ESPSF TANK INSTALLATION AND DELUGE … · ISRO PROPULSION COMPLEX ... Witnessing of welder’s...

Enclosure-A

SPECIFICATIONS FOR

INSTALLATION OF NEW PROPELLANT

TANKS & SS PIPING ERECTION WORKS

AND

FABRICATION, INSTALLATION, TESTING

AND COMMISSIONING OF DELUGE SYSTEM

AT EARTH STORABLE PROPELLANT

STORAGE FACILITIES

ISRO PROPULSION COMPLEX

MAHENDRAGIRI - 627133

INTRODUCTION

The scope of work involves installation of new propellant tanks and associated SS piping erection

works and Fabrication, Installation, Testing and Commissioning of Deluge system at Earth

Storable Propellant Storage facilities at ISRO Propulsion Complex (IPRC), Mahendragiri.

This specification document consists of two parts,

PART-A: INSTALLATION OF NEW PROPELLANT TANKS AND SS PIPING ERECTION

WORK AT EARTH STORABLE PROPELLANT STORAGE FACILITIES (N2O4 AND UH-25)

PART-B: FABRICATION, INSTALLATION, TESTING AND COMMISSIONING OF DELUGE

SYSTEM AT EARTH STORABLE PROPELLANT STORAGE FACILITIES (N2O4, UH-25 AND

MMH)

Contractor shall refer Part-A & Part-B for detailed scope of works to be carried out.

1. GENERAL REGULATIONS:

1.1. The contractor shall strictly comply with established security procedures of IPRC for the entry

and exit of the contractor’s men and materials,

1.2. The contractors shall make their own arrangement for transportation, food, accommodation,

medical treatment, other logistic facilities and insurance coverage for their men and

materials.

1.3. It shall be the Contractor’s responsibility to construct temporary shed, if required, for housing

their machines/equipments and materials throughout the execution of the contract.

1.4. The contractor shall be responsible for the secure custody of their own materials and IPRC

shall not be liable for any loss or damage to the contractor’s items.

1.5. Electricity shall be provided by IPRC to the contractor on chargeable basis at a fixed main

point in the facility. The contractor shall obtain Electrical permit from Department and arrange

for their own IP66 type Power Distribution Board (PDB) with Earth Leakage Circuit Breakers

(ELCB) and power supply cable of suitable rating for sufficient length. The contractor shall

arrange for the cabling from the PDB to the contractor’s equipment. The PDB and temporary

cabling shall comply with IPRC’s electrical safety regulations.

1.6. Water shall be provided by IPRC, free of charge, at a fixed tap point in the facility. The

contractor shall arrange hoses for distribution.

1.7. Custody of Free Issue Materials: It is the responsibility of the contractor to ensure safe

custody of the materials free issued by IPRC. In case any damage is caused to IPRC’s

materials, the contractor is liable to pay to IPRC the price of the damaged materials.

However, the following fabrication losses shall be permitted.

Material Salvageable Losses Unaccountable

Pipes 3 % 0.75 %

Pipe Fittings 0 % 0 %

Fasteners 0 % 0.5 %

2. SAFETY REGULATIONS:

The contractor shall execute the works only during the presence of Department’s supervisor

or contractor’s representative. Since the work is to be carried out in the existing facility, the

contractor shall strictly comply with the general safety norms & regulations stipulated by

IPRC.

• Use of Personal Protective Equipment (PPE) is mandatory and the contractor shall

provide all necessary PPE to their workmen and ensure compliances of wearing

necessary PPE inside project site.

• Contractor shall arrange and use sufficient fire blankets to avoid falling of welding

spatter on the equipment/ storage tanks.

• Contractor shall ensure high standard of housekeeping in the project site. The

materials shall be stacked/ positioned properly and the work area shall be cleaned

thoroughly on daily basis.

Prior to commencing the work, the contractor shall obtain work permits and safety permits

in the prescribed formats from IPRC.

3. INSPECTION AND QUALITY ASSURANCE:

The work shall be subjected to inspection by Systems Reliability Group (SRG), IPRC. The

scope of inspection shall be as follows,

a. Witnessing of welder’s performance qualification test to be performed by the contractor.

In case the welder already possesses valid performance qualification test certificate,

the same shall be submitted for review.

b. Fit-up check of the tack welded pipeline assemblies.

c. Witnessing of Dye-Penetrant Testing to be performed by contractor.

d. Review of radiographic films of the butt welded joints.

e. Witnessing of Hydraulic and Pneumatic pressure tests.

f. Witnessing of chemical cleaning (Pickling and Passivation) of tanks and pipe lines.

g. Examination of final documents and as built drawings.

The work executed by the contractor shall be sound in quality as to be qualified by these

tests. If any defect is revealed during these tests, it shall be the responsibility of the

contractor to rectify the defect or re-execute the work.

4. WELDING PROCEDURE:

The contractor shall employ the welding procedure to be specified by IPRC.

Welder’s Performance Qualification: If the welder employed by the contractor possesses a

valid performance qualification certificate for welding of pipe thickness for the

pipes/schedule numbers, the same shall be submitted to IPRC for review. If the welder is

not qualified, they shall undergo performance qualification in compliance with Section IX of

ASME, which is to be arranged by the contractor. The pipes required for the test coupon

and radio-graphic test for the purpose of welder’s performance qualification shall be

provided by IPRC.

5. GENERAL TERMS & CONDITIONS:

5.1. Period of work contract: The work shall be carried out facility wise. ie. N2O4 facility, UH-

25 and MMH facility. Within 2 months from the date of issuing and acceptance of work

order, the contractor shall prepare and submit the piping isometric drawings & plan of work

schedule for Department clearance and mobilize men and equipments for the

commencement of works. All the works shall be completed within 6 months from the date of

actual commencement of work at site/ site clearance from Department.

5.2. Quantity variations in the work order: The total quantity of works executed with respect

to work order is permitted to vary +/- 25% of the total value of work order. However, if any

additional work arises beyond 25% over the total price specified in the work order during

the time of execution, the same shall be notified to the Department to make suitable

amendment to the work order.

5.3. Payment: Payment will be made monthly and on pro-rata for the completed work. The

contractor shall consolidate the quantum of the work executed and raise a Running Account

Bill (RAB) once in a month. Final payment will be made to the extent of 100% of actual work

commenced by contractor at the prices corresponding to each work item to be agreed upon

as per Annexure-I & II of the work contract, after the satisfactory completion of the work.

5.4. Income Tax as applicable will be deducted from your bills. PAN no. to be indicated in the

bills for making payment. Service Tax Registration Number shall be furnished for claiming

service Tax, if any.

5.5. The labours being deputed shall be Indian Nationals only. Bio data of the technicians being

deputed shall be submitted to the contact person immediately on receipt of the order who

will in turn forward to the Senior Administrative officer for issuing entry pass.

5.6. The working personnel shall adhere to all security & safety requirements of IPRC, labour

rules & statutory requirements.

5.7. Minimum wages and other labour related statutory conditions as per the respective Acts

shall be followed.

5.8. Insurance coverage for contractor’s employees/ labours: The contractor shall obtain Group

Insurance (for the technicians deployed for the work) vaild till the tenure for work from any

Nationalized Insurance company at your cost and proof shall be submitted before

commencement of work.

5.9. The work shall not be sub contracted without written permission from IPRC.

5.10. In case any damage is caused to IPRC’s materials, the contractor shall be liable to

compensate IPRC for the loss. The extent of damage and compensation to be paid thereof

shall be worked out by IPRC and same shall be final and binding on contractor.

5.11. Arbitration: All disputes, differences, claims and demands arising under or pursuant to

this agreement shall be referred to Arbitration of sole Arbitrator to be appointed by Director,

IPRC, and shall be subject to and governed by the provisions of the Arbitration and

Concilation Act 1996 and any statutory modification.

PART- A

INSTALLATION OF NEW PROPELLANT TANKS AND SS PIPING ERECTION WORK

1. INTRODUCTION:

It is planned to replace the old N2O4 (2 Nos.) and UH-25 (3 Nos.) Stainless Steel

propellants storage tanks of 40 m3 capacity and N2O4 & UH-25 drain tanks (1 No. each) of

1 m3 capacity with corresponding new tanks in Earth storable propellant storage facilities

at IPRC, Mahendragiri.

2. SCOPE OF THE CONTRACTOR:

2.1 The work involves installation of stainless steel tanks, fabrication and erection of pipe

lines, structural supports, platforms including minor civil work, testing, painting of supports

and platforms, supply of structural materials, paints etc. as detailed below in the

description of work.

2.2 Preparation of piping isometric drawings for execution of work and as-built piping

isometric drawings upon completion of work.

2.3 All tools, tackles, machineries etc. required for tank installation, fabrication and erection of

pipelines, platform, supports, chemical cleaning, painting etc.

2.4 Radiography equipment, films and chemicals for DP test, paint and primer.

2.5 Chemicals required for chemical cleaning of pipelines and storage tanks.

2.6 Materials required for civil work.

2.7 MS chequered plates, structural items required for modification/fabrication of platforms,

supports etc.

3. SCOPE OF SERVICES BY IPRC:

3.1 Supply of free issue materials namely storage tanks, flow components, valves, pipes,

flanges & pipe fittings, gasket, bolts and nuts for flanged joints.

3.2 Supply of water for hydrostatic testing, DM water for chemical cleaning purpose and

gaseous Nitrogen at required pressure for pneumatic pressure test at free of cost.

3.3 Supply of electricity at a single place near the work spot on chargeable basis.

(Approximate charge is Rs 8/- per kW-h as on date). The party should have proper

electrical accessories including Energy meter, switchboard, cables and earthing cables

etc.

3.4 Necessary clearance and work permit (Hot work) from Safety Department.

4. DESCRIPTION OF WORK:

4.1 INSTALLATION OF EQUIPMENTS :

4.1.1 Removal of installed old N2O4 / UH-25 SS 304L propellant storage tanks (2 Nos. of N2O4,

3 Nos. of UH-25 tanks) and N2O4 / UH-25 drain tanks (1 No. of N2O4, 1 No. of UH-25

tanks) and Installation of new seven numbers of SS 304L propellant tanks (2 Nos. of

N2O4, 3 Nos. of UH-25 tanks and 2 Nos. of UH-25 & N2O4 drain tanks).

4.1.2 Removal of N2O4 / UH-25 propellant tanks involves lifting and moving of existing tanks

outside the storage facility dyke area and position the tanks at level ground.

4.1.3 In UH-25 storage facility, it is required to dismantle and move away the installed high

pressure N2 gas cylinders (2 Nos. – 1 m3 and 200 bar) in order to facilitate the removal &

installation of storage tanks.

4.1.4 Installation of new N2O4 / UH-25 propellant tanks involves lifting and moving of the tanks

into the storage facility dyke area and installation of the tanks on the existing concrete

pedestal.

4.1.5 All the new tanks to be installed have to be transported from Isrosene Storage Facility

(ISF) tanker parking area to the corresponding propellant storage facilities which is

approximately 6 kms away inside IPRC premises.

4.1.6 All the above installation works have to be carried out in the existing N2O4 / UH-25

storage facilities.

4.1.7 After installation, all the new propellant tanks have to be hydro tested to 7.5 kg/cm2(g).

4.1.8 The dimension & weight details of the tanks and cylinders along with work quantity are

given in Annexure-I. (Work item No.: 1 to 3)

4.2 FABRICATION, INSTALLATION AND HYDRO TESTING OF PIPE LINES :

4.2.1 All the existing pipelines along with the associated valves which pose hindrance for

moving the old tanks out of the facility have to be dismantled and installed back along with

the available valves and flow components after the installation of new tanks inside the

facility. The details of the works are given in Annexure-I. (Work item No.: 4 (b))

4.2.2 The pipelines to be installed includes newly fabricated pipelines, dismantled portion of the

existing lines as per the piping layout. The elevation of the piping will vary from 150mm to

5000mm. The details of the works are given in Annexure-I. (Work item No.: 4 (b)).

4.2.3 The work involves cutting of pipe lines to suit site conditions and to the dimensions as per

the existing piping layout, edge preparation as per standards, fit up, welding, DP test,

installation of pipe lines along with all components and valves as per the site conditions/

layout. The rate to be quoted for welding should be inclusive of DP test wherever

applicable.

4.2.4 The welding of pipelines and flanges & pipe fittings should be carried out by Argon arc

process (100% TIG welding) for stainless steel. All the welding works except position

welding should be carried out outside the storage area. All SS filler wire should conform to

A 120 or equivalent. Filler wire of AWS standards shall be used according to parent

material. Manufacturer’s test certificate for filler wires should be provided. The details of

the welding works are given in Annexure-I. (Work item No.: 4 (a))

4.2.5 Hydro test should be conducted after D.P test and radiography clearance for weld joints.

The pipelines should be hydro tested to 7.5 kg/cm2 (g) or pneumatic tested to 5.5 kg/cm2

(g). The pneumatic test for the weld joints is to be carried out wherever hydro test is not

possible.

4.3 RADIOGRAPHY (X-RAY) OF SS BUTT WELD:

4.3.1 All the S.S. butt weld should be radiographed as per standard. The details of the

radiography works are given in Annexure-I. (Work item No.: 5)

4.3.2 The quality of radiography shall be 2% sensitivity level. While taking radiography, only

BARC approved persons should be employed. Necessary safety aspects should be

followed and BARC certificate should be shown before starting the work. Survey meter

should be used during the work.

4.3.3 All the radiographic films shall be made available for review with proper identification by

the Department inspection personnel and the inspection reports and the films shall be

submitted to the Department for archival after the successful execution of the work.

4.4 MODIFICATION OF PLATFORMS AND SUPPORTS :

4.4.1 In order to facilitate the removal of old tanks and positioning of new tanks, the existing

working platforms and supports including the MS chequered plates, structural materials

like beams, channels, angles, pipe/rod, clamps, ladder and handrails may be dismantled

for handling of the tanks inside the facility and reinstalled. Minor modification if required to

suit the site conditions shall be carried out. The approximate quantity of work is given in

Annexure-I (Work item No.: 6 (a))

4.4.2 The removal of structural working platforms also calls for the retrieval of instrument cable

trays installed on the structural materials for routing the instrument command pressure

lines (Instrument air tubings with ferrule fittings) along with 4 Nos. of cubicle box for

housing solenoids and the instrument cable routing GI pipes with threaded ends. These

have to be installed back in position after the erection of the structural platforms. The

approximate quantity of work is given in Annexure-I (Work item No.: 6 (a))

4.4.3 The pipelines shall be installed with properly designed piping supports. Procurement of

MS chequered plates, structural materials and clamps for replacing damaged pipelines/

modified structures are in the scope of the contractor. The approximate quantity is given in

Annexure-I. (Work item No.: 6(b))

4.5 PAINTING AND COLOUR CODING :

4.5.1 Painting includes supply of reputed make primer and two coats of synthetic enamel paint.

4.5.2 All the SS tanks (both new and installed tanks), installed equipments like scrubbers and

structural materials (new and existing) should be painted. The surface to be painted

should be properly cleaned by rubbing before painting for the installed existing items. The

approximate quantity of work is given in Annexure-I (Work item No.: 7 (a))

4.5.3 Proper colour coding should be given with band size of 3-inch. The colours for colour

coding are brilliant green, white, golden yellow, post office red, azure blue, crimson red,

light brown where ever applicable. The quantity of work are given in Annexure-I. (Work

item No.: 7 (b))

4.6 CHEMICAL CLEANING (PICKLING AND PASSIVATION):

4.6.1 All newly installed SS pipe lines and fitting inside and outside including the welding joints

and inside of the replaced valves should be properly pickled and passivated.

4.6.2 All the five numbers of the new N2O4 / UH-25 storage tanks and two numbers of new

N2O4 / UH-25 drain tanks inside should also be pickled and passivated. Pickling and

passivation should be done as per the following procedure. The quantity of work are

given in Annexure-I. (Work item No.: 8 (a) & (b))

4.6.3 PICKLING:

• Cleaning with water.

• Pickling with a solution containing by hydrofluoric and nitric acid. The composition

of the pickling solution and duration of the pickling are adjusted after the trial test

on sample piece to remove uniformly less than 25 µm thick material. The tentative

composition is

o 5% Hydrofluoric acid (by wt.)

o 15-20% Nitric acid and (by wt.)

o Balance DM water

o Rinsing with DM water

4.6.4 PASSIVATION:

This is done after the pickling operation. A solution having the following composition shall

be used.

� HNO3 - 25% by volume

� DM Water- 75% by volume

� Temperature – Ambient

Duration of passivation should be minimum 2 hrs and finally rinsing with Demineralised

water (DM). After Passivation, DM water shall be passed and pH value to be checked

which should show neutral value.

4.6.5 Chemical cleaning (Pickling and Passivation) should be done after hydro test. No

mechanical cleaning should be carried out after chemical cleaning.

4.7 MINOR CIVIL WORK :

4.7.1 It is required to break open a portion of the existing dyke wall and make path way to

facilitate removal of old tanks and positioning of new tanks at both storage facilities.

4.7.2 After the installation and commissioning of the tanks it is also required to construct a

portion of dyke wall where it was broken to facilitate tank movement into the N2O4 / UH-

25 storages. The materials required for the above work are in the scope of the contractor.

4.7.3 The reconstructed brick masonry shall be applied with two coats of white washing over the

plastered surface. The quantity details are given in Annexure-I. (Work item No.: 9)

5. DOCUMENTATION:

The Contractor shall provide the following documents to the Department after

completion of the works under the scope of this contract.

a. As-built drawings showing actual installation details in both hard and soft copy.

b. Test certificates and inspection reports such as material test certificates, hydro

testing of storage tanks & pipelines, pneumatic test for pipelines etc.

c. Test certificates and inspection reports of fabrication (including the

radiographic films)

6. PRICE BID FORMAT:

Price shall be quoted as per the price format (Part-A) given in Annexure-I.

PART-B:

SPECIFICATIONS FOR FABRICATION, INSTALLATION, TESTING AND COMMISSIONING

OF DELUGE SYSTEM AT EARTH STORABLE PROPELLANT STORAGE FACILITIES (N2O4,

UH-25 AND MMH)

1. INTRODUCTION

The proposed work is for dismantling of existing deluge system circuits, Fabrication,

Installation, Testing and Commissioning of new Deluge Systems at Earth Storable

Propellant Storages (UH-25, MMH & N2O4) in C-Top Area at ISRO Propulsion Complex

(IPRC), Mahendragiri. The description and quantum of work is given below.

1) Erection of Deluge Skids ------ 5000Kilogram

2) Carbon Steel Pipe (≤ 40 Sch.) Butt Welding with DPT

------ 3400 Inch Diameter

3) Carbon Steel Pipe (≤ 40 Sch.) Socket Welding with DPT


4) Carbon Steel Pipe (≤ 40 Sch.) Mitre Welding with DPT


5) Pipe Bending (Pipe size ≤ DN 25) ------ 30 Inch Diameter

6) Radiographic Testing ------ 340 Inch Diameter

7) Hydraulic Pressure Testing ------ 5000 Inch Meter

8) Installation of Pipelines ------ 5000 Inch Meter

9) Fabrication of Structural Works ------ 14000Kilogram

10) Supply and Installation of Foundation Bolts ------ 100 nos.

11) Supply and Installation of Anchor Bolts ------ 200 nos.

12) Dismantling of Pipeline Assemblies ------ 2000 Inch Meter

13) Dismantling of Structural Material ------ 1500Kilogram

14) Supply and Painting of Surface with Primer & PU Paint

------ 2150 Square Meter

15) Supplying, Wrapping & Coating of Underground Pipes

------ 60 Square Meter

16) Minor Civil Works - PCC ------ 6Cubic Meter

17) Minor Civil Works - RCC ------ 6Cubic Meter

18) Minor Civil Works - Brick Masonry ------ 6Cubic Meter

19) Minor Civil Works - Earth Excavation and Filling ------ 6Cubic Meter

20) Dismantling of Concrete Structure/ Flooring - PCC

------ 6Cubic Meter

21) Dismantling of Concrete Structure/ Flooring - RCC

------ 6Cubic Meter

22) Dismantling of Brick Masonry ------ 6Cubic Meter

2. SCOPE OF WORK BY CONTRACTOR

Under this work, contractor has to dismantle the existing pipelines, structural steel supports

etc., and carry out fabrication of pipes & structural steels at site or at a different location

identified by IPRC, transportation of goods/materials required for this work, erection, testing

and commissioning of the Deluge system including any civil works as per direction of IPRC

Engineers. The overall scope of work to be executed on the part of the contractor shall be

as follows:

2.1. Dismantling of existing pipelines and associated structural supports as per the direction of

IPRC Engineers.

2.2. Preparation of piping isometric drawings for execution of work and as built piping isometric

drawings upon completion of work.

2.3. Deputing skilled laborers like welder, fitter, rigger, helper, radiographer, painter, Supervisors

etc.

2.4. Providing welding equipment, drilling machine, bending machine, grinding machine, gas

cutting set, radiographic equipment, scaffolds, ladders, Slings, D-Shackles, material

handling equipment and any other tools and tackles for the execution of work.

2.5. Supply of consumables such as welding electrodes, consumables for Dye Penetrant

Testing, films for radiographic test, wire brush and other consumables for mechanical

cleaning, Argon gas, Dissolved Acetylene (DA), Gaseous Oxygen (GO2), etc. for gas

cutting, hack-saw blades, cotton waste, PTFE thread tape, etc.

2.6. Supply and installation of foundation bolts and anchor bolts.

2.7. Supply of paint and its consumables and application of painting on the surface of pipes and

structures.

2.8. Supply of anticorrosion tape and synthetic primer and application of underground pipe

coating and wrapping to protect the pipes from corrosion.

2.9. Supply of raw materials for minor civil works.

2.10. Supply of hydraulic pressure test pump, flexible hose, valve, calibrated pressure gauge,

adaptor, closure etc., for pressure test.

2.11. Carrying out welder’s performance qualification test (if required).

2.12. Shifting and transportation of the Free-Issue Materials (FIMs) within IPRC.

2.13. Providing any other materials or service required for executing the work described.

2.14. Disposal of scrap materials and returning of free-issue materials like structural materials,

pipes, fittings, etc. to an identified place after completion of the described work.

3. SCOPE OF SERVICES BY IPRC

For the execution of the work, IPRC shall provide the following services:

3.1. Providing Preliminary P&I diagram and preliminary pipeline isometric drawings for

fabrication.

3.2. Supply of Free Issue Materials namely Structural materials (Beams, Channels, angles etc.

and plates for fabricating structural support), pipes, pipe fittings (elbows, tees, couplings,

flanges, reducers etc.), flow components (manual valves, Deluge valves, filters, etc.),

fasteners, pipe clamps and gaskets.

3.3. Supply of electricity at a single place near the work spot on chargeable basis. Approximate

charge is Rs 8/- per kW-h as on date.

3.4. Supply of water at a fixed point at free of cost.

3.5. Inspection of fit ups, root welding, final welding, DP testing, X-ray/Gamma ray, Hydro

testing, painting works.

4. DESCRIPTION OF WORK

The description of work as enumerated in Annexure-II to be performed by the contractor is

given as follows:

4.1. Erection of Deluge Skids (Work Item 1)

The price under this heading shall be per “Kilogram (Kg)” of the equipment erected. Truck

for transportation, material handling equipment such as crane, along with essential tools

and tackles, riggers, operators shall be arranged by contractor. The scope of work to be

done by the contractor shall be as follows:

a. Provision of riggers/ laborers for loading the Deluge Skids/ Equipment on truck,

transportation to and unloading at the work site.

b. Positioning of the Deluge Skids/ Equipment on the foundation.

c. Checking for the level of the Deluge Skids/ Equipment by using U-tube water level,

spirit level, etc. and correcting level differences.

d. Installation of flow components (≥ 25 kg).

4.2. Pipe Fabrication, Welding and DP Testing (Work Items 2 To 4)

The prices under this heading shall be per “inch-diameter (inch-dia) Joint” for pipes of

schedule number ≤40. The pipe sizes vary from DN 15 to DN 450.The pipe sizes ≤DN150

is schedule 40 and for ≥DN200 is schedule 10.The scope of work for pipe weld joints shall

include all operations associated with making each joint including cleaning, marking-out,

cutting, profiling, beveling, grinding, aligning, fitting-up, placement of wind shields, weather

protection and final welding, together with final cleaning of welds and DP Testing. Profile

cutting on pipes for fixing of ½ inch half coupling shall be done by core cutting and the pipe

internal shall be cleaned by means of blowers. The grade of the welding electrodes shall be

got approved by IPRC before commencing the welding works. DP Testing shall be carried

out for the root and final passes of the welding in the presence of IPRC inspector. Argon

gas, welding rods and consumables required for DP Testing shall be supplied by the

contractor and is included under this heading.

4.2.1Carbon Steel Pipe Butt Welding and DP Testing (Work Item 2)

The root welding of the butt joints shall be carried out by TIG welding process and final

welding of the joints shall be carried out by Shielded Metal Arc Welding (SMAW). The

welding involves, but not limited to, pipe to pipe, pipe to butt weld fittings and flow

components, butt weld fittings to butt weld fittings and flow components.

4.2.2Carbon Steel Pipe Socket Welding and DP Testing (Work Item 3)

The welding shall be performed by SMAW process. The welding involves, but not limited to,

welding of straight pipe to socket weld fittings and flow components. Branch, fillet and stub

welding shall also be paid for at the unit prices under this heading.

4.2.3Carbon Steel Pipe Mitre Welding and DP Testing (Work Item4)

This work shall involve all the operations including bevel cutting of pipes to the required

number & angle and welding the bevel-cut pieces to form a bend. The number of bevel

cuttings required shall be as per ASME B31.1. The root welding shall be performed by TIG

welding process and final welding of the joints shall be carried out by SMAW process.

4.3. Pipe Bending (Work Item 5)

The prices under this heading shall be per “inch-diameter (inch-dia)” for pipe size≤DN25.

The pipe bends shall be employed in lieu of elbow fittings for the pipe sizes ≤DN25. The

pipes under the bending process shall produce wrinkle-free bends. Unless specified

otherwise, the radius of curvature measured to the centre-line of the pipes shall be equal to

3 times the nominal pipe size (diameter). The bending shall normally be done in cold

condition.

4.4. Radiographic Test (Work Item 6)

The prices under this heading shall be per “inch-diameter (inch-dia) Joint” for pipes.

Generally 10% of total butt-welded joint will be subjected to radiographic test. The joints to

be radiographed shall be randomly selected by IPRC engineers. The discretion as to

whether to insist on radiographic test for additional joints or not shall remain with the

Engineer in charge of the facility. If the fabricated pipeline segment is removable, the same

shall be transported to and radiographed at IPRC’s laboratory by IPRC, in such case no

charge shall be payable to the contractor. The discretion to whether the fabricated pipeline

segment is removable for transportation or not shall remain with the Engineer in charge of

the facility. After completion of all the butt welded joints, the radiographic equipment along

with accessories and operators shall be mobilized to the work site.

The scope of work by the contractor shall cover all operations and arrangements such as

supply of X-ray/ Gamma ray equipment, penetrometers, scaffoldings, screens, films,

facilities for developing the films, etc. required for performing radiographic test. In all

radiographic films, 2-2T sensitivity level shall be maintained. The unit prices shall include

supply of good quality film and developing charges for film. The developed film, after review

and acceptance by IPRC’s inspector, shall be handed over to IPRC along with the joint

identification number marked on the films.

4.5. Hydraulic Pressure Test (Work Item 7)

The price under this heading shall be per “inch-metre (inch-m)” length of the pipeline tested.

After welding, DP Testing and radio-graphic test, if any, the pipeline assembly shall be

subject to pressure test to a pressure of 15 bar(g) or as specified IPRC Engineers. The test

methodology and acceptance criteria shall be as per ASME B31.3. Water at atmospheric

pressure shall be supplied by IPRC, free of charge, at one point in the work site. The

contractor’s scope shall be as follows:

a. To arrange for hydraulic pressure test pump and high pressure flexible hose from

hydraulic test pump to the pipeline assembly, along with valve, temporary closure,

adaptor, calibrated pressure gauge, PTFE thread tape etc. to handle pressures up to

20 bar.

b. Closures of opening by blind flanges and plugs in half couplings.

c. To arrange for low pressure flexible hose from IPRC’s tap point to the hydraulic

pressure test pump.

d. To operate the hydraulic pressure test pump and maintain the test pressure in the

pipeline assembly during inspection.

e. Post hydraulic pressure test, removal of plugs and fixing of water spray nozzles in half

couplings.

4.6. Installation of Pipelines (Work Item 8)

The prices under this heading shall be per “inch-metre” length of the pipeline installed. The

scope of work covered under this heading shall include all the work required for proper

installation of pipelines, including fittings, flow componentsand instruments. The end

connections of the flow components may be threaded or flanged or welded. The work shall

involve connecting pairs of flanges like the flange between the pipeline and a flanged valve

by tightening the fasteners, fixing of gaskets and screwing in threaded fitting like pressure

gauges to a mating fitting like a threaded valve. However, the welding joints shall be paid

for separately under the heading “Welding and DP Testing” vide Paragraph 8.2. There shall

be no limitation to the number of flanged or threaded connections per inch-metre length of

the pipeline installed. The work shall include shifting, handling rigging, scaffolding, lifting,

plumbing and alignment of pipes and fitting in their respective positions and to their

respective supports. The pipelines shall be securely anchored to the supports with suitable

U-Clamps and packing materials. Pipelines may have to be routed over hilly terrain yard,

paved yard, structures and inside trenches. Making pathway for access to such areas,

removal of bushes along the routing and movement of the welding equipment and cablings

to such areas shall be under the contractor’s scope. Payment for the work done under this

heading shall be made only after the pipeline is properly located and permanently

supported in its final position in the field.

4.7. Fabrication of Structural Works (Work Item 9)

The price under this heading shall be per “kilogram” of fabricated structure. The scope of

work includes fabrication, assembly and installation of all types and size of structures like

truss/frame works, pipe supports, base plates, chequered plates and any other type

structures as may be required by IPRC. It also includes handling, fabrication, cutting,

drilling, welding, assembly, installation and adjustment of the structures according to the

requirements at specified locations. There shall be no limitation to the number of welds or

drillings to be carried out per kilogram of the structural works. The payment shall be made

based on the weight of the fabricated structure. The weight shall be calculated based on

geometry of the structure and density of the steel used.

4.8. Supply and Installation of Foundation Bolts (Work Item 10)

The price under this heading shall be per “number” of foundation bolts installed. The scope

of work includes supply of foundation bolts (M16 x 750 N) as per IS 5624, including washer

and hexagon nut conforming to IS 1360 (Part 3) and installation of foundation bolts for

erection of structures/ equipment at the locations directed by IPRC Engineer. It includes

fixing of foundation bolts as per the PCD of base plate and providing necessary torque after

installations. Payment shall be made only after the installation of foundation bolts in its final

position in the field and shall be made only for the installed quantity of foundation bolts.

Necessary precautions shall be taken to prevent damage to the foundation bolts thread

during installation of equipment/ structure.

4.9. Supply and Installation of Anchor Bolts (Work Item 11)

The price under this heading shall be per “number” of anchor bolts installed. The scope of

work includes supply of M16 Hilti Make (HSL-3-G M16/25) anchor bolts and installation as

per manufacturers’ recommendations at the locations directed by IPRC Engineer. It

includes drilling of holes for fixing and providing necessary torque after installations.

Payment shall be made only after the installation of anchor bolts in its final position in the

field and shall be made only for the installed quantity of anchor bolts.

4.10. Dismantling of Pipeline Assemblies (Work Item 12)

The prices under this heading shall be per “inch-metre” length of the segment of the

pipeline assembly dismantled. The scope of work includes removal of existing pipelines by

cutting the pipeline assembly, removing U-clamps from supports as required by IPRC and

stacking it at the temporary scrap yard identified near to the worksite and shifting to the

location at IPRC as specified by Engineer in-charge.

4.11. Dismantling of Structural Materials (Work Item 13)

The price under this heading shall be per “Kilogram” of dismantled structure. The scope of

work includes removal of all types and sizes of structures like pipe supports, chequered

plates and any other types of structures as required by IPRC and stacking it at the

temporary scrap yard identified near to the worksite and shifting to the location at IPRC as

specified by Engineer in-charge.

4.12. Supply and Application of Painting (Work Item14)

The price under this heading shall be per “square meter (m2)” of the surface area painted.

The scope of work includes supply of paint materials & consumables and painting of all

carbon steel pipes and structural works using brush. Pipe surface and structural surface

shall be prepared for mill scale, rust, and foreign matter by means of wire brush or

mechanical power tools before applying paints. Primer shall be done within 4 hours of

completion of cleaning. First coat of primer having minimum thickness of 100 microns

(DFT), second coat of Intermediate coating having minimum thickness of 80 microns (DFT),

third & fourth coats of Polyurethane paint having minimum thickness of 30 microns (DFT)

per coat shall be applied.

• First Coat: Primer – Protectomastic of Berger or equivalent make of Asian / Nerolac.

• Second Coat: Intermediate Coating - Epilux HB MIO Coating of Berger or equivalent

make of Asian / Nerolac.

• Finishing Coats: Polyurethane Paint - Bergerthane Finish of Berger or equivalent make of

Asian / Nerolac.

The paint colour scheme shall be as follows;

• Carbon Steel Pipes : Fire Red to RAL 3000

• Structural Supports : Smoke Grey

• Platform Hand Rails : Golden Yellow

4.13. Supply and Application of Wrapping and Coating Materials for Underground Piping

(Work Items 15)

The price under this heading shall be per “square meter (m2)” of the surface area where

Wrapping and Coating Materials is applied. The scope of work includes supply of synthetic

primer coating, type B conforming to IS 9912/AWWA C203, 4mm thick coal tar based

anticorrosion tape conforming to IS 15337/AWWA C203 and the application of underground

pipes coating and wrapping shall be done according to code of practice IS 10221.

The pipe surface shall be degreased and the rusts shall be cleaned by wire brush. Priming

shall be done within 4 hours of completion of cleaning. One coat of synthetic primer shall be

applied on pipes immediately after cleaning either by brush or spray. The primer shall be

allowed to become touch dry prior to wrapping the tape. Before wrapping the coal tar based

anticorrosion tape to the pipe, the primer-coated pipe shall be gently heated by a run of

LPG torch or suitable heat source. The tape shall be wrapped either by spiral or

circumferential method to the pipe and there shall be a minimum of 12.5 mm overlap per

single wrap. Over the weld joints, after necessary inspections, the procedure for coating

and wrapping shall be of a bare pipe. Overlap on each side of weld joint shall be a minimum

of 50 mm. In wrapping application, care shall be taken that there are no air pockets or

bubbles beneath tape and tape shall be in intimate contact with the primed steel.

4.14. Minor Civil Works (Work Items 16 To 22)

The prices under this heading shall be per “cubic meter (m3)” of the completed works. The

scope of work shall include supply of steel reinforcement rods, binding wires, cement, sand,

gravels, etc. and the work includes excavations of earth for making foundations of

structures and equipment,. The typical works under this heading include the following:

a. Breaking of existing PCC/ RCC pavements/ structures.

b. Excavation of earth, leveling for laying the pipelines, providing pipe supports and filling

of earth after laying the underground pipes.

c. Provision of foundation and pedestals for deluge skids/ equipments & pipe supports as

required by IPRC.

d. Grouting of pipe supports or other structural works.

e. Dismantling of existing brick masonry and construction of brick masonry.

f. Two coats of white washing of the concrete surfaces after plastering.

The composition shall be as follows:

• PCC - Cement: Sand: Gravel = 1:4:8

• RCC - Cement: Sand: Gravel = 1:1.5:3

• Brick masonry - Cement: Sand = 1:6

• Plastering - Cement: Sand = 1:5

5. SUBMISSION OF DELIVERABLES

Following deliverables shall be submitted by the Contractor.

5.1. As-Built Drawings

Upon completion of installation, before raising final RAB, the vendor shall submit hard and

soft copies of as-built drawings showing actual installation details.

5.2. Test Reports and Certificates

• Inspection reports of weld fit up, root weld, final weld and DP testing.

• Radiography clearance report and Films.

• Hydraulic pressure test report.

• Foundation bolts and anchor bolts test certificates.

6. PRICE FORMAT:

Unit price of the each work item shall be quoted as per the price format enclosed in

Annexure-II. Offer without quotation of all items will not be acceptable.

ANNEXURE – I

PART-A: PRICE BID FORMAT FOR INSTALLATION OF NEW PROPELLANT TANKS AND

SS PIPING ERECTION WORK

1. REMOVAL OF TANKS:

Sl. No.

Name of equipment Capacity Size Weight Number Off

Unit Price Total Price

1 N2O4 Storage tanks – D&F (Existing)

40 m3 2500ID x 8500

Long x 8 mm thick 7000 kg 2

2 UH-25 Storage tank – A, B &C (Existing)

40 m3 2500 ID x 8500


3 Drain tanks (UH-25 & N2O4) (Existing)

1 m3 800 ID x 2150


4 N2 gas cylinders in UH-25 storage

1 m3 560 OD x 5.5 m

Long 2000 kg 2

2. INSTALLATION OF TANKS :

Sl. No.



1 N2O4 Storage tanks – D&F

40 m3 2500ID x 8500


2 UH-25 Storage tank – A, B &C

40 m3 2500 ID x 8500

Long x 12mm thick 7500 kg 3

3 Drain tanks (UH-25 & N2O4)

1 m3 800 ID x 2150 Long

x 6 mm thick 400 kg 2

4 N2 gas cylinders in UH-25 storage

1 m3 560 OD x 5.5 m

Long 2000 kg 2

3. HYDRO TESTING OF TANKS:

Sl. No.



1 N2O4 Storage tanks – D&F

40 m3 2500ID x 8500


2 UH-25 Storage tank – A, B &C

40 m3 2500ID x 8500



1 m3 800 ID x 2150 Long

x 6 mm thick 400 kg 2

4. FABRICATION, INSTALLATION AND HYDRO TESTING OF PIPE LINES

(a) FABRICATION AND STAINLESS STEEL WELDING (SS304L, 10sch/ 40sch) INCLUDING DP TEST:

Sl. No. Item Nominal dia

(DN),mm

Schedule Unit of

measurement

Qty Unit price

in Rs.

Total

price Rs.

1 SS Socket

Welding

including

DPT(per inch

diameter for

different sizes

and schedules)

DN 15 40S Inch Dia. 55

2 DN 20 40S 30

3 DN 25 40S 140

4 DN 50 40S 60

5 DN 80 40S 30

6 DN 100 40S 40

7 SS Butt

welding

including

DPT(per inch

diameter for

different sizes

and schedules)

DN 50 10S Inch Dia. 140

8 DN 80 10S 45

9 DN 100 10S 60

10 DN 150 10S 90

(b) DISMANTLING OF PIPELINE ASSEMBLIES AND INSTALLATION OF STAINLESS STEEL PIPE

LINES ALONG WITH VALVES AND HYDRO TESTING/ PNEUMATIC TESTING:

Sl. No. Item Nominal dia

(DN), mm

Sched

ule

Unit of

measurement Qty

Unit price

in Rs.

Total price

Rs.

1 Dismantling &

Installation of SS

pipes along with

hydro testing /

pneumatic testing

(per Inch meter for

different sizes)

15

<=40

sch Inch meter

20

2 20 15

3 25 174

4 50 688

5 80 90

6 100 80

7 150 180

5. RADIOGRAPHY (X-RAY) FOR STAINLESS STEEL BUTT WELDS:

Sl.

No. Item

Nominal dia

(DN),mm Schedule

Unit of

measurement Qty

Unit price

in Rs.

Total

price Rs.

1 Radiography (per

Inch diameter for

different sizes)

DN 50

<=40 sch Inch Dia

140

2 DN 80 45

3 DN 100 60

4 DN 150 90

6. (a) DISMANTLING AND INSTALLATION OF PLATFORMS AND SUPPORTS:

Sl. No. Items Unit of

measurement Quantity

Unit price in Rs.

Total price Rs.

1 Dismantling and installation of working platforms

kg 12000

2 Retrieval & Installation of Instrument cable trays & instrument command pressure tubing

m 120

3 Retrieval & installation of cable routing pipes (GI) 25 NB with threaded ends

m 164

4 Cubicle box (Size: 400 x 400 mm, Wt.: 75 kg) Nos. 4

6. (b) SUPPLY OF STRUCTURAL MATERIALS & FABRICATION OF DAMAGED/MODIFIED

STRUCTURAL PLATFORM:

Sl. No. Total weight in kg (Approx.) Price Per Kg Total Price

1. 500

7. PAINTING AND COLOUR CODING

(a) PAINTING OF TANK SURFACE WITH PRIMER AND PAINT FOR TWO COATS:

(Painting work including supply of reputed make primer and synthetic enamel paint)

Sl. No.

Item Total area m2 Price per m

2 Total Price

1. N2O4/UH-25 Storage tanks – 8 Nos. & Drain

tanks – 2 Nos.

540

2. Scrubbers- 6 Nos. 60 3. Working platforms &

Structural materials 575

(b) COLOUR CODING: Band size 3 inch Length

Sl. No. Size Number of bands

(approx)


1. 15 NB 5

2. 20 NB 15

3. 25 NB 120

4. 40 NB 120

5. 50 NB 300

6. 80 NB 150

7. 100 NB 15

8. 150 NB 15

8. CHEMICAL CLEANING (PICKLING AND PASSIVATION):

(a) CHEMICAL CLEANING FOR BOTH INSIDE AND OUTSIDE OF PIPE LINES FITTINGS AND INSIDE

OF THE VALVES:

Sl.

No. Item

Nominal

dia.

(DN),mm

Schedule Unit of

measurement Qty

Unit price in

Rs. Total price Rs.

1

Chemical

cleaning(per

Inch meter

for different

sizes)

15

Any

Schedule Inch meter

35

2 20 45

3 25 60

4 50 200

5 50 60

6 80 120

7 100 80

(b) CHEMICAL CLEANING OF TANKS (INSIDE):

Sl. No.

Name of equipment

Capacity Size Surface

Area Number

Off Unit Price

Total Price

1 N2O4/UH-25 Storage tanks

40 m3

2500ID x 8500 Long x 12mm thick

310 m2 5


1 m3 800ID x 2100 Long x

6mm thick 10 m

2 2

9. MINOR CIVIL WORK: (Including dismantling of existing brick masonry and construction of brick

masonry and two coats of white washing of the plastered surface)

Sl. No.

Details of work Quantity (approx)

Price per cubic meter

Total Price

1. Brick masonry and plastering

5 m3

Part-A Total Price: _____________

ANNEXURE-II

PART-B: PRICE FORMAT FOR FABRICATION, INSTALLATION, TESTING AND

COMMISSIONING OF DELUGE SYSTEMS

Sl.No. Work Item Unit Quantity Unit Price

(Rs.) Total Price

(Rs.)

1 Erection of Deluge Skids Kilogram 5000

2 Carbon Steel Pipe (≤ 40 Sch.) Butt Welding with DPT

Inch Diameter

3400

3 Carbon Steel Pipe (≤ 40 Sch.) Socket Welding with DPT

Inch Diameter

2300

4 Carbon Steel Pipe (≤ 40 Sch.) Mitre Welding with DPT

Inch Diameter

125

5 Pipe Bending (Pipe size ≤ DN 25)

Inch Diameter

30

6 Radiographic Testing Inch Diameter

340

7 Hydraulic Pressure Testing Inch Meter 5000

8 Installation of Pipelines Inch Meter 5000

9 Fabrication of Structural Works Kilogram 14000

10 Supply and Installation of Foundation Bolts

nos. 100

11 Supply and Installation of Anchor Bolts

nos. 200

12 Dismantling of Pipeline Assemblies

Inch Meter 2000

13 Dismantling of Structural Material

Kilogram 1500

14 Supply and Painting of Surface with Primer & PU Paint

Square Meter

2150

15 Supplying, Wrapping & Coating of Underground Pipes

Square Meter

60

16 Minor Civil Works - PCC Cubic Meter 06

17 Minor Civil Works - RCC Cubic Meter 06

18 Minor Civil Works - Brick Masonry

Cubic Meter 06

19 Minor Civil Works – Earth Excavation and Earth Filling

Cubic Meter 06

20 Dismantling of Concrete Structure/ Flooring - PCC

Cubic Meter 06

21 Dismantling of Concrete Structure/ Flooring - RCC

Cubic Meter 06

22 Dismantling of Brick Masonry Cubic Meter 06

Part-B Total Price:_______________________

ESPSF TANK INSTALLATION AND DELUGE … · ISRO PROPULSION COMPLEX ... Witnessing of welder’s...

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