
3.
All fittings and pipe work above 40mm dia NB shall be flanged, minimum 300#
rating as per ANSI 16.5 and with steel spiral wound gaskets except those required
as insulating joints.
4.
All fittings on LPG lines shall be forged fittings. Mitered fittings shall not be
allowed in LPG lines.
5.
All fittings of 40 mm and below shall be socket welded.
6.
All pipe work leaving the tank is to be fitted with insulating flange kits.
7.
If a small size tapping is to be taken from a large dia pipe e.g. for taking tapping
for pressure gauges, for vent line for SRVs, PRV etc., the same shall be done using
a half coupling of specification mentioned below.
8.
Specification of fittings shall be as follows:

For sizes above 40 mm CS forged fittings, butt welded conforming to
material SA 420 Gr WPL 6 suitable for low temperature. These fittings
shall be compatible to the corresponding pipe material.
For sizes 40 mm and below CS forged fittings, socket welded conforming
to material SA 350 LF 2 of rating 3000. These fittings shall be compatible
to the corresponding pipe material.
9.
All studs and nuts shall be supplied zinc plated and material specifications shall
be as per ASTM A 193 Gr B7 for studs & ASTM A 194 Gr 2H for nuts.
10.
All pipe work shall comply with SMPV rules of CCOE, Nagpur, India. All piping shall
be rated for propane as per ASME B 31.3 with minimum design pressure of 32
kg/sqcm with a factor of safety of four. The materials of pipes shall be low carbon
or alloy steel conforming to American Standard ASTM-SA-333, grade 6 or API-5L.
The pipeline shall be tested at one and half times of the design pressure, if hydro
tested or ten percent in excess of design pressure if pneumatically tested.
11.
All ball/gate valves shall be suitable for LPG operations constructed as per
manufacturing standard API 6D and shall be fire safe as per API 607/BS
6755(PartII). CONTRACTOR TO SUBMIT TEST CERTIFICATE OF TPIA
CERTIFYING THE VALVES ARE MANUFACTURED AS PER API 6D AND ARE FIRE
SAFE.
TECHNICAL SPECIFICATION FOR PIPE WORK

1.0
SCOPE :
1.1
All the items of work covered under this tender shall be carried out as per the
specifications, drawings and details to be furnished to the Contractor. However,
the Engineer-in- charge/Site Engineer reserves the right at any time to give
additional/alternate specifications and instructions for erection of any particular
work and the Contractor shall execute such works in accordance with such
additional/alternate specifications and instruction of Site Engineer.
1.2
All acts, deeds, matters and things required to fulfill the Contractor's obligations
and to full fill municipal and or other statutory requirements for due execution of
the work shall be deemed to be included in the scope of work.
The scope of work under this technical specification covers:
Supply of all pipes(seamless for LPG & ERW for other), fittings, elbows,
tees, WNRF flanges 300# (for LPG applications), slip on flanges 150#,
blind flanges, full & half couplings, end caps etc.,
Transportation of contractor/owner supplied materials/equipment to all
places as required for the execution of this job.
Lifting of the equipment in the proper sequence so that safe and orderly
progress of the work is ensured.
Fabrication, erection and welding of the above ground and under ground
piping as per the following codes and standards
ANSI B 31.3
API 1104
: Code for Petroleum Refinery Piping.

: "Standard for Welding Pipeline
and Related Facilities."
ASME SECTION IX
: Code for Welding Qualification.
IS : 823
: Standards for Procedure for Manual Metal Arc Welding
2.0
TRANSPORTATION :
2.1
The work of transportation of Owner's supplied materials/ equipment include the
following :a)
All works and operations necessary to lift and to remove the materials/equipment
from Owner's designated stockpiles/store-yards/ godown, loading, handling,
transporting safely to the construction site and unloading by suitable means as
approved by the Engineer-in-charge/Site Engineer.
b)
Supply,
procurement, mobilisation and deployment of all labour, materials,
equipment and machinery necessary for lifting, removing, transporting and
unloading the Owner's supplied materials/equipment to the work sites.
c)
The contractor at his own cost shall arrange to store/stock materials/equipment

brought from Owner warehouse etc. to work site in such a manner that they are
protected from dirt. rain water and other foreign matter.
d)
It shall be the duty of the contractor to handle the equipment, valves, pipes and
fittings, coated lining material etc., in such a manner that no damage is done to
them. The contractor should also ensure that no damage while handling is done on
other materials.
e)
All other acts, deeds, matters and things whatsoever ancilliary, auxillary or
incidental to the above including but not limited to the grading and creation of
temporary approaches/accesses and ramps etc., as may be required.
f)
Transportation
of excess material from site to warehouse
loading/unloading and stacking as directed by owners/consultants.
3.0
including
LIFTING OF EQUIPMENT:
3.1
The Contractor shall be responsible for organising the lifting of the equipment in the
proper sequence, so that safe and orderly progress of the work is ensured. Rigging
procedures for all major lifts (upto 5.0 MT) and maximum crane capacity shall be
submitted by the Contractor to the Site Engineer. However, approval to rigging
procedure proposed by the contractor shall not relieve the Contractor from his
responsibility.
3.2
The slings used for lifting various loads shall be tested by a test load before carrying
out actual installation. The weight of the test load shall be 50% higher than the
weight of the equipment
to be lifted.
4.0
FABRICATION & ERECTION OF ABOVE GROUND AND UNDERGOUND PIPING
4.1
This specification covers the requirements for fabrication, erection, installation and
testing of above ground/underground piping system.
4.2
Fabrication, installation/erection and assembly shall be done as indicated in the

Process and Instrument diagram and piping layout drawings.
4.3
Contractor shall promptly notify Engineer-in-charge of any defective or damaged

material, materials that are not as per specification and materials that differ in any
manner from the
designations in the drawings.
5.0
CODES AND STANDARDS :

In these specifications reference is made to the following standards and Codes, and
all other relevant standards, the latest issues of which shall be used.
ANSI B 31.3
Code for Petroleum Refinery Piping.
API 1104
"Standard for Welding Pipeline

and Related Facilities."
ASME SECTION IX
IS : 823
: Code for Welding Qualification.

Standards for Procedure for Manual Metal Arc Welding
6.0 FABRICATION :
The piping drawings specify the shape and dimensions of pipe
components sufficient for fabrication.
and piping
The dimensions indicated on the drawings are true and contain no allowance for
weld gaps.
Gaskets less than 1.5 mm thick (1/16" M) are ignored in dimensional computations.
All pipe branches shall be at 90 degree, unless otherwise indicated on the drawings.
Pipe cuttings shall be accurate, smooth and true to template, Slag & cutting dross
shall be removed before fitting.
Installation & protection during fabrication of the components
accordance with the manufacturer's installation instructions.
shall be in
Branch connections shall be made by Site Fabricated intersections, couplings etc. as

indicated in the drawings and as directed by Engineer-in-charge.
Material which have been damaged or found to have defects shall not be used in
fabrication except that minor surface marks may be dressed provided that the
nominal wall thickness is not encroached upon after considering the manufacturing
tolerances defined in the appropriation material codes. Insert patching or cuts or
dents or pounding of dents shall be prohibited.
The Contractor shall provide facility to fabricate reinforcement pads, flanges, mitred
fittings such as bends, reducers etc., whenever required by Engineer-in-charge, by
using pipes supplied by owner. All other materials, consumable, etc. shall be
provided by contractor.
Fabrication piping, valves, fittings, sections of piping etc. shall be thoroughly
cleaned. All sand, dirt or other foreign matter shall be removed. The ends of
completed sections of pipeline shall be closed with suitable blinds, caps or other
approved methods. All fabricated piping shall be protected against rust and
corrosion pending erection, by the Contractor at his own cost.
7.0
TOLERANCES :
7.1
In addition to tolerances contained within the applicable codes or standards of the

respective material the following shall also apply.
7.2
For pipes subjected to internal pressure, the difference between maximum and
minimum outside diameter at any section across the axis of bent portions shall not
exceed 5% of the nominal outside diameter. Wall thickness of the pipes after
bending shall not be less than 87.5% of the nominal wall thickness.
7.3
All linear dimensions involved in the relative position of branches, bosses, flanged
ends, instrument tapping and change in the direction to each other, shall be
maintained within + 3 mm ( + 1/8").
7.4
All angular dimensions of bends and branches shall be maintained within + 1/4
degree.
7.5
Misalignment of flanges from the indicated position shall be within 1.5 mm (

1/16").
7.6
Alignment of flanges and branch welding ends measured across any diameter
shall not deviate from the indicated position more than 2.5 mm per meter ( 1/32"
per foot) of diameter.
7.7
Flange faces shall be perpendicular to the axis of the pipeline.
8.0
PREPARATION OF PIPE AND OTHER FITTINGS :
8.1
Prior to aligning pipe for welding, the ends of the pipe shall be machine bevelled.
Bevel dimensions shall be as per applicable codes.
8.2
The bevelled ends of each joint of the pipe shall be thoroughly cleaned of paint,
rust, mill scale, dirt or other foreign materials to avoid defects in the completed
welds by methods approved by the site Engineer.
8.3
Any foreign matter or obstruction remaining inside the pipe shall be removed by
appropriate means.
8.4
Coupling and half coupling shall be accurately shaped and set on to suit the
contour of the run pipe.
8.5
Pipes shall be properly supported and aligned by jigs or clamps as required in

order to preclude extraneous loads and minimise strains during taking.
8.6
Small tack welds i.e. between 12.5 mm (1/2") and 18 mm (3/4") in length
penetrating to the bottom of the groove may be used in fitting up.
8.7
Unless otherwise specified all pipe to pipe joints shall be butt welds.
8.8
Pipes with a wall thickness of 6 mm (1/4") and greater shall not have internal
misalignment of pipe wall exceeding 1.5 mm (1/16").
8.9
Pipes with a wall thickness less than 6 mm (1/4") shall not

misalignment of pipe wall exceeding 25% of pipe wall thickness.
have internal
8.10
9.0
9.1.
When misalignment is greater than the above, component shall be aligned by

drifting, rolling or machining in accordance with the Code, ensuring that the
nominal wall or minimum wall thickness is not encroached upon after considering
the manufacturing tolerances defined in the appropriate material specifications.
WELDING :
Welding Equipment :No welding process or procedure shall be adopted without prior approval of
Engineer-in charge. Unless otherwise specified, welding shall be done in accordance
with the codes API-1104.
All welding machines, transformers/Diesel generators as may be required, line up
clamps, bevelling machines and other equipment used in connection with the
welding work must be
satisfactory and must be kept in good mechanical
condition so as to produce sound welds.
9.2
Welding Process :-
9.2.1
Welding under this specification shall be done with following welding process
subject to the approval of Engineer-in-charge / representatives.
a)
Manual Metal Arc Process.
b)
Oxy - acetylene Welding Process.
9.2.2
Automatic or semiautomatic welding shall be made only with the specific approval
of the Engineer-in-charge, of the entire procedure and material.
9.2.3
Combination of the welding process of usage of electrodes of different classes or

makes in a particular joint, shall be adopted only after the welding procedure has
been duly qualified and approved by the Engineer-in-charge.
9.3
Roots Pass : -
9.3.1
Root Pass shall be made with respective electrodes mentioned in the electrodes
specifications. The size of the electrode shall not be greater than 3.25 mm (10
SWG). Welding may be done with direct current with due regards to polarity and
current values recommended by the electrode manufacturers. Upward techniques
shall be adopted for welding pipes horizontally fixed in position. For thickness
less than 3 mm and pipe size 50 mm NB and below Oxy-acetylene welding is
recommended.
9.3.2
The soundness of weld depends to a large extent on complete fusion of the root
edges. Hence the root pass of butt joints shall be such as to achieve full
penetration. The depth of incomplete penetration shall not exceed 0.8 mm or 0.2
times wall thickness. The total length of such imperfections shall not exceed 38
mm in any 150 mm of weld length.
9.3.3
Welding shall not be interrupted during the root-pass, other than change of
electrode or change of welder's position.
9.3.4
Each interruption of welding and on completion of each run, craters, weld

irregularities and slag shall be removed by grinding.
9.3.5
During the process of welding, displacements, shocks, vibrations or stresses shall

be carefully avoided in order to prevent weld cracks.
9.3.6
Fillet welds shall be made by shielded metal arc process regardless of the
thickness and class of material. Electrode size shall not exceed 3.25 mm.
9.4
Joints Finishing : -
9.4.1
When the welding is completed, butt joints shall have a capping (cover pass) so as
to have gradual notch-free finish and good fusion at the joint edges.
9.4.2
The welds shall be free from undercuts and any other defects and shall have
regular appearance.
9.4.3
Welder's number shall be stamped clearly on each and every joint, adjustment to
the weld in order to identify the welder if defects are found after tests.
9.5
Inspection and Test :-
9.5.1
Owner's representative/agency appointed by the Owner will have free access to all
working places for inspection of procedures, quality etc., during working periods.
Contractor shall provide all assistance to carryout such inspections.
9.5.2
All prefabricated as well as field welded joints shall be subjected to visual

examinations. Dye penetrant test will be done on all the joints of seamless
pipelines which shall be followed by 10% radiographic examinations.
9.5.3
Visual examination shall be 100% on all the joints and shall reveal surface
defects such as misalignment, excessive reinforcement, concavity of the welds,
shrinkage, cracks, inadequate penetration, undercuts and surface porosity.
9.5.4
Radiographic examination shall be carried out on joints selected by Engineer-incharge. This will be 10 % on LPG Lines on a random basis. However, depending
the number of welders, and joints welded by each welder exceeds 100 Joints,
10% random will remain unchanged. But a minimum number of 5 joints in full
shall be radiographed from each
welder's joints if total number of joints
done by any welder are found below 100 joints of any size.
9.6
Radiographic Inspection :
The extent of radiography inspection coverage is as follows :
9.6.1
Radiographic examination shall be carried out as per API Code 1104/ASTM-E-94.

The quality of radiographic examination, acceptable limits , repair and removal of
defects shall be as per ASTM-E-142 and ANSI B31.3 Cracks and lack of fusion
shall not be permitted. The contractor shall be responsible for carrying out
radiography, rectification of defects and re-radiography, of the rectified. He shall
make weld necessary arrangements for the equipment as well as radiographic
films for the satisfactory completion of the job.
9.6.2
The welding engineer of the agency carrying out radiographic examination shall
submit the radiographs together with his findings, report and recommendation as
to the acceptability or otherwise of welds radiographed to the site engineer. The
site engineer's or his representative's decision as to the acceptability or otherwise
of the welds irrespective of the opinion or advice tendered by the welding engineer
shall be final and binding upon the contractor.
9.6.3
The independent agency to be appointed by the contractor for

radiographic
inspection shall be appointed only with the prior approval of the
Owner/Consultant.
9.6.4
All the joints of seamless pipes will be subject to DP Test
9.6.5
Radiographic examination shall be carried out on joints to be

specified by
Engineer-in- charge. This will be 10 % on LPG Lines on random basis.
9.7
Qualification of Welders and Procedure Tests : -
9.7.1
Only skilled welders shall be employed.
9.7.2
Welders shall be properly qualified in accordance with the requirements of API

1104/ASME Section IX or IS:823.
9.7.3
For carrying out the welding tests the contractor shall furnish the welding
equipment and electrodes. Test specimens, 2 1/2 cm in width, shall be cut from
the nipple at right angle to the weld. The test specimens shall be subjected to
tensile, root bend, face bend and neck break tests. These tests shall be arranged
by the Contractor at his own cost but shall be witnessed by Engineer-in-charge or
his representative.
9.7.4
The manner of performing the test and the results required shall be in accordance
with the code API-1104.
9.7.5
In the event that satisfactory results are not obtained the welder shall not be
employed on the job.
9.7.6
Welding Procedure qualification tests shall be carried out in accordance with job
requirements and the relevant requirements laid down in the above said Codes.
The Contractor shall submit the welding procedure to the Engineer-in-charge who
will check and approve the welding procedure after conducting the necessary
tests, prior to start of production welding. Standard tests shall be performed in all
cases. In addition to these standard tests, tests like macro examination, hardness
test, dye penetration examination, charpy V notch and U notch impact tests, etc.
shall be carried out on specimens depending on the type of base material,
operating conditions and requirement laid down in specification. It shall be the
responsibility of the Contractor to carry out all such tests.
9.8
STENCILLING OF WELDS :-
9.8.1
All welds shall be marked by the welders according to number assigned to them
by the
Contractor who will furnish to the Engineer-in-charge a record of all
number assigned. Should any welder leave during the course of the job, his stamp
shall be avoided and shall not be duplicated on the job.
(100 %).
9.8.2
No punch or steel stenciling will be permitted.
9.9
WELDING PROCDEDURE : -
9.9.1
The pipe shall be aligned so that the longitudinal mill weld in the pipe is on the top
90 Degree of the pipeline (except on vertical bends) and in such a way that the
longitudinal mill welds are staggered not less than 45 degree.
9.9.2
Welding surfaces shall be thoroughly cleaned so as to be dry and free from paint,
oil, rust, scale and other materials detrimental to weld quality. Each bead shall be
cleaned of scale, oxides, dirt, slag and other impurities before any succeeding weld
passes are made.
9.10
D E F E C T S :-
9.10.1
Defects revealed by visual inspection, D.P. Test & Radiographic inspection of welds
shall be repaired/rectified by the Contractor at his cost to the satisfaction of the
Site Engineer. The repaired portion shall be re-examined by radiography. The
repairs carried out shall meet the approval of the Site Engineer.
9.11
WELDING CONSUMABLES :
9.11.1 Base Material : In general, the piping materials used are of Carbon Steel conforming to the
following specifications:
Pipes :
IS-1239/IS-3589 - ERW Heavy
A 106, Gr. B
(Utility Lines)
( LPG Lines)
Fittings:
A-234 Grade WPB B.W. -
LPG & Utility Lines
A-105, S.W & BW Forged
LPG & Utility Lines
MITRE Fittings:
To be fabricated from pipes supplied by contractor for sizes as per site requirement.
No mitre bends are allowed on LPG lines.
Flanges :
------SORF - A-105 150#/300# as per ANSI B16.5.
Filler Material :
---------------The contractor shall use welding rods, electrodes, as mentioned below :
Material Welding Process Filler Metal

----------------------------------- ---------Root
Final
Pipe
{A 106 Gr. B )
E 6010
E7018
{IS-3589/
{IS-1239
E6010
E6013
Flanges {A 105
{IS:2062
E6010
E6010
E7018
E6013
Contractor to consider reputed makes like Advani Orlikon, Esab D & H. or Honavar for
electrode.
Welding Rods and Electrodes :
a. The electrodes shall be stored properly by the contractor to prevent moisture
absorption and shall be handled in such a manner as to avoid damage to the coating.
Manufacturer's
instruction in this connection shall be strictly followed.
b. All low Hydrogen type electrodes shall be completely dry when used. These shall be
pre dried in suitable ovens at controlled temperature of 200 - 250 Degree Celcius for
not less than four hours and then used on the job.
c. Electrodes, wire and flux, when used shall be free of rust, oil, grease, earth or any
other matter, which could be harmful for the quality of welding.
d. Electrodes of following makes shall be used :
1) Advani Oerlikon
2) D & H
3) ESAB
4) Honavar
9.11.2
The welding consumables used shall meet requirements of the relevant codes
and shall produce a deposit which is compatible in chemical analysis and similar
in mechanical properties to the parent material.
9.11.3
Only consumables which have received the prior approval of Engineer-in-charge

shall be used.
9.11.4
Before proceeding with welding, Contractor shall submit for approval to site
Engineer, Type, brand and size for each batch of consumables for use in each
class of piping.
9.11.5
Different grades of electrodes shall be completely separated. The Contractor

shall have facilities available for storing and testing electrodes at recommended
temperature where specified. The consumables shall be stored and handled at
all times during construction so as to avoid damage to them and to the
containers in which they are transported. Those in open in open containers shall
be protected from excessive moisture changes. Electrodes, filler wires and fluxes
that show signs of damage or deterioration shall not be used.
9.12
Inspection of Pre-Fabricated Piping :-
9.12.1
Pipe work that has been done shall be checked with the relevant drawings and
other related documents to verify that it, as fabricated, complies with dimensions
and specifications.
9.12.2
Fabrication shall have dimensions falling within the tolerances defined earlier.
9.12.3
All welds shall be visually examined and shall also be subjected to radiographic
inspection as provided above.
9.12.4
Contractor shall provide tools/instruments like spirit levels, dumpy levels, scale,
tapes, gauges, calipers etc. for taking levels & measurements whenever required
by Engineer-in-charge.
9.13
Protection : -
9.13.1
When necessary the external surfaces of all fabricated pipe work shall be painted
with rust preventor or base primer to provide a protective coating against rust
during transit or storage.
9.13.2
Flanges and pipe ends, fitting, other components are to be protected by blank
flanges and plastic caps against mechanical damage and ingress of dust, dirt
and water, wherever necessary.
9.13.3
While lifting externally coated pipes properly constructed webbing or fabric

slings must be used so as to avoid mechanical damage to the coating.
10.0
ERECTION :
10.1
The gaskets used during testing provided by the Contractor and these shall be
removed after the hydrostatic testing and new gaskets for permanent retention
shall be fixed only after flushing of the lines. New gaskets shall be provided by
HPCL.
10.2
All shop fabricated piping shall be routed and located in accordance with the
approved piping drawings. Utmost care shall be taken so that during erection no
damage will be done to the adjacent, valves etc.
10.3
Stud bolts and nuts for the LPG line flange joints shall be as per following
standards :
STUDS : A 193, Grade B7
NUTS
: A 194, Grade 2H,
10.4
Gaskets shall be CAF material (Permanite 081 or equivalent), thickness as

specified, for flanges of 150# and higher rating and 3 mm thickness when plate
flanges are used in low pressure application.
10.5
The assembly of various piping components shall be done so that the completed
erected piping conforms to the requirement of this specification good engineering
practice as well as meets the requirements of the engineering drawings.
10.6
While bolting gasketed flanged joints, the gaskets shall be properly located to
remain on the gasket sealing and tightened by hand to ensure that the gasket is
centered. Tightening by tools must be in diagonally and clockwise in increments
of 1/4, 1/2 of total load.
10.7
All bolts shall extend completely through their nuts by a least 2 threads to a
maximum of 3 mm projection.
10.8
All screwed connections will be secured by teflon taps. Minimum length of

engagements for pipe threads shall be as per the requirements of relevant
standards. The Contractor shall install all fittings, required for vents and drains
valves of all sizes of on-line instruments (P.I. & T.I.) etc. as detailed on the
drawings. However, panel mounted
instruments shall be installed by
instrument Contractor.
10.9
Mismatch and Prefabricated Piping :-
Any mismatch found from shop welded piping, such as flange joints falling on pipe
supports (rack) or flanged joint of an adjacent piping interferes, drain point falling on
supports etc. shall be promptly rectified & installed by the Contractor.
10.10
Supports, Guides and Anchors : -
10.10.1 For line size 50 NB and above the type and location of pipe supports are
indicated on the drawing. For site run piping 40 mm NB and below the type and locations
of the supports will be decided by the Contractor in consultation with the Engineer-incharge/representatives.
10.10.2 Where additional or temporary supports are required to be provided for erection
or testing, these shall be provided by the Contractor without any extra cost to Owner.
8.10.3 Field supports, `U' clamps and special supports are to be provided by the piping
Contractor. Welding of guides, shoes, pipes saddles to the pipes shall be within the scope
of piping
Contractor.
11.0
11.1
CLEANING & FLUSHING :

Cleaning of Fabricated/Erected Piping :-
11.1.1 All piping, valves and fittings shall be cleaned thoroughly inside and outside using
detergent (quality approved by Owner) before erection.
11.1.2 All field fabricated piping shall be cleaned at the completion of fabrication. Care
shall be taken to see that all burrs, welding icicles, and weld spatter are removed by
reaming, chipping, filling or to her means. All foreign materials such as cement, mortar,
sand, heavy oil film and lose scale shall be removed from the interior of pipe by thoroughly
flushing with water.
11.1.3 All equipment, on-line instruments etc. shall be isolated by closing of valves or
slip blinds to protect such items before flushing and cleaning operation is started.
11.1.4 Strainer baskets and similar items shall be removed from the lines before
cleaning and replaced immediately after cleaning/flushing.
11.2
Protection & Cleaning of Valves :-
11.2.1 All possible precaution shall be taken to prevent dirt, grease, or other foreign
matters entering the valve. All foreign particles shall be removed by wiping with clean
linen cloth and
protected with suitable blinds till the valves erected.
12.0 HYDROSTATIC TEST AND PROCEEDURE :
12.1 Before carrying out the hydrostatic testing all line shall be thoroughly cleaned.
12.2 The pressure gauges to be used in testing shall be checked at instruments shops or
with any other outside agency designated by Owner/Contractor.
It shall be the
responsibility of the
Contractor to get the calibration of pressure gauges done.
12.3 Line shall be slowly filled with water. It shall be ensured that no air pockets will be
left over in the line.
12.4 All equipment such as pumps, vessels, relief valves, pressure gauges etc. shall be
disconnected from the piping or isolated by blinds or blanked off during the test.
12.5
All prefabricated and field welded lines shall be tested to the following pressures.
Lines should hold the pressure for at least half an hour prior to inspection. All butt joints
shall be inspected for leaks under pressure.
12.6 After erection of the pipe lines all the extended/modified lines if any upto nearest
isolation valve or any other point as modified by the Engineer-in-charge for the purpose of
this
specification shall be subjected to the same conditions as above.
12.7 When an existing line or portion thereby modified, cut or welded, this shall be
tested once again. The nature of the test and test pressure shall be same as above.
12.8 New lines connected with the existing lines will be tested by providing suitable
blanks before hooking-up. Such lines shall be drained, flushed and kept ready for hookup.
12.9 Valves installed on field welded line shall be considered as a part of piping and the
whole system shall be tested to the specified test pressure one side of the valve in shut-off
position shall be unbolted during the test in order to inspect the valve seating from the
open end.
12.10 Existing piping which has not been relocated or modified be isolated by blinds or
blanked off during the test.
12.11 Temporary line laying/connection with the existing system for testing purpose be
carried out at no extra cost to Owner.
12.12 When it is impracticable to isolate the piping to be tested, the condition for the
test shall be determined jointly by the Owner's and Contractor's representatives.
12.13 The Engineer-in-charge shall be notified well in advance by the Contractor of all
testing and such testing shall be witnessed by Engineer-in-charge/representatives.
12.14 Tests shall be considered complete only after Engineer-in- Charge gives approval
and records the line number.
12.15 All lines shall be drained fully after hydrostatic, testing and closed with suitable
blinds to prevent entry of dust or any foreign particles.
13.0 TEST RECORDS :13.1 Records shall be maintained for each piping system after testing. These records
shall contain the following information:
a)
b)
c)
d)
Date of Test.
Identification of Piping Tested (Line Number).
Test Fluid.
Approval by Owner/Consultant/Representatives.
14.0 FLANGE BONDING & GROUNDING :14.1 On all LPG Lines, provision for electrical bonding shall be provided on all flanged
joints. Copper flat strips of suitable width shall be used for bonding as per drawings.
Grounding
from such bonding shall be spaced at about every 75 m. (Grounding shall
be carried out by Electrical Contractor).
15.0 PAINTING
All the pipe lines (both ERW & seamless pipe lines) shall be sand blasted up to grade SA
2.5 as per Swedish standard SIS 055900 and the painting has to be carried out as
detailed below:
a) Surface preparation
: Grade SA 2.5
15.1 PRIMER PAINTING

Epilux 4 HB Zinc richprimer of Berger or equivalent make (ASIAN/NEROLAC etc.,)
No of coats
:1
Paint thickness(DFT) : 75 microns
15.2 MID COATING
Epilux 4 MIO coating of Berger or equivalent make (ASIAN/NEROLAC etc.,)
No of coats
:1
Paint thickness(DFT) : 75 microns
15.2 FINISH PAINT
First quality synthetic enamel paint of approved make (BERGER/ ASIAN/NEROLAC etc)
No of coats
:2
Paint thickness(DFT) : 20 microns per each coat
SPECIFICATION FOR MECHANICAL EQUIPMENT ERECTION

1.0
GENERAL
This specification describes a general outline for the installation of the equipment
involved. The field circumstances shall be taken into consideration and methods suitable
to the site conditions shall be adopted in consultation with and concurrence of the
erection supervisor, erection manuals and instructions. The successful accomplishment of
the project is greatly influenced by the team work, workmanship and skill of the workers
and supervisors. The Contractor shall employee only such workers and supervisors who
have considerable experience of similar work, temperamentally in good harmony and cooperation.
2.0
SCOPE OF WORK
The work under this contract shall include furnishing of all labour, tools, erection
equipment, consumable materials and other necessary materials not provided by owner.
He shall also provide other services required to take delivery of the equipment supplied by
the owner at the site, transport them to the site of erection, unpack, clean, assemble,
install, test and start up for commissioning all equipment as herein specified and shown
on the drawings. The work of erection/ installation, test and trial runs has to be carried
out in accordance with the manufacturer's instruction and/or drawings,
sketches/diagrams, and instructions given by the Engineer-in-charge.
The contractor shall also provide necessary labour and tools and tackles for unloading the
equipment from trucks, trailers, etc., whenever these are received at site, during the
tenure of contract.
3.0
RECEIVING HANDLING OF EQUIPMENT
3.1
All equipment issued to the contractor as free issue item from stores of the
Employer of Employer's agencies shall be checked by the contractor for the equipment
crates, boxes being intact, in the presence of Employer and shall be accepted by the
contractor for the storage and safe custody. Contractor for the storage and safe custody.
These equipment shall be loaded, transported, unloaded and stored in the manner
approved by Employer and the contractor shall be responsible for the safety of the
equipment during loading, unloading, transportation and storage.
3.2
Whenever the equipment is received in wooden crates/boxes the contractor shall
carefully dismantle these crates / boxes and store all timber and packing materials as
required by employer. All such packing materials shall remain the property of Employer.
3.3
It shall be the responsibility of the Contractor to study the requirements of
installation and instructions for commissioning of the same, by employing skilled
technicians experienced in the type of services required. The Contractor shall be fully
responsible for the safe custody of the equipment to commissioning and handing over of
the same to the Employer.
4.0
PRECAUTIONS TO BE TAKEN BY CONTRACTOR
4.1
The Contractor shall take adequate care and precautions to prevent loss / damage
of material and equipment while in his custody. The responsibility of the contractor starts
from the time of withdrawal of equipment/material from Employer's custody till handing
over the same to Employer after complete erection and testing and surplus
material/equipment are accounted for and accepted by the Employer/consultant's
engineer. In case of loss or damage to any item or part thereof while in the custody of the
contractor, he shall be liable to pay cost of replacement of such item/damaged part
and/or cost of repairs to be carried out.
4.2
During the execution of the work the Contractor shall at his own cost keep
structures, materials and equipments adequately and safely braced by struts, guys and
any other approved means as required till installation is satisfactorily completed. The
Contractor shall design, provide and erect the struts, guys, shoring, bracing, planking
support in such way that they do not interfere with work of other agencies and shall not
damage or cause distortion to other works executed by him or other agencies.
4.3
Openings for level gauges, thermowells and other instruments shall be protected
during and after erection.
4.4
All accessories like pressure gauge, temperature indicators, safety
shall be tagged and kept separately till erection.
valves,
etc.
4.5
All flange connections and openings shall be kept blanked with wooden covers to
prevent entry of foreign matter, if not provided by the manufacturer's.
5.0
ERECTION OF EQUIPMENT
5.1
The Contractor shall make careful check of all the equipment before erection and
ensure that protective greases and wrapping applied on the machined surface and other
parts by the equipment supplier for protection during transportation and storage are
intact. Any defects noticed shall be reported and corrective action taken. Special care
shall be taken by the Contractor for bearings, rotating parts, etc. to prevent seizing.
Generally, the packages shall not be opened until required for installation. Orientation of
all the foundations, elevations, lengths, positions of anchor bolts and diameter of holes in
base plates, supporting saddles of equipment, etc., shall be checked by the Contractor
well in advance. Minor rectification work like chipping of foundation shall be carried out
by the Contractor after obtaining prior approval of the Employer/ Consultant's Engineer.
The Contractor will be provided with necessary equipment drawings of the related areas.
5.2
The Contractor shall also check the nozzle orientation on vessels/tanks and see
their compliance with the drawings and specifications supplied. Any discrepancy shall be
brought to the notice of Employer/Consultants Engineer and start work only after his
approval.
5.3
Rigging procedures of all major lifts above 5 MT and at maximum crane capacity,
shall be submitted by Contractor for approval of the Employer/Consultants' Engineer.
However, such approvals shall not relieve the Contractor from the responsibility of safe
rigging and lifting of the equipment, machinery etc.
5.4
Drilling and tapping of holes in base plates, fixing of couplings on shaft after
enlarging the pilot bores to correct size with keyways, etc. and dowelling including
provision of dowel pins or similar arrangement for retaining the alignment shall be carried
out by Contractor, as part of erection work.
5.5
All joints shall be assembled without undue stresses. Flanges must be parallel and
correctly aligned.
5.6
The Contractor shall study in details the complete work with the help of relevant
drawings, specifications and equipment suppliers special requirements specified in his
instructions manual. The Contractor shall prepare detailed procedures, outlined sequence
of operation, prepare time schedule for each operation and seek approval of
Employer/Consultants' Engineer.
5.7
Wherever necessary the Contractor shall remove the anticorrosive coating applied
on the machine/equipment by the supplier, carefully and completely with light oil
approved by the Employer/Consultants' Engineer.
5.8
After checking orientation and overall dimensions of the foundations, location and
sizes of anchor bolts, shape of foundation shall be checked as per foundation drawing with
reference to the equipment centre line.
5.9
On the chipped and prepared foundation surface, the contractor shall set up liners
for installation and centering of equipment. Liners shall be so arranged that the load of
equipment is uniformly and exactly distributed to the foundation. Liners shall be placed
as near as possible to both sides of anchor bolts. Where distance between anchor bolts is
too long additional liner shall be set up in between. The heights of each liner shall be
measured on the basis of standard level bench mark. The liners shall be fixed with
approximate grouting material.
The upper surface of the foundation shall be watered sufficiently, at least 24 hours prior to
setting of liners, to ensure good adhesion of grouting material.
5.10 The Contractor shall assemble, couple, fix, fit, install, level, align and grout the
equipment/materials on foundations, structures, platforms, floors, etc., as the case may
be. He shall bolt, weld, cut, drill, rivet and brace all components and fix them rigidly with
one another on the foundation supports etc.
5.11 All necessary shims scaffolding, temporary supports, staging, grouting, sand, etc.
required for erection of the equipment shall be provided by Contractor.
5.12
The Contractor shall assemble, position and fix all internals of the equipment.
6.0
ASSEMBLY, LEVELLING & ALIGNMENT
6.1
Some of the equipment will be shipped by suppliers in knocked down condition.
All drive motors, etc. will be shipped separately. The contractor shall assemble all such
parts and sub-assemblies as per the manufacturer's/ supplier's/employer/consultant
engineer's instructions.
6.2
The contractor shall assemble, position and fix all internals of the equipment.
6.3
Method of lifting and handling of equipment and its sub-assemblies shall be
thoroughly discussed by the contractor with the engineer-in-charge. The equipment
wherever required shall be levelled for temporary setting using screw jacks at the lower
parts of common bed.
6.4
The contractor shall re-check the clearances of the part indicated by the engineerin-charge at the time of erection.
6.5
The centering or alignment of the equipment is done by the supplier in his factory.
However, there are chances of this alignment getting disturbed during transportation of
the equipment. The contractor shall, therefore recheck the alignment and take remedial
steps as per the instructions given in the installation manual of suppliers or as advised by
Engineer-in-charge, if any misalignment is observed. For motor driven equipment the
driving and driven shafts shall be fully aligned, deflection and face deviation of the shafts
shall individually be measured and it shall be confirmed that values are within the
tolerances. All readings of the inspection shall be properly recorded and submitted to
Engineer-in-charge. All alignment shall be done with Master level gauge, dial Gauge
etc. which will be arranged by the Contractor.
6.6
After completion of alignment, the equipment shall be erected in accordance with
procedure approved by Engineer-in-charge/Manufacturer. After perfect alignment of
driven shaft is achieved these shall be coupled and base plates shall be cleared for
grouting. Care shall be taken during grouting to see that the base plate level and
alignment are not disturbed.
7.0 THE EQUIPMENT ARE CLASSIFIED AS FOLLOWS :
(A)
Static equipment like tanks, vessels.
(B)
Dynamic or rotary equipment like pumps, compressors, etc.
7.1
Erection of Static Equipment.
7.1.1
Installation and centering of vessel, shall generally carried out in the order as
given below :(i)
( ii)
(iii)
Set liners on prepared foundations.

Place vessel on the liners and set anchor bolts.
Carry out provisional centering, levelling and alignment by shims and packing
(however positioning of the vessel shall be accurately carried out.
(iv)
Fix the foundation bolts by pouring mortar into anchor pockets.
( v )
Carry out completely the centering for level by tightening the anchor bolts and
allow
for grouting of vessel.
7.1.2
Where the vessel having flat bottom is directly placed on the foundation, the
vessel shall be installed without excessive concentrated force against bottom plate. The
equipment foundation shall be checked by the contractor for dimensions, position (center
marking), height (level marking), disorder in the foundation concrete, such as abnormal
concentration of aggregates, porous state size of anchor bolt, damage if any or rust of
threaded parts, etc.
7.1.3 The foundation shall be thoroughly cleaned after chipping. liners shall be placed
as near as possible to both sides of each anchor bolt. If wedge liners are used for
complete centering respective gradient of the wedge liners shall be within 1/20 and two
wedge liners shall be in back to back position, so as to make their top and bottom faces
flat and parallel. Oil and other foreign matters stuck on surface of liners shall be entirely
removed. Centering shall be carried out by center marking and level marking scribed on
the foundation. Centering of vessel for level and perpendicularity shall be carried out in
both directions intersecting at right angles on the same plans.
7.1.4 Prior to installation of the vessel, the contractor shall check the following with the
Engineer-in-charge suppliers's drawing/instruction manual :
(i)
Whether hydraulic or pneumatic pressure testing of

the vessel required.
( ii)
Whether cleaning of inside of vessel is necessary.
(iii)
Whether anticorrosive treatment for internal surface of vessel is necessary.
( iv) Whether piping, instrument, etc. are to be connected to the vessel.

Foreign matter such as rust on contact face of flanges of nozzles, manholes, etc., shall be
completely removed.
After obtaining approval from Engineer-in-charge, that the vessel has been erected in
accordance with the requirement including various tolerance of the specification, the
equipment shall be released for grouting.
7.2
Erection of Rotary Equipment - (Pumps, Compressors, etc.) :
7.2.1
All equipment will be supplied in either three individual
(i)
Pump or Compressor.
( ii)
Motor or Engine.
(iii)
Base Plate.
parts, as -
The base plate may be either common or separate. They shall be erected on prepared
foundation by the Contractor and levelled with packing plates, shims and wages with the
help of precision levels and other instruments. The pump and the driver shall then be
coupled and aligned. After alignment the equipment shall be grouted by the Contractor.
Final alignment shall be done after all piping connections are made. Tolerances for
alignment shall be maintained as specified in the manufacturer's instruction manual, to
ensure that piping connections do not induce any stresses on the equipment. The
alignment shall be checked by the Contractor by disconnecting the piping or in the
working condition or in both conditions. Any connection necessary for proper alignment in
ambient and working conditions shall be carried out by the contractor as per the
instructions of the site-in-charge.
7.2.2 Levelling shall be carried out on four corners of the base plate ends for both the
directions of shaft and at right angle to the shaft.
7.2.3 The alignment of the unit shall be carried out on the basis of the finished surfaces,
which are as near as possible to the centre of the shaft.
7.2.4 Where adjustment between shaft and coupling is required for
the adjustments shall be carried out to the coupling and not to the shaft.
their
fitting,
7.2.5 The alignment of the unit shall be carried out until complete alignment of driving
and driven shaft is obtained. While aligning, the deflection and face deviation of the driving
and driven shaft shall individually be measured and should conform to the allowable limits
specified by supplier in his drawing/instruction manual.
7.2.6 After completion of alignment, it shall be conformed that the shaft can be rotate
smoothly and freely by hand.
7.2.7 After connection of piping, the alignment of the pump shall be rechecked. Any
misalignment induced by the piping connections shall be corrected by adjusting piping.
7.2.8 Running test of motor, diesel engine shall be performed with no load and it shall
be confirmed that vibrations, sound and temperature are not abnormal.
7.2.9 After running test of motor or engine, the driver and the
coupled with confirmation of rotating direction of unit and motor.
driven unit shall be
7.2.10 Trial running of the assembled unit shall be performed and it should be confirmed
that vibration, sound and temperature readings are within the acceptable limits specified
by the supplier.
7.3 TRIAL RUNS :
7.3.1 All pumps will be subjected to trial runs. The duration of trial runs shall be 72
hours continuous. Prior to carrying out trial runs, the equipment will be subjected to
necessary checkups by the Engineer-in-charge and trial runs shall be commenced only
after Engineer-in-charge's approval.
Contractor shall provide as part of the work necessary stilled personnel for conducting the
trial runs. The duration of the trial runs may be extended, if it is considered necessary in
the opinion of the Engineer-in-charge and the contractor shall provide personnel for such
extended period also without extra charge. Final inspection of bearings etc., shall be
carried out by the contractor, after the machinery is subjected to test, as part of testing.
During trial runs, details such as bearing temperatures, cooling water inlet and outlet
temperatures, temperatures in the lube oil system, outlet pressure, etc., shall be
recorded, wherever necessary, by the contractor. Test Reports shall be prepared in the
approved proforma, by the contractor, containing all the above details and submitted to
the Engineer-in-charge as part of the completion document.
8.0
LIST OF EQUIPMENT TO BE ERECTED
8.1
The type of static and dynamic equipment to be installed, is given in the Schedule
of Rates. The Contractor shall fill in the applicable rates in the columns provided.
9.0 MISCELLANEOUS STEEL
All bolts, anchor bolts, nets, lock washers, supports and other miscellaneous items not
furnished by the equipment supplier or by the Employer or otherwise called for in this
specification shall be supplied by the Contractor. Before installing the equipment the
contractor shall verify location of bolts and if discrepancy exists he shall notify the
Employer.
10.0 GROUTING
10.1
Grouting of anchor bolts, holes, pockets and under base plates or under
equipment, have been broadly classified into two categories :
(A) Non-shrinking Grout
(B) Ordinary Grout.
A. Non-shrinking Grout
Non-shrinking grout consists of :One (1) Part of ordinary portland cement,
One (1) Part of clean dry well graded sand,
One (1) Part of ferro grout or similar additive approved by the Engineer-incharge,
minimum amount water just enough to make the mix place able.
Non-shrinking grout shall be generally used for grouting the following equipments
i)
ii)
iii)
All vertical tanks.

All horizontal vessels.
Rotating equipments, Pumps, Compressors.
B. Ordinary Grout
Ordinary grout consists of one (1) part of portland cement, two (2) parts of clean, dry
well graded sand, minimum amount of water just enough to make the mix placeable.
Ordinary grout shall be generally used for grouting the following equipments :
i) All structural framework.
ii) All other miscellaneous foundations.
The grouting material shall solidly fill the spaces to be grouted and permanently retain the
original volume so that the base plates are held firmly in the set position. The amount of
water used in the mixture shall be kept to a minimum just enough to make the mixture
placeable and for the grout to have a consistency too stiff for the grout to flow.
The top of the foundation shall be clean and free of all laithance, loose particles, oil,
grease, etc. shall be wetted thoroughly leaving no puddles prior to grouting. All trapped
pockets shall be repaired using ordinary grout. Under no account shall neat cement be
used for grouting.
11.0 PLACEMENT
a) All anchor bolt holes shall be completely filled with grout.
b) The finished surface shall be floated smooth and shall slope away from the base plate
(approximately 1:25).
c) After the initial set is over the grout shall be kept thoroughly wet for a minimum
period of 5 days.
d)
During grouting care shall be taken to ensure that the base plate level and the
alignment is not disturbed and that no honey-combing takes place in the grout.
APPROVED MAKES OF THE EQUIPMENTS

1.
UNLOADING PUMP CORKEN, EBSRAY, BLACKMER, SIHI
2.
BY PASS VALVE FOR UNLOADING PUMPS - CORKEN, EBSRAY, BLACKMER
3.
LPG UNLOADING COMPRESSORS CORKEN INGERSOLL RAND
4.
SAFETY FITTINGS(SRV,NRV,TRV,EFCV ETC) REGO.MGM, FISHER
5.
REMOTE OPERATED VALVES AUDCO,VIRGO,MICRO FINISH, FLOWCHEM
6.
HIGH LEVEL ALARM SBEM, CHEMTROL
7.
MAGNETIC FLOAT TYPE ROCHESTER GAUGE
8.
MAGNETO RESTRICTIVE TYPE LEVEL INDICATOR VEEDER ROOT, SBEM
9.
CATHODIC PROTECTION RAYCHEM
10.
TEMPERATURE GAUGE THERMAX, H.GURU, GOA INSTRUMENT
11.
PRESSURE GAUGE FEIBG, H.GURU, GLUCK
12.
AIR COMPRESSOR INGERSOLL RAND, ELGI
13.
BALL/GATE/NR VALVES AUDCO,VIRGO,MICRO FINISH, FLOWCHEM,STEEL

STRONG
14.
SEAMLESS PIPES MAHARASHTRA, JINDAL
15.
SOLENOID VALVES AVCON/ASCO
16.
STRAINERS MEHTA NANAVATI, KWIK FLOW
FOR
FIRE FIGHTING & SAFETY
SPECIFICATIONS FOR FIRE FIGHTING EQUIPMENT

1.
WATER MONITOR 75 MM SIZE
ISI Certification Marked Stand Post type Water Monitor of 75 mm size consisting of 100
mm NB base flange, swivel joint, lock, water barrel, nozzle, handle etc. The monitor shall
be of M. S. Seamless construction, gunmetal/copper alloy swivel joints with locking
arrangement, duly treated with anti-corrosive treatment, nozzle of aluminium alloy,
permitting horizontal rotation of 360 deg. in either direction, 80 degree upwards and 45
degree downward traverse. The monitor shall be suitable for a discharge capacity of
minimum 2580 Ipm at a pressure of 7 Kg/cm2 having minimum horizontal throw of 60
mtrs and vertical throw of 30 mtrs. The water monitor shall be with ISI mark as per
IS:8442. All equipment to be inspected and approved by TPIA before dispatch and the
inspection report to be provided to HPCL for acceptance of the material.
2.
FIRE HYDRANT POST :
Hydrant post shall be stand post type with double outlet. The vertical post shall be 100
mm nominal dia. With two arms of 80 mm dia opposite to each other. The bottom inlet
flange of hydrant shall be 100 mm NB SORF flange conforming to ANSI B 16.5 150 Ibs
rating and 190 mm PCD. Both outlet flange shall be 80 mm dia. SORF flange conforming
to ANSI B 16.5 150 Ibs rating and 150 mm PCD. Independent gunmetal single headed
landing valves as per IS:5290 Type A bearing ISI Mark shall be provided on each outlet
point. The hydrant valves shall have instantaneous type female coupling outlet outlet
fitted with male blank cap. The coupling shall be as per IS903. Top end of hydrant shall
be blind and total height of the hydrant shall be 600 mm. The centre of the hydrant arms
shall be at a distance of 450 mm from the base flange. Both outlet flanges shall be at a
distance of 150 mm from the centre of vertical post in opposite directions. The hydrant
vertical post and hydrant arms shall be made of seamless black steel tube of heavy duty
conforming to IS:1239. Each assembly shall be hydrotested to a pressure of 15 kg/cm2
to check for flanged joint leaks. Each Hydrant post shall be painted with Fire Red colour
paint and shall be supplied along with two sets of gaskets. GI Nut Bolts, washers etc. All
equipment to be inspected and approved by TPIA before dispatch and the inspection
report to be provided to HPCL for acceptance of the material.
3.
FIRE FIGHTING HOUSE :
63 mm x 15 mtrs. long cotton synthetic fibre seamless circular woven jacketed, rust proof,
rubberished fabric reinforced rubber lined fire hose, bearing IS:636/1988 Type-A mark
capable of withstanding 35.7 Kg. bursting pressure binded with gunmetal instantaneous
type male and female coupling hearing IS: 903 mark with copper wire. The hose and
coupling shall be ISI Marked. All equipment to be inspected and approved by TPIA before
dispatch and the inspection report to be provided to HPCL for acceptance of the material.
4.
FRP FIRE HOUSE BOX :
Fibre Glass Fire Hose Box size: 750 mm x 600 mm x 250 mm (30 x 24 approx.),
moulded out of Fibre Reinforced Plastic (FRP) suitable for accommodating 02 Nos. of 15
metre Fire Fighting House with nozzle. The box shall be provided with double door and
shall have locking arrangements. Provision for break glass recess for key shall be given in
the box. The front doors shall be provided with transparent acrylic sheet fitted with rubber
beading for transparency. The box shall be painted with red colour glossy finish. The box
shall be capable to resist the weight of hose with couplings. Suitable wall mounting
bracket shall be provided in the cabinet. All equipment to be inspected and approved by
TPIA before dispatch and the inspection report to be provided to HPCL for acceptance of
the material.
5.
JET NOZZLES :
Jet nozzles with branch pipes made out of gunmetal suitable for 63 mm dia fire hose with
instantaneous coupling and 16 mm dia. Nozzle orifice capable of discharging 450 Ipm at
7 Kg/cm2 as per IS:903 ISI Mark. All equipment to be inspected and approved by TPIA
before dispatch and the inspection report to be provided to HPCL for acceptance of the
material.
6.
FOG NOZZLE :
Fog nozzle made out of gunmetal chromium plated suitable for 63 mm dia fire hose,
having arrangement for straight stream, high pressure fog and shut off as per IS:952 and
with coupling as per IS:903. All equipment to be inspected and approved by TPIA before
dispatch and the inspection report to be provided to HPCL for acceptance of the material.
7.
10 KG. DCP FIRE EXTINGUISHER (ISI MARK) :
With ISI Mark-2171 (Latest) complete with initial charging of CO2 CARTRIDGE (200 gms)
with ISI Mark-4947 (Latest) and dry chemical powder with ISI Mark-4308 (Latest).
SPECIFICATIONS :
Size of filler opening (inner dia) not less than 75 mm.
Length of inner container not less than 35 cm.
Cap shall be of gunmetal with chromium plating.
Hose shall be of braided plastic high pressure with one meter length with nozzle of ABS
Plastic.
All other components, design and performance, anticorrosive treatment shall be as per
IS:1271 latest.
Certification that every extinguisher shall be of Radiographic quality welding and
fabrication and design of vessel shall be as per IS2825. 10% radiography of weld joints
& 50% "T" joints to be done. Design calculation of the extinguisher shall be submitted
along with the offer.
In addition to markings stipulated in IS:2171 (latest) the following permanent punching at
the bottom ring is required.
Manufacturer's name
Year of manufacturing
Manufacturers serial number
Purchase Order No. and date.
Inspector Stamp.
The date of hydraulic rest shall also be marked. Space shall be left for writing the
dates of subsequent hydraulic test
Dry Chemical Powder filling height shall be marked on the extinguisher.

All fire extinguishers shall be inspected and approved by TPIA before dispatch and the
8
75 KG. DCP FIRE EXTINGUISHER (ISI MARK) :
Made of 6 mm thick M.S. Sheet (B.Q. Plate & design of vessel as per IS:2825) with
radiography quality welding. The extinguisher shall be conforming to IS:10658-1983.
Extinguisher to be treated with anticorrosive treatment. Non ferrous parts shall be
gunmetal. Design calculation of the extinguisher shall be submitted along with the offer.
The hose shall be of minimum 05 mm meters length and the bursting pressure shall not
less than 50 Kg/Cm2.
Drain plug of not less than 25 mm diameter to be provided on the body.
The nozzle shall be of Trigger Controlled and capable of discharging powder as per ISI
Specification.
Automatically and manually operated Safety Relief Valve to be provided as per IS:10658
(Latest) specification.
Pressure gauge having minimum 50 mm dia. and range from 0 to 42 Kg/Cm2 to be
provided on the body.
The extinguisher to be mounted on robust trolley having two heavy duty bearing fitted
rubberised wheels and strong handles for easy mobility.
ISI Marked CO2 gas cylinder shall be of 2 Kg. Capacity and shall be approved by
Department of Explosives with protector and thermal insulation and to be fitted with ISI
marked wheel type Valve.
Dry Powder with ISI Mark IS:4308 (Latest). The powder shall be packed in plastic rigidex
material type bags with heavy duly LD lines duly hermetically sealed. The materials of
packing and sealing is to be made in such a way that if the pack is kept inside the water
bucket for 24 hours, not a single drop of water will penetrate inside the bag & the
characteristics of the powder shall remain unaffected against moisture.
Painting Two coats primer (red oxide) painting and then fire red painting by spray method.
As per IS-2825, Dye penetrated test of the fillet weld of all nozzles and attachment No
discontinuities in the welding.
As per IS:2825 Radiography (10% covering 50% of "T"
allowed.
Joints) -
No discontinuities
The extinguisher shall be hydro tested at 30 Kg/cm2 and shall not develop any leaks at
this pressure.
In addition to markings stipulated in IS:10658 (latest) the following permanent punching
at the bottom ring is required.
Manufacturer's name
Inspector Stamp.
The date of hydraulic rest shall also be marked. Space shall be left for writing the
dates of subsequent hydraulic test
Dry Chemical Powder filling height shall be marked on the extinguisher.
All fire extinguishers shall be inspected and approved by TPIA before dispatch and the
9
DRY CHEMICAL POWDER (ISI MARK):
Dry Chemical Powder for fire fighting having chemical composition of sodium based,
shall be highly free flowing and siliconised to make powder water repellent and anti
caking. The powder shall be packed in rigidex imported materials bag with heavy duty LD
liners duly hermetically sealed. The material of packing and sealing is to be made in such
a way that if the packet is kept inside of the bucket full of water for 24 hours, the
characteristics of the powder shall remain unaffected against moisture.
The dry Chemical Powder shall be conforming to IS:4308-1982 with all the last
amendments and bearing ISI Mark.
10.
4.5 Kg. CO2 FIRE EXTINGUISHER (ISI MARK) :
CO2 type 4.5 Kg. Capacity fire extinguisher assembled out of seamless steel cylinder
having Explosive (CCE) Approval and ISI Mark ( manufactured to IS:2878) complete with
ISI marked wheel type valve, one meter length high pressure wire braided discharge hose
with horn, wall mounting bracket and carrying handle. The cylinder shall be fully charged
with CO2 Gas. All other components, design and performance, anticorrosive treatment
shall be as per IS:2878 latest, In addition to markings stipulated in IS:2878 (latest) the
following permanent punching to be provided :
11.
Manufacturer's name
Inspector Stamp.
LIST OF APPROVED MAKES :
NEW AGE, VIMAL FIRE, STEELAGE,VIJAY FIRE, HD FIRE PROTECT, ZENITH
TECHNICAL SPECIFICATION OF GAS LEAK DETECTOR UNIT

GAS DETECTOR
Service
Head Model
Material
Mounting
Sensor Principle / Nos
Enclosure Protection
Approvals
Sensor Assembly
CONTROLLER
No of Channels / Inputs
Power supply
Mounting
Status Indication
Audio Alarm
Alarm setting
Alarm Levels
Operating Temperature
Calibration
Power Indication
Alarm knowledge
Supply of cables/FLP glands/FLP
enclosures for sensors/ Mounting
Accessories,
laying,
erection,
termination and commissioning
PENTAX,OLDHAM
or
approved
equivalent
LPG/Propane
FLP-1
Cast Aluminium LM-6
Surface
Catalytic Combustion type / 5 Nos
Flameproof to Gr II A and II B as per
IS:2148 and weather proof to IP 65
Sensor Transmitters along with FLP/ExP
housing to be approved by CMRS
Dhanbad and CCOE, Nagpur
SS 316
To be located in Control Room
5 / from sensor
230V AC, 50 Hz +/- 10%
Flush Panel Mounting
3 LEDs (Red, Yellow & Green)
Miniature buzzer built in
Slid switch
High : 1000 ppm
Medium : 500 ppm
Low : 100 ppm
Upto 50 deg C
Individual for each channel
Led
Push Button ( Common)
Included
FOR
CIVIL WORKS
CIVIL WORKS
GROUP-1: EARTHWORK
1.0
SCOPE :
This section covers general requirements of carrying out earthwork in excavation in
different materials, filling in areas as shown in drawings, backfilling in site grading,
around foundations, in plinths, etc., conveyance and disposal of surplus spoils or
stacking them properly as shown on the drawings & as directed by ENGINEER and all
operations covered within the intent & purpose of this specification.
2.0
APPLICABLE STANDARDS / CODES :

The following Indian Standards / Codes, unless otherwise specified herein, shall be
applicable. In all cases, the latest revision of the Standards / Codes, shall be referred to :IS 783 Code of Practice for laying of concrete pipe.
IS 1200 Method of Measurement of Building Works.
IS 3764 Safety code for excavation work.
3.0
GENERAL :
CONTRACTOR shall furnish all tools, plants, instruments, qualified supervisory personnel,
labour, materials, any temporary works, consumables, anything and everything necessary,
whether or not such items are specifically stated herein, for completion of the job in
accordance with specification and requirements.
CONTRACTOR shall carry out the survey of the site before commencing excavation and set
properly all lines and establish levels for various works such as earthwork in excavation for
site grading, foundations, plinth filling, roads, drains, cable trenches, pipelines, etc. Such
survey shall be carried out by studying thoroughly the drawings for the existing plant and
modus operandi for earthwork shall be discussed with ENGINEER. Ground levels shall be
taken and properly recorded by the CONTRACTOR and shall be checked and certified by
ENGINEER.
The excavation shall be carried out to correct lines and levels. This shall also include,
where required, proper shoring to maintain excavations and also the furnishing, erecting
and maintaining of substantial barricades around excavated areas and warning lamps to
ensure safety at night.
The rates quoted shall also include for dumping of excavated materials in required heaps,
bunds, riprap with regular slope as directed by ENGINEER, within the lead specified and
leveling the same so as to provide stability and natural drainage. Soil excavated shall be
stacked properly as directed by ENGINEER. As a rule, all softer materials shall be laid
along the centre of heaps, the harder and more weather resisting materials forming the
casing on the sides and the top.
4.0
CLEARING :
The area to be excavated, and / or filled shall be cleared of fences, plants, bushes,
vegetation, slush, etc. and other objectionable matter. The materials so removed shall be
disposed off as directed by ENGINEER. Where earth fill is intended, the area shall be
stripped of all loose / soft patches, top soil containing objectionable matter / materials
removed before fill commences.
5.0
5.1
EXCAVATION AND DEWATERING :

ALL TYPES OF SOILS INCLUDING SOFT ROCKS :
All excavation work shall be carried out in all types of soils, disintegrated rock, boulders,
weathered rock, etc., manually or by mechanical equipment, as directed by ENGINEER.
Excavation for permanent work shall be taken out to such widths, lengths, depths, and
profiles of P.C.C./ Plum concrete as are shown on the drawings, or such other lines are
grades as may be specified by ENGINEER. Initially, excavation shall be carried out to a
depth 150 mm above the final level. The balance shall be excavated with special care. Soft
pockets shall be removed even below the final excavation and shall be carried out just
prior to laying the P.C.C.
CONTRACTOR may, to facilitate his work or similar other reasons, excavate and also
backfill later, if specifically approved by ENGINEER, at his own cost, outside the lines
shown on the drawings. Should any excavation be taken below the specified elevation,
CONTRACTOR shall fill it up, with concrete of the grade specified on drawings, up to the
required elevation. No extra payment shall be made to CONTRACTOR on this account.
All excavations shall be done to the minimum dimensions as required for safety and
working facility. However, prior approval of ENGINEER shall be obtained by CONTRACTOR
in each individual case, for the method he proposes to adopt for the excavation, including
dimensions, side slopes, dewatering, disposal, etc. This approval, however, shall not in
any way absolve CONTRACTOR of his responsibility for any consequent loss or damage.
The excavation must be carried out in the most expeditious and efficient manner. Side
slopes shall be as steep as will stand safely for the actual soil conditions encountered.
Every precaution shall be taken and the slope dressed to a modified stable one. Removal
of the slipped earth will not be paid for.
Excavation shall be carried out with such tools, tackles and equipment as described
hereinbefore.
5.2
DEWATERING :
All excavation shall be kept free of water. Grading in the vicinity of excavation shall be
controlled to prevent surface water running into excavated areas. CONTRACTOR shall
remove by pumping or other means approved by ENGINEER any water, inclusive of rain
water and subsoil water accumulated in excavation, and keep all excavations dewatered
until the foundation wok is completed and backfilled. Sumps made for dewatering must
be kept clear of the excavations / trenches required for further work. Method of pumping
shall be approved by ENGINEER but in any case, the pumping arrangement shall be such
that there shall be no movement of subsoil or blowing in thereof due to differential head of
water during pumping. Pumping arrangements shall be adequate to ensure no delays in
construction.
When there is a continuous inflow of water and quantum of water to be handled is
considered, in the opinion of ENGINEER, as large, well point system. Single stage or
multistage, shall be adopted. CONTRACTOR shall submit to ENGINEER his scheme of well
point system including the stages, the spacing, number of diameter of well points,
headers, etc. and the number, capacity and location of pumps for approval. The cost of
dewatering shall be included in the items for excavation.
FILL AND BACK FILLING :
GENERAL :
All fill material shall be subject to ENGINEERs approval. If any material is rejected by
ENGINEER, CONTRACTOR shall remove the same forthwith from the site within 24 hours
at no extra cost to the OWNER. Surplus fill material shall be deposited / disposed off as
directed by ENGINEER after the fill work is complete.
No earthfill shall commence until surface drains have been properly intercepted, or
otherwise properly dealt with, as directed by ENGINEER.
MATERIAL :
Only selected excavated materials shall be used as backfill. Fill material shall be free from
clods, silt, salts, sulphates, organic or other foreign material. All clods of earth shall be
removed.
If any selected fill material is required to be borrowed, CONTRACTOR shall make
arrangements for bringing such material from outside borrow pits. The material and
source shall be subject to prior approval of ENGINEER. The approved borrow pits areas
shall be cleared of all bushes, plants, rubbish, etc. Top soil containing salts / sulphate
and other foreign material shall be removed. The materials so removed shall be disposed
off, as directed by ENGINEER.
FILLING IN PITS AND TRENCHES AROUND FOUNDATIONS OF STRUCTURES, WALLS,
ETC.
As soon as the work in foundation has been accepted and measured, the space around
the foundations, structures, pits, trenches, etc. shall be cleared of all debris and filled
with earth in layers not exceeding 15 cm., each layer being watered, rammed and
properly consolidated, before the succeeding layer is laid. Each layer shall be
consolidated to the satisfaction of ENGINEER. Earth shall be rammed with approved
mechanical compaction machines. Usually no manual compaction shall be allowed unless
ENGINEER is satisfied that in some cases manual compaction by tampers is unavoidable.
The final backfilled surface shall be trimmed and leveled to proper profile, as shown on
the drawings and as directed by ENGINEER.
SAND/MURUM FILLING IN OTHER PLACES :
At places backfilling shall be carried out with local sand/murum if directed by ENGINEER.
The sand /murum used shall be clean, medium grained and free from impurities. The
filled-in-sand shall be kept flooded with water for 24 hours to ensure maximum
consolidation. Any temporary work required to contain sand under flooded condition shall
be to CONTRACTORS account. The surface of the consolidated sand/murum shall be

dressed to required level or slope. Construction of floors or other structures on fill shall
not be started until ENGINEER has inspected and approved the fill.
6.5
FILLING IN TRENCHES :
Filling in trenches for pipes and drains shall be commenced as soon as the joints of pipes
and drains have been tested and approved by ENGINEER. The backfilling material shall be
properly consolidated by watering and ramming, taking due care that no damage is
caused to the pipes.
In case of trenches in cutting, the filling upto a level 30 cm above the top of the pipe shall
be carried out with approved fine materials, such as earth, sand, murum, etc. The filling
upto the level of the centreline of the pipe shall be carried out by hand compaction in
layers not exceeding 8 cm. Whereas, the filling above the centreline of the pipe shall be
carried out by hand compaction or by approved means in layers not exceeding 15 cm, the
filling from a level 30 cm. above the top of the pipe to the top of the trench shall be
carried out manually or other approved mechanical methods, as directed by ENGINEER.
Filling of the trenches shall be carried out simultaneously on both sides of the pipe to
avoid unequal pressure on the pipe.
7.0
7.1
MEASUREMENT AND PAYMENT :

FOR EXCAVATION IN ALL TYPES OF SOILS EXCEPT HARD ROCK :
All excavation except in hard rock shall be measured net. Dimensions for the purpose of
payment shall be reckoned on the horizontal area of the P.C.C./ Plum concrete at the
base for foundations of the walls, columns, footings, bullets, rafts, or other foundations /
structures to be built, multiplied by the mean depth from the surface of the ground in
accordance with the drawings and recorded ground levels duly approved by ENGINEER.
Excavation in side slopes will not be paid for. CONTRACTOR may make such allowance in
his rates to provide for excavation in side slopes keeping in mind the nature of the soil
and safety of excavation.
Group 2 : CEMENT CONCRETE AND ALLIED WORKS
1.0
1.0 SCOPE :
This specification covers the general requirements for concrete to be used on jobs using
on-site production facilities including requirements in regard to the quality, handling,
storage of ingredients, proportioning, batching, mixing & testing of concrete, and also
requirements in regard to the quality, storage, bending and placement of reinforceme
This also covers the transportation of concrete from the mixer to the place of final deposit
and the placing, curing, protecting, repairing and finishing of concrete.
2.0
2.0 APPLICABLE CODES AND SPECIFICATIONS :

The following specification, standards and codes shall form part of this specification. All
standards, tentative specifications, codes of practice, referred to herein, shall be the latest
editions, including all applicable official amendments and revisions.
In case of discrepancy, if any, between this specification and those referred hereunder, the
more stringent shall govern. Decision of the Engineer shall be final in this regard.
APPLICABLE I.S. SPECIFICATIONS AND CODES OF PRACTICE

I.S. : 269 - Specification for Ordinary, and Low Heat Portland
Cement.
I.S. : 383-
Specification for coarse and fine aggregates from

natural source for concrete.
I.S. : 432 - Specification for mild steel and medium tensile steel
(parts I & II) bars and hard drawn steel wire for
concrete reinforcement.
IS : 456 - Code of practice for plain and reinforced concrete.
IS : 516
- Method of test of strength of concrete.
IS : 1199 - Method of sampling and analysis of concrete.

IS : 1200 - Method of measurement of building & civil
Engineering works.
IS : 1566 - Specification for hard drawn steel wire fabric for

concrete reinforcement.
IS : 1786 - Specification for HYSD bars for concrete reinforcement.
IS : 2386 - Method of test for aggregates for concrete. (parts I to VIII)
I.S : 2502 - Code of practice for bending and fixing of bars for
Concrete reinforcement.
I.S. : 2645 - Method for integral cement waterproofing compound.
I.S. : 3025 - Method of sampling and test (Physical and Chemical ) for
water & waste water.
IS : 3370 - Code of practice for concrete structures for storage
(parts I-IV) of liquids.
IS : 3696 - Safety code for scaffolds and ladders. (parts I & II).
IS : 8112 - High strength ordinary Portland Cement 43 grade.
IS : 9103 - Specification for Admixtures for concrete.
IS : 10262 - Recommended guidelines for concrete mix design.
IS : 12269 - High strength ordinary portland cement - 53 grade.
3.0 GENERAL :
The quality of materials & method and control of manufacture and transportation of all
concrete work irrespective of mix, whether reinforced or otherwise, and shall conform to
the applicable clauses of this specification.
4.0 MATERIALS FOR STANDARD CONCRETE :
The ingredients to be used in the manufacture of standard concrete shall consist solely of
a standard type Portland Cement, clean sand natural coarse aggregate, clean water, and
admixtures, if specially called for on drawings and/or in the specifications.
4.1 CEMENT :
Unless otherwise specified, cement shall be High Strength Ordinary Portland Cement
(Grade 43/53 ) of approved make in 50 kg bags. Changing of brands or type of cement
within the same structure will not be permitted. CONTRACTOR shall make his own
arrangements for the storage of adequate quantity of cement.
Approved makes are : Ultratech/JKLaxmi/Birla-Uttam/Birla Diamond & prism,
/Vasavdatta/ ACC/ Nagarjuna /JPRewa /Gujarat Ambuja /Bhima of Coramandal /Zuari
Cement bags shall be stored in a dry enclosed shed (storage under tarpaulin will not be
permitted), well away from the outer walls and insulated from the floor to avoid contact
with moisture from ground & walls, and so arranged as to provide ready access. Damaged
or reclaimed or partly set cement will not be stacked in any tier and shall be stacked
separately or removed from shed. The storage arrangement shall be approved by
ENGINEER. Consignment of cement shall be stored as received and shall be consumed in
the order of their receipts at site.
Cement held in storage for a period of ninety (90) days or longer shall be tested. Should at
any time ENGINEER has reasons to consider that any cement is defective, then
irrespective of its origin, date of manufacture and/or manufacturers test certificate, such
cement shall be tested immediately at a National Test Laboratory/Approved Laboratory
and until the results of such tests are found acceptable, it shall not be used in any work.
CONTRACTOR shall not be entitled to any claim of any nature on this account.
4.2 AGGREGATES :
4.2.1 GENERAL :
a) Aggregates in general designate both fine and coarse inert materials use in the
manufacture of concrete.
b) Fine Aggregates are aggregates most of which pass through 4.75 mm IS sieve.
c) Coarse Aggregates are aggregates most of which are retained on 4.75 mm IS sieve.
All fine and coarse aggregates proposed for use in the work shall be subject to
ENGINEERs approval and after specific materials have been accepted, the source of
supply of such materials, shall not be changed without prior approval of ENGINEER.
Aggregates shall, except as noted above, consist of natural sands, crushed stone and
gravel from a source known to produce satisfactory aggregate for concrete and shall be
chemically strong, hard, inert, durable against weathering, of limited porosity and free
from deleterious materials that may cause corrosion of the reinforcement or may impair
the strength and/or durability of concrete. The grading of aggregates shall be such as to
produce a dense concrete of specified strength & consistency that will work readily into
position without segregation and shall be based on test on concrete, as specified later in
this group.
4.2.2. FINE AGGREGATES :
4.2.2.1 GENERAL :
Fine aggregates, except as noted above, shall consist of natural or crushed sand
conforming to IS : 383. The sand shall be clean, sharp, hard, strong and durable and shall
be free from dust, vegetable substances, adherent coatings, clay, alkali, organic matter,
mica, salt, or other deleterious substances which can be injurious to the setting
qualities/strength/durability of concrete.
4.2.2.2 SCREENING AND WASHING :
Sand shall be prepared for use by such screening or washing or both, as necessary, to
remove all objectionable foreign matters while separating the sand grains to the required
size fraction.
4.2.2.3 FOREIGN MATERIAL LIMITATIONS :
The percentage of deleterious substances in sand shall conform to IS : 383.
4.2.2.4 GRADATION :
Unless otherwise directed or approved, the grading of sand shall be within the limits
indicated hereunder :
---------------------------------------------------------------------------------------------------I.S. Sieve
PERCENTAGE PASSING FOR
Designation
Grading
Grading
Grading
Grading
Zone-I Zone-II Zone-III
Zone-IV
---------------------------------------------------------------------------------------------------10.00 mm
100
100
100
100
4.75 mm
90 100
90 100
90 100
95 100
2.36 mm
60 95
75 100
85 100
95 100
1.18 mm
30 70
55 90
75 100
90 100
600 micron
15 34
35 59
60 79
80 100
5 20 8 30 12 40
15 50
300 micron
150 micron
0 10 0 10 0 10
0 - 15
----------------------------------------------------------------------------------------------------Where the grading falls outside the limits of any particular grading zone of sieves, other
than 600 micron I.S. sieve, by total amount not exceeding 5 %, it shall be regarded as
falling within that grading zone. This tolerance shall not be applied to percentage passing
the 600 micron I.S. Sieve or to percentage passing any other sieve size on the coarser
limit of Grading Zone I or conforming to Grading Zone IV shall be used. Sand used for
preparing concrete shall belong to Grading Zone-II.
4.2.2.5 FINENESS MODULUS :

The sand shall have a fineness modulus of not less than 2.2 nor more than
3.2. The fineness modulus is determined by adding the cumulative
percentages retained on the following I.S. Sieve sizes (4.75 mm, 2.36 mm,
1.18 mm, 600 micron and 150 micron) and dividing the sum by 100.
4.2.3 COARSE AGGREGATES :
4.2.3.1 GENERAL :
Coarse aggregates for concrete, except as noted above, shall conform to IS :
383. This shall consist of natural or crushed stone & gravel and shall be clean
and free from elongated, flaky or laminated pieces, adhering coatings, clay
lumps, coal residue, clinkers, slag, alkali, mica, organic matter or other
deleterious matter.
4.2.4 SAMPLING AND TESTING :
Samples of the aggregates for determination of suitability shall be taken
under the supervision of ENGINEER and delivered to the laboratory well in
advance of the scheduled placing of concrete. Records of tests which have
been made on proposed aggregates and on concrete made from this source of
aggregates shall be submitted to ENGINEER.
4.2.5 STORAGE OF AGGREGATES :
All coarse and fine aggregates shall be stacked separately in stock piles in the
material yard near the work site to avoid intermixing of different aggregates.
Contamination with foreign materials and earth during storage and heaping of
the materials shall be avoided. The aggregates shall be of specified quality
not only at the time of receiving at site but also at the time of loading into the
mixer. Rakers shall be used for lifting the coarse aggregates from stock piles.
Coarse aggregates shall be piled in layers not exceeding 1.20 metres in height
to prevent coning or segregation. Each layer shall cover the entire area of the
stock pile before succeeding layers are started. Aggregates that have become
segregated shall be rejected. Rejected material after remixing may be
accepted, if subsequent tests demonstrate its conformity with required
gradation.
4.2.6 SPECIFIC GRAVITY :
Aggregates having a specific gravity below 2.6 (saturated surface dry basis
shall not be used without special permission of ENGINEER.
4.3 WATER :
Water used for both mixing and curing shall be free from injurious amounts of
deleterious materials. Potable water is generally satisfactory for mixing curing
concrete.
5.0 CONCRETING WORK :
5.1 DESIGN MIX :
Mix design will be carried out giving proportions of the ingredients, sources of
aggregates and cement, along with accompanying test results of trial mixes as
per IS : 10262 shall be submitted to the ENGINEER for his approval before it
is used for the works.
5.1.1 PROPORTIONING AND WORKS CONTROL :
5.1.1.1 GENERAL :
Proportioning of ingredients of concrete shall be made by any of the two
following two methods, as directed by ENGINEER.
a) With preliminary tests by designing the concrete mix. Such concrete shall
be called Design Mix Concrete.
b) Without preliminary tests, adopting Nominal Mix Concrete.
As far as possible, controlled concrete shall be used for all concrete works.
Ordinary concrete in grades permitted in accordance with IS : 456 may be
used if shown on drawings or approved by the ENGINEER. In all cases the
proportioning of ingredients and works control shall be in accordance with IS :
456 and shall be adopted for use after the ENGINEER is satisfied regarding its
adequacy and after obtaining his approval in writing.
5.1.1.2 MIX DESIGN CRITERIA :
Concrete mixes will be designed by the CONTRACTOR to achieve the strength,
durability and workability necessary for the job, by the most economical use
of the various ingredients. In general, the design will keep in view the following
considerations :
Consistent with the various other requirements of the mix, the quantity of
water shall be kept at the lowest possible level.
The nominal maximum size of coarse aggregate shall be as large as possible
within the limits specified.
The various fractions of coarse and fine aggregates should be mixed in such a
proportion as to produce the best possible combined internal grading giving
the densest and most workable mix.
The finished concrete should have adequate durability in all conditions to
withstand satisfactorily the weather and other destructive agencies the
structure is expected to be subjected to in actual service.
The requirement of adequate structural strength is catered for by the choice
of proper grade of concrete by the ENGINEER. The CONTRACTOR shall strictly
abide by the same in his design concrete mix.
Notwithstanding anything mentioned in various tables given in IS: 456 giving
specific values and degrees of workability for different condition of concrete
placing minimum cement content and maximum water-cement ratio for
concrete exposed to sulphate attack and for concrete to ensure durability
under different conditions of exposure, strength requirement for different
grades of concrete.
5.1.2 MINIMUM CEMENT CONTENT :

The Minimum cement content for each grade of concrete shall be as per BIS
456, 2000.
5.1.3
STRENGTH REQUIREMENT :In case of D In case of Design Mix Concrete, the water cement ratio of such value has to
give acceptable test results as per IS : 456, will be selected by trial and error. The values
of water-cement ratios for different concrete grades and mix designs shall be established
after conducting sufficiently large number of preliminary tests in the laboratory to the
satisfaction of the ENGINEER. Frequent checks on tests shall be carried out and the
water-cement revised if the tests produce unsatisfactory results. Notwithstanding
anything stated above, CONTRACTORs responsibility to produce satisfactory test results
and to bear all the consequences in case of default remain unaltered.
In case of ordinary concrete, the maximum water-cement ratio for different grades of
concrete specified in Table-3 of IS : 456 and no tests are necessary. The acceptance test
criteria for nominal mix concrete shall be as per IS : 456.
5.2
SURFACE PREPARATION
5.2.1
FOUNDATION BEDDING, BONDING AND JOINTS :

All surfaces upon or against which concrete will be placed shall be suitably prepared by
thoroughly cleaning, washing and dewatering, as indicated on the drawings, or as
directed by the ENGINEER, to meet the situations encountered in the work.
Soft or spongy areas shall be cleaned and backfilled with either a soil-cement mixture,
lean concrete or clean sand, till compacted to a minimum density of 90% Modified
Proctor, unless otherwise mentioned in Schedule of Quantities.
5.2.2
PREPARATION OF EARTH STRATA OF FOUNDATIONS :

All earth surfaces upon or against which concrete is to be placed, shall be well
compacted and free from moisture mud or debris. Soft, yielding soil shall be removed
and replaced with P.C.C. as directed by ENGINEER. The surface of absorptive soils
against which concrete is to be placed shall be moistened thoroughly so that no moisture
will be drawn from the freshly placed concrete.
5.2.3
PREPARATION OF CONCRETE SURFACES :

The preparation of concrete surfaces upon which additional concrete is to be placed
later, shall preferably be done by scarifying and cleaning, while the concrete is between
its initial and final set. This method shall be used wherever practicable and shall consist
of cutting the surface with picks and stiff brooms and by use of an approved combination
of air and water jet as directed by ENGINEER. Utmost care shall be exercised in
performing this work to removal of mortar and the weakening of the surface by loosening
of aggregates.
The final required result shall be that pitted surface from which all dirt, unsound
concrete, laitance and glazed mortar have been removed.
5.2.4
BONDING TREATMENT (MORTAR) :

After rock or concrete surfaces upon which new concrete is to be placed have been
scarified, cleaned and wetted, as specified herein, they shall receive a bonding treatment,
immediately before placement of the concrete.
The bonding medium shall be a coat of cement-sand mortar. The mortar shall have the
same cement-sand proportions as the concrete which shall be placed thereon. The watercement ratio shall be determined by site conditions and as approved by ENGINEER.
Bonding mortar shall be placed in sufficient quantity to completely cover the surface by
about 5 mm thick for concrete surfaces. It shall be brushed or broomed over the surface
and worked thoroughly into all cracks, crevices and depressions. Accumulations or
puddles of mortar shall not be allowed to settle in depressions and shall be brushed out
to a satisfactory degree, as approved by ENGINEER.
Mortar shall be placed at such a rate that it can be brushed over the surface just in
advance of placement of concrete. Only as much area shall be covered with mortar as
can be covered with concrete before initial set in the mortar takes place. The amount of
mortar that will be permitted to be placed at any one time, or the area which it is
required to cover, shall be in accordance with ENGINEERs directions.
5.2.5
CLEANING AND BONDING FORMED CONSTRUCTION JOINTS :

Vertical construction joints shall be cleaned as specified above or by other method as
approved by ENGINEER. In placing concrete against formed construction joints, the
surfaces of the joints, where accessible, shall be coated thoroughly with the specified
bed-joint bonding mortar immediately before they are covered with concrete, or by
scrubbing with wire brooms dipped into the fresh concrete. Where it is impracticable to
apply such a mortar coating, special precautions shall be taken to ensure that the new
concrete is brought in intimate contact with the surface of the joint, by careful pudding
and spading with aid of vibrators and suitable tools.
5.3
PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL INSPECTION AND APPROVAL

Before the concrete is actually placed in position, the inside of the formwork shall be
inspected to see that they have been cleaned and oiled. Nonstaining oil shall be used as
approved by ENGINEER. Temporary openings shall be provided to facilitate inspection,
especially at bottom of wall forms, to permit removal of saw dust, wood shavings, binding
wire, rubbish, dirt, etc. Openings shall be placed or holes drilled so that these materials
and water can be removed easily. Such openings/holes shall later be properly plugged.
Various trades shall be permitted ample time to install drainage and plumbing lines, floor
& trench, drains, conduits, hangers, anchors, inserts, sleeves, bolts, frames and other
miscellaneous embedments to be cast in the concrete as indicated on the drawings or, as
is necessary for the proper execution of the work. CONTRACTOR shall co-operate fully
with all such agencies and shall permit the use of scaffolding, formwork, etc. by other
trades at no extra cost.
All embedded parts, inserts, etc. shall be correctly positioned and securely held in the
forms to prevent displacement during placing and vibrating of concrete.

All anchor bolts shall be positioned using templates and kept in place.
Reinforcement and other items to be cast in concrete shall have clean surfaces that will
not impair bond.
Prior to concrete placement, all work shall be inspected and approved by ENGINEER. If
found unsatisfactory, concrete shall not be poured until after all defects have been
rectified by the CONTRACTOR. All the costs in respect of rectification work shall be
deemed to be included in the quoted rates.
5.4
PROCEDURE FOR CONCRETE PLACEMENT :
5.4.1
ENGINEERS APPROVAL OF EQUIPMENT & METHODS :

Before any concrete is placed, the entire placing programme consisting of equipment,
layout, proposed procedures and methods shall be submitted to ENGINEER for approval
and no concrete shall be placed until ENGINEERs approval has been received in writing.
Equipment for conveying concrete shall be of such size and design as to ensure a
practically continuous flow of concrete during depositing without segregation of
materials, considering the size of the job and placement location.
5.4.2
TIME INTERVAL BETWEEN MIXING AND PLACING :

Concrete shall be placed in its final position before the cement reaches its initial set and
concrete shall normally be compacted in its final position within thirty minutes of leaving
the mixer. Concrete once compacted, it shall not be disturbed.
5.4.3
AVOIDING SEGRETATION :
Concrete shall, in all cases, be placed from as near as practicable position directly in its
final position, and shall not be re-handled or caused to flow in a manner which will cause
segregation, loss of materials, displacement of reinforcement, shuttering or embedded
inserts, or impair its strength.
For locations where direct placement is not possible, and in narrow forms, CONTRACTOR
shall provide suitable chute and Elephant Trunks to confine the movement of concrete.
5.4.4
PLACING BY MANUAL LABOUR:

Except when otherwise approved by ENGINEER, concrete shall be placed in the
shuttering by shovels or other approved equipment and shall not be dropped from a
height more than 1.5 M or handled in a manner which will cause segregation.
5.4.5
PLACING CONCRETE THROUGH REINFORCING STEEL :

When placing concrete through reinforcing steel, care shall be taken to prevent
segregation of the coarse aggregate. Where the congestion of steel makes placing
difficult, it may be necessary to temporarily move the top steel aside to get proper
placement and restore reinforcing steel to its design position.
5.4.6
BLEEDING :
Should bleeding of free water on top of concrete being placed into the forms occur, the
conditions causing this defect shall be corrected before further concreting is resumed.
5.5
COMPACTION :
5.5.1
GENERAL :
Concrete shall be compacted during placing, with approved vibrating equipment until the
concrete has been consolidated to the maximum practicable density, is free of pockets of
coarse aggregates and fits tightly against all form surfaces, reinforcement and embedded
fixtures. Particular care shall be taken to ensure that all concrete placed against the form
faces and into corners of forms or against hardened concrete at joints is free from voids
or cavities. The use of vibrators shall be consistent with the concrete mix and caution
exercised not to over vibrate the concrete to the point that segregation results and water
appears on the top surfaces.
5.5.2
USE OF VIBRATORS :
The exact manner of application and the most suitable machines for the purpose must be
carefully considered and operated by experienced men. Immersion vibrators shall be
inserted vertically at points not more than 450 mm apart and withdrawn when air
bubbles cease to come to the surface. Immersion vibrators shall be withdrawn very
slowly. In no case shall immersion vibrators be used to transport concrete inside the
forms.
Particular attention shall be paid to vibration at the top lift of wall.
5.5.3
PENETRATION OF VIBRATORS :
The immersion vibrator shall penetrate the layer being placed and also penetrate the
layer below while the under layer is still plastic, to ensure good bond and homogeneity
between the two layers and prevent the formation of joints.
5.5.4
VIBRATION AGAINST REINFORCEMENT :

Care shall be taken to prevent contact of immersion vibrator with reinforcement steel
and/or embedded parts. Immersion vibrators shall not be allowed to come in contact
with reinforcement steel after start of initial set. They shall also not be allowed to come in
contact with forms of finished surfaces.
5.6
STONE POCKETS AND MORTAR PONDAGES :

The formation of stone pockets or mortar pondages in corners and against faces of forms
shall not be permitted. Should these occur, they shall be dug out, reformed and refilled
to sufficient depth and shape for thorough bonding, as directed by ENGINEER.
5.7
CONSTRUCTION JOINTS AND KEYS :
5.7.1
GENERAL :
Concrete shall be placed without interruption until completion of the part of the work
between predetermined construction joints, as specified hereinafter. Time lapse between
the pouring of adjoining units shall be as specified on the drawings or as directed by
ENGINEER.
If stopping of concreting becomes unavoidable anywhere, a properly formed construction
joint shall be made where the work is stopped. Joints shall be either vertical or horizontal
unless otherwise shown on drawings. In case of an inclined or curved member, the joint
shall be at the right angles to the axis of the member. Vertical joints in walls shall be kept
to a minimum. Vertical joints shall be formed against a stop board; horizontal joints shall
be level and wherever possible, arranged so that the joint lines coincide with the
architectural features of the finished work. Battens shall be nailed to the form work to
ensure a horizontal line, and if directed, shall also be used to form a grooved joint. For
water storage bullet walls and similar work, joints shall be formed as per IS : 3370.
Concrete that is in the process of setting shall not be disturbed or shaken by traffic either
on the concrete itself or upon the shuttering. Horizontal and vertical construction joints
and shear keys shall be located and shall conform in detail to the requirements of plans,
unless otherwise directed by ENGINEER IN CHARGE.
5.7.2
DOWELS :
Dowels for concrete work, not likely to be taken up in the near future, shall be encased in
concrete as per drawings and as directed by the ENGINEER.
5.7.3
TREATMENT OF CONSTRUCTION JOINTS OF RESUMING CONCRETING:

A stiffer mix shall be used for the top lift of horizontal pours to avoid laitance. All liatance
and loosed stones shall be thoroughly and carefully removed by wire brushing / hacking
and surface washed. Just before concreting is resumed, the roughened joint surface shall
be thoroughly cleaned and loose matter removed and then treated with a thin layer of
cement grout of proportion specified by ENGINEER and worked well into the surface. The
new concrete shall be well worked against the prepared surface before the grout mortar
sets. Special care shall be taken to obtain thorough compaction and to avoid segregation
of the concrete along the joints / plane.
5.7.4
EXPANSION AND CONTRACTION JOINTS :

Provision shall be made for expansion and contraction of concrete by use of special type
joints located as shown on the drawing, Contraction joint surfaces shall be treated as per
specifications, drawings or as directed by ENGINEER.
5.8
RAIN OR WASH WATER :

No concrete shall be placed in wet weather or on a water covered surface. Any concrete
that has been washed by heavy rains shall be entirely removed, if there is any sign of
cement and sand having been washed away from the concrete placed. To guard against
damage which may be caused by rains, the works shall be covered with tarpaulins
immediately after the concrete has been placed and compacted. Any water accumulated
on the surface of the newly placed concrete shall be removed by approved means and no
further concrete shall be placed thereon until such water is removed. To avoid flow of
water over/around freshly placed concrete, suitable drains and sumps shall be provided.
5.9
BONDING MORTAR :
Immediately before concrete placement begins, prepared surfaces except formwork,
which will come in contact with the concrete to be placed, shall be covered with the
bonding mortar.
5.10
CLEANING OF EQUIPMENT :
All equipment used for mixing, transporting and placing of concrete shall be maintained
in clean condition All pans, buckets, hoppers, chutes, pipelines & other equipment shall
be thoroughly cleaned after each period of placement.
5.11
CURING, PROTECTING, REPAIRING AND FINISHING :
5.11.
1
CURING :
5.11.
2
CURING WITH WATER :
All concrete shall be cured by keeping it continuously damp for the period of time
required for complete hydration and hardening to take place. Preference shall be given to
the use of continuous sprays, or ponded water, continuously saturated coverings of
sacking, canvas, hessians or other absorbent materials, or approved effective curing
compounds applied with spraying equipment capable of producing a smooth, eventextured coat. Extra precautions shall be exercised in curing concrete during cold and hot
weathers as outlined hereinafter. The quality of curing water shall be the same used for
mixing concrete.
Fresh concrete shall be kept continuously wet for a minimum period of 14 days from the
date of placing of concrete, following a lapse of about 12 hours after laying concrete.
The curing of horizontal surfaces exposed to the drying winds shall, however, begin
immediately after the concrete has hardened. Water shall be applied to unformed
concrete surfaces within 1 hour after concrete has set. Water shall be applied to formed
surfaces immediately upon the removal of forms. Quantity of water applied shall be
controlled so as the prevent erosion of freshly placed concrete.
5.11.
3
CONTINUOUS SPRAYING :
5.11.
4
CURING EQUIPMENT :
5.12
PROTECTIVE FRESH CONCRETE :
Curing shall be assured by use of an ample water supply under pressure in pipes, with all
necessary appliance of hose, sprinkle and spraying devices. Continuous fine mist
spraying or sprinkling shall be used, unless otherwise specified or approved by
ENGINEER.
All equipment and materials required for curing shall be on hand and ready for use
before concrete is placed.
Fresh concrete shall be protected from the elements, from defacement & damage due to
construction operations by leaving forms in place for an ample period as specified later
in this specification. Newly placed concrete shall be protected by approved means such
as tarpaulins from rain, sun & winds. Steps, as approved by ENGINEER, shall also be
taken to protect green concrete from damage by debris, excessive loading, vibration,
abrasion or contact with other materials, etc. that may impair the strength and/or
durability of the concrete. Workmen shall be warned against and prevented from
disturbing green concrete during its setting period. If it is necessary that workman have
to enter the area of freshly placed concrete bridges be placed over the area, as directed
by ENGINEER.
5.13
REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE :
5.13.
1
GENERAL :
5.14
SAMPLING AND TESTING CONCRETE IN THE FIELD :
Immediately after the shuttering is removed, the surface of concrete shall be very
carefully gone over all defective areas called to the attention of ENGINEER. Defective
areas shall be repaired or replaced by CONTRACTOR as directed by HPCL at no
additional cost to HPCL..
Facilities required for sampling materials and concrete in the field, shall be provided by
CONTRACTOR at no extra cost.
Test cubes for each grade of concrete and for quantity placed in each pour shall be
made as specified in IS : 456. Such samples shall be drawn on each day, for each grade
of concrete & during each concreting operations. Additional cubes shall be taken for 7
days test as required by ENGINEER. The laboratory test results shall be tabulated
maintained at site and furnished to ENGINEER. ENGINEER will accept the concrete
according to Acceptance Criteria specified in the IS : 456.
5.15
CONSISTENCY :
Slump test shall be carried out as often as demanded by ENGINEER invariably from the
same batch of concrete from which the test cubes are made. Slump test shall be done
immediately after sampling.
LIMITS OF CONSISTENCY
Degree of workability
5.16
Very low
Slump in mm with standard

Cone as per IS:1199
Min.
Max.
0
25
Low
25
50
Medium
25
75
Use for which concrete is

suitable
Concreting
of
shallow
sections with vibration
Concreting
of
lightly
reinforced sections with
vibration.
Concreting
of
lightly
reinforced sections without
vibration,
or
heavily
reinforced
section
with
vibration.
HOT WEATHER EQUIPMENT :

All concrete work performed in hot weather shall be in accordance with IS : 456, except
as herein modified.
Admixture may be used only when approved by ENGINEER.
Adequate provisions shall be made to lower concrete temperatures by selecting timing of
concreting, normally cool hours, using cool ingredients, eliminating excessive mixing,
preventing exposure of mixers and conveyors to direct sun-light, the use of reflective
paint on mixers, etc. The temperature of the freshly placed concrete shall not be
permitted to exceed 38 deg. C.
Consideration shall be given to providing shade aggregate stockpiles from direct rays of
the sun and spraying stockpiles with water, use of cold water when available and burying,
insulating, shading and / or painting white the pipe lines & water storage bullets.
In order to reduce loss of mixing water, the aggregates, wooden forms, subgrade,
adjacent concrete and other moisture absorbing surfaces shall be well wetted prior to
concreting. Placement and finishing shall be done as quickly as possible.
Extra precautions shall be taken for the protection and curing of concrete. Consideration
shall be given to continuous water curing and protection against high temperatures and
drying hot winds for a period of at least 12 days immediately after concrete has set and
after which normal curing procedures may be resumed.
5.17
SLOTS, OPENINGS ETC. :

Slots, openings, holes, pockets, pipe sleeves, etc. shall be provided in the concrete work
in the positions indicated on the drawings or as directed by ENGINEER. Any deviation
from the approved drawings shall be made good by CONTRACTOR at his own expense
without damaging any other work. Sleeves, bolts, inserts, etc. shall also be provided in
concrete work where so specified.
6.0
FORMWORK :
The formwork shall consist of shores, bracings, sides of beams and columns, bottom of
slabs, etc. including ties, anchors, hangers, inserts, etc. complete which shall be properly
designed and planned for the work. False work shall be so constructed that vertical
adjustments can be made to compensate for take up and settlements. Wedges shall be
used at the top or bottom of timber props, but not at both ends, to facilitate vertical
adjustment or dismantling of the formwork.
6.1
DESIGN OF FORMWORK :
The design and engineering of the formwork as well as its construction shall be the
responsibility of CONTRACTOR. If so instructed, the drawings and/or calculations for the
design of the formwork shall be submitted to ENGINEER for approval before proceeding
with work, at no extra cost to OWNER. ENGINEERs approval shall not, however, absolve
the CONTRACTOR of his full responsibility for the design and construction of the
formwork. The design shall take into account all the loads, vertical as well as lateral,
forms would be carrying, including live and vibration loadings.
6.2
FORMWORK REQUIREMENTS :
Forms shall conform to the shapes, lines, grades and dimensions, including camber of
the concrete as called for on the drawings. Ample studs, walers, braces, ties, straps,
shores, etc. shall be used to hold the forms in proper position without any distortion
whatsoever until concrete has set sufficiently to permit the removal of forms. Forms shall
be strong enough to permit the use of immersion vibrators. The formwork shall be close
boarded. Timber shall be well seasoned, free from sap, shakes, loose knots, work holes,
warps or other surface defects. Faces coming in contact with concrete shall be free from
adhering grout, plaster, paint projecting nails, splits or other defects. Joints shall be
sufficiently tight to prevent loss of water and cement slurry from concrete.
Plywood shall be used for Exposed Concrete surfaces; where called for Sawn and wrought
timber may be used for unexposed surfaces. Inside faces of forms for concrete surfaces
which are to be rubbed finished shall be planed to remove irregularities or unevenness in
the face. Formwork with linings will be permitted.
All new and used material for lumber shall be maintained in a good condition with
respect to shape, strength, rigidity, water tightness, smoothness and cleanliness of
surfaces. Form lumber unsatisfactory in any respect shall not be used and, if rejected by
ENGINEER, shall be removed from the site.
Formwork, during any stage of construction showing signs of distortion or distorted to
such a degree that the intended concrete work will not conform to the exact contours
shown on the drawings, shall be repositioned and strengthened. Poured concrete affected
by the faulty formwork, shall be removed in its entirety and the formwork corrected, as
directed by ENGINEER, prior to placing new concrete.
Forms for substructure concrete may be omitted when, in the opinion of ENGINEER, the
open excavation is firm enough to act as the form. Such excavation shall be slightly larger
than that required by the drawings to compensate for irregularities in excavation and to
ensure concrete cover and the design requirements.
Forms shall be so designed and constructed that their removal will not damage the
concrete. Face formwork shall provide true vertical and horizontal joints, conform to the
architectural features of the structure as to location of joints and be as directed by
ENGINEER.
When exposed smooth or rubbed concrete finishes are required, the forms shall be
constructed with special care so that the resulting concrete surfaces require a minimum
finish.
6.3
MOULD OIL :
Care shall be taken to see that the faces of formwork coming in contact with concrete are
perfectly cleaned and two coats of mould oil or any other approved material applied
before fixing reinforcement and placing concrete. Such coating shall be insoluble in
water, non-staining and not injurious to the concrete. It shall not become flaky or be
removed by rain or wash water. Reinforcement and/or other items to be cast in the
concrete shall not be placed until coating of the forms is complete. Adjoining concrete
surfaces shall also be protected against contamination from the coating material.
6.3.1
CHAMFERS AND FILLETS :

All corners and angles exposed in the finished structure shall be formed with mouldings
to form chamfers or fillets on the finished concrete. The standard dimensions of
chamfers and fillets, unless otherwise specified, shall be 20 mm x 20 mm. Care shall be
exercised to ensure accurate moulding. The diagonal face of the moulding shall be
planed or surfaced to the same texture as the form to which it is attached.
6.4
WIRE TIES :
Wire ties passing through the walls shall not be allowed. In their place bolts passing
through sleeves shall be used.
6.5
REUSE OF FORMS :
Before reuse, all forms shall be thoroughly scraped, cleaned, nails removed, holes,
suitably plugged and joints examined and when necessary, repaired and the inside
surfaces retreated to prevent adhesion, to the satisfaction of ENGINEER. Warped lumber
shall be resized. CONTRACTOR shall equip himself with enough formwork to complete
the job in the stipulated time.
6.6
REMOVAL OF FORMS :
CONTRACTOR shall record on the drawing or a special register, the date on which the
concrete is placed in each part of the work and the date on which the shuttering is
removed therefrom.
Under no circumstances shall forms be struck until the concrete reaches a strength of at
least twice the stress due to self weight and any construction/erection loading to which
the concrete may be subjected to, at the time of striking formwork, as directed by
ENGINEER.
In normal circumstances (generally where temperatures are above 20 deg. C), forms may
be struck after expiry of the following periods :
a) Walls, columns and vertical sides of
beams.
b) Slabs (Props left under)
24 to 48 hours
ENGINEER.
3 days
c) Beam soffits (Props left under
7 days
as
directed
by
the
d) Removal of props under slabs :

7 days
i. Spanning up to 4.5 m
14 days
ii. Spanning over 4.5 m
e) Removal of props under beams :
i. Spanning up to 6 m.
14 days
ii. Spanning over 6 m
21 days
Striking shall be done slowly with atmost care so to avoid damage to arises and
projections and without shock or vibration, by gently easing the wedges. If after removing
the form work, it is found that timber has been embedded in the concrete, it shall be
removed and concrete member made good as specified earlier.
Reinforced temporary openings shall be provided, to facilitate removal of formwork which
otherwise may be inaccessible as directed by ENGINEER.
Tie rods, clamps, form bolts, etc. which must be entirely removed from walls or similar
structures, shall be loosened not sooner than 24 hours nor later than 48 hours after the
concrete has been deposited. Ties, except those required to hold forms in place, may be
removed at the same time. Ties withdrawn from walls and grade beams shall be pulled
towards the inside face. Cutting ties back from the faces of walls and grade beams shall
not be permitted.
For liquid retaining structures, no sleeves for through bolts shall be used, nor shall
through bolts be removed. The bolts, in this case, shall be cut at 25 mm depth from the
surface and then the hole shall be made good by sand cement mortar of the same
proportion as that of concrete, just after striking the formwork.
7.0
REINFORCEMENT :
7.1
SUPPLY :
Reinforcement bars shall be High Yield Strength Deformer bars (TMT) Fe 415 Grade as
per latest edition of IS 1786. Wire mesh or fabric shall be in accordance with I.S. 1566.
Substitution of reinforcement will not be permitted except upon written approval from
ENGINEER.
STORAGE :
7.2
The reinforcement shall not be kept in direct contact with the ground but stacked on top
of an arrangement of timber sleepers or the like.
If the reinforcing rods/bars have to be stored for a long duration, they shall be coated
with cement wash before stacking and/or be kept under cover or stored, as directed by
ENGINEER. Fabricated reinforcement shall be carefully stored to prevent damage,
distortion, corrosion and deterioration.
All reinforcement shall be clean, free from grease, oil, paint, dirt, loose mill scale, loose
rust, dust, bituminous material, or any other substances that will destroy or reduce the
bond. All rods shall be thoroughly cleaned before being fabricated. Pitted and defective
rods shall not be used. All bars shall be rigidly held in position before concreting. No
welding of rods to obtain continuity shall be allowed, unless approved by ENGINEER.
7.3
7.4
LAPS :
Laps and splices for reinforcement shall be as shown on the drawings. Splices in adjacent
bars shall be staggered and the locations of all splices, except those specified on the
drawings, shall be approved by ENGINEER. The bars shall not be lapped unless the
length required exceeds the maximum available length of bars at site.
BENDING :
Reinforcing bars, supplied bent or in coils, shall be straightened before they are cut to
size. Straightening of bars shall be done in cold and without damaging the bars. This is
considered as a part of reinforcement bending fabrication work and contractors rates are
deemed to include this work.
All bars shall be accurately bent according to the sizes and shapes shown on the detailed
working drawings. They shall be bent gradually by machine or other approved means.
Reinforcing bars shall not be straightened and rebent in a manner that will injure the
material; bas containing cracks or splits shall be rejected. They shall be bent cold.
Bars incorrectly bent shall be used only if the means used for straightening and
7.5
7.6
rebending be such as shall not, in the opinion of ENGINEER, injure the material. No
reinforcement shall be bent when in position in the work without approval, whether or not
it is partially embedded in hardened concrete. Bars having kinks or bends other than
those required by design shall not be used.
FIXING :
Reinforcement shall be accurately fixed by any approved means and maintained in the
correct position shown in the drawings by the use of blocks, spacers and chairs as per
I.S. 2502 to prevent displacement during placing and compaction of concrete. Bars
intended to be in contact at crossing points shall be securely bound together at all such
points with 16 gauge annealed soft iron wire. The vertical distances required between
successive layers of bar in beams or similar members shall be maintained by the
provision of mild steel spacer bars at such intervals that the main bars do not perceptibly
sag between adjacent spacer bars.
COVER :
Clear concrete cover for reinforcement shall be maintained as stated on drawings.
The correct cover shall be maintained by cement mortar blocks or other approved
means. Reinforcement for footings, grade beams and slabs on subgrade shall be
supported on precast concrete blocks as approved by ENGINEER. The use of pebbles or
stones will not be permitted.
The 28 days crushing strength of cement mortar cubes/precast cover blocks shall be at
least equal to the specified strength of concrete in which these cubes/blocks are
embedded.
7.7
INSPECTION :
8.0
Erected and secured reinforcement shall be inspected and approved by ENGINEER prior
to placement of concrete.
EMBEDDED PARTS ENCASED IN CONCRETE :
Embedded parts to be encased in concrete shall be unpainted. The encasing shall be
done in concrete with 10 mm maximum size aggregate.
9.0
GROUTING :
9.1
STANDARD GROUT :
The proportions of grout shall be such as to produce a flowable mixture consistent with
minimum water content and shrinkage. The grout proportions shall be as specified on
drawings and as directed by ENGINEER.
a) Sand shall be such as to produce a flowable grout without any tendency to segregate
:
b) Surfaces to be grouted shall be thoroughly roughened and cleaned of all foreigh
matter and laitance.
c) Prior to grouting, the hardened concrete surfaces to be grouted shall be saturated
with water.
Forms around base plates shall be reasonably tight to prevent leakage of the grout.
Adequate clearance shall be provided between forms and base plate to permit grout to be
worked into place properly.
Grouting, once started, shall be carried out quickly and continuously to prevent
segregation, bleeding and breakdown of initial set. Grout shall be worked from one side
of one end to the other to prevent entrapment of air. To distribute the grout and to
ensure more complete contact between base plate & foundation and to help release
entrapped air, link chains can be used to work the grout into plate.
9.2
Grouting through holes in base plates shall be by pressure grouting. Variations in grout
mixes and procedures shall be permitted if approved by ENGINEER.
INSPECTION :
All materials, workmanship and finished construction shall be subject to the continuous
inspection and approval of ENGINEER.
All materials supplied by CONTRATOR and all work or construction performed by
CONTRACTOR immediately replaced at no additional expense to the OWENR and to the
entire satisfaction of the ENGINEER.
Approval of any preliminary materials or phase of work shall in no way absolve the
CONTRACTOR from his responsibility of supplying concrete and/or producing Finished
concrete is accordance with the specifications and drawings.
9.3
All concrete shall be protected by the CONTRACTOR against damage until finally
accepted by the OWNER or his representative.
CLEAN-UP :
Upon the completion of concrete work, all forms, equipment, construction tools,
protective coverings and any debris resulting from the work shall be removed from the
premises.
All the debris i.e. empty containers, scrap wood, etc. shall be removed daily, as directed
by ENGINEER.
The finished concrete surfaces shall be left in a clean condition to the entire satisfaction
of the ENGINEER.
GROUP-3 : BRICK WORK AND UNCOURSED RUBBLE MASONRY WORK
1.0
BRICKS :
Bricks used in works shall conform to the relevant Indian Standards. They shall be sound,
hard, homogenous in texture, well burnt in kiln without being vitrified, table moulded,
deep red, cherry or copper coloured, of regular shape & size shall have sharp & square
edges and parallel faces. The bricks shall be free from pores, chips, flaws or humps of any
kind. Bricks containing unground particles and/or which absorb water more than 15% of
their weight when soaked in water for twenty-four hours shall be rejected. Overburnt or
under-burnt shall be liable to rejection. The bricks shall give a clear ringing sound when
struck and shall have a minimum crushing strength of 75 K/sq.cm., unless otherwise
noted on drawings. The classes and quality requirements or bricks shall be as laid down
in IS : 1077.
The size of the brick shall be 23.0 x 11.5 x 7.5 cm, unless otherwise specified, but
tolerance of up to plus 3 mm in each direction shall be permitted. However, bricks
conforming in size stated in IS : 1077 could be used. Bricks shall be provided with frogs.
Only full size bricks shall be used for masonry work. Brickbats shall be used only with the
permission of the ENGINEER to make up required wall length or for bonding. Sample
bricks shall be submitted to the ENGINEER for approval and bricks supplied and used in
works shall conform to the approved samples. Brick samples shall be got tested as per IS
3495 by the CONTRACTOR at no extra cost to OWNER. Bricks rejected by ENGINEER
shall be removed from the site of works within 24 hours.
Specification of sand used for brickwork shall be same as that specified for concrete work
shall belong to Grading Zone-II.
2.0
MORTAR :
Mortar for brick masonry shall be prepared as per IS : 2250. Mix for cement mortar shall
be as specified in the respective items of work. Gauge boxes for sand shall be of such
dimensions that one complete bag of cement containing 50 kgs. of cement forms one
unit. Sand shall be free from clay, shale, loam, alkali and organic matter and shall be of
sound, hard, clean and durable particles. Sand shall be approved by ENGINEER. It shall
be thoroughly washed until it is free of any contamination.
For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry
condition. Water shall then be added and mixing continued to give a uniform mix of
required consistency. The mortar shall be thoroughly mixed and the same shall be used
within 25 minutes of mixing. Mortar left unused beyond the above specified period shall
not be used in work and shall be rejected.
The CONTRACTOR shall arrange for test on mortar samples, if so directed by the
ENGINEER. Retempering of mortar will not be permitted.
3.0
WORKMANSHIP :
All bricks shall be thoroughly soaked in clean water for at least one hour immediately
before being laid. The cement mortar for brick masonry work shall be as specified in the
respective item of work. For laying bricks a layer of mortar shall be spread over the full
width of the length of the lower course. Each brick shall be pressed into the mortar and
shoved into final position so as to embed the brick fully in mortar. Bricks shall be laid with
frogs uppermost.
4.0
UNCOURSED RUBBLE MASONRY PITCHING WORK :

Rubble stone for uncoursed masonry pitching work carried out using approved trap /
basalt / granite and shall be hard, tough, sound, durable, dense, clean, of close texture
and free from unsound material, cracks, decay and weathering. Water absorption when
tested as per IS standards shall not be more than 5%.
The stone shall, in the smallest dimension, be equal to the thickness of the pitching
course specified with a tolerance of 25 mm. Stone shall be sufficiently flat bedded.
Specification for mortar shall be as per clause No.2.0
Specification for workmanship shall be as per clause No.3.0.
5.0
CEMENT POINTING :
The joints of masonry shall be raked at least 12 mm deep. The dust shall then be brushed
out of the joints and the wall washed with water.
The mortar shall consist of surkhi mortar in proportion of 1:2. This mortar shall be filled
into joints and well pressed with special steel trowels. The joints shall not be touched
again after it has once begun to set.
The joints of the pointed work shall be neat. The lines shall be regular and uniform in
breadth and the joints shall be flat as directed. No false joints shall be allowed.
The work shall be kept wet for seven days after the pointing is complete.
GROUP-4 : MECHANICAL
SUPPLY FABRICATION AND ERECTION OF STRUCTURAL STEEL
1.0
SCOPE :
This section covers the general requirements for supply of steel material, where
specified, fabrication and delivery at site of structural and miscellaneous steelwork.
2.0
APPLICABLE CODES AND SPECIFICATIONS :

a) MATERIALS :
1.
IS : 808
Rolled Steel Beam, Channel and Angle Sections.
2.
IS : 814
Specifications for Covered Electrodes for Metal

Arc Welding for Structural Steel.
3.
IS : 823
Code of Procedure for manual metal arc welding of

mild steel.
4.
IS : 919
Recommendations for limits & fits for engineering

(part I & II).
5.
IS : 1161
Specifications for Steel Tubes for structural

purpose.
6.
IS : 1363
Haxagon Head Bolts.
7.
IS : 1367
Technical supply conditions for threaded steel

fasteners.
8.
IS : 1369
Dimension for screw thread runouts & undercuts.
9.
IS : 1852
Rolling and cutting tolerances for hot-rolled steel

products.
10.
IS : 2062
Structure Steel (Standard Quality)
11
IS : 2074
Ready Mixed Paint, Red Oxide Zinc Chromate And

Priming.
12
IS : 4353
Recommendations for submerged arc welding of

mild steel and alloy steels.
b) CODES OF PRACTICE :
1
IS : 800
Code of Practice for Construction in Steel.
IS : 8060
Code of Practice for use of tubes in general building

construction.
IS : 816
Code of Practice for use of Metal Arc Welding for

General Construction in Mild Steel.
3.0
STEEL SUPPLIED BY THE CONTRACTOR :
The CONTRACTOR shall furnish to the ENGINEER duplicate copies of all mill orders covering
the material ordered by him for this project and the test reports received from the Mills for
the ENGINEERs check and information.
If mill tests reports are not available for any steel materials the same shall be got tested by
the CONTRACTOR to the ENGINEERS satisfaction to demonstrate conformity with the
relevant specification.
Unidentified stock material may be used, only with the prior permission from the
ENGINEER in writing, for short sections at locations specifically selected by the ENGINEER
and also for connections where, in the opinion of the ENGINEER, the quality of such
materials would not adversely affect the strength and / or durability of the structure. The
ENGINEER may also permit use of such materials for other works, if adequate random
samples taken out and tested demonstrate conformity with specification and requirement
for the work for which these materials are proposed to be carried out.
4.0
SUBSTITUTIONS :
Wherever the CONTRACTOR, in order to accommodate his / others materials in stock,
desires to substitute structural steel or plates for the sizes shown on drawings, such
substitutions shall be made only after authorisation in writing is given by the ENGINEER.
The ENGINEER may also direct the substitution to be made, when he considers that such
substitutions are necessary.
5.0
FABRICATION :
5.1
GENERAL :
All workmanship and finish shall conform to IS : 800 . All materials shall be finished
straight as per the tolerance limits as specified. All holes and edges shall be free of burrs.
Shearing and chipping shall be neatly and accurately carried out and all portions of work
exposed to view shall be neatly and accurately done and finished. Material in the shops
shall be kept clean and shall be protected from damage.
5.2
CONNECTIONS :
Shop connections shall be effected either by welding, or bolting, as specified on the drawings.
Bolts shall be in accordance with specifications.
5.3
STRAIGHTENING :
Rolled material, before being worked, shall be straightened. If straightening or flattening is
necessary, it shall be done by methods that will not injure the material. Heating and/or
forging shall not be permitted for straightening.
5.4 CUTTING :
Cutting may be carried out by shearing, cropping or machine flame cutting, if permitted by
the ENGINEER. All re-entrant corners shall be shaped notch free to a radius of at least 12
mm. Sheared or cropped edges shall be dressed to a neat workman like finish and shall be
free from distortion and burrs. The kerf on machine flame cut edges shall be removed.
Hand flame cutting shall be undertaken only if so permitted by the ENGINEER and shall only
be carried out by an expert in such work. Hand flame cut edges shall be ground smooth and
straight.
Edge planing of sheared, cropped or gas cut edges is not intended, unless the sheared,
cropped or gas cut edges are such as to warrant it, or is specifically called for.
5.5
WELDING :
Electrodes for shielded-arc manual welds shall comply with the requirements of IS : 814 and
shall be of approved make.
The electrodes for manual arc welding shall be suitable for use in the position and type of
work, as laid down in the above specifications and type of work, and as recommended by the
manufacturers. Electrode classification group 1 or 2 as given in IS : 814 shall be used for
welding steel conforming to IS : 2062.
All welds shall be made by only welders and welding operators who have been properly
trained and are qualified by tests and to perform the type of work required as prescribed in
the relevant applicable standards.
All welds shall be free from defects like blow holes, slag inclusions, lack of penetration,
undercutting, cracks, etc. All welds shall be cleaned of slag or flux and show uniform sections,
smoothness of weld metal, feather edges without overlap and freedom from porosity.
5.6
TOLERANCES :
The dimensional and weight tolerance for rolled shapes shall be in accordance with IS : 1852.
The acceptable limits for straightness (slope and camber) for rolled or fabricated members
are :Struts and columns L/1000 or 10 mm whichever is smaller
For all other members not primarily
in compression such as purlins, girds,
bracings and the web members of trusses
and latticed girders.
L/500 or 15 mm whichever is
smaller
Where L is the length of finished member, as the ENGINEER may specify.

5.7
DIMENSIONS, WORKMANSHIP & CLEANLINESS :

Members shall be inspected at all stages of fabrication and assembly to verify that
dimensions, tolerances, alignment, surface finish and painting are in accordance with the
requirements shown on the approved shop drawing.
5.8
HANDRAILS :
Handrails shall be provided on open sides of platform, stairways and landings as shown on
drawings. Handrails shall be of standard weight mild steel pipe of flush welded construction,
ground smooth, provided with double rail, top rail about 1 metre above platform level and
pipe posts spaced as shown on drawings.
Smooth uniform curves and bends shall be provided at stair return and also wherever
required / specified. Posts connected to curb plates shall have a neat closure at the a bottom
and 6 mm. Thick plate neatly welded to posts for attachments to curb plate. All necessary
fittings including inner dowels at splices, brackets, bolts, bends, flanges and chains, where
required shall be furnished by the CONTRACTOR. Open ends of all the pipe posts shall be
plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all
points of direction changes in the handrail.
The rate quoted for handrails shall be as per running metre of completed handrailing
including posts, fitting, etc. It shall be clearly understood that individual lengths of runners,
posts, etc. will not be measured for purposes of payment.
6.0
ERRORS :
Any error in shop work which prevents proper assembling and fitting up of parts in the field by
moderate use of drift pins or moderate amount of reaming will be classified by the ENGINEER
as defective workmanship. All charges incurred by the ENGINEER either directly or indirectly
because of the poor workmanship will be deducted from the amount due to the CONTRACTOR
before payments made. The amount of such deduction will consist of the sum total of the
costs of labour direct or indirect, material, plant, transportation, equipment rental and
overhead expenses. In case the ENGINEER choose to reject the material because of poor
workmanship, the cost of all handling and returning the material to the CONTRACTOR, if he
so desires, shall entirely be to CONTRACTORs account. All the replacement materials shall
conform to the same specification as for the original materials, & shall be supplied free and in
all such cases, the cost of handling, transport and delivery to site shall be borne by the
CONTRACTOR.
7.0
PAINTING :
All fabricated steel material, except those galvanised, shall receive protective paint coating.
The surface of steelwork to be painted shall be thoroughly cleaned of all loose mill scale,
rust, grease, dirt and other foreign matter by hand tool cleaning, power tool cleaning or
flame cleaning as specified and as directed. In power brushing, sufficient care shall be
exercised not to burnish mill scale to a slick finish to which paint may not adhere properly.
The paint treatment specified shall be applied either by brushing or spraying on the
thoroughly cleaned and dry surface. Airless spraying shall be done if so specified. Surfaces
inaccessible after assembly shall receive an additional coat of the specified paint prior to
assembly.
Paint shall be stirred frequently to keep the pigment in suspension. All paint delivered to the
fabrication shop shall be ready mixed in original sealed containers as packed by the paint
manufacturers and no thinners shall be permitted. No painting shall be done in frosty/foggy
weather or when the humidity is high enough to cause condensation on the surface to be
painted. Paint shall not be applied when the temperature of the surface to be painted is 45
deg. or higher.
8.0
STRUCTURAL STEELWORK IN TUBES :
8.1
SCOPE :
This section covers the specific technical requirements for the following:a) Supply, inspection, and testing at site of tubular structural steelwork.
b) Fabrication, erection and testing at steelwork.
8.2
SUPPLY, ERECTION AND TESTING OF MATERIALS :

Materials for tubular steelwork supplied by CONTRACTOR shall conform to IS:1161, YST 210.
The class of tubes shall be as specified on drawing. All materials shall be free from injurious
defects.
9.0
FABRICATION ERECTION AND TESTING OF TUBULAR STEELWORK :

The supply and erection of tubular steel work shall include inspection, delivery at site,
cleaning, cutting, aligning welding connecting and installing all tubular steelwork in position
as shown on drawing and as directed by ENGINEER.
Wherever tubes of different thickness are to be butt welded, the necessary beveling shall be
carried out by the CONTRACTOR at no extra cost to OWNER.
The CONTRACTOR shall be supplied with the drawings for tubular steel work connections. The
tubes shall be cut to the exact shape and welded properly. The thickness of the weld shall be
as specified on drawing. Welded joint shall be ground smooth.

10.0
WELDING :
Tack welds used in assembling tubes shall be made by a qualified welder. Tack welds which
are not to be removed shall be made with an electrode which is the same as or equivalent to
the electrode to be used for the first pass.
All welds shall be full penetration, welds and homogenous with no voids. Any cracks or
blowholes that appears on the surface of joint shall be removed by chipping.
All stipulations for welding work as mentioned in this specification (para 6.6) shall apply for
the welding of tubular steelwork, in addition to that mentioned above.
GROUP - 5
SPECIFICATION FOR BULLET MOUND MATERIALS
1.0
GENERAL SCOPE OF WORK :

The area to be covered by the mound shall be cleared of all trees, stumps, roots, bushes
and other objectionable matter before starting the works. The excavation shall be carried
out as per the specifications laid down in Group I of these specifications and the
excavated natural soil surface shall be dressed and well compacted with a vibro roller
before commencement of the murrum filling works.
The contractor shall take precautions to prevent the excavated area and the sub-grade
formation level being flooded by rain or surface water. If required the contractor shall
make his own arrangements at no extra cost for dewatering of trenches.
2.0
GROUND IMPROVEMENT & SAND BED
2.1
Murrum / sand as specified shall be used for the ground improvement work.
The quality of MURRUM shall be strictly as approved by HPCL and the decision of HPCL in
this regard will be final and binding on the contractor. Murrum shall be laid in layers, each
layer in loose state shall not be more than 200 mm in thickness. Water as per OMC
requirement shall be sprinkled on the layer and after allowing for soaking, compaction
shall be done using a vibro roller ( 10 MT static weight) of 20 MT - 30 MT weight in
dynamic state. The layer shall be compacted to obtain a degree of minimum 98% with
respect of the max. Dry density ( Modified Proctor density ) determined in the lab under
Optimum Moisture Content ( OMC ) condition. Each layer shall be tested for compaction
at rate of 1 test per every 500 Sqm area. Each test shall consists of 6 samples. Contractor
shall bear the cost of all laboratory and field tests for the job.
2.2
The sand to be used for ground improvement shall be as per clause 2.4 below. The quality
of sand shall be strictly as approved by HPCL and the decision of HPCL in this regard will
be final and binding on the contractor.
2.3
The geo-textile layer (Terram 1,000 or equivalent approved quality) shall be laid directly
on the top of the murrum layer prior to the commencement of the sand bed preparation
work as per the approved drawings.
2.4
The bullet bed material shall be sand laid in layers, each layer in loose state shall not be
more than 300 mm in thickness so as to give compacted thickness of 200-250 mm.
Water to the tune of 3 to 5 lit/ sq.m. shall be sprinkled on the sand layer and after
allowing for soaking, compaction shall be done using a vibro roller (10 MT static weight)
of 20 MT-30 MT weight in dynamic state. The layer shall be compacted to obtain a
degree of compaction of minimum 98% with respect to vibrated dry density of sand
determined in lab. The required sand filling shall be completed in layers as above to reach
the desired level up to the bottom of the bullets. (Ref BS: 1377 1900 Part 4, Clauses 3.3
and 3.4.)
2.5
The sand bed shall be laid to the falls & to the levels and full depth as shown on the
drawings and the bed for the bullets shall be excavated out of the fully compacted bed
using a template formed to the exact shape and size of the bullets.
2.6
If welding trenches are to be used they shall be backfilled with sand and compacted in
accordance with the above clauses. The trenches shall be adequately propped and braced
to ensure that there is no loss of compaction of the adjacent sand bed.
3.0
SAND SURROUND/FILLING BETWEEN BULLETS
3.1
The sand surround to each bullet shall be material in compliance with clause 5.2 laid
around the bullets during the mound filling operation to a 300 mm minimum thickness
and shall be hand compacted into position.
3.2
Filling material between bullet surrounds shall be sand in compliance with clause 5.2 laid
in maximum 200 mm layers, or other suitable material.
3.3
Sand filling placed between bullets and a line extending out at 45 from the enter of the
bullet above the bullets enter line shall be hand compacted and fill placed outside this
line shall be light machine compacted (both to minimum of 93% maximum dry density).
Compaction shall be sufficient to avoid significant settlement of the sand filling/mound
surface but shall be such as not to impose undue stresses on the bullets.
3.4
3.5
The sand filling shall be placed equally, in maximum 200 mm layers (uncompacted
depth), on each side of the bullets so as to avoid any lateral displacement/rotation of the
bullets during compaction.
3.6
Sand filling shall be brought up to the levels and slopes as denoted on the drawings to
below the drainage layer.
4.0
DRAINAGE LAYER ABOVE BULLETS
4.1
A 1,000 micron UPVC membrane shall be laid on top of the compacted sand fill, to falls
and levels denoted on the drawings, with a 1m minimum lap at joints and with the higher
sheet overlapping the lower sheet.
4.2
A geo textile membrane of Terram 1,000 or equivalent (to be approved by HPCL / TPIA)
shall be laid on top of the UPVC membrane to protect it from the stone layer laid above
this membrane.
4.3
A perforated PVC drain pipe shall be laid as denoted on the drawings, between the Terram
and the UPVC membrane and shall be surrounded by pea gravel and overlain by a 5 mm
to 50 mm stone layer. The PVC drainage pipe shall conform to BS 4962:1989, whereas
the drainage pipe shall conform to BS:5911.
5.0
MATERIAL SPECIFICATION
5.1
The sand fill required for ground development shall be as per Clause 5.2 below.
5.2
The sand for the bullet bed, bullet surround and filling between bullets shall consist of
material complying with the following specification :a) Good quality clean, non-aggressive sand with a maximum organic Material
Content of 3% by weight.
b) A max. silt content of 10% by weight (particles smaller than 0.063 mm).
c) A maximum particle size of 5 mm.
d) A grain size distribution Uniformity Coefficient (D60/D10) of between 2 & 8
5.3
The pea gravel shall consist of clean washed, single sized, 8mm round stone free from all
organic matter, sulphates or any other deleterious material and laid as surround to the
perforated PVC drain pipe, minimum 150 mm thickness.
5.4
The stone layer to the top of the mound shall consist of clean, well graded stone free from
all organic material, sulphates, or any other deleterious material, and with a particle size
of 5mm to 50mm. Depth varies from 150 mm minimum to 350 mm maximum.
5.5
The side slopes to the mound shall be protected by good quality stone pitching
constructed out of stones of size 225 average and grouted together to form an
impermeable finish, all as denoted on the drawings with 1:4 cement mortar for joints.
Raised pointing of pitching is to be carried out with 1:2 cement mortar.
6.0
SUMMARY TABLE
6.1
A summary of the proposed materials, grading and compaction requirements for the
bullet mound is given in the following
Table 6.1.
ITEM
Fill to underside of
sand bed
Bullet sand bed
GRADING
COMPACTION
Clean Sand to
98% of max. laboratory dry density,
5.2
Clean sand to
98% of max. laboratory dry density,
Clause 5.2
Bullet sand surround, Clean sand to
Hand compacted to minimum
300 mm
Clause 5.2
93% max. laboratory dry density.
Mound filling between Clean sand to
Hand compacted or light machine
bullets
Clause 5.2 or
compacted to minimum 93% max.
other suitable
laboratory dry density.
Material
Pea Gravel
Clean stone to
N/A
Clause 5.3
Stone Drainage Layer Clean stone to
N/A
Clause 5.4
Stone Pitching
Stone to Clause
N/A
5.5
NOTE: Contractor shall submit the Quality Assurance plan for the Entire mounded bullets
construction
TESTING OF BUILDING MATERIALS

For particle size test, it is recommended that the set of sieves and weighing machines be
arranged by the contractor at site. Necessary manpower for conduction of the tests also
to be arranged by the contractor.
For crushing strength of concrete, it is recommended that the contractor arrange the
compression testing machine at the site along with the calibration certificate for gauge.
In case, if any of the machine comes to repairs and tests could not be carried out at the
site, contractor shall arrange to transport the material to an approved laboratory to carry
out the tests.
Sl.
NO.
MATERIAL
TESTS
Water
Cement
a) Ph value
b) Limits of Acidity
c) Limits of Alkalinity
d) Percentage of solids
e) Chlorides
f) Suspended matter
g) Sulphates
h) Inorganic solids
i) Organic solids
(a) Fineness
(b) Soundness
(c) Setting time ( Initial &
Final )
(d) Compressive strength
(e) Consistency
(a)Particle Size
distribution
(b) Sp. Gravity
(c) Deleterious substance
(d) Organic impurities
(e) Water absorption
(f) Fineness modulus
(a) Percentage of soft /
deleterious material
(b) Particle Size
distribution
(c) Organic impurities
(d) Sp. Gravity
(e) Bulk density
(f) Aggregate crushing
strength
(g) Aggregate impact
value
(h) Alkali Reactivity
(i) Flakiness index
(a) Physical properties
(b) Chemical test
Sand
For
concreting
4.
Coarse
aggregate
For
concreting
Reinforce
ment steel
TEST
PROCED
URE
I.S.
3025
ACCEPTANCE
CRITERIA
PERIODICITY
I.S. 456
From the source at

the beginning of
work / change of
source.
I.S.
4031
I.S. 8112 /
12269
IS 2386
IS 383
Zone - II
I.S.
2386
I.S. 383
Manufacturers test
certificate and Lab
test for each batch
brought to site.
Every 40 Cum or
part thereof.
One test for each

source
Every 40 cum or
part thereof
I.S.
1608
I.S. 1786
Each lot from each

source for each dia.
(c) Bend & rebend test

(d) Elongation test
(e) 0.2% Proof stress
(f) Tensile strength
6.
Concrete
For PCC>
M10
Cement
concrete
(For RCC)
Sand for
filling
(a) Slump test
I.S.
1199
I.S. 456
(a) Slump test

(b) Cube test
( Each sample consists
of 6 cubes, three cubes
for 7 days strength and 3
cubes for 28 days
strength.)
I.S.
1199
I.S. 456
(a) Particle size

distribution
(b) Organic content
(c) Silt content
(d) Uniformity coefficient
(D60/D10)
(e) Max. Dry density
(f) Optimum Moisture
content
I.S.
2386
Min. Qty 10 MT.

Test to be repeated
for every 10 MT or
part there of.
15 Cum or part
thereof
Every 5 cum
Qty.
I.S.
2720
Max. organic
content 3% by
wt.
Silt content
10% by
weight
Particle size
max. 5mm
Uniformity
coefficient 2.0
to 8.0
Compaction
as per PO
specs.
No. of
Samples
1-5
M3 : 1
6-15 M3 : 2
16-30 M3 : 3
31-50 M3
:
4
51& above: 4 plus
one additional
sample for each
additional 50 M3 or
part thereof.
One lab test for
each source or as
per direction of
Engineer-in-charge
Field compaction
test:
1 test for 500 M2
area of each layer.
There shall be min.
10 density
measurements for
each test.
FOR
ELECTRICAL WORKS
TECHNICAL SPECIFICATIONS FOR PMCC/MLDB PANELS

1.0
SCOPE :
This specification covers the design, manufacturing and supplying of PMCC & MLDB
required by M/s HINDUSTAN PETROLEUM CORPORATION LIMITED for their Consumer
Facility at M/s, BAMUL, Bengaluru.
2.0
The
scope
of
work
shall
cover
the
design,
fabrication,supply,testing,commissioning of PMCC panel.
The equipment shall be suitable for 415 V, 50 Hz, 3 phase power supply & for an
ambient temperature oupto 55 deg C and relative humidity of 100%. The PMCC
panel shall be of Double Front Type & the main Bus Bar shall be rated for
1000A. The vendor should submit four sets of drawings for approval to HPCL
before taking up the manufacturing of the PMCC Panel.
SPECIFICATIONS:
I.
INCOMING FEEDERS:
1 No of 400 Amps MCCB for Incoming power supply from BAMUL

Feeders to comprise of:
KA breaking capacity, 4 pole type MCCB with door, interlocked, shutter assembly, built
in under voltage protection.
1 set of 1000 A TPN bus bar of Aluminium with colour coded heat shrink
sleeves
1 No. each of 144 sq.mm Voltmeter, Ammeter with selector switch & HRC
control fuses
1 No. each of 144 sq.mm Power factor & Frequency meter.
1 no energy meter with control fuses
1 set of phase indicating lamps with fuses
1 No space heater with thermostat and MCB
Provision for terminating 3.5 C 300 sq.mm cable from the bottom of the panel.
II. OUTGOING FEEDERS
1.
2.
3.
4.
5.
6.
Motors of suitable rating for Vapourisers

:5
Motors of suitable rating for LPG unloading pumps
:4
Motors of suitable rating for LPG compressors
:3
4 KW for power supply to ROVs, all instruments,DV etc : 2
32 A TPN SFU feeders
:2
63 A TPN SFU feeders
:2
Nos
Nos
Nos
Nos
Nos
Nos
The outgoing feeders shall have the minimum requirements as detailed below:
i.
ii.
1 No TP SFU with HRC fuses, links & bases suitable for the feeder
specified.
1 No suppressed scale ammeter with selector switch along with 1 nos CTs
of 15VA class I accuracy.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
1 no 3P contractors (AC 3 duty) with 2NO+2NC auxiliary contacts suitable

for the feeder specified.
1 no. auxiliary contactor with 2NO+2NC contacts for remote indication etc.
1 no. bimetallic thermal overload relay with built in single phase inventor
2 nos. push button for reset & stop.
3 nos indicating lamps with HRC control fuses for ON,OFF & TRIP
1 HRC fuse for control supply
Branch bus bars (TPN) with colour coded heat shrink sleeves.
1 No electronic timer
Provision for terminating 1 no power & 1 no control cable
The above MCCB feeders shall be provided with the following:

a) Under voltage & shunt trip and shall also provide overload & short circuit
protection.
b) Ammeter with selector switch to show the current on all the three phases
c) CT of 150 VA class I for meeting etc.
d) 2 Nos indicating lamps with HRC control fuse for ON & OFF indication.
e) Provision for terminating the power cable.
NOTE:
1. For feeders upto 22 KW capacity, the requirements(x) specified for outgoing
feeders are not applicable.
2. Feeders above 22 KW shall be fully automatic star delta feeders
3. All the feeder to have the following provisions:
a) Provision for remote ON & OFF
b) Provision for remote Ammeter
c) Provision for remote ineterlock
4. Provision has to be made to trip 5 nos of feeders in case of exigency. All these
feeders shall trip together as & when remote signal is received.
5. For items 5 & 6 32 A & 63 A TPN SFU Feeders shall comprise of suitable
capacity MCB, HRC fuses, indicating lamps, provision for terminating the
cables etc., complete.
1.0
METEOROLOGICAL DATA
Ambient temperature
Humidity
: 50 deg C ( Max.)
: 100% ( Max.)
POWER SUPPLY DETAILS

Supply Voltage
Frequebcy
4.0
: 3 phase, 415 V, +/- 10% variation.

: 50 Hz + 3% variation
DEVIATIONS
Any deviations in the equipment offered shall be clearly brought out in the offer. In
the absence of the same, it will be presumed that the equipment offered is in
compliance with the specification.
5.0
COMPLETENESS OF OFFER:
Offer must be complete giving all the required data & necessary drawings.
6.0
QUANTITY
1. Power & Motor Control center(PMCC) & MLDB
7.0
1 No
STANDARDS:
All materials, equipments and accessories used in the manufacture shall conform
to the latest editions of relevant Indian / British standards including amendments
and addenda, some of which are listed below:
1. IS 375 : Marking and arrangement for switchgear bus bars, main connection and
auxiliary wiring.
2. IS 722 : A.C.Electric Meters
3. IS 1248 : Direct acting electrical indicating instruments
4. IS 2147 : Degree of Protection provided by enclosures for low voltage switchgears.
5. IS 13947.1 : Low voltage switch gear & control gear General rules 1993
IS 13947.2 : Low voltage switch gear & control gear Circuit breakers 1993
IS 13947.3 : Low voltage switch gear & control gear Switches, Disconnectors,
Fuse Combination units 1993
IS 13947.4 : Low voltage switch gear & control gear Electro Mechanical
Contactors and motor starters 1993
IS 13947.4 : Low voltage switch gear & control gear Control Circuit Devices &
Switching elements 1993
6. IS 12703 : Low Voltage Fuses { Part 1:2:4 (rev 0)}
7. IS 2705 : Current Transformers
8. IS 3156 : Voltage Transformers
9. IS 3231 : Electric relays for power system protection
10. IS 3202 : Code of practice for climate proofing of electrical equipment.
11. IS 3427 : Metal closed switch gear and control gear.
12. IS 4237 : General requirements for switchgear and control gear for voltage not
exceeding 1000 volts.
13. BS 162 : Specification for electric power switchgear and associated apparatus
14. IS 8623 : Factory built assemblies of switchgear and control gear.
15. IS 694 Part I & II : PVC insulated cables( for voltage upto 1100 V with copper and
aluminium conductors)
16. IEC 255-1-0 : Specification for Electronic Timers
In the absence of specific Indian Standard Specifications, International Electro
Technical Committee specifications shall be followed.
8.0
CONSTRUCTION OF PMCC & MLDB:
8.1
The PMCC & MLDB shall be floor mounted, double front and totally enclosed to
make it dust and vermin proof.
8.2
Switch boards shall be fabricated from 14 swg CRCA sheet steel minimum.
The base frame of the panels shall be made from ISMC 100 and a min angle
section of 75x40x6mm to be provided at the bottom of each cabinet.
14 SWG MS sectionalized entry plates shall be provided for multi core entries and
6 mm hylam sheet for single core entry points.
The height of all panels shall not be more than 2000 mm and the depth of the
panel shall not be more than 500 mm for single front and 800 mm for double front
except for the circuit breaker panels, where the depth could be about 1000 mm.
The circuit component shall be mounted on sectionalized 12 SWG 2.5mm thick MS
sheets with suitable threading in the sheets to facilitate easy maintenance, future
addition etc.,
Switchgear shall be floor mounted, free standing, totally enclosed and dust, damp
& vermin proof. Non deteriorating gaskets to be used between all adjacent units
and beneath all covers and doors of dust proofing.
The switchgear panels shall have minimum IP-52 degree of protection. (as per IS
2147)
Hinges provided for doors shall not be visible from front.
Switchgear shall be self ventilated.
8.3
Switch boards shall be fully compartmentalized. When compartment door is opened,

bus bar, cable alley and any live terminals shall be shrouded by barrier plates.
8.4
Switch boards shall comprise of a number of vertical panels of same height and
bolted together to form PMCC/MLDB.
Clearance between phases & between phase and earthing as well as the insulation
levels shall be in accordance with relevant IS/BS.
8.4(a) Switch gear construction, mounting of various equipments viz., circuit breakers,
instruments, relays, bus bars and secondary wiring shall be done with due
considerationto the following:
i.
ii.
iii.
iv.
v.
vi.
vii.
Facility for inspection, maintenance and repairs.

Minimum vibration and noise.
Risk of accidental short circuits and open circuits.
Interchangeability of components.
Risk of accidental contact and danger to personnel due to live parts.
Secure and vibration proof connections for power and control circuits.
When rear door is opened, only cable connections shall be accessible.
8.5
Adequate lifting facilities shall be provided on each section of the switchboards.

Lifting eyes shall be removable. Suitable bolt to be provided to plug threaded hole
after lifting lug removed.
8.6
Bus bars:
There shall be 3 nos of bus bars for phases & 1 no for neutral. These shall be of
Electrical Grade Aluminium and of sufficient cross section to carry rated current
without any damage. The bus bars shall be supported on epoxy resin cast insulators
and covered by heat shrinkable PVC with colour coded sleeves. The main bus bars
shall be rated as indicated in the single line diagram and suitable for extension on
both
sides.
Two separate sets of vertical bus bars should be provided for the front and rear
modules in double front switchboards.
Tapping points shall be treated against oxidation and shall be insulated in a similar
manner to the main bus bars. Appropriate identification markings/labels shall be
provided on the bus bars and tappings for distinguishing the various phases and
neutral. Bus bars shall be air insulated, enclosed having barriers / covers.
CAUTION LIVE BUS BAR board shall be provided on barriers/covers.
8.7
Outgoing feeder modules shall be of fixed type. Incomer ACB feeders shall be of
fully draw out type and shall be provided with mechanical & electrical interlock.
8.8
Power and control cables shall be terminated on fixed terminals.
8.9
Provision shall be made to ensure that compartment door cannot be opened when
the feeder switch /ACB is ON. The cables shall be neatly clamped in the cable alley
so that disconnecting the cables from the terminals can be done easily.
8.10
Fabricated panel shall undergo 7 tank pre treatment of degreasing, pickling &
phosphating etc., two coats of Zinc chromate primer and two coats of epoxy based
paint of approved shade shall be applied.
8.11 All cable entries shall be from bottom

8.12
Equipments inside the compartment shall be arranged in a logical manner for ease
of reference at site. The equipment reference mentioned in wiring diagram shall be
provided on the equipment.
8.13
Cable shall be terminated at bus bar extensions back of the panel for incomer or
large diameter cables and at stud type terminal blocks in the cable alley for other
out going power feeders and clamp type terminals for control cables. The terminal
block shall be identified with feeder number. Minimum distance between gland
plate and termination shall be approximately 200 mm.
8.14
Removable un drilled gland plates for the panel shall be provided complete with
gaskets, nuts and bolts for proper fixing.
8.15
For terminating instrumentation cable/ cables to DC marshalling box shall be

provided in each shipping section. Internal wiring shall be terminated at this box.
Live terminals if any, shall be segregated and shrouded with caution labels LIVE
TERMINALS.
8.16
Control supply voltage will be 230 V AC and shall be derived by tapping phase and
the neutral from the incoming side of the SFUs
8.17
One Green, red and one amber indicating lamps of LED type shall be provided on
each starter feeder for OFF, ON & TRIP indication in PMCC.
8.18 Only stop (stay put) and reset push button shall be provided on the starter door.
8.19
All starters upto 22 KW shall be of DOL type and 22 KW and above shall be star
delta type.
8.20
Motor starter feeders shall have following additional features incorporated.

1. BMR shall have in built single phasing prevention feature and shall be of hand
reset type.
2. One current transformer with accuracy class 1, 5 VA rating shall be provided on

feeders having capacity more than 22 KW for remote (LCS) metering. CT
Terminals shall be brought out to terminal block and shorting link shall be
provided.
8.21
Each panel shall be provided with space heaters ( min 2 nos x 75 watts each) shall
be provided for panel heating, operating on 230V AC and controlled by thermostat,
toggle switch, fuses etc.
9.0
FEATURES OF CIRCUIT BREAKERS/STARTERS AND OTHER FEEDERS:
9.1
The circuit breaker including its operating mechanism with equipment shall be
mounted on trolley / carriage moving on guides designed to align correctly and
allow smooth movement.
9.2
Incoming and out going power connections for each draw out cubicle between
fixed portion of the panel and trolley shall be by means of self aligning plug in
contacts. Both male and female contacts shall be of silver plated copper. Contact
design shall ensure adequate pressure normally and increase in contact pressure
during short circuit.
9.3
Control wiring connection between trolley and fixed part of panel shall be made by
sliding type terminals, preferably in the front of circuit breaker so that
inspection/testing is easy.
9.4
The draw out design shall have three positions SERVICE, TEST, and ISOLATE
for circuit breaker and motor starter feeders. For switch fuse feeders, only
SERVICE and ISOLATE positions shall be provided.
9.5
Position indicator shall be provided on the service panel to indicate the position of
the C, B trolley viz., SERVICE, TEST, and ISOLATE.
9.6
In the TEST position, it shall be possible to check the feeder operation without
energizing the power circuit.
9.7
It shall be possible to withdraw the circuit breaker trolley up to the TEST and
ISOLATE position without opening the front door.
9.8
Automatic safety shutters shall be provided in all CB panels for all openings which
will provide access to the live parts of the switchgear upon withdrawal of any
portion of the switchgear components parts.
9.9
There shall be provision for locking the trolley in all the three positions for
complete safety.
9.10
Feeder compartments shall be totally closed from all sides with door on the front
side.
9.11
The draw out portion of the cubicles shall be effectively connected to the earth bus
through scraping contacts. It must be ensured that the draw out portion gets
earthed before the feeder moving contacts are plugged into stationary contacts in
service position.
9.12
It shall be possible to withdraw or engage breaker only in open position.
9.13
Compartment door of breaker shall not open unless breaker is in open position.
9.14
Automatic safety shutters shall be provided to cover live contacts when carriage is
withdrawn.
9.15
Releases shall have potential free alarm contacts.
9.16
Facility shall be provided for blocking under voltage release.
9.17
Operating mechanism shall be trip free.
10.0
BUS BARS AND INSULATING MATERIALS
10.1
The switchgear shall have single bus bar pattern with air insulated bus bars
housed in a separate compartment, segregated from all other compartments, with
sheet steel barriers. Bus bars shall be of high conductivity electrolytic copper or
aluminium, suitable for carrying the rated and short time current without over
heating. Bus bars shall be adequately supported on insulators to withstand
dynamic stresses due to short circuits. Maximum bus bar temperature shall not
exceed 85 deg C under normal operating conditions.
10.2
All bus bar connections and bus taps to individual feeders shall be either by means
of 1100/650 V grade PVC insulated wires or links insulated with shrunk PVC
sleeves. Bus bars shall be colour coded for ready identification of three pahses.
10.3
All insulating materials used in manufacture shall be non-hygroscopic and shall be

treated for preventing fungus growth. Surface of insulators shall be highly glazed
and treated with silicone compound to minimize accumulation of dust,
condensation of moisture and tracking. The insulating materials shall preferably be
non carbonizing type.
11.0
AIR CIRCUIT BREAKERS/MCCBs
11.1
The circuit breakers shall be air break type and of horizontal fixed construction
conforming to IS: 13947-2
11.2
Circuit breakers shall be power operated and the closing mechanism of the circuit
breakers shall be motor wound, spring charged with a provision of manual
charging.
11.3
The operating mechanism shall be mechanically and electrically trip free and non
pumping. Anti pumping mechanism shall be built in for safety purpose.
11.4
A mechanical OFF push button suitable for front of board operation and a
mechanical ON-OFF indicator shall be provided. The mechanical ON push
button should be shrouded to prevent inadvertent mal-operation.
11.5
A shut trip coil shall be provided for tripping the circuit breakers. Shunt trip coil
shall be easily accessible from the front of the panel and easily replaceable.
11.6
Provision shall be made for remote closing and tripping of the circuit breakers with
electrically operated mechanism.
11.7
In case of spring charged mechanism, spring charged indication (mechanical)

shall be provided.
11.8
Interlock shall be provided to prevent plugging in or withdrawal of circuit breaker

trolley unless it is open. Any attempt to do so shall trip the circuit breaker
instantly.
11.9
Ready to close interlock / indicator shall be provided on the front facia of the
ACB to prevent closing of circuit breaker unless all the suitable parameter for safe
closing are met. For example, under voltage release has to be energized, shunt
release shall be de-energised, breaker should be in connected/test/disconnected
position, spring should be fully charged etc., if these conditions are met, then
Ready to Close indicator should show OK.
11.10
Main contacts shall have adequate contact pressure to carry the rated and short
time current without excessive temperature rise. The contacts shall be inspectable
for wear from the Arc chamber and easily replaceable. In the worst case of main
contact getting welded, it shall be possible to replace them at site.
11.11 The main power contacts shall be silver alloy plated or shall be of suitable material
to minimize erosion of contact due to arcing & anti weld property. The main power
contacts shall be provided with a Contact Erosion Indicator to assess the
healthiness of the contacts for the fault breaking capacity the breaker is rated for.
11.12
Auxiliary switches directly operated by the breaker mechanism shall be provided

for control and interlocks. The contacts shall be rated for 6 amps at 240 V AC. All
spare contacts shall be wired upto the terminal block. Numbers of contacts shall
be sufficient to wire the indicating lamps/closing coil/shunt trip coil/motor limit
switch etc. At least 2NO+2NC contacts shall be made available for external
interlocking.
11.13
The ACB fault protection unit shall be offered with the following protection as
specified.
- Overload protection : Inverse time delay overload release (40% - 100%
operating current)
- Short circuit protection : ( Instantaneous short-circuit release, short time delay
short circuit current release, short-time-delay short circuit release with definite
time delay for better co-ordination between two ACBs/Fuses) 1.5 to 12 operating
current.
- Earth fault protection with operating time delay(20% to 60% of rated current).
Individual LED for indication of overload, short circuit, earth fault should be made
available on the protection unit.
11.14
MCCB shall conform to IS 13947 2 shall be rated for the short circuit breaking
capacity specified (25 KA) and shall all be of current limiting type.
11.15
MCCB shall be provided with min 1 No+1NC auxiliary contacts rated for 5 A at
240V 1 Ph, 50 Hz AC or 1.3 A at 110 DC(Inductive Load)
11.16
The MCCB should have integral trip free mechanism that prevents the breaker
contacts from being closed should an overload or short circuit occur.
11.17
The accessories eg., under voltage release, shunt trip, auxiliary switch, alarm
contact etc., should be fittable at site. The MCCB shall be line contactable at both
ends to facilitate bus bar connections.
11.18
The MCCB shall be fixed with overload release providing inverse time
characteristics.
11.19
MCCBs shall be provided with solenoid closing mechanism to make them suitable
for remote closing operation. The closing solenoid shall be suitable for specified
control supply voltage.
11.20 MCCBs shall be fully rated at 50 deg C ambient temperature.

11.21
MCCB operating handle ON and OFF positions shall be displayed and the
operating handle shall be mounted on the door of the compartment housing
MCCB.
12.0
SWITCH DISCONNECTOR FUSE
12.1
Switch disconnector fuse shall be of two position (ON/OFF) type, heavy duty (AC
22/23 category as specified), load break, quick make and break type complying
with the requirements of IS 13947-3 and suitable for front of board operation.
12.2
Switch disconnector fuse ha to be interlocked with compartment door to prevent

opening or closing of the door in the closed (ON) position of the switch
disconnector fuse in case of compartmentalized switch board. Provision for pad
locking the switch disconnector fuse in open or closed position also to be made.
12.3
The switch disconnector fuse unit shall have positive indication of contact
separation.
13.0
FUSES
13.1
All fuses shall be IS 13703, non deteriorating high rupture capacity, DIN type
mounted in suitable switch disconnector units. For control application, BS
type(bottle type) fuse is permissible.
13.2
Fuses for motor feeders (DIN type) shall be so chosen that they do not operate
during starting of the respective motors and shall provide adequate protection for
all feeder components as per type 2 co-ordination conforming to IS 13947-4
13.3
For switch disconnector fuse feeders, the rating of the fuse, if not specified, shall
be same as that of the switch rating.
13.4
Fuses shall be provided with operation indicators and shall be possible to change
fuses with the SDF off but circuit live.
13.5
All fuses in control, indication and metering circuit shall be HRC, link type designed
for continuous operation for an ambient temperature of 55 deg C.
13.6
Insulating fuse pulling handles shall be available for each size of fuse with the
switch gear.
14.0
MOTOR STARTERS / CAPACITOR FEEDERS
14.1
Motor starters shall comprise of one main TP isolator, HRC Fuses for power and
control (or MCCB if required), main power contactor/s, auxiliary contactor/s,
bimetallic thermal overload relay, stop/reset push buttons, terminals etc., as
mentioned in the data sheets.
Switch disconnector fuse
Contactors
BMR
Stop push
: Quick make, quick break, AC 23 duty type as per IS

13947-3
: Magnetic air break as per IS 13947-4, AC 3 duty, if
not specified.
: Hand reset type with 1 NO and 1 NC contact and
reset push button with single phasing protection
built-in. Hand/auto reset shall be possible at site.
: With 1 NC contact, stay put type with mushroom
head button.
14.2 Starters shall be direct on-line or automatic star delta type as specified in the data
sheets. Starters shall be of AC 3 utilisation category as specified in IS 13947. Star
delta starters shall be automatic with three contactors and a timer. Reversing
starters shall have forwarded and reverse contactors electrically interlocked with
each other.
14.3
Capacitors feeders shall comprise of a switch disconnector fuse unit ( specifically

suitable for capacitor switching duty), and capacitor duty contactor (AC 6B) as
indicated in SLD. The capacitor duty contactor shall have a series built in resistor
for reducing the in rush current while switching in. The resistor shall be by passed
immediately after switching operation.
15.0 INDICATING LAMPS

Indicating lamps shall be low burden type with series resistor. Lamps shall be
filament type except where LED lamps are specifically called for. Lamp covers
provided shall be of similar colour as LED lamp to enhance visibility. LED lamps
shall have in built surge suppressors and shall have minimum Lux out put of 300
Lux.
Red
Green
White
Amber
White
RYB
C.B. ON
C.B. OFF
Trip supply supervision
Auto trip
Spring Charged ] when specifically called for
Potential Indication
16.0 CURRENT TRANSFORMERS

16.1 Current transformers shall conform to relevant Indian Standards. The design and
construction shall be sufficiently robust to withstand thermal and dynamic stresses
due to maximum short circuit current available at the point of installation of current
transformer.
16.2 Secondary terminals of the CT shall be brought out suitably to a terminal block
which will be easily accessible for testing and for external connections.
Terminals shall be marked in accordance with IS 2705. A rating plate as per IS
2705 shall be provided on each current transformers.
16.3 Current transformers shall preferably be capable of being left open on the
secondary side with the primary circuit carrying rated full load current without
overheating or damage.
17.0 INSTRUMENTS AND RELAYS
17.1 All relays and instruments shall be flush mounting type. The instruments shall
preferably be of the rectangular shape and shall have adequate scale strength.
Protective relays shall be in accordance with the protective scheme specified. All
relays and instruments shall be mounted in dust light, damp proof, tropicalised
cases. Instruments and relays shall be able to withstand a high voltage test of 2000
volts RMS for one minute. Wherever possible, metering instruments and relays shall
be draw out type. Minimum size of indicating instruments will be 144 sq.mm
17.2 Relays shall be provided with hand reset type mechanical operation indicator of
direct acting type or fitted with an auxiliary unit where required. The auxiliary unit
shall be shunt reinforcing, shunt seal in or series seal in type as specified. It shall
also be provided with minimum two parts of self, hand or combined self or hand
reset type contacts if specified.
17.3 CT secondary rating and current setting range of relays shall be as specified in the
drawing. All indicating instruments shall be of Industrial Grade 1 accuracy as per IS
1248 and energy meters as per IS 722.
18.0 CONTACTORS
18.1 The contactors shall be air brake type equipped with three main contacts and
minimum 2 NC & 2 NO auxiliary contacts. The main contacts of a particular
contactor shall have AC 3 rating as shown in the relevant switch board data sheet
for contactor.
18.2 The auxiliary contacts shall be rated for minimum 5 A at 240V AC and 1.3A at 110V
DC ( Inductive load)
18.3 Unless specified otherwise, the coil of the contactor shall be suitable for operation
on 240V 1 Ph AC supply and shall work satisfactorily between + 10 and -15% of the
rated coil voltage.
18.4 The contactor drop off voltage shall be between 15% to 65% of the rated coil
voltage.
19.0 THERMAL OVERLOAD RELAY WITH BUILT IN SINGLE PHASE PREVENTOR
19.1 Thermal overload relay shall be 3 element, positive acting and ambient temperature
compensated type with adjustable setting range & built in single phase preventor.
19.2 Thermal overload relays shall be manually reset type with the reset push button
brought out front of the panel. The reset push button shall be capable of being
operated without opening the component door.
19.3 Thermal overload relays shall be provided with min 1 NO + 1 NC and 1.3 amps at
110V DC (Inductive load)
20.0 RELAYS
20.1 All relays shall be back connected, draw out type, suitable for flush mounting and
fitted with dust tight covers.
20.2 The relay cases shall have provision for insertion of test plugs in the front for testing
and calibration purposes. It shall be possible to test the relays without
disconnecting the wiring and without withdrawing the relay. The insertion of test
plug shall automatically short circuit the CTs and permit extension of external
power supply to the relay.
20.3 The relays shall be provided with hand reset type built in flag indicators. It shall be
possible to reset the flag without opening the relay case.
20.4 Each protective relay shall be provided with min 2 nos. potential free contacts of
required configuration.
20.5 Each tripping relay shall be lock out type with hand reset coil cut off contact. Min 4
nos. potential free auxiliary contacts of required configuration shall be provided for
each tripping relay if the no of contacts are not indicated in the feeder data sheets.
The tripping relay shall be suitable for satisfactory operation from 50% to 110% of
the specified control supply voltage.
21.0 CONTROL AND SELECTOR SWITCHES / CONTROL FUSE AND CONTROL FUSE
BASE
21.1 Control and selector switches shall be of rotary type provided with escutcheon
plates engraved with switch operating positions.
21.2 Selector switches shall have stay put positions with oval handle. The number of
contacts and their operation in each switch shall be as per the requirement
specified in Data Sheets or contact development diagrams.
21.3 The control fuse link carrier shall be of CAM operated type for ease of
maintenance& inspection. It shall be possible to isolate the fuse link/ fuse link
carrier by drawing out the fuse link holder in the extreme draw out position.
21.4 The control fuse base shall be DIN rail mountable for ease of maintenance and
assembly.
22.0 ANNUNCIATORS
22.1 Annunciators when specified in the data sheet/SLD shall have audible alarm and
visual display through translucent plastic window of preferably 50 mm x 65 mm
size engraved with appropriate function in block letters on each window.
ACKNOWLEDGE, RESET and LAMP TEST push buttons shall be provided

common for the annunciation system on the switchgear.
22.2 On receipt of an alarm impulse, audible alarm shall be sounded and lamp inside
appropriate window shall start flickering. On pressing of ACKNOWLEDGE button,
the audible alarm button shall stop sounding and lamp shall become steady. By
pressing RESET button, the troble lamp shall not reset unless the alarm conditions
have disappeared. Annunciators shall provide seal in lamp indication and audible
alarm shall be ready to operate for any new alarm condition immediately after
audible alarm is reset for a previous alarm condition.
23.0 EARTHING
The switchgear shall be provided with a continuous earth bus having sufficient cross
section to carry the fault current for the specified duration without exceeding the
safe temperature throughout its entire length. All non current carrying metal work of
the switchgear shall be effectively bonded to this earth bus. Bonding washers( star
washers) shall be used when sections of switchgear are bolted together to ensure
earth continuity.
24.0 INTERNAL WIRING
24.1 Switchgear shall be complete with all internal wiring and ready for purchasers
external cable connections at the out going terminals. All inter modular wiring
within the switchgear for control and interlock loopings shall be carried out by the
switchgear manufacturer.
24.2 The wiring inside the switchgear shall be carried out with 1100/650 V Gr PVC
insulated wires of gray colour.
24.3 Min size of conductor for power circuits shall be 2.5 sq.mm copper or 6 sq.mm
aluminium.
24.4 All control except CT secondary wiring shall be carried out with min 1.5sq.mm
copper conductor. CT secondary wiring shall be carried out with min 2.5sq.mm
copper conductor.
24.5 All wiring shall be securely fixed and neatly arranged to enable easy tracing of
wires.
24.6 All terminal blocks and wires shall be tagged for identification in accordance with IS
375
24.7 All wirings of external connections shall be brought out to the individual terminals
on a ready accessible terminal block. All terminal blocks shall be shrouded or
provided with transparent covers.
24.8 Clamp type control terminal blocks shall be provide for outgoing control cables. Min
10% OR 4 Nos. spare terminals shall be provided for future use. Control terminal
block shall be separated from power terminal blocks by means of an insulating
barrier.
25.0 SPACE HEARTERS

25.1 Adequately rated anti condensation space heaters shall be provided in each breaker
panel and in cable alleys of the switchgear to maintain switchgear inside
temperature 10 deg C above outside ambient temperature.
25.2 Space heater shall be strip type rated for operation on 240V, single phase, 50 Hz
AC supply unless otherwise specified.
25.3 Each heater shall be complete with a rotary type ON/OFF switch, HRC fuse in the
phase, neutral link in neutral and a control thermostat.
25.4 Isolator and link type HRC fuses for control of space heater for motor controlled by
the motor starter / circuit breakers wired through auxiliary contact of the
contactor/circuit breaker shall be provided wherever specified.
26.0 AUXILIARY SUPPLY
Auxiliary supply for control, indication, space heater etc., shall be made available at
one point on the switchboard. Vendors shall provide auxiliary supply bus in the
switchboard for further distribution inside the switchboard and adequate rated
switch/MCB to receive these supplies. Vendors shall also provide suitable switch
and fuse or MCB in each sub circuit as per requirement.
27.0 CABLE TERMINATION
27.1 Cable entry to switchgear shall be either from top or bottom of the switchgear as
specified in the data sheet.
27.2 Ample space shall be provided in the cable compartment to accommodate PVC
insulated aluminium conductor cables as specified in the data sheet.
27.3 Removable undrilled gland plate shall be provided for termination of cables.
27.4 Access for cabling shall be from the rear/front. The cubicle width shall be adequate
for a cable jointer to enter and work within the cubicle during cable joining.
27.5 Cables upto 150 sq.mm aluminium shall be provided with clip-on type ( slide lock)
design, generally manufactured by M/s Elmex / Technoolast and above 150 sq.mm
terminals shall be provided of brass stud type design of rugged construction. All
power terminals shall be colour coded with red, yellow and blue for phases and
black for neutral.
27.6 Every cable, either for control or power duty shall be provided with crimping type
copper lugs of suitable size as specified. The lugs shall be fitted with contact
greases and the crimping pressure shall be as follows:
a) Copper lugs : Upto 35 sq.mm
--- 1200 psi
Above 35 sq.mm
. 2000 psi
B Bimetallic lugs ----- 1000 psi
27.7 Cable glands shall be Siemens type brass glands. These glands shall be provided
for all the outgoing connections at both ends for power as well as control circuits
and also for the incoming cable or cables. Crimping type lugs only are to be used.
27.8 Earth bus bars shall be of tinned copper/alum. with holes but the bolts and nuts
and washers shall be cadmium plated. Earth bus bar shall be provided all around
the cubicle at the bottom and it shall be of the same size as neutral bus bars but
the maximum size will be 50 x 6 mm with duplex external earth connection
arrangement.
27.9 Bi-metallic lugs shall be used wherever copper cables are being terminated on
aluminium bus bars or vice versa.
28.0 PAINTING & FINISHING
All metal works and ,etal parts of the switchboards shall undergo 7 tank pre
treatment of degreasing,pickling in acid,cold rinsing, phosphating, passivating and
then sprayed with 2 coats of Zinc Chromate primer. The finishing treatment shall be
by application of 2 coats of Epoxy based paint of colour as specified.
Primer
Finish Paint
: 2coats of Zinc Chromate

: 2coats of oven dried epoxy, silver gray (shade : 628)
29.0 NAME PLATES AND LABELS

29.1 One name plate giving the designation of the switchboard shall be affixed
prominently on top of the switchboard. Details of designation will be specified later.
29.2 Labels giving following details shall be affixed on each feeder panel:
i.
ii.
iii.
Feeder No.
Equipment reference number and description
Rating (KW/KVA/AMP)
29.3 All components whether mounted inside the switchboards or on the door shall be
permanently and clearly labeled with reference number and/or letter of their
function. (Rating of fuses shall form a part of the fuse designation).
29.4 All labels shall be non corrodible anodized aluminium with white engraved letters on
black back ground. All the letters shall be in capital.
29.5 Labels for feeder panel designation shall be fixed on the front side of respective
panels with chrome plated self tapping, counter sunk head screws. These labels
shall be identical size to permit interchange.
30.0 TESTING AND INSPECTION
After completion of all work at the manufacturers worls for the
panels/switchboards shall be inspected and tests witnessed by the purchasers
representative or TPIA. However, stage inspection may be carried out from time to
time to check progress of work and workmanship.
The following work shall be carried out:
i.
All routine tests specified in relevant Indian Standards shall be carried out
on all circuit breakers.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
Tests for protective relay operation by primary or secondary injection

method.
Operation of all parameters.
Secondary wiring continuity test with low voltage (6 volts) tester.
Insulation test with 500 volts megger before and after HV test
HV test on power and control circuits/components (2 KV for one minute)
Earth continuity test with a low voltage (6 volts) tester.
Simulating external circuits for remote operation of breaker, remote
indicating lights and other remote operations, if any, for operational test.
Measurement of power required for closing /trip coil of the breaker.
Pick up and drop out voltage for shunt trip and closing coils.
CT polarity test.
Vendor shall provide all facilities such as power supply, testing instruments and
apparatus required for carrying out the tests. Required copies of test certificates for
all the tests carried out along with copies of type test certificates and certificates
from sub vendor for the components procured from them are to be submitted
before dispatch of the switchboards.
Approved TPIA : BVIS/EIL/RITES/IRS/LLOYDS
Note: All routine & acceptance tests as specified by the applicable standard code
shall be conducted. Type test certificates for fault level, certified by CPRI Bhopal
should be submitted along with the bid. The vendor shall also submit a list of
guaranteed technical particulars with the bid.
31.0 DRAWING AND INFORMATION
The vendor to furnish, generally, the following drawings:
i.
ii.
iii.
iv.
v.
General arrangement drawing showing front view, plan, foundation plan,

floor cut outs and trenches for external cables, elevations, transport
sections with weights.
Sectional drawings of various types of feeder, panels showing general
constructional features, mounting details of various devices, bus bars,
current transformers, cable boxes, terminal boxes for control cable etc.,
complete
Schematic and control wiring diagrams for each type of feeder and
protection including indicating devices, metering instruments, alarms,
space heaters etc., Vendor drawings to be based on purchasers control
wiring diagrams if furnished.
Terminal plans showing terminal numbers, ferrules markings, device
terminal numbers, function etc., and
Relay wiring diagrams.
Vendor shall furnish 3 copies of above drawings for purchasers review. After final
review, required number of copies and reproducible shall be furnished as final
certified drawings.
The information furnished shall include the following:
i.
Technical literature giving complete information of the equipment.
ii.
iii.
Erection, operation and maintenance manual complete with all relevant

information, drawings and literature for auxiliary equipment and
accessories, characteristics for relays etc.
An equipment list with detailed specification.
32.0 TOOLS
One complete set of all special or non standard tools per switchboard required for
installation, operation and maintenance of switchboard shall be supplied.
33.0 SPARES
The price list of recommended commissioning and operating spares shall be
provided along with the technical bids.
34.0 DEVIATIONS
Deviations from the specifications must be stated clearly by the bidder. In the
absence of such a statement, it will be assumed that the requirements of the
specifications are met without exception.
35.0 MAKE OF COMPONENTS
1. Indicating instruments
2. Air Circuit breakers
3. MCCBs
4. CDG relays
5. Contactors/SFUs
6. Push Buttons
7. Indicating lamps
8. Current Transformers
9. BMR
10. Terminals
11. Wires
12. Selector switches
13. KWH meter
14. Electronic timers
15. Fuse switch units
16. HRC Fuses
17. MCBs
18. Automatic change over switch
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
AE/MECO/ENERCON
GE/L&T/Siemens
Siemens/Schneider/GE/L&T
GE/Alsthom
Siemens / L&T
Siemens/Teknic
Teknic/Mathura/Siemens/Vaishno
Indcoil/AE/IMD
Siemens / L&T
Elmex/connectwell
Finolex/Polycab/CCI
Kaycee/ Siemens / L&T
Simco/ ENERCON/ L&T
Siemens/EAPL
Siemens/ L&T/GE
GE/ Siemens / L&T/ Schneider
Siemens/GE/MDS/ L&T/ Schneider
Havells
TECHNICAL SPECIFICATIONS FOR RELAY BOX PANEL

The relay box panel shall be working on AC 230V for the following:
1.
To energise a control contactor located in MCC panel
2.
To provide 230V AC power to ROVs 2 Nos and High Level Alarms 2 Nos through
individual ON-OFF switch. There should be a provision to close the individual ROVs
from the relay box panel through a push button/toggle switch. Also, panel should
have indicators to indicate ROVs open/close status.
3.
It shall have a push button for switching ON the panel. The panel should have
provision for receiving power supply from UPS and distributing through relays to
the instruments on the mounded storage vessels. It should also have provision to
stop all pumps, compressors and vapourisers.
4.
In case of trip signal received from the High Level Alarm, the relay box panel, through
relays, shall immediately close the ROV and also stop all pumps, compressors and
vapourisers. Reset PB shall be provided to reset the power to all contactors &
equipment. There should be a provision to close the ROV and trip all LPG
equipment through a manual push button station on the relay box panel. This ESD
shall also be activated from the field through a FLP push button station located
near the LPG pump house.
5.
The relay box panel shall have the provision to show indication/signal of high level
alarm trip for 2 Nos of LPG storage vessels. The high level alarm & ROVs should be
interlocked in the relay box in such a way that the high level alarm trip signal from a
storage vessel should close the corresponding liquid ROV of the storage vessel.
The following indication shall be provided on the RELAY BOX PANEL
A.
B.
C.
D.
E.
A voltmeter for incoming AC supply

Indication for ON,OFF & TRIP
Selector switches/ PBs/Toggle switches for various purposes
Indication lamps for ROVs open/close status
Indication lamps for high level alarm tripping.
PANEL MANUFACTURERS SCOPE OF SUPPLY

1. The housing shall be made up of 14 gauge CRCA sheet with two coats of Zinc
Chromate red oxide primer and two coats of enamel paint of approved colour.
2. A terminal strip shall be provided with 10% extra terminals than that required.
3. Removable gland plate shall be provided at the bottom of the panel.
4. Main supply to panel shall be 230V AC from UPS so as to provide uninterrupted
power supply in case of MAINS Failure. Float battery charger has to be provided by
the vendor to keep the batteries in charged condition. In normal condition, power
is supplied to all field instruments, solenoid valves, pressure switches etc., and
also for charging batteries. In case of mains failure, auxiliary batteries shall
provide power to the system. Minimum battery back up required is 30 minutes.
The battery charger shall have provision for Trickle Boost & auto Charging.
Provision shall be made in the battery charger that when the main supply resumes,
the system supplies enough power for entire system including for charging of
batteries. Vendor to note that supply of suitable rated batteries and charger is
included in the scope and accordingly quote the rates.
5. Test, accept and reset shall be provided to check the panel condition.
6. Accept push button shall also accept wailing hooter and flash annunciation during
emergencies and on accepting, the hooter shall stop and the annunciation will
only be a glow lamp instead of a flasher.
7. An Aluminium earth bar of adequate size shall be provided throughout the length
of the panel. 2 nos. earthing studs shall be taken out for external earthing.
8. Copper bus bar shall be provided inside the panel to receive power from battery
banks and distribute it to the system.
9. The following shall also be provided on the relay box panel in addition to switches,
push buttons, instruments etc., as indicated in the Requirements of Panel
Voltmeter for mains AC Voltage.
Voltmeter for DC Voltage.
Ammeter for current drawn from AC mains.
Ammeter for total DC current.
Ammeter for battery charging current.
Indication for Mains AC ON, DC ON, Control supply to relay box panel ON.
ON, OFF switches for switching on Main AC power & DC power to panel
and also provision to isolate batteries, if required.
HRC fuses for AC incoming & DC power, power supply to all instruments.
Switches for cutting off power supply to any instrument without affecting
the other areas.
Reset push button for timer.
Test position for siren testing.
Accept push button for siren.
Provision for proper ventilation, opening should be provided in the panel.

Spare parts for two years trouble free operation.
All voltmeter, ammeter, shall be of 4 x 4 size. Annunciation windows for indication of
trip condition of individual risk areas & annunciation windows for individual fire
fighting engines shall be of 1 x 1 size. Annunciation lamps will be provided with
light laminating diodes.
10. All contactors required to complete the circuiting.
11. All cabling required inside the panel upto terminal block including dressing
accessories.
12. Suitable arrangement shall be made to isolate the batteries from the panel in case
the battery terminals are connected in reverse order.
13. 24V DC siren of 1.6 km range.
14. Panel shall be manufactured as per the technical specifications for MLDB panels.
LIST OF APPROVED MAKES OF ACCESSORIES

1.
2.
3.
4.
5.
6.
7.
8.
Control Selector switches

Annunciation Lamps
Push Buttons
Current Transformers
Lugs
Meters
Terminal Strips
Contactors
:
:
:
:
:
:
:
:
Keycee
IIC/Teknic
Mathura
Indcoil/AE/IMD
Dowells
IMP make
Elmex
Siemens / L&T/GEC
9. Push Buttons
10. Sirens
11. Timers
12. Battery charger
13. Fuse & Fuse Base
14. MCB
: L&T
: Kheraj
: Vendors to specify(preferred make L&T)
:Vendors to specify (SAB-NIFE)
: Siemens / L&T/ English Electric
: MDS/INDO KOPP
TECHNICAL SPECIFICATIONS FOR ERECTION AND COMMISSIONING OF

ELECTRICAL EQUIPMENT / PANELS
1.0
INSTALLATION, TESTING, COMMISSIONING

Vendor scope of work under electrical work includes installing the equipment /
panels in the field and control room, lay the interconnecting cable outside and
inside the control room, cable terminations including supply of double (all
field/LPG areas) / single (within control room) compression glands, cable lugs,
numbering of cable connections, earthing of panels, check out, testing and
commissioning of the entire electrical system.
a.
b.
c.
d.
e.
f.
g.
h.
i.
2.0
Vendors responsibility at site shall also include all activities necessary to be

performed to complete the job including:
Receipt of hardware and software and checking of completeness of supplies.
Installation of the system including free supply equipment, if any.
Field cable laying.
Field cable termination and inter cabinet cabling and termination.
Check out equipment installation.
Making and checking of interconnections.
Loop checking (100%)
Commissioning and debugging of the system.
Commissioning, performance tests and acceptance tests and acceptance tests in
the presence of HPCL.
EARTHING
a. Each panel, cabinet, console and other equipments in control room shall be
provided with an earthing lug. All these earthing lugs shall be properly secured to
the AC main earthing bus.
b. All circuit grounds of electronic instruments, shields and drain wires of signal
cable shall be connected to instrument ground bus which is electrically isolated
from the AC mains earthing bus. This bus shall be typically 25 mm wide and 6 mm
thick copper. The instrument grounds bus is connected to independent instrument
system ground bus through insulated wires.
c. All active barriers, if used, shall be securely grounded. The active barrier ground
wire shall be capable of carrying a maximum fault level current.
3.0
LOOP CHECKING
a. Loop checking shall be carried out by the vendor including checking the
interconnections, configuration and over all system functioning.
b. Vendors scope of work in loop checking shall include termination of field cable in
the control room through Multi Cable Transit (MCT), checking of interconnection
between instrument/equipment, ferruling and tagging of interconnecting cables in

control room and performing over all loop performance check.
c. Vendor shall perform loop checking properly and thoroughly. Any discrepancy
found during checking shall be brought to the notice of the Engineer-In-Charge.
d. The input signal shall be simulated by disconnecting/connecting the field wires for
all field switches connected to the system.
e. After completing the loop checking, vendor shall connect back any terminal and
connection removed for loop checking.
f.
4.0
All the system function shall be checked thoroughly for proper functioning. The
tests shall include:
Visual and mechanical.
Complete system configuration loading.
Demonstration of all system functions.
Checking system configuration loading.
Checking of correct functioning of all keyboards.
Termination of all system diagnostics.
Complete checking of relays.

SPARE PARTS
Vendor shall include special tools, test equipments, initial stock of maintenance
spares for a period of two years operations and consumables for 6 months after
system take over as they are essential for proper maintenance and operation of the
system. In addition, estimated requirement of spares per annum should also be
indicated. Full particulars for the above shall be provided separately. The list also
to include item wise price for the spares. Spares and consumables required, if any,
upto the system take over shall be supplied by the vendor free of cost.
The successful vendor shall provide a guarantee that the spare parts for the
system would be available for a minimum period of 5 years. After this period, if
vendor discontinues the production, he shall give at least 12 months notice prior to
such discontinuance so that the owner may order his bulk requirement for the
future.
TECHNICAL SPECIFICATIONS FOR THE SUPPLY OF CABLES

1.0
SCOPE: This specification is for the supply of 1.1 KV Lt power & control cables.
The cables shall be manufactured, tested at manufacturers works in accordance
with IS 7098(Part-II) & IS 1554 and delivered at site.
2.0
L.T. POWER & CONTROL CABLES
2.1
POWER SUPPLY DETAILS

a) Supply Voltage
b) Frequency
c) Fault level
:
:
:
415 Volts + 6%
50 Hz + 3%
35 MVA at 415 Volts
2.2
CONSTRUCTION ( 1.1 KV POWER & CONTROL CABLES)
2.2.1
Conductor : The conductor shall be composed of plain copper or Aluminium wire

complying with IS 8130-1984
2.2.2
Insulation:
a. The insulation shall be heat resisting type of type C PVC compound conforming
to IS 5831-1984.
b. The insulation shall be PVC applied with extrusion. The average thickness,
tolerance & application of insulation shall not be less than specifications in IS
1554 Part(I) 1988.
c. Test for thickness of insulation and sheath -
IS 1554 (Part I)
d. Physical tests for insulation and outer sheath:

1. Tensile strength & elongation at break
2. Aging in air oven
3. Shrinkage test
4. Hot deformation
5. Loss of mass in air oven
6. Heat shock test
7. Thermal stability
IS
IS
IS
IS
IS
IS
IS
5831-1984
5831-1984
5831-1984
5831-1984
5831-1984
5831-1984
5831-1984
7
11
12
15
10
14
e. Insulation resistance test
IS 5831-1984
43
f.
IS 1554(Part I)1988
45
g. High Voltage test at room temperature
IS 1554(Part I)1988
45
h. Flammability test
IS 1554(Part I)1988
53
High voltage test(water immersion test)
Acceptance Test
1.
2.
3.
4.
5.
6.
7.
8.
Annealing test ( for copper)

Tensile test( for Aluminium)
Wrapping test( for Aluminium)
Conductor resistivity test
Test for thickness of insulation and sheath.
Tensile strength & elongation at break of insulation and sheath.
Insulation resistance test.
High Voltage test at room temperature.
Routine Tests
a. Conductor resistance test
b. High Voltage test at room temperature.
The sampling of cables for the above mentioned tests shall be as per IS 1554
Part(I) 1884. The vendor shall furnish 6copies of test certificates for the tests
performed and the results obtained.
2.2.3
Filter and inner sheath:

Filter and inner sheath material shall be of PVC compound (type ST2) which shall
not be harder than PVC used for insulation. It shall be compatible with
temperature ratings of the cable and shall have no deleterious effect on any other
component of cable and shall be of HR type.
2.2.4
Armouring:
Armouring shall be GI around steel wire for YWY cable and GI steel strip for AYFY
cables and shall comply with the requirements of IS 3975-1979. It shall comply
with the requirements of non magnetic materials also. The method of armouring
shall conform to IS 1554.
2.2.5
Outer Sheath:
Outer sheath shall be of PVC compound type ST 2 as per IS: 5831-1984
3.0
The conductor shall be solid for cables of size 1.5 sq.mm to 10 sq.mm (excluding
10 sw.mm) and stranded for size 10 sq.mm and above as per IS 8130-1984. The
cross section of neutral shall be as per IS 1554 Part(I) 1988.
Cores shall be identified by different colours of PVC insulation and shall be laid as
per IS 1554 Part(I) 1988. Inner sheath, armouring and outer sheath shall be as per
IS 1554-1988.
4.0
INSPECTION, TEST AND TEST CERTIFICATES:

The following tests shall be conducted on the cables:
Type Tests:
Test
Requirement as per
Test method as per IS

10810 Part No.
a. Test on conductor
1.
2.
3.
4.
5.
Annealing Test(for copper)

Tensile Test( for Aluminium)
Wrapping test
Conductor resistance test
Test for armour wire/strip
IS 8130
IS 8130
IS 8130
IS 8130
IS 1554 Part(I) 1988
& IS 3975-1979
1
2
3
5
36 to 42
4.1
Manufacturers test certificates are acceptable for all cable quantities below 500 m
length for each size.
5.0
GUARANTEE
Vendor shall give guarantee of 12 months from the date of commissioning or 18
months from the date of dispatch, whichever is earlier. During this period, if any
defect is found due to bad workmanship or wrong material used, the vendor shall
replace or repair the same free of cost.
6.0
IDENTIFICATION/MARKING/PACKING & DELIVERY

This shall be strictly as per IS 1554 Part(I) 1988. In addition, length of cable shall
be marked at every meter of the cable. All the cables shall bear BIS mark.
7.0
THIRD PARTY INSPECTION

Cables shall not be delivered without third party inspection. Approved third parties
are : EIL/BV/RITES?PDIL/LLOYDS/IRS
Scope of inspection shall consist of the following:
1.
2.
3.
4.
Type Tests
Acceptance tests
Routine Test
Optional Test
:
:
:
:
Manufacturers test certificate

review
review
review
review
TECHNICAL SPECIFICATIONS FOR LAYING CABLES

1.0
LAYING OF UNDER GROUND CABLES

A. All civil works including supply, labour and materials included in vendors
scope of supply.
B. Cable supplied by the vendor shall be laid in trenches in the route specified at
a depth of 750 mm with a 100 mm thick sand cushion below & 150 mm thick
sand cushion above and a layer of 230 mm width bricks on top laid width wise,
including excavation, back filling, cable markers @ 100 m c/c, 100 mm dia GI
pipes for road crossings, cable entries etc., complete as per technical
specifications and as directed by EIC.
C. Where cables rise from trenches/under ground pipes to instruments, they shall
be taken through GI pipes of adequate size upto a maximum 300 mm above
the floor level.
D. Cables shall be pulled carefully through the pipes so that there is no damage to
the cables. If required, cable lubricant shall be used.
E. Where the cable pass through foundations, walls or any under ground
structures, necessary duct and opening shall be provided. However, for cutting
holes in the existing foundation or structure, prior permission from HPCL shall
be taken. All the openings in walls etc., have to be closed and made good after
laying the cables.
2.0
LAYING OF CABLES ABOVE GROUND

Wherever buried cable laying is not possible, vendor shall adopt over head cable
laying.
a. Cables laid above ground shall be run on perforated GI cable trays (supply and
erection included in vendors scope), fixed on walls, ceilings or structures and
shall be run on parallel or at right angles to the beams, walls or columns.
Cable dressing is important and shall be done properly as per instructions

from EIC.
b. Individual cables, cable groups which run along the structure may directly be
clamped to the structure by means of 16 gauge Aluminium saddles on 25 x 6
mm saddle bars. Proper nylon locking type straps, aluminium clamps
etc.,must be used for binding / clamping of temporary fastening etc.,steel
wires, cables, armour etc., shall never be allowed for such purposes. Cables
shall be supported adequately to avoid unsightly sagging. Normally, the
distance between the two supports shall be 300 mm for cables of diameter
upto 25 mm. For cables of higher diameter the distance may be upto 450 mm.
However, uniform distance shall be maintained from aesthetic consideration.
All cables shall be supported near the glands
LIST OF APPROVED SUB VENDORS
1. Active barrier ( Galvanic Isolator) MTL/Stahl (Germany) / P&F/Equivalent
2. UPS TATA Libert / Gujarat hirel Control ltd / Siemens / Numeric/Equivalent
3. Multi cable transit system New Merchantile Impex / Lycab/ Roxtec /
Equivalent.
4. Temperature Elements General Instruments/Detriv/Electrical & Electronic
Instrument Corpn./ Equivalent
5. Earthig relay Anderson/Scully/ Equivalent
6. Cables (T/C extension) KEI Industries/Toshniwal cables/Fort Gloster/Finolex
7. Compression Fittings Excelsior/Astec Insts./ Excel Hydro Pneumatic/
Equivalent
8. Instrument Fittings Tehnomatic/ Microprecision/Chemtrols/ Equivalent
9. JB and Cable Gland Baliga/Flame Proof Equipment/ Ex Protecta/CEAG/FCG/
Equivalent
10. SS Tubing Chokshi Tubes/ Remi metal/ Nikka Tubes/ Equivalent
11. Cable Tray - Hopes Metal / Indiana/Globe Electricals/ Equivalent
12. FLP Fittings Baliga/Flame Proof Equipment/ Ex-Protecta/CEAG/FCG/
Equivalent.
SPECIAL COMMERCIAL TERMS

1.
PAYMENT TERMS
All payments will be made by HPCL in Indian Rupees only including for B.Q. Steel
Plates/other materials/equipment imported by the contractor. All import of
materials/equipment required as per the tender shall be done by the Contractor under
their own Import License. HPCL will not issue any Import License to the contractor.
Vendor to note that no Payment shall be released till the Design is approved by TPIA,
CCOE & HPCL. All payments shall be released after basic Design is approved.
1.0 MOUNDED STORAGE VESSELS, BQ PLATES
The payment released shall be subject to following conditions :
A.
The value of the item for Design & Drawings approval from TPIA,HPCL and CCOE
will be limited to 5% of the total value for mounded storage vessels(mechanical)
part of the order.
i. 90% of the payment for design and drawings subject to a maximum of 5% of
the total PO value will be made on completion of design, preparation of
fabrication/construction drawings, obtaining approval of TPIA & HPCL and
obtaining approval of CCOE subject to submission of BG for an equal mount.
Ii. Balance 10% will be paid after the completion of the total work and handing
over of the facility.
Iii. BG shall be releases after completion of the total work and handing over of the
facility.
B.
BQ STEEL PLATES
1
70% of the quoted item rate or 70 % suppliers invoiced rate, which ever
is lower, will be paid on submission of shipping documents for BQ Plates
as per the specifications, against a Bank guarantee for an equal amount
along with the third party inspection clearance certificates, on pro-rata
basis.
30% of the quoted item rate or suppliers invoiced rate, which ever is
lower, will be paid on delivery and identification of the plates by the TPIA
at vendors works.
The difference between the quoted rate and the payment made against
supply of steel plates shall be released along with the progressive bills for
fabrication payment as per schedule of fabrication payment.
FABRICATION
All payments will be released on pro rata basis against submission of BG for an
equal amount of the invoice amount along with the third party inspection
clearance certificates.
30% of the item rate will be paid on Rolling of the shells, completion of L &
C Seam welding, dish end fabrication and Radiography at site on pro-rata
basis.
30% of the item rate will be paid on completion of internal stiffeners,

erection of the dish ends including welding of all nozzles, flanges, lifting
lugs, pads, manholes, bottom pipe line, vortex breaker, internal ladder
including NDT and radiography.
20% of the item rate will be paid on completion of psot weld heat
treatment, completion of hydro testing, erection of accessories and
submission of dispatch documents.
Balance 20% of the item rate will be paid on receipt of vessel at site,
erection in position, pressure vessel complete in all respects and issuance
of Certificate of Control by TPIA. The BG under A,B & C above will be
returned on submission of the certificate of control.
BULLET PROTECTIVE POLYEURATHANE COATING

1
40% of the item rate will be paid on supply of material to site on pro-rata
basis.
60% of the item rates will be paid on completion of the coating as per
specifications and clearance by TPIA
CATHODIC PROTECTION SYSTEM

1
40% of the item rate will be paid on supply of material to site on pro-rata
basis.
60% of the item rates will be paid on completion, testing and

commissioning of the system as per specifications and approval of TPIA.
INSTRUMENTS & FITTINGS

1
70% of the item rate on supply of equipment to site along with third party
inspection reports.
30% of the item rate on completion of erection and commissioning of the

instruments.
GROUND IMPROVEMENT & CIVIL WORKS

1
90% of item rate will be paid through progressive R.A.Bills.
PUMPS, COMPRESSORS, LPG VAPOURIZERS, VALVES, ROVs, FF EQUIPMENT &

OTHER MECHANICAL EQUIPMENT
1
90% of item rate will be paid upon approval of TPIA for dispatch and
receipt of the equipment at site
10% of item rate will be paid upon erection, testing and commissioning.
VALVES, ROVs, FF EQUIPMENT & MECHANICAL PIPING WORKS (LPG, FIRE

HYDRANT,SPRINKLER SYSTEM) & STRUCTURAL STEEL WORKS.
1
60% of the item rates will be paid on receipt at site of all required pipes,
elbows, flanges, tees, blinds required for the piping along with TPIA
approvals / release notes for all these items.
2.
30% of the item rate on pro rata basis will be released upon completion of
fabrication, welding, inspection, hydro testing and painting.
3
I
10% of item rate will be paid after completion of the total work and
handing over the mounded bullets.
10% of item rate will be paid upon commissioning.
ELECTRICAL PANELS, RELAY BOX, FLP FITTINGS & OTHER ELECTRICAL

EQUIPMENT.
2
90% of item rate will be paid upon approval of design, fabrication,

inspection, testing and approval of TPIA for dispatch and receipt of the
equipment at site.
10% of item rate will be paid upon erection, testing and commissioning.
CABLING
1
60% of the item rates will be paid on receipt at site of all required quantities
of cable, cable glands, lugs, FLP push button stations along with TPIA
approvals / release notes for all these items.
2.
30% of the item rate on pro rata basis will be released upon completion of
cable laying, fixing of glands, termination at both ends, loop checking and
testing.
10% of item rate will be paid upon commissioning.
NOTE:
AGAINST ALL THE ABOVE PAYMENTS NECESSARY STATUTORY DEDUCTIONS WILL BE
EFFECTED AND 10% RETENTION MONEY WILL BE WITHHELD.
ALTERNATIVELY THE PARTY CAN SUBMIT A BANK GUARANTEE FOR 10% OF THE
ORDER VALUE, BEFORE RAISING ANY BILLS, IN WHICH CASE THE 10% DEDUCTION
TOWARDS RETENTION MONEY WILL NOT BE EFFECTED FROM THE RUNNING BILLS.
2.0 RETENTION MONEY :

For details of retention money clause No.11 of General Terms and Conditions shall be
referred.
3.0. BASIS OF PRICE AND DUTIES :
The entire work of design of foundation, supply, fabrication, erection, testing of mounded
vessel as per scope of work covered under this contract shall be treated as Indivisible
Works Contract. The tenderer should quote for this work accordingly. The price quoted
should be firm and inclusive of all duties including sales tax on works contract, Central
sales tax, Octroi, Packing & Forwarding Charges, Freight and insurance including Transitcum-storage -cum-erection/Third party insurance and all other taxes, royalties and duties.
Excise duty is not applicable for this job & the parties not to include the same.
The tenderer shall quote their basic price on the above-said lines. HPCL does not have any
project duty concession. Hence, full duty should be paid by the contractor.
NOTE :
3.1
All duties, taxes & statutory levies including works Contract Sales Tax are to be
included in the Basic Price for each item.
3.2
The Foreign Exchange rates prevailing on the date of due date of this tender
enquiry will be considered for the purpose of price calculations for the imported
BQ plates.
The bidder shall mention in the tender Unpriced & Priced Bids the foreign
currency considered by him. The tenderer shall also give a break-up of the foreign
exchange component involved in his quoted rates for item no. 4 of Bill of quantities
.
3.3
The tenderer is required to mention the existing rates of Customs Duty (along with
any surcharge, etc.) as presently applicable. The tenderer shall specify the heading
and sub-heading of the Tariff manual under which the steel plates are falling. The
tenderer may note that all duties are to be considered assuming that concessional
project duties are not applicable to HPCL in the present case. The tenderer is
required to mention the relevant tariff rate for customs Duty in the unpriced and
priced copy of the Price Bid attached at the end of the tender document.
3.4
Customs and F.E. variation:
A)
Any variation due to upward revision in the rate of Customs Duty (as specified in
Para 3 above and foreign exchange ( as specified in para 2 above) upto the date of
import receipt in India (not later that 4 months from the date of LOI) will be
reimbursed by HPCL. No interest shall be paid on any variation. Variation on
account on rates of R.E. and C.D., shall be payable, after the receipt of BQ steel
plates at our site, duly supported with third party inspection certificate meeting
tendered technical specifications.
B)
Tenderer will have to submit proof of earlier and existing rates, under the same
tariff head for claiming variation towards Customs Duty. Similarly, for claiming the
variation towards foreign exchange, actual bank debit or letter of credit document
mentioning the applicability of F.E. rate shall be submitted in original for

verification. In any case the tenderer will have to submit the original bank
documents for verification of the F.E and C.D rates, along with their bills for supply
of steel plates.
C)
Any variation due to downward revision on account of above, shall be passed on to

HPCL on similar lines.
D)
No F.E / C.D. variation towards import of fittings/ instrumentation shall be

allowed.
E)
All Statutory Deductions shall be as per applicable rates & as

towards these is admissible for this tender.
4.
WATER & POWER: Water & Power shall be arranged by the Contractor at no extra
cost. HPCL will not provide the same.
5.
DELIVERY PERIOD: 20 (Twenty) Weeks from the date of issue of LOI or advise to
start the work by Site/ Ch Manager-E&P,LPG,SZ, Chennai, whichever is later.
6.
Site will be handed on AS IS WHERE IS BASIS for the execution of this job. HPCL
will not provide any infrastructure to the contractor at site.
7.
COMPENSATION FOR DELAY (LIQUIDATED DAMAGE CLAUSE)
no
variation
For details of Liquidated damages Clause No.10 of the General Terms and
Conditions shall be referred.

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TECHNICAL SPECIFICATIONS

TECHNICAL SPECIFICATION FOR BOILER QUALITY

: Plates Conforming to BS 1501 part I, 224, 490.LT

: Lloyds / Bureau Veritas (at the works of Supplier of

: As per PD 5500 or equivalent

: As per SA 578 Level I

Maximum Tensile Stress

The Steel shall be made to fine grain particles.

Marking as per specification, accordingly Purchase Order No. shall be stenciled

C) TEST CERTIFICATE: The material shall be duly certified by Lloyds or by Bureau

Number of PTC required per Vessel:

For Long Seams: One No. / Welder / procedure/heat

PTC Testing Requirement:

Design Parameters / Material Specifications/Nozzles for Mounded

2. Volumetric Water Capacity

: Vendor to specify considering 85% highest

: PD 5500 Latest edition and OISD 150

: 14.5 Kg/cm Gauge at Top

7. Hydraulic Test Pressure

: 100% before and after PWHT

10. Post weld Heat Treatment

11. Wet Fluorescent Magnetic Particle Testing: Required after PWHT

: Required after PWHT

13. Mapping of plate thickness

14. Joint efficiency

15. Length of Pressure Vessel

16. Dia of Vessel

: 2900 mm (approx). Vendor to specify

17. Dished Ends

: Hemispherical/ vendor to specify

All Openings will be of Flanged type with Nozzle Construction.

The maximum differential settlement allowed is 25 mm. Total settlement allowed

Shell, Dished Ends, Stiffener : BS 1501 Part I 224 Gr.490 or equivalent

: SA 350 Gr. LF2 - ASA 300

: SA 350 Gr. LF2 6000 lbs.

: SA 320 Gr. L7 or SA 194 Gr. 4 / Gr. 7

650 mm dia Manhole with cover

50 mm dia Nozzle for Liquid

40 mm dia Nozzle for Liquid

Nozzle of suitable size (2.5 NB say)

1" Nozzle for Pressure Gauge

2" / As required Nozzle for Magnetic Dip

Suitable Size Nozzle for

50 mm NB vapour outlet / Spare

Lifting lugs suitably spaced on

Cleats as required for providing

: No.of cleats to be provided

BSP for temperature Gauge

50 mm dia Nozzles for High Level

Earthing Boss and CP Connection

2. Name plate with following details

SPECIFICATION OF HIGH LEVEL ALARM SWITCH

Cable glands : Explosion proof, flame proof, double compression type.

: TOKYO KEISO, JAPAN OR APPROVED EQUIVALENT

: As per scope of supply

: Explosion proof as per IS-2148

: 2" ANSI # 300 RF

: -27 to +55 deg C

: NPT 1/2 adapter

: Approved by CCOE Nagpur

* Vendor to provide the technical literature of the model being offered.

: WILL BE GIVEN LATER

: 2 NOS. PER LPG PR. VESSEL

FULL NOZZLE/SEMI NOZZLE