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GAIL (India) Limited (A Govt. of India Undertaking)

A Maharatna Company VIZAG, INDIA

UPGRADATION AND AUGMENTATION OF FIRE WATER SYSTEM AT VIZAG DT & CHERALAPALLY RT FOR VSPL

NETWORKS

BID DOCUMENT FOR

COMPOSITE WORKS OF FIRE PROTECTION FOR VIZAG &

CHERALAPALLY

OPEN DOMESTIC COMPETITIVE BIDDING

E-Tender no. 8000006103

Bid Document No.: 05/51/23NB/GAIL/001-ii)

VOLUME – II OF III

PREPARED AND ISSUED BY

MECON LIMITED (A Govt. of India Undertaking)

Delhi, India

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GAIL (INDIA) LIMITED

UPGRADATION AND AUGMENTATION OF FIRE WATER SYSTEM AND ASSOCIATED WORKS AT

VIZAG DT & CHERALAPALLY RT

Bid Document No.: 05/51/23NB/GAIL/001

MECON LIMITED

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C O N T E N T S

VOLUME-II OF III

1. Particular Job Specification

2. Appendix-I (List of Approved Parties for Bought out Items)

3. Appendix-II (Data Sheets/ QAP for Mechanical Items)

4. Annexure-I to PJS (Civil & Structural Works)

5. Annexure-I to PJS (Instrumentation Works)

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PARTICULAR JOB SPECIFICATION

UPGRADATION AND AUGMENTATION OF FIRE WATER SYSTEM AND ASSOCIATED WORKS AT VIZAG

DT & CHERALAPALLY RT

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CONTENTS Sl. No. Description 1.0 PROJECT DESCRIPTION 2.0 WORK TENDERED 3.0 METEOROLOGICAL DATA OF SITE 4.0 SCOPE OF WORK AND SERVICES 5.0 BRIEF FUNCTIONAL DESCRIPTION 6.0 TECHNICAL SPECIFICATION FOR PIPES, VALVES, SLUICE GATES & FITTINGS 7.0 DESIGN CRITERIA 8.0 STATUTORY REGULATIONS, LICENCES & PERMITS 9.0 HANDING OVER THE WORK ON COMPLETION 10.0 SCHEDULE OF RATES / BILL OF MATERIALS 11.0 SCOPE OF SUPPLY 12.0 DOCUMENTS, SPECIFICATION, STANDARDS AND DRAWINGS 13.0 RESOURCES FACILITIES 14.0 CONSTRUCTION 15.0 SURVEY AND LEVEL/SETTING OUT WORK 16.0 ORDER OF WORKS/PERMISSIONS/RIGHT OF ENTRY/CARE OF EXISTING

SERVICES 17.0 INSPECTION OF SUPPLY ITEMS 18.0 ESCALATION 19.0 DOCUMENTS TO BE SUBMITTED/ PRODUCED ALONGWITH R.A. BILLS

Appendix-I (List of Approved Parties for Bought out items) Appendix-II ( Data Sheets / QAP for Mechanical Items etc.) Annexures to PJS

Annexure-I : Technical Input of Civil & Structural Works Annexure-II : Technical Input of Instrumentation Works

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1.0 PROJECT DESCRIPTION M/s GAIL (India) Limited has been operating its Vizag - Secunderabad LPG Pipeline (VSPL) for transportation of LPG from Vizag to Secunderabad. Presently, approx. 0.8 MMTPA of LPG is being transported to meet the LPG demand of bottling plants enroute VSPL. The LPG is transported from Vizag to Vijayawada through 12” dia (350 km) and Vijayawada to Secunderabad through 10”dia (250 km) pipeline. Augmentation of Vizag to Secunderabad section to 1.33 MMTPA is being met by installation of 2 nos. (1 working+ 1 stand by) Electric Motor Driven Centrifugal pumps at Vijayawada IP station.

The entire system was designed as per the applicable national and international codes and engineering standards prevailing at that point of time, namely, API, ASME, ANSI, B31.3/16.5/16.29, NEMA, OISD 116/117 etc.

Fire Water Systems at installations along these pipelines have been designed as per OISD-117 (Oil Industry Safety Directorate) which is now required to be upgraded as per guidelines laid in OISD: 214 and PNGRB. Therefore, GAIL (India) Limited appointed MECON as PMC to carry out the up-gradation and augmentation of existing fire water systems for Vizag Dispatch Terminal & Cheralapally Receiving Station as per the report prepared by MECON for the same. This tender covers the minimum requirement for the various activities to be performed by the contractor for the engineering and construction of Mechanical Works for fire protection system (Spray system, pipe laying etc.), Civil works, Fabrication, Erection of Structural Steel Works, Electrical and Instrumentation Works, Erection of equipments including Erection, Testing and commissioning of Fire Water Pumps and associated works.

1.1.1 Details of Proposed Facilities:

a. Laying of new aboveground fire water network piping with isolation valves,

fittings, bends in the plant at few areas as per the drawing ..

b. Installation of available and new hydrants and monitors as per OISD

stipulations.

c. Installation of Fire water diesel engine driven horizontal centrifugal pumps.

Electric motor driven Jockey pumps (1 working + 1 standby) has also been

provided to keep the network pressurized. The pumps have manual

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running in addition to auto start. Suitable system for running of main pumps

shall also be provided in control room.

d. Installation of medium velocity water spray system for process areas viz.

LPG Pump House, Metering Area, Scrapper Area etc.

2.0 WORK TENDERED 2.1 The work tendered in this bid package consists of supply of materials as

required, installation, testing and commissioning of Fire Water Pumps including all Associated Mechanical, Civil, Structural, Electrical, Instrumentation works. The work being tendered is covered as indicated below: Part – I :

Sl. No.

Description Scope of Work

. Upgradation of fire water system, Vizag DT & Cheralapally RT

- Laying of aboveground fire water line including valves, flanges & fittings, hydrants, monitors, relocation of hydrants monitors etc. wherever required

- Supply and installation of medium velocity water

spray system - Supply and installation of emulsifier system for

transformer area and soak pit in Vizag - Civil & structural works including supply of all

materials for pedestals, pavements, repair etc. - Erection of fire water pumps - Supply, installation, testing & commissioning of

LEL detectors and installation of LEL panel and integration with water spray system.

- Complete erection & assistance in

commissioning of fire water Pumps including Electrical & Instrumentation Works.

2.2 All works of the pipeline & other works included in the scope will be done

simultaneously from the date of issue of FOA. Bidder will organize equipment and manpower accordingly to meet this requirement as per

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instruction of Engineer-in-charge. 3.0 METEOROLOGICAL DATA OF SITE

The fire protection systems shall be designed taking into account the meteorological data prevailing at the project site as mentioned below.

Temperature Minimum - (-) 5o C Maximum - 55o C Relative Humidity Maximum - 50% Rainfall - 25mm Wind Velocity - Maximum – 100 Km/Hr Environment - Dry & Hot (Desert Condition) 4.0 SCOPE OF WORK AND SERVICES 4.1 General The scope of work of the Tenderer shall include design, engineering, supply,

fabrication/manufacture, assembly, inspection, shop testing, piping, transportation, receipt at site storage, installation, painting, testing and commissioning, obtaining statutory approval and demonstration of integrated performance of all equipment required for fire protection system which broadly includes pumps, motors, diesel engines, fire detection cum alarm system, accessories and other hand appliances at various locations (detail of which mentioned elsewhere in the specification) for the Terminals as per the indicative list of items mentioned alongwith tentative quantities.

The tenderer shall furnish the list of commissioning and two (2) years maintenance and operational spares in the offer. Complete details of all spare parts, their relation to the equipment and their itemized prices shall be furnished in the tender. Prices shall be mentioned in the price envelope and item wise list of spares without price shall be furnished in the unpriced bid.

4.2 The scope of work and services to be rendered by the Tenderer for installation of fire fighting system shall include but shall not be limited to the following activities.

i/ Design, engineering, manufacture/fabrication, assembly, shop testing and shop painting,

sequential packing, delivery FOR site, unloading, unpacking, storage at site, site handling, preparation of erection drawings, erection as per approved drawings, site testing, painting, commissioning and fulfillment of guarantee of fire protection systems, sub-systems and integrated systems as described above and also covered under this tendering specification.

ii/ Miscellaneous materials and services, if not otherwise specifically asked for, shall include

the following : - Constructing site office, covered store, open storage at designated place including supply of

construction material and removal of the same on completion of work.

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- Site cleaning, removal and disposal of debris, maintaining clean condition in and around the working place and as instructed by authorised representative of MECON / Owner.

- Distribution of electric power supply for erection work through licensed electrical contractor /

licensed electrician. Construction power shall be made available by Owner at one place. - Supply, installation, testing, commissioning of fire water pumps, motors, panels, diesel

engines, diesel tanks, electrical & instrumentation work, accessories, fire fighting appliances and all associated facilities.

- Underground reservoir drawings, detailing for provision of puddle flange, inlet & outlet

locations, general arrangements of filling, baffle walls details etc. for further detailing of pipeline and pump house layout.

- Owner shall made available incoming power supply in the pump house. However,

termination, connection, fixing of cable at the panel including supply of panels shall be done by the bidders. The cables (power / control) from MCC / panel to respective pump motors diesel engines, battery charger etc. including termination shall be considered by the bidders.

- All piping integral to or between any equipment furnished under this specification, except as

otherwise specified. - All necessary isolation valves fitting at the tapping points and branch pipes. - Coupling guards for all exposed shafts and couplings. - Base plates, thrust blocks, duck-foot bends, matching flanges, supporting materials and

shims. - All necessary instruments, power and control wiring integral to any equipment furnished

under this specification. This shall include terminal blocks and integral wiring to these terminal blocks for equipment requiring external connection.

- All erection accessories, consumables and miscellaneous materials, though not specifically

indicated in this specification, but actually required for completing the job in all respects. - All necessary connections for hook-up with Purchaser's pipe network. - Erection, testing and commissioning of materials and system as a whole. - Initial fill of gas and other fire extinguishing media. - All necessary fixtures, supports. iii/ To obtain No Objection Certificate from the local statutory fire authorities / TAC for the

complete system. 4.3 Formats for Work Permit System: 4.3.1 Work permit system in line with OISD:105 as per GAIL’s HSE Management System shall be

followed. 4.3.2 Permits shall be issued in SAP system and shall be issued to EIC as per GAIL’s procedure.

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5.0 BRIEF FUNCTIONAL DESCRIPTION

The main intentions of provision of first aid and inbuilt fire fighting systems are to extinguish the fire at its inception or to control its spread and to assist the fire department in taking required action and thereby reducing the loss suffered as a result of fire. The Fire Water layout drawing no. MEC/23NB/05/21/M/FF/001 of the plant is enclosed for ready reference.

The fire protection system envisaged for the plant calls for early detection of fire and quenching the same by various systems envisaged besides giving out an audio visual alarm. The first aid fire fighting arrangements cover the provision of portable fire extinguishers, etc. as per the requirement of OISD: 189 and TAC.

5.1 Hydrant Service

A well-designed Hydrant system is the backbone of entire fire fighting system as it fights fire of all classes of risks. The entire DT is covered with water based fire hydrant network. For the purpose of hydrant system design, the MS has been considered as medium Hazard occupancy as per TAC classification. The designed main consist of MS coated /DI pipes, 200 mm dia. ring mains. Distribution mains form ring around each unit, which is connected to the ring main running in the vicinity, which mainly consist of fire water storage facility, main fire pumps, jockeys pumps, double outlet landing valves, monitors etc. The work shall be carried out as per OISD: 214. Water to the hydrant network supplied by pumps exclusively envisaged for fire fighting purpose. One number diesel engine driven centrifugal pump of 616 m3/h has to be provided as main pump. The delivery pressure at rated capacity will be 8.8kg/cm2. One number diesel engine operated pump of 616m3/h capacity with 8.8 kg/cm2 delivery pressure will be provided as a stand-by, which will start automatically in case of main pump fails to develop desired pressure in the network. For the purpose of starting the diesel engine pump, suitable auto start panel, battery, battery charger etc will also be provided. Two numbers jockey pump of 10m3/h capacity and 9.8 Kg/cm2 delivery pressure as proposed in TAC is also being provided. All these pumps will be installed in the pump house. All the pumps are being provided with emergency power supply backup.

The fire water network lines shall be continuously kept pressurized at 9.5 kg/cm2 (g) (at the hydraulically remotest point of application). Any drop in pressure below 9.5 kg/cm2(g) shall be made up with the help of 2 nos. of electric driven jockey pumps (one operating + one standby) each of 10m3/h capacity and discharge pressure 9.8 Kg/cm2. If pressure continues to fall more than 1.0 kg/cm2 (g), there shall be alarm in the pump station and control room, where fire panels are installed. The first fire water pump will start so as to maintain the pressure in the fire water header. However, if the pressure continues to fall further by another 1 Kg/cm2, there shall be an alarm in the pump station & control room and second fire water pump will start on activation of the system, a signal shall be given in the control room.

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Supply of water to the hydrant network is through existing aboveground steel tank water reservoir. The total capacity of the water reservoir is 2600m3. The system has provision to re-circulate the firewater for test run of pumps. PCV will be installed on recirculation line to regulate pressure in the network. The system shall also be equipped with the facility to dispose off entire water in the event of contamination. Above ground fire water pipes shall be painted fire red confirming to shade no. 536 of IS: 5. All fire water piping shall be hydro tested to a pressure of 18 Kg/cm2. Adequate nos. of isolation valves in the fire water network shall be provided over and above already provided, if so required to ensure easy maintenance at the affected part of the network and at the same time uninterrupted water supply to the rest of the network for fire fighting remains available.

5.2 Automatic Water Spray System

A deluge type water spray network shall be designed in accordance with NFPA 15 and API 2030.This system shall be located over the equipment areas and designed to provide water at the net rate as specified. High velocity water spray system has been considered for Transformers and Medium Velocity Water Spray system has been envisaged for LPG Pump House, booster pumps, filtration & metering area, scrapper launcher area to provide cooling and / or exposure protection to such type of risks where extinguishment is always not possible. 6” / 4” Φ tapping shall be taken from the ring mains exclusively for the spray system. The system comprises of piping, valves, deluge valves, sprinkler based detection system and actuation of deluge valve through signal from LEL detector panel, sprayers and other accessories. Wiring from LEL detector panel to deluge valve solenoid shall be in the scope of this tender. The temperature rating of the detector sprinkler shall be at least 30`C above the highest ambient temperature at the site of installation. In case of increase in temperature in and around the area under coverage, the sprinkler bulbs breaks and the pressure is released from priming chamber of deluge valve faster than it is supplied through the restricted priming line. Therefore clapper moves and allows the inlet water supply to flow through the outlet into the system and associated alarm device and water is sprayed through sprayers to combat fire. The mode of actuation of Deluge Valve shall be hydraulic type as well as through solenoid valve to be actuated through signal received from LEL detector panel. The LEL detectors and panels are not covered in this tender. However wiring from panel to deluge valve is in the scope of bidder. The density of water application by sprayers shall be 20.4 / 10.2 LPM / M2. For the effective protection of the areas, the risk area shall be divided into several zones of width not less than 10M. Each zone shall be controlled by an individual Deluge Valve and flow shall not be more than 13,500 LPM. Each zone shall be so designed that the pressure at the hydraulically most un-favorable sprayer / sprinkler is not less than 1.4 bars and that the most favorable sprayer / sprinkler is not more than 3.5 bars and that the velocity in distribution pipes shall not exceed 5 m/sec. The detection network piping shall be similar to the sprayer network viz. there shall be same number of detectors as there are number of sprayers. Medium velocity spray system shall be provided for high temperature zone areas etc. High velocity water spray system shall be provided for the transformer area.

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Systems shall comprise of network of pipelines with distribution control, units, open spray nozzles- stainless steel material (capable of spraying water with medium velocity and high velocity), automatic fire detection cum alarm facility, deluge valves, instrumentation (pressure switches, limit switches, pressure gauges), solenoid valve, wiring from solenoid valve to LEL panel, isolation valve & deluge valve housing / room. Water required for the system shall be drawn from existing fire network. Design Criteria for High Velocity Water Spray Systems The High Velocity Water Spray System shall be designed as per the stipulation of TAC rules on the subject as well as NFPA’s guidelines. Following salient parameters shall be followed by tenderer for the design of the system. Water application rate – 10.2 lpm / m2 of the surface area of the entire area including bottom surface, boiler nozzles etc. The system shall be so hydraulically designed that the pressure at the hydraulically most remote projector in the network shall not be less than 3.5 bars. Max. Permissible pressure in any projector = 5.0 bars. Velocity in the feed pipe shall not be more than 5 m/s. There shall be common header for (HVWS & MVWS) headers shall be inter-connected with a non-return valve in between so that hydrant system can be a back-up for the spray system. Q.B. detectors shall be installed in two rings one at top and another at bottom around the protected area. Maximum spacing between detectors shall be 2.5 m. Projectors shall be installed in rings encircling the protected area. One ring shall be provided at the top and subsequently rings for every 3 m from top to bottom shall be provided. Design criteria for medium velocity spray system (MVWS) The medium velocity water spray shall be designed as per the stipulation of TAC rules on the subject as well as NFPA’s guidelines. Following salient parameters shall be followed for the design of the system. Water application rate for pump house – 20.4 lpm / m2 and for other areas-10.2 lpm / m2 of the exposed surface area. The system shall be so hydraulically designed that the pressure at the hydraulically remotest sprayer shall satisfy the following conditions: The protected area shall be divided into several zones, each of which shall fed by individual deluge valve. In event of fire water shall be sprayed on the zone concerned (i.e. zone under fire) along with preceding and succeeding zones. Distribution of sprayers: Sprayers shall be providing to spray water on both the top side and bottom side of the process area. Spacing between sprayers shall not be more than 4m.

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The sprayers shall be installed in rows and spaced at not more than 3 m from each other. Provision for manual operation of the system shall also be made to operate the system in case of failure of the automatic mode. For the protection of deluge valves from mechanical damage and atmospheric conditions civil/structural rooms shall be provided. Standard fence and door shall be provided in addition to illumination facility.

6.0 TECHNICAL SPECIFICATION FOR PIPES, VALVES, SLUICE GATES & FITTINGS 6.1 T.S. for Pipes for hydrant system

Pipes and pipe fittings in general shall comply with the requirements of BIS codes and TAC norm. The pipes shall be manufactured / supplied as specified below:

i) Upto 150 mm nominal size - M.S ERW Black pipes conforming to IS-1239- 1984 Part-I (heavy grade) With Plain ends.

ii) 200 mm to 400 mm size - M.S. ERW Pipes conforming to IS-3589 -1973

but thickness as specified below Nominal Dia O.D X Thickness in mm DN 200 mm : 219.1 x 6.35 DN 250 mm : 273.0 x 7.14 DN 300 mm : 323.9 x 7.14 DN 350 mm : 355.6 x 7.14 DN 400 mm : 406.4 x 7.14 6.2 T.S. for Pipes and valves for Spray (HVWS & MVWS) system

The material of construction and manufacturing standard of pipes, fittings, valves, fasteners, gaskets, etc. shall be as described in table-1 below:-

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Table-1 Nominal pressure (PN) - 10 Kg/Cm2 Test Pressure (PT) - 15 Kg/Cm2

S. No.

Items Nominal dia.(mm)

Specification

1. Pipe 65 and below 80 100 to 150 200 to 250

250 and above

IS-1239 (Part-1) - '90 Heavy, IS-1239 (Part-1) - '90 Heavy, IS-1239 (Part-1) - '90 Heavy, IS-3589 Gr.410 ERW pipe commercial quality or equivalent. Thickness as specified.

2. Pipe fittings A 234 Gr. IS-1239/3589/2062

2.1 Screwed fittings 65 & below IS-1239 (Part-1) - 90 Galvanised

2.2 Fabricated fittings

Bends 150 and above

Mitered bends with radius 1.5 DN from black pipe.

Tees/Crosses 150 and above

Fabricated from black pipes by smithing.

Reducers 150 and above

Fabricated from black pipes by taper cutting and welding.

3. Bolting All sizes IS – 1367

4. Gaskets All sizes Spiral wounded graphite filled gasket as per B 16.5, 150 #, ASTM A-105, CS Slip on, RF

5. Flanges All sizes Slip on flanges to IS-6392 - `71 machined from Carbon Steel plates to IS-2002-`92 Gd. 2 with bore to suit pipe O.D.

Fittings shall be supplied as per IS: 1239-1992 Part II for pipes up to 150 mm dia and shall be fabricated from pipes for dia 200 mm and above. 6.3 Technical specification for valves:

The valves & sluice gates shall be designed, manufactured and tested as per relevant Indian Standards or as per other International standards acceptable to the Purchaser and will be suitable for the duty conditions specified below. All underground valves will be provided with valve chambers with RCC covers. The size of chambers shall be suitable for easy maintenance of the valve. Complete civil work for this is in the contractor's scope.

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Table-2

S. No. Items Nominal dia.(mm) Specification

1. Isolation Below 50 Forged Carbon steel gate valve, screwed as per API – 602 standard, class 800 # ASTM A-105, trim 13% Cr, Bolt/Nut – B7/2H, Socket end threading as per ANSI B.16.11 Gasket SPW S.S. 304 with CAF Hand Wheel - Cast steel

50 to 300 Cast Carbon Steel flanged gate valve as per standard API-600 class 150 # , Body & bonnet material ASTM A 216 Gr. WCB, Trim 13% Cr S.S, Spindle & Gland bush – A1S1 410. Hand wheel C.S, Gasket SW S.S-304 + LAF, flange drilled to ANSI – B.16.5 along with companion slip-on welded flange (without hub) drilled as per B.16.5 and gasket, Nut & bolt etc. Hand Wheel - C.S.

2. Throttling 50 and below Gunmetal globe valve, Screwed, as per IS-778-`84 Class-2

7.0 DESIGN CRITERIA 7.1 Codes and Standards: STANDARDS 7.1.1 All materials, equipments, piping, valves, fittings etc. dimensional standards, tolerance,

prices of manufacture and testing procedure shall be in accordance with the latest revision of relevant Indian, British, American standards wherever applicable.

7.1.2 The material used and equipment supplied shall be new and the best of their kind and shall

comply with the latest revisions of all relevant standards. The tenderer shall indicate in his tender the relevant standards to which the equipment, piping, fittings, etc. offered by him shall comply with. The latest revisions of applicable standards indicated in the technical specification shall be used for the design, manufacture, inspecting and testing of the items covered in this specification. The following codes and standards shall be considered for design: -

OISD-113: Classification of areas for electrical installations at hydrocarbon processing

and handling facilities.

OISD-117: Fire Protection Facilities for Petroleum Depots, Terminals and Lube Oil Installations.

OISD-163: Process control room safety.

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OISD – 179 & OISD - 214

National Fire Protection Association, USA (NFPA) codes

Standard for installation of centrifugal pumps (NFPA-20)

Standard for water spray systems (NFPA- 15)

Standard for sprinkler systems (INFPA-13)

API-25 10 A: Fire protection considerations for design and operation of LPG storage facilities.

Auto start system with bypass arrangement for jockey pumps in case of pressure drop in the fire hydrant line.

Foam and Dry Chemical Power extinguishers of capacity as per SOR shall also be provided and located along with other fire fitting facilities.

Standard for Horizontal Centrifugal Pumps for clear, cold, fresh water IS: 1520-1980

Technical requirement for roto-dynamic special purpose pumps IS: 5120-1971

Horizontal Centrifugal self priming pumps IS:8418-1977

Code of acceptance tests for centrifugal, mixed flow and axial flow pumps IS: 9137-1978, BS-5316-latest edition, ISO-2548-1973

Technical specification for centrifugal pumps ISO:9908-1993

End suction centrifugal pumps ISO: 2858-1995

Single faced sluice gates IS:3042-1965

Single faced cast iron thimble mounted sluice gates IS:13349-1992

Sluice valves for water works purpose (50-300mm size) IS: 780-1984

Copper alloy gate, globe and check valves for general purpose. IS:778-1984

Specification for cast iron check valves BS 5153-1991

Foot valves for water works purposes IS:4038-1986

Landing valves IS:5290-1993

Valve inspection & test IS:6157-1981

Specification for inspection and test of steel valves BS:6755-1986

Mild steel tubes, tubular and other wrought iron fittings IS:1239, part-1-1990 & Part-2-1992

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Seamless or electrically welded steel pipes for water, gas and sewage IS:3589-1991 Steel pipe flanges for water, oil, steam etc. IS:6392-1971 Butt welded fittings ANSI B16.9 Circular flanges for pipes, valves and fittings BS1560-latest editions Code for pressure piping ANSI B31.1 Steel pipe flanges ANSI B 16.5 Code of practice for laying of electrically welded steel pipes for water supply IS:5822-

1994 Excavation work-code of safety IS: 3764-1992 Criteria for design of anchor blocks for penstock with expansion joints IS:5330-1984 Covered electrode for manual metal arc welding of carbon and carbon manganese

steel IS:814-1991 Approved tests for welding procedure IS: 7307 (Part-I)-1974 Approved tests for welders working to approved welding procedures IS:7310(Part-I)-

1974 Specification for arc welding of carbon and carbon manganese steels BS:5135-1984 Code of practice for coating & wrapping IS:10221 Code of practice for radiographic testing IS:2595-1978 Recommended practice for radiographic inspection of fusion welded butt joints in

steel pipes IS:4853-1982 Recommended practice for radiographic inspection of fusion welded butt joints in

steel pipes IS:1182-1983 Safety code for industrial radiographic practice IS:2598-1966 Ready mixed paint, stoving, red-oxide-zinc chrome priming IS:2074-1992 Code of practice for painting of ferrous metals in building IS:1477-1971 Colors for ready mixed paints and enamels IS:5-1994 Steel for general structural purposes IS:2062-1992

Fire safety of industrial building: electrical generating & distributing stations IS

3034:1993

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8.0 STATUTORY REGULATIONS, LICENCES & PERMITS 8.1 The contractor shall adhere to all applicable statutory requirements including TAC, OISD,

Inspectorate of Factories, Indian Electricity Rules and other statutes of Govt. of India and state government. The contractor shall himself ascertain all applicable requisite regulations.

8.2 The contractor shall be solely responsible for obtaining necessary clearances from various

statutory bodies including those of Govt. of India / State Govt. and as applicable during the course of manufacture/ fabrication, testing, transportation and delivery of plant and equipment. The rates quoted in this connection shall be deemed to include any fees payable to Govt./ Fire Authorities/ Statutory bodies for obtaining approval.

8.3 Contractor shall keep constant liaison with the local Fire Authority, Electrical Authority and all

other Statutory Authorities whose approval and permissions/ sanctions before and after execution of the work are required to be obtained.

8.4 It shall be the Contractor's responsibility to obtain the approvals and permissions, sanctions,

No Objection certificates from relevant Fire Authorities for work done by him to enable owner to take up the operation of plant. Contractor shall comply with all requirements of the appropriate authorities, submit documents, test reports and conduct such tests as may be required by the concerned authority to its full satisfaction.

9.0 HANDING OVER THE WORK ON COMPLETION The contractor shall be responsible for handing over the work complete in all respects and in

proper finished condition, on completion of the work. If there is any damage or disfiguration/ stains on the finished surfaces including on wall, floors, ceiling, columns, beams etc. due to contractors use, damage or any other reason during the period of construction, the same shall be rectified suitable by the contractor without any extra payment.

10.0 SCHEDULE OF RATES / BILL OF MATERIALS The quantities of different material, pipes/ fittings, valves, flanges, erection, accessories etc.

mentioned in the specification and SOR are approx. quantities and any change in requirements will be as per the finally approved drawings. Any item, instrument which is not specifically mentioned in the SOR, but required for the completeness of the system, will have to be supplied and erected by the contractor and the financial implication shall be built in the testing and commissioning item.

10.1 Procurement 10.1.1 CONTRACTOR shall procure and supply all the materials other than OWNER

supplied materials, required for permanent installation of terminals in sequence and at appropriate time. All equipment, materials, components etc. shall be suitable for the intended service. Approved vendor list has been indicated in the bid package for various items. For items, which are not covered in the vendor list, CONTRACTOR shall obtain Owner’s prior approval for the vendor. Equipment requiring specialized maintenance or operation shall be avoided as far as possible. Equipment offered shall be field proven.

10.1.2 CONTRACTOR shall procure all materials, components, equipment, consumable

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etc. required for successful completion of the pipeline system. CONTRACTOR shall also procure and supply spares required for pre-commissioning and commissioning/ start up as recommended for all items supplied by him as per specifications provided in the bid package. Where no specification is available in the contract, the same shall be prepared by the CONTRACTOR based on the piping material specification and shall be subject to Owner’s approval.

10.1.3 Material take-off with complete description of size, rating, material, thickness and

specifications. 10.1.4 Only single offer shall be provided by the bidder fully complying with the

specifications/ drawings/ requirements for Owner’s review and approval. CONTRACTOR shall provide for inspection of the items at vendor's works by the OWNER/ Owner’s REPRESENTATIVE or by a reputed inspection agency and shall submit inspection reports for Owner’s clearance.

10.1.5 Stores management for contractor supply items as well as free issue materials

including receipt, warehousing, preserving the material in good condition, issue of material to construction site, reconciling/ handing over surplus material to OWNER for OWNER supplied items at Owner’s store.

10.1.6 Carryout proper documentation of inspection and quality assurance programmes for

all equipment and bulk materials duly approved by OWNER. CONTRACTOR shall maintain an accurate and traceable listing of procurement records for the location, quality and character of all permanent materials in the Project.

10.1.7 CONTRACTOR shall immediately report to the OWNER of all changes, which will

affect material quality, and recommend any necessary corrective actions to be taken. 10.1.8 Submit periodic manufacturing progress reports highlighting hold ups and

slippages, if any, to OWNER and take remedial measures. 10.1.9 Interact with authorities such as Sales Tax, Octroi, Excise, Customs etc. as

necessary and arrange for transportation of the materials under his scope of supply to site.

10.1.10 All purchase requisitions including purchase orders shall be approved by OWNER/

Owner’s REPRESENTATIVE. 10.1.11 Compliance with vendor's and supplier's instructions and recommendations for

transportation, handling, installation & commissioning. 10.2 Construction 10.2.1 General 10.2.1.1 All construction works shall be carried out as per "Approved for Construction"

drawings, procedures, specification and applicable codes and standards. Any changes at site shall also need prior approval from the OWNER and revision of drawings. Construction drawings will be furnished to the Contractor in a phased manner and as per the requirement in accordance with the procurement and construction plan prepared and furnished by him & agreed by Owner/ Consultant. .

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10.2.1.2 Providing schedules, progress reporting, organization chart at construction site, quality assurance plan and developing quality control procedures, as per requirements indicated elsewhere in the bid package.

10.2.1.3 Coordination and supervising the work of sub-contractors. 10.2.1.4 Transportation of appropriate materials and taking delivery of Company supply

materials, store, worksite, intermediate storage points, maintaining and operating an adequate material control procedure at worksite.

10.2.1.5 Fabrication of all piping, structural components as per approved drawings. 10.2.1.6 All Civil / Structural Works, Electrical, Instrumentation Works, laying and

commissioning works shall be performed in accordance with relevant specifications and requirements enclosed elsewhere in the bid package.

10.2.1.7 CONTRACTOR shall provide complete details of manpower, equipment etc. to be

deployed. Mobilising and providing all equipments, manpower (skilled and unskilled), consumable and other resources etc. for each spread as required for the execution of the complete job defined herein and thereafter demobilising the same upon completion of work.

10.2.1.8 Provide, maintain and operate all temporary facilities required for the construction

related works and remove after completion of work. 10.2.1.9 Hook up/ tie-in of piping system with terminal facilities. 10.2.1.10 All works related to testing, dewatering, swabbing, drying pre-commissioning and

commissioning of the work tendered. 10.2.1.11 Idle time preservation of pipeline, if required. 10.2.1.12 All incidental and associated works and any other works not specifically listed therein

but are required to be carried out to complete entire work related to pipelines and terminals.

10.2.1.13 Loading, unloading, handling, stacking, storing and shifting to workshop / work site of

all materials that may be used for the construction of pipeline system either supplied by OWNER at their designated stack yard/ dump site / store and / or by CONTRACTOR as the case may be.

10.2.3 Laying Works 10.2.3.1 Pipeline Works

• Erection of all valves and equipments, Pump, etc. as detailed in SOR.

• Supply of assorted pipe, fasteners, gaskets, fittings, flanges, valves & utility piping & piping supports and other supply wherever specified as per SOR.

• Taking delivery of free issue materials from GAIL’s designated stores and its transportation to the place of erection.

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• All fabrication, erection, testing and commissioning of piping above ground at all elevations and below ground at all depths including all valves and valve actuators and other fittings and associated piping works as per drawings and specifications.

All mechanical works of under ground and above ground, complete piping including fabrication, welding, all non destructive testing of welds repairs/ pretesting, hydrostatic testing, cleaning/ flushing, functional testing, cutting of mainline and bevelling (if required), excavation in all types of soil for installation of piping and pipe supports.

• Installation of all inline/ online instruments.

• Obtaining all necessary approvals and work permits from concerned local authorities having jurisdiction including hot work permit as applicable for performing the work.

• Carrying out welding including cutting, edge preparation (inclusive of grinding the edges on fittings, flange, etc. to match with the matching edges of different thickness wherever required, bending, pre-heating wherever required, NDT including radiography of gamma-ray and other non-destructive tests specified. NDT requirements for process and other piping shall be in accordance with relevant specifications enclosed with the tender document.

• Preparation of isometric drawings and final bill of material based on piping GAD supplied by MECON.

• Cleaning and servicing of all free issue materials including equipment, valves to make it suitable for installation.

• All utility and fire hydrant lines as detailed in SOR.

• Completion of all piping and mechanical works as detailed in SOR.

• Terminal station piping shall be hydrostatically tested to the test pressure in accordance with Specification for piping fabrication, erection. Test pressure shall be 1.5 times design pressure and minimum duration of test shall be six (6) hours. All ball and plug valves in the piping network being hydro tested shall be kept in the partially open position.

10.2.3.2 Erection of Rotating Equipment (Fire Water Pump set)

Transportation of Rotating Equipments and accessories from Owner’s stores to site, assembly of sub-assemblies / parts, erection of Rotating Equipments on foundation, leveling, aligning and grouting, preparation of Rotating Equipments for trial runs, carrying out no load / trial runs, return of any unused material to the owners store sand hand over in fit condition for the start-up of the Plant, as per instructions of Engineer-in-charge.

Defects due to Contractor’s fault noticed during trial runs shall be rectified by him. The detailed indicate in SOR estimated numbers, dimensions and weights of the Rotating Equipments. The actual data dimensions and weights will be in the vendor data manuals.

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The term Rotating Equipments signifies all pumps, compressors, steam & gas turbines, diesel engine / steam turbine / gas turbine generator sets along with drivers accessories & auxiliary systems.

DRAWINGS, SPECIFICATIONS AND CODES: The following drawings will be provided by the Owner, which are to be followed for erection of each Rotating Equipment. i) General Arrangement drawings with outline dimensions including

foundation details. ii) Manufacturer's instruction manuals / erection drawings as available from

them.

ERECTION OF ROTATING EQUIPMENTS : - All Rotating Equipment erection shall be done by experienced fitters. For

this purpose the contractor shall employ experienced and suitably qualified erection supervisor and crew who have done similar jobs.

- The Rotating Equipment manufacturer's instructions as available regarding

installation and trail runs will be passed on to the Contractor during the course of work, The requirement prescribed therein shall be met in addition to what is stated in these specifications. Erection shall be carried out as per instructions of the Rotating Equipment manufacturer’s representative, whenever present at site. In all other cases instructions of the Engineer-in-charge, regarding procedure / sequence of erection shall be binding on the contractor.

- For all Rotating Equipment, the Contractor shall follow the proper

sequence for assembly and erection. Couplings of rotating equipment received along with driver in assembled condition shall be dismantled by the Contractor, if required and alignment shall be rechecked. Realignment, if required, shall be done before recoupling.

- Where drivers and couplings are provided separately, drilling and tapping

of holes in the base plates for fixing drivers, fixing of coupling on shafts, after enlarging the pilot bores to the correct size with key way etc. and dowelling including provision of dowel pins bores to the similar arrangements for retaining the alignment shall be carried out by the Contractor as part of erection work. Shims & wedges as required for alignment shall be supplied by the contractor. The contractor's quoted rates shall be deemed to be inclusive of these of works / supplies.

- All process and utility (such as cooling water, steam flushing, quenching,

lubricating oil, sealing etc.) connections connected with rotating equipment and its auxiliaries shall be fabricated and / or installed by the Contractor

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from materials supplied by the Owner as per drawings, specification and instructions of the Engineer-in-charge.

- All piping and accessories supplied with the rotating equipment such as

seal oil system cooling water system & Lube oil system etc. shall be tagged separately and kept in Contractor's stores till erection. All flanged connections and openings snail be kept blanked with dummies / plugs to prevent entry of foreign matter.

- All the instruments such as pressure gauges, sight glasses, temperature

recorders etc. including instrument panels, if any, with necessary connections, shall be installed by the Contractor as part of rotating equipment erection and no separate payment will be made.

- After initial alignment, the Rotating Equipment shall be properly grouted.

Grouting shall be carried out as per the specifications and instructions of Engineer-in-Charge. Wherever grout holes are provides in the base plates, grout shall be filled through them also.

- The special grouting materials used i.e. whether non-shrinking grout or

epoxy grout shall be as per the equipment manufacturer's specifications. - Unless otherwise specified by the equipment manufacturer, the grouting

material shall be non-shrinking grout of pre-mix type with a minimum compressive strength (28 day) of 40 N/mm2. The grout material shall be supplied and applied by the contractor and deemed to be included in the quoted rates in the Schedule of Rates (SOR).

- Where the equipment manufacturer recommends epoxy grout, the same

shall be supplied and applied by the contractor. Extra cost for the same shall be applicable as quoted by the contractor in the Schedule of Rates (SOR).

- After the piping has been connected, the alignment shall be re-checked by

the Contractor, to ensure that piping connections do not induce any undue stresses on the Rotating Equipments. After making necessary corrections on the piping, if any, re-alignment shall be done by the Contractor and he will ensure that no undue stresses are induced on the Rotating Equipment.

SPECIAL INSTRUCTIONS

- Contractor in addition to general instructions for erection as out lined in

para above shall also follow the following special instructions.

Pumps Pumps shall be supplied as free issue for erection as follows:

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(a) Pumps with drivers and accessories fully assembled on a common skid (Base plate).

(b) Pumps mounted on base plate and couplings and driver supplied

loose in separate packing. (c) Various major components such as pump, drivers, couplings, gear

boxes & base plates in separate packing 10.2.3.3 Civil & Structural Works

Civil Works Civil works shall be carried out as per the scope detailed in particular scope of

work as detailed in Technical Input (Annexure-I) and SOR. 10.2.3.5 Instrumentation

Instrumentation works shall be carried out as per the scope of work as detailed in Technical Input (Annexure-II) and SOR enclosed elsewhere with the tender.

10.2.3.6 VOID

10.2.3.7 Painting • Painting (including supply of all materials) of all equipment, piping, structural

steel elements for pipe supports, and all structural miscellaneous items as required and as directed by Company. Paint shall be suitable for highly corrosive environment as per specification No. MEC/S/05/21/07. Painting shall include primer and finish coats as per specifications. Prior to painting surface shall be sand blasted as per instruction of Engineer-in-charge.

• Wherever the gas charged piping network exists, the sand blasting may be replaced by soft material such as copper grit blasting to avoid sparking.

• For equipment, valves and other free issue items only one finish coat of final paint will be provided.

10.2.3.8 Other Works • Obtaining all necessary approvals and work permits, as applicable, for

performing the work.

• Carrying out all additional surveys, test and collection of data not furnished by company but required for construction of facilities.

• Extension/ provision of the utilities at desired locations from the consumers battery limit; the utilities are firewater, instrument air, plant air, drinking water, service water and electrical power.

• Any other work not specifically listed herein but required for the construction of the terminals and making it ready for the operation.

11.0 SCOPE OF SUPPLY 11.1 Material to be supplied by Company as Free Issue

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(a) Centrifugal Pumps 11.2 Company storage point for issue of materials shall be from the Company’s store as

indicated below: Materials shall be issued at designated store of GAIL. Contractor has to lift materials from storage/ dump yard located inside the plant premises, Khera. However, other free issue materials as soon as reached at site, GAIL may directly hand over the same to contractor at site or shall hand over from its store / dump yard at Khera. Contractor shall preserve the received material in good condition along with required documentation as per clause no. 4.3 mentioned below. Contractor shall also return materials after completion of work to GAIL’s designated store at above-mentioned location as directed by Owner/ Engineer-in-charge.

11.3 Conditions for issue of Company Supplied Material Contractor shall prepare and submit Material Issue Vouchers to enable stage wise issue

of materials. All materials shall be issued for incorporation in permanent works only and shall not be used for any temporary or ancillary works without the written consent of Engineer-in-charge. These materials shall be issued to the contractor from the Owner’s storage points. Contractor shall be responsible, at this own cost, for lifting of the materials from Owners issue points, measuring, weighing, loading, unloading, transportation and return of materials to designated storage points. Contractor shall also be responsible for constructing covered godowns with adequate supports and clearances for safe storage of materials.

11.3.1 All materials issued by the COMPANY to the CONTRACTOR shall be preserved against

deterioration and corrosion. Any damages/losses suffered on account of poor or improper storage while under CONTRACTOR'S custody and non-compliance with the requirements stipulated herein shall be considered as losses suffered due to willful negligence on the part of the CONTRACTOR and he shall be liable to compensate the COMPANY, for the losses suffered, at penal rates as elaborated elsewhere in the bid document.

Various equipments/ materials intended for the installation will be received by

COMPANY in unpacked, skidded, crated, packed or loose condition and will be stored in the COMPANY warehouses & open yards. In general, material will be issued to the CONTRACTOR in "as-received" condition. It will be the CONTRACTOR'S responsibility to draw, load and transport all materials from COMPANY's designated place (s) of issue to the point of installation.

All materials supplied by the COMPANY shall be duly protected by the CONTRACTOR

at his own cost with appropriate preservative like primer/lacquer coating, grease etc, if required.

The Contractor shall be required to take Insurance Cover in terms of general conditions

of contract. 11.3.3 All machined surfaces shall be properly greased and shall be maintained and

protected from damages. 11.3.4 Openings of equipment, machinery etc. shall be kept blocked/ covered with blinds to

prevent entry of foreign matter.

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11.3.5 All valves, instruments, control valves, actuated valves, pressure gauges,

thermometers etc. supplied alongwith equipment and machinery shall be stored separately, inside the covered godown on racks.

11.3.6 As far as possible materials shall be transported to the erection site, just prior to their

actual erection and shall not be left laying around indefinitely. Instructions for the Engineer-in-charge shall be followed strictly in this regard.

11.3.7 Repairs of Pipe Defects Immediately prior to aligning pipe for welding, the beveled ends of each joint of pipe

and the area immediately adjacent thereto (at least 25 mm from the edge on the inside and outside of the pipe) shall be thoroughly cleaned of paint, rust mill scale, dirt or other foreign matter by use of power driven wire buffing wheels, disc sanders, or by other method approved by COMPANY. This shall be done at no extra cost.

All damaged ends of pipe that are bent, cut or otherwise mutilated such that, in the

opinion of the COMPANY, faulty alignment or unacceptable welding would result, shall be repaired or cut-off and re-beveled to the correct angle with a bevelling machine of a type approved by COMPANY.

CONTRACTOR shall re-bevel dented bevel ends with a depth of dent between 1

and 3 mm. Dents over 3 mm depth shall be repaired by cutting and re-beveling. 11.4 Material to be Supplied by Contractor The procurement and supply, in sequence and at the appropriate time, of all

materials and consumables required for completion of the work as defined in this Bid document except the materials specifically listed under para 4.1 above, shall be entirely the CONTRACTOR'S responsibility and item rates quoted for the execution of the CONTRACT shall be inclusive of supply of all these materials. The material to be supplied by the Contractor shall be as per specification and preferred make as indicated in Appendix-I or duly approved / recommended for use by GAIL/ MECON.

11.4.1 Terminals 11.4.1.1 Piping, Equipment & Vessels

a) Piping material assorted pipe, flanges, fittings and valves in Contractor’s

scope as detailed in SOR. Contractor shall supply complete material for utility lines indicated in SOR.

b) Studs, nuts, washers, U bolts, clamps, clips, pipe supports, gaskets for piping works.

c) Shims, wedges and packing plates (machined wherever required). d) Galvanized steel piping of all sizes for instrument air/ service air. e) Fire hydrant system and MVWS system as indicated in SOR. f) Painting material All other items/ materials as may be required for completion of contractual scope of work and in SOR but not covered under material to be supplied by company as free issue material at 4.1.

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11.4.1.2 Civil & Structural All materials as elaborated in respective SOR and scope of work enclosed as Annexure-I elsewhere with the tender.

11.4.1.3 Instrumentation All instrumentation items as per particular SOR and scope of work for

instrumentation item Annexure-III SOR in Contractor’s scope of supply. 11.4.1.4 All painting materials. Paint shall be suitable for highly corrosive environment. 11.5 Detailed list of items to be procured and supplied by contractor for terminal shall be

as indicated below:-

i) All electrical area lighting and building lighting ii) Portable fire fighting equipments iii) Fire Hydrant System iv) High & Medium Velocity Water Spray System v) Assorted Pipes vi) Flanges vii) Fittings viii) Valves ix) ‘Strainer x) Pressure Safety Valves & Pressure regulating / control valve xi) Control Panel & Field Mounted Instruments xii) Instrumentation Items xiii) Any other item required to complete the job/ as indicated in SOR.

11.6 General 11.6.1 All consumables for welding such as oxygen, acetylene, inert gases and all types

of electrodes suitable for pipes of grades as specified in the specification, low hydrogen electrodes, filler wire, solder wire, brazing rods, flux etc. for welding / cutting and soldering purpose.

11.6.2 Equipment like hydrostatic pump etc., water and corrosion inhibitor for water used

for hydrostatic testing including all pipes, fittings and equipment, metallic blinds, temporary gaskets as required for filling, pressurizing and dewatering in connection with hydrostatic testing completion.

11.6.3 All pipes, fittings and equipment metallic blinds temporary gaskets as required for

filling, pressuring and dewatering in connection with hydrostatic testing completion.

11.6.4 All consumables for welding of structural steel. 11.6.5 Materials and equipment required for all types of test such as radiography,

magnetic particle and dye penetrant examination. 11.6.6 All safety tools/tackles, devices / apparatus / equipment etc. including ladders and

scaffoldings etc. complete as required.

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11.6.7 Any other material not specifically listed herein, but required for the execution of the work. 11.6.8 List of materials required to be supplied and quantities indicated in SOR is tentative.

These quantities can vary during execution to any extent and the same unit rate shall be applicable for payment. Final quantities will be based on the drawing issued to the contractor for construction. Quantities covered in SOR are for as erected quantities. Bidder will procure additional materials as required to cover cutting, scraps, wastages and damages during erection, testing and commissioning. For these extra quantities no additional payment will be made.

12.0 DOCUMENTS, SPECIFICATION, STANDARDS AND DRAWINGS 12.1 Owner shall furnish piping and Instrumentation diagrams (P & I D), fire water network

layout along with the tender. Owner shall also supply design & engineering drawings and construction drawings including general arrangement drawings for piping, electrical, mechanical & instrumentation systems and other related/ required systems, at appropriate times and as requisitioned by contractor in his time schedule.

12.2 Contractor shall prepare isometric drawings & bill of materials and submit the same

for Owner/ Consultant’s approval/ record.

Contractor shall prepare drawing for utilities line as required as per SOR and submit the same for Owner/ Consultant’s approval/ record.

12.3 No construction small or big shall be carried out without proper construction drawings

duly approved by Owner's Engineers at Delhi or site office or Owner's representative duly authorized to do so.

12.4 After Completion of construction & commissioning, Contractor shall incorporate all

the correction in drawings, prepare and issue the drawings "as-built drawings" as listed below to Owner as final submission of drawings. P&ID, layout drawing, piping GAD, Isometric, all electrical & instrumentation drawing, all civil drawings. For final submission only 4 sets of documents plus the original transparencies shall be handed over by Contractor. Any construction done by Contractor without duly approved drawings shall be wholly at his risk and cost. Contractor shall also submit soft copy of pipe book in excel alongwith hard copy. Soft copy of all as-built drawings shall be also submitted in AutoCAD. For details of documentation to be submitted for mainline and terminal refer enclosed specification for documentation for pipeline construction Specification enclosed elsewhere with the tender.

12.5 Drawing and Documents 12.5.1 The drawings accompanying the Bid document are indicative of scope of work and

issued for tendering / bidding purpose only. These drawings indicate the general scheme as well as the layout to enable the contractor to make an offer in line with the requirements of the owner. Final construction shall be done as per approved construction drawings issued by COMPANY.

12.5.2 "Approved for Construction" drawings will be furnished to the contractor progressively

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based on construction progress achieved by Contractor. No extra claims whatsoever shall be entertained for any variation between Bid Drawings and Approved for Construction Drawing.

13.0 RESOURCES FACILITIES 13.1 Recruitment of Personnel by Contractor The Contractor shall not recruit personnel of any category from among those who

are already employed by the other agencies working at the sites but shall make maximum use of local labor available.

13.2 Land for Residential Accommodation Owner shall not provide any land for residential accommodation of contractors staff

and labor. 14.0 CONSTRUCTION OWNER reserves the right to inspect all phases of CONTRACTOR's operations to

ensure conformity to the SPECIFICATIONS. Owner will have Engineers, Inspectors or other duly authorized representatives, made known to the CONTRCTOR present during progress of the WORK and such representatives shall have free access to the WORK at all times. The presence or absence of a OWNER's representative does not relieve the CONTRACTOR of the responsibility for quality control in all phases of the WORK. In the event that any of the WORK being done by the CONTRACTOR or any SUB-CONTRACTOR is found by OWNER's representatives to be unsatisfactory or not in accordance with the DRAWINGS, procedures and SPECIFICATIONS, the CONTRACTOR shall, upon verbal notice of such, revise the work in a manner to conform to the relevant DRAWINGS, procedures and SPECIFICATIONS.

14.1 Rules & Regulations CONTRACTOR shall observe in addition to Codes specified in respective

specification, all National and Local Laws, Ordinances, Rules and Regulations and requirements pertaining to the WORK and shall be responsible for extra costs arising from violations of the same.

14.2 Procedures Various procedures and method statements to be adopted by CONTRACTOR

during the construction as required in the respective specifications shall be submitted to OWNER in due time for APPROVAL. No such construction activity shall commence unless approved by OWNER in writing.

14.3 Field Inspection CONTRACTOR shall have at all times during the performance of the WORK, a

Competent Superintendent on the premises. Any instruction given to such superintendent shall be construed as having been given to the CONTRACTOR.

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14.4 Erection and Installation The CONTRACTOR shall carry out required supervision and inspection

as per quality Assurance plan and furnish all assistance required by the OWNER in carrying out inspection work during this phase. The OWNER will have engineers, inspectors or other authorized representatives present who are to have free access to the WORK at all times. If an OWNER’s representative notifies the CONTRACTOR's authorized representative not lower than a Foreman of any deficiency, or recommends action regarding compliance with the SPECIFICATIONS, the CONTRACTOR shall make every effort to carry out such instructions to complete the WORK conforming to the SPECIFICATIONS and approved DRAWINGS in the fullest degree consistent with best industry practice.

14.5 Construction Aids, Equipment, Tools & Tackles CONTRACTOR shall be solely responsible for making available for executing the

work, all requisite Construction Equipments, Special Aids, Cranes, Tools, Tackles and testing equipments and appliances. Such construction equipments etc. shall be subject to examination by owner and approval for the same being in first class operating condition. Any discrepancies pointed out by OWNER shall be immediately got rectified, repaired or the equipment replaced altogether, by CONTRACTOR. OWNER shall not in any way be responsible for providing any such equipment, machinery, tools and tackles.

The OWNER reserves the right to rearrange such deployment depending upon the

progress and priority of work in various sections. Tie-end between main line and starting point of terminal is included in the scope of

contract, as and when main line section is available for Tie-ins. 15.0 SURVEY AND LEVEL/SETTING OUT WORK 15.1 Before the WORK or any part thereof are begun, the CONTRACTOR's agent and

the Engineer-in-Charge's representative shall together survey and take levels of the SITE and decide all particulars on which the survey is to be made, and on which measurements of the WORK are to be based. Such particulars shall be plotted by the CONTRACTOR and after agreement the drawings shall be signed by the Engineer-in-Charge.

15.2 The CONTRACTOR shall be entirely responsible for the horizontal and vertical

alignment, the level and correctness of every part of the WORK and shall rectify any errors or imperfections therein. Such rectifications shall be carried out by the CONTRACTOR at his own cost, when instructions are issued to this effect by the Engineer-in-Charge or his representative.

15.3 The Engineer-in-Charge shall furnish the relevant existing grid point with Bench Mark

on the land. It shall be CONTRACTOR's responsibility to set out the necessary control points in and to set out the alignment of the various works. The CONTRACTOR shall have to employ efficient survey team for this purpose and the accuracy of such setting out work shall be CONTRACTOR's responsibility.

15.4 The CONTRACTOR shall give the Engineer-in-Charge not less than 24 (twenty four)

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hours notice in writing of his intention to set out or give levels for any part of the WORK so that arrangements may be made checking the same.

15.5 WORK shall be suspended for such times as necessary for checking lines and levels

on any part of the WORK. 15.6 The CONTRACTOR shall at his own expense provide all assistance, which the

Engineer-in-Charge may require for checking the setting out of WORKS. 15.7 Before commencement of any activity, contractor's quality control set up duly

approved by company must be available at site. 16.0 ORDER OF WORKS/PERMISSIONS/RIGHT OF ENTRY/CARE OF EXISTING

SERVICES 16.1 The order in which the WORK shall be carried out shall be subject to the approval of

the Engineer-in-charge and shall be so as to suit the detailed method of construction adopted by the CONTRACTOR, as well as the agreed joint programme. The WORK shall be carried out in a manner so as to enable the other contractors, if any, to work concurrently.

OWNER reserves right to fix up priorities which will be conveyed by

Engineer-in-Charge and the CONTRACTOR shall plan and execute work accordingly.

16.2 Existing Service 16.2.1 Drains, pipes, cables, overhead wires and similar services encountered in course of

the works shall be guarded from injury by the CONTRACTOR at his own cost, so that they may continue in full and uninterrupted use to the satisfaction of the Owners thereof, or otherwise occupy any part of the SITE in a manner likely to hinder the operation of such services.

16.2.2 Should any damage be done by the CONTRACTOR to any mains, pipes, cables or

lines (whether above or below ground etc.), whether or not shown on the drawings the CONTRACTOR must make good or bear the cost of making good the same without delay to the satisfaction of the Engineer-in-Charge.

17.0 INSPECTION OF SUPPLY ITEMS All inspections and tests shall be made as required by the specifications forming part

of this contract. Contractor shall advise Owner/ Consultant in writing at least 10 days in advance of the date of final inspection/tests. Manufactures inspection or testing certificates for equipment and materials supplied, may be considered for acceptance at the discretion of Owner/ Consultant. All costs towards testing etc. shall be borne by the contractor within their quoted rates. All inspection of various items shall be carried out based on Quality Assurance Plan, which will be submitted by the Contractor and duly approved by Owner/ Consultant.

18.0 ESCALATION The Unit Rates quoted shall be kept firm till completion of work and no price

Escalation shall be paid.

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19.0 DOCUMENTS TO BE SUBMITTED/ PRODUCED ALONGWITH R.A. BILLS

i) Computerized R.A. Bill/ Manual Bill, with IT No./ ST No./ Labor License No. printed thereon.

ii) ESI/ EPF clearance certificates for the last month alongwith R.A. Bills.

iii) Insurance Policy as per relevant clauses of Contract Agreement.

iv) Attendance Register and Salary Records.

v) Photocopy of the measurement book to be attached with R.A. Bills.

vi) Any other document required for the purpose of processing the bills.

vii) Registration Certificate with Sales tax authorities of state concerned.

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TENDER PURPOSE DRAWINGS LIST -MECHANICAL S.No. Description Drawing No. Remarks

VIZAG DESPATCH STATION

1 Layout of Fire water System Vizag

MEC/23NB/05/28/VIZAG/FF/001

2 P&ID for Fire Water System for Dispatch Terminal Vizag


3 Automatic Operated MVWSS Layout for Metering Area


4 Automatic Operated MVWSS Layout for LPG Pump House


5 Automatic Operated MVWSS Layout for Scrapper Launcher Area


6 Automatic Operated MVWSS Layout for Booster Pump Area


7 Automatic Operated MVWSS Layout for Transformer Area


CHERLAPALLY RECEIVING STATION

1 Layout of Fire water System Cheralapalli

MEC/23NB/05/28/CHERALAPALLI/FF/001

2 P&ID for Fire Water System for Receiving Terminal Cheralapalli


3 Automatic Operated MVWSS Layout for Metering & Filtration Area


4 Automatic Operated MVWSS Layout for Scrapper Launcher Area


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LIST OF SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS

(Appendix-I to Particular Job Specification of Work)

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Appendix-I To Particular Job Specification of Work

LIST OF SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS

A) Mainline & Mechanical

i) Pipes (1239/3589) 1. TISCO, Calcutta 2. Jindal Pipes, New Delhi 3. Ajanta Tubes, New Delhi 4. Gujrat Steel Tubes 5. Khandelwal

ii) Valve

a) Globe Valves 1) M/s BDK (New Delhi) 2) M/s Datre Corpn (Calcutta) 3) M/s KSB Pumps (New Delhi) 4) M/s L&T (New Delhi) 5) M/s Neco Schuber & Salzer Ltd. (New Delhi) 6) M/s Niton Valve (Mumbai) 7) M/s Ornate Valves (Mumbai) 8) M/s Panchavati Valves (Mumbai) 9) AV Valves Ltd. 10) BHEL (Trichy), India 11) Econo Valves Pvt Ltd, India 12) Fouress Engg (I) Ltd (Aurangabad) 13) Guru Industrial Valves Pvt Ltd 14) Leader Valves Ltd, India 15) NSSL Ltd. (Neco Schubert & SalzerLtd) 16) Oswal Industries Ltd, India 17) Petrochemical Engineering Enterprises, India 18) Sakhi Engineers Pvt Ltd 19) Shalimar Valves Pvt Ltd 20) Steel Strong Valves India Pvt Ltd, India b) Ball Valves

1. Larsen & Toubro, Chennai 2. Virgo, Pune 3. Microfinish Valves, Hubli 4. Flow Chem, Ahmedabad

c) Check Valves 1. M/s Advance Valves Pvt. Ltd., Noida 2. M/s Aksons & Mechanical Enterprises, Mumbai 3. M/s Larsen & Toubro Limited (M/s Audco India Limited, Chennai) 4. M/s AV valves Ltd., Agra

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5. M/s BDK engineering India Ltd., Hubli 6. M/s BHEL,OFE&OE Group, New Delhi 7. M/s Datre Coroportion Limited, Calcutta 8. M/s Leader Valves Ltd., Jalandhar 9. M/s Neco schubert &Salzer Ltd., New Delhi 10. M/s Niton Valves Industries (P) Ltd., Mumbai 11. M/s Precision Engg.Co., Mumbai 12. Econo Valves Pvt Ltd, India 13. Fouress Engg (I) Ltd (Aurangabad) 14. KSB Pumps Ltd (Coimbattore), India 15. NSSL Ltd. (Neco Schubert & SalzerLtd) 16. Oswal Industries Ltd, India 17. Panchvati Valves & Flanges Pvt Ltd, India 18. Petrochemical Engineering Enterprises, India 19. Sakhi Engineers Pvt Ltd 20. Shalimar Valves Pvt Ltd 21. Steel Strong Valves India Pvt Ltd, India d) Plug Valves 1. M/s Breda Energia Sesto Industria Spa, Italy 2. M/s Fisher Sanmar Ltd., Chennai 3. M/s Larsen & Toubro Ltd., New Delhi 4. M/s Nordstrom Valves, USA 5. M/s Serck Audco Valves, UK 6. M/s Sumitomo Corporation India Pvt. Ltd., New Delhi 7. M/s Z Corporation, Korea 8. M/s Hawa Valves (India) Pvt. Ltd., Mumbai 9. M/s Steel Strong Valves India Pvt. Ltd., Navi Mumbai

iii) Flanges 1. M/s Aditya Forge Ltd., Vadodara 2. M/s Amforge Industries Ltd., Mumbai 3. M/s CD Engineering Co., Ghaziabad 4. M/s Echjay Forgings Pvt. Ltd. (Bombay), Mumbai 5. M/s Echjay Industries Ltd., Rajkot 6. M/s Forge & Forge Pvt. Ltd., Rajkot 7. M/s Golden Iron & Steel Works, New Delhi 8. M/s JK Forgings, New Delhi 9. M/s Metal Forgings Pvt. Ltd., Mumbai 10. M/s Perfect Marketings Pvt. Ltd., New Delhi 11. M/s Sky Forge, Faridabad 12. M/s S&G, Faridabad 13. Chaudhry Hammer Works Ltd, India 14. JAV Forgings (P) Ltd, India 15. Kunj Forgings Pvt Ltd, India 16. MS Fittings 17. R.N. Gupta & Co. Ltd, India 18. R.P. Engineering Pvt Ltd, India 19. Sanghvi Forgings & Engineering Ltd 20. Shri Ganesh Forgings Ltd., India

8000006103 35 of 101


21. Uma Shankar Khandelwal & Co., India

iv) Fittings 1. M/s Commercial Supplying Agency, Mumbai 2. M/s Dee Development Engineers Ltd. 3. M/s Eby Industries, Mumbai 4. M/s Flash Forge Pvt. Ltd., Vishakhapatnam 5. M/s Gujarat Infra Pipes Pvt. Ltd., Vadodara 6. M/s M.S. Fittings Mfg. Co. Pvt. Ltd., Kolkata 7. M/s Stewarts & Lloyds of India Ltd., Kolkata 8. M/s Teekay Tubes Pvt. Ltd., Mumbai 9. M/s Pipe Fit,Baroda 10. M/s Sky Forge, Faridabad 11. M/s S&G, Faridabad 12. M/s Sawan Engineers, Baroda 13. Eby Fasteners, India 14. Leader Valves Ltd, India 15. R.N. Gupta & Co. Ltd, India 16. Exten Engg Pvt Ltd 17. Sivananda Pipe & Fittings Ltd 18. Tube Products Incorporated

v) Gaskets 1. IGP Engineers (P) Ltd., Madras 2. Madras Industrial Products, Madras 3. Dikson & Company, Bombay 4. Banco Products (P) Ltd., Vadodara 5. Goodrich Gaskets Pvt Ltd 6. Starflex Sealing India Pvt Ltd, India 7. Teekay Meta Flex Pvt Ltd 8. UNIKLINGER Ltd

vi) Fasteners

1. Nireka Engg. Co. (P) Ltd., Calcutta 2. Precision Taps & Dies, Bombay 3. AEP Company, Vithal Udyoug Nagar 4. Fix Fit Fasteners, Calcutta 5. Precision Engg. Industries, Baroda 6. Echjay Forgings Pvt. Ltd., Bombay 7. Capital Industries, Bombay 8. Boltmaster India Pvt Ltd, India 9. Deepak Fasteners Limited, India 10. Fasteners & Allied Products Pvt Ltd, India 11. Hardwin Fasteners Pvt Ltd, India 12. J.J. Industries, India 13. Multi Fasteners Pvt Ltd, India 14. Nexo Industries, India 15. Pacific Forging & Fasteners Pvt Ltd, India 16. Pioneer Nuts & Bolts Pvt Ltd, India 17. Precision Auto Engineers, India

8000006103 36 of 101


18. President Engineering Works, India 19. Sandeep Engineering Works, India 20. Syndicate Engineering Industries, India

vii) Welding Electrodes

1. For Mainline – Lincon make 2. For Terminal – Lincon & D&H or equivalent

viii) Fire Fighting Equipments Chetan Engineers, Ahmedabad a) Fire Extinguishers

1. Avon Services (Production & Agencies) Pvt. Ltd., Bombay 2. Kooverji Devshi & Co., Bombay 3. Zenith Fire Services, Bombay 4. Safex Fire Services, Bombay 5. Reliable (Fire Protection) India Ltd., Bombay 6. Brij Basi Hi 7. tech Udyog 8. Bharat Engg Works, India 9. Gunnebo India Ltd 10. Nitin Fire Protection Industries Ltd, India 11. Supremex Equipments, India 12. Vimal Fire Controls Pvt Ltd., India b) Fire Hydrants, Monitors, Deluge Valve, Nozzles 1. Zenith 2. Minimax 3. Newage 4. HD Fire 5. Vijay Fire 6. Asco Strumech Pvt Ltd, India 7. Brij Basi Hi 8. tech Udyog 9. Gunnebo India Ltd 10. Nitin Fire Protection Pvt Ltd 11. Shah Bhogilal Jethamal & Brothers 12. Venus Pumps & Engineering Works

c) RRL Hose 1. Jayshree 2. Newage

d) Hoses 1. Ashit Sales Corporation, Bombay 2. Royal India Corporation, Bombay 3. Gayatri Industrial Corporation

8000006103 37 of 101


4. Simplex Rubber Products Ltd., Ahmedabad 5. Zaverchand Marketing Pvt. Ltd., Baroda 6. Presidency Rubber Mill, Calcutta 7. The Cosmopolite, Calcutta 8. Simplex Rubber Products, Thane

e) Hose Delivery 1. Chhatarya Rubber & Chemical Industries, 2. Nitin Fire Protection Industries Ltd, India

f) Fire Hose Accessories 1. Asco Strumech Pvt Ltd 2. Brij Basi Hi-tech Udyog 3. Gunnebo India Ltd 4. Shah Bhogilal Jethamal & Brothers 5. Vimal Fire Controls Pvt Ltd., India

B) INSTRUMENTATION

i) Field Mounted Instruments like PG, TG 1. AN Instruments 2. General Instruments 3. Wika 4. Waree

ii) RTD

1. General Instruments Ltd., Mumbai 2. Nagman Sensor Pvt. Ltd. 3. Pyro Electric, Goa

iii) SS Tubes Fittings

1. Swagelok, USA 2. Parker, USA 3. Sandvik, Sweden 4. Choksi Tubes

iv) Inst. Valves & Manifolds

1. Swagelok, USA 2. Parker, USA

v) Control & Signal Cables 1. Associated Cables 2. Associated Flexibles 3. Universal 4. Delton 5. Brook 6. KEI India

8000006103 38 of 101


vi) Pressure Safety Valve (PSV)

1. Key Stone, Baroda 2. Sebim, New Delhi 3. Tyco Sanmar, New Delhi 4. BHEL, New Delhi 5. Parcol SPA 6. Tai Milano SPA 7. Fisher Rosemount (Now M/s Emerson Process). 8. Nuopignone, Italy 9. Sarasin, France

vii) FCV

i) M/s ABB Ltd., Nashik ii) M/s Fisher Xomox, New Delhi iii) M/s Fouress Engg. New Delhi iv) M/s MIL Control Ltd., Noida v) M/s Samson Control, Thane vi) M/s Forbmarshal, Pune

C) ELECTRICAL

LT Power/ Control Cable 1. INCAB Industries Ltd. 2. UNIVERSAL Cables Ltd. 3. ASEAN Cables & Industries Ltd. 4. CCI Ltd. 5. NICCO Corporation Ltd. (Cable Division) 6. FORT Gloster Industries Ltd. 7. Industrial Cable (I) Ltd. 8. TORRENT Cables Ltd. 9. Finolex 10. KEI

Ceiling/Exhaust/Pedestal Fans & Circulators

1. Bajaj Electricals Ltd. 2. Crompton Greaves Ltd. 3. Alstom Ltd. 4. Khaitan Electricals Ltd. 5. Orient General Industries Ltd. 6. The Jay Engg. Works Ltd. (Usha Brand)

Lighting Fixtures

1. GE Apar Lighting Pvt. Ltd. 2. Bajaj Electricals Ltd. 3. Crompton Greaves Ltd. 4. Philips India Ltd.

Lighting Fixtures Flameproof

1. Bajaj Electricals Ltd. 2. Baliga Lighting Equipment Pvt. Ltd. 3. Crompton Greaves Ltd.

8000006103 39 of 101


4. CEAG Flameproof Controlgear Pvt. Ltd. 5. Flexpro Electricals Pvt. Ltd. 6. Philips India Ltd. 7. Sudhir Switchgears Pvt. Ltd. Batteries (Lead Acid) 1. Amco Batteries Ltd. 2. Exide Industries Ltd. 3. HBLNIFE Power System Ltd. 4. Amara Raja Batteries Ltd.

Batteries (Nickel Cadmium) 1. Amco Batteries Ltd. 2. HBLNIFE Power Systems Ltd. LTAC Motors

1. Siemens (above 160m frame) 2. NGEF 3. CGL 4. Bharat Bijlee Ltd. (upto 250M frame) 5. KEC 6. ABB Ltd. 7. Alstom Ltd. LT AC Motors (Flame Proof)

1. Alstom Ltd. 2. Bharat Bijlee Ltd. 3. CGL 4. KEC

Indicating Lamps

1. Bhartia Industries Ltd. 2. Alstom Ltd. 3. L&T Ltd. 4. Siemens Ltd. 5. Vaishno Electricals

Indicating Meters

1. Automatic Electric Ltd. 2. Alstom Ltd. (EE) 3. Industrial Meter Ltd. 4. MECO Instruments Ltd.

Push Buttons

1. Bhartia Industries Ltd. 2. Alstom Ltd. 3. L&T

8000006103 40 of 101


4. Siemens Ltd. 5. Telemenchanique & Controls (India) Ltd. 6. Vaishno Electricals

Switches-Control

1. Bhartia Industries Ltd. 2. Easum Reyrolle Relays & Devices Ltd. 3. Alstom 4. Kaycee Industries Ltd. 5. L&T 6. Siemens Ltd.

Terminals Blocks

1. Connectwell 2. Controls & Switchgear Co. Ltd. 3. Elmex Controls Pvt. Ltd. 4. Essen Engineering Co. Pvt. Ltd.

Contractors – AC Power

1. Bhartia Industries Ltd. 2. L&T Ltd. 3. Siemens Ltd. 4. Telemenchanique & Controls (India) Ltd.

Heavy Duty Switch/ Fuse Switch

1. Bhartia Industries Ltd. 2. Controls & Switchgear Co. Ltd. 3. Alstom Ltd. 4. L&T Ltd. 5. Siemens Ltd. Miniature Circuit Breakers (MCBs) and Lighting DB 1. Havell’s India Ltd. 2. Indo Asian Fusegear Ltd. 3. MDS Switchgear Ltd. 4. Siemens Ltd. 5. S&S Power Switchgear Ltd.

Overload Relays – Thermal

1. Bhartia Industries Ltd.. 2. L&T Ltd. 3. Siemens Ltd. 4. Telemenchanique & Controls (India) Ltd.

Switches – 5/15A Piano/ Plate, Switch Socket

8000006103 41 of 101


1. Anchor Electronics & Electricals Pvt. Ltd. 2. Kingal Electricals Pvt. Ltd. 3. North-West Switchgear Ltd.

Switch Socket Outlets (Industrial)

1. Alstom Ltd. 2. Best & Cromption Engineering Ltd. 3. Bhartia Industries Ltd. 4. Crompton Greaves Ltd. 5. Essen Engineering Company Pvt. Ltd. Solar Street Lighting 1. Tata BP Solar (I) Ltd. 2. REIL, Jaipur. 3. CEIL, Sahibabad. Air Conditioner 1. Voltas. 2. Bluestar. 3. Carrier. DG Sets 1. Kirlosker 2. Sudhir 3. Jackson 4. Control & Switcgear

UPS System and Inverter 1. EMERSON 2. DB POWER 3. APLAB 4. KELTRON 5. HI-REL Power Control Circuit (PCC)

1. L&T Ltd. 2. Siemens 3. Bhartia Industries

5. Elecmech Switchgear & Instrumentation Transformers 1. Kirloskar 2. Voltamp 3. Crompton Greaves 4. Transformers & Rectifiers 5. Bharat Bijali Air Break Switch 1. Southern Switchgear 2. Switchgear Manufacturing Co. 3. AMEI Power Ltd. Lightning Arrestors 1. Oblum Electric Industries

8000006103 42 of 101


2. Jayshree Insulators 4. LAMCO 5. WS Industries

HT Insulators 1. Jaya Shree 2. BHEL 3. WS Industries 7.0 MCCB/MCB FOR POWER DISTRIBUTION BOARD

A) SIEMENS B) L&T C) MERLIN GERIN D) MDS E) INDO ASIAN F) AEG G) HAGER H) HAVELL’S, I) ABB J) SCHNEIDER ELECTRIC INDIA PVT.LTD

F) “T” TYPE STRAINER

1) M/s Gujarat Otofilt, Ahmedabad 2) M/s Genius Filters & Systems (P) Ltd., Vishakapatnam 3) M/s Delta Filters & Separators (P) Ltd., Navi mumbai 4) M/s Multitex Filters (P) Ltd., New Delhi 5) M/s Bhagwati Filters (P) Ltd., Ahmedabad 6) M/s Patel Filters Ltd., Ahmedabad 7) M/s Industrial Filtration Services 8) M/s Forum Filters & fabricators, Ankleshwar 9) M/s Filteration & Separation, Kalpavruksh 10) M/s Grand Prix Fab. (P) Ltd., New Delhi

1) For procuring bought out items from vendors other than those listed above, the same may

be acceptable subject to the following: -

a) The vendor/ supplier of bought out item(s) is a manufacturer/ supplier of said item(s) for intended services and the sizes being offered is in their regular manufacturing/ supply range.

b) The vendor / supplier should not be in the Holiday list of GAIL / MECON / other

PSU. c) Should have supplied at least one single random length (i.e. 5.5 meters to 6.5

meters) for item assorted pipes / tubes and minimum 01 (One) number for other item(s) (other than assorted pipes / tubes) of same or higher in terms of size and rating as required for intended services.

The bidder should enclose documentary evidences i.e. PO copies, Inspection Certificate etc. for the above, along with their bids.

8000006103 43 of 101


2) For any other item(s) for which the vendor list is not provided, bidders can supply those

item(s) from vendors/ suppliers who have earlier supplied same item(s) for the intended services in earlier projects and the item(s) offered is in their regular manufacturing/ supply range.

The bidder is not required to enclose documentary evidences (PO copies, Inspection Certificate etc.) along with their offer, however in case of successful bidder, these documents shall required to be submitted by them within 30 days from date of Placement of Order for approval to GAIL / MECON.

3) The details of vendors indicated in this list are based on the information available with

MECON, Contractor shall verify capabilities of each vendor for producing the required quantity with. PMC does not guarantee any responsibility on the performance of the vendor. It is the contractor’s responsibility to verify the correct status of vendor and quality control of each party and also to expedite the material in time.

8000006103 44 of 101

DATA SHEETS FOR MECHANICAL ITEMS

8000006103 45 of 101

DATA SHEET

OF GATE VALVE

8000006103 46 of 101

NOTES:

1. Bidder shall clearly write all / any deviation against each part/material of valve in the space provided for wherever bidder agrees with GAIL's spec bidder shall indicate "Agreed".

2. No cutting / overwriting by bidder on GAIL's spec is allowed.

3. Testing as per API 596.

4. Pre dispatch inspection at vendors works by GAIL/MECON Representative.

5. Guarantee of the material for a period of one year against any manufacturing defect shall be offered.

Specification of Isolation Valve

Standard : API 600

Size range : 4" to 20"

Piping Class : A1A, A3A, Rating : 150 Class

Ends : FLGD to B 16.5 R.F. SERR. Fin

SN Valve Description Construction Material

1.

Body Cast ASTM A216 GR. WCB

2. Bonnet Bolted ASTM A216 GR. WCB

3. Stem Rising 13% CR steel (no Casting)

4. Wedge disk Flexible 13% CR facing

5. Body seat ring Renewable 13% CR steel

6. Stem packing Renewable with valve open on stream

Graphite asbestos with sacrificial wire reinforcement

7. Hand wheel Non rising Malleable iron /cast ST/ FAB. ST/ Duct. Iron

8. Bonnet bolts ASTM A 193 GR B7 (GALV)

9. Bonnet nuts ASTM 194 GR 2H (GALV)

10. Bonnet gasket Spiral wound SS 304 with CA filler

11. Back seat & shoulder 13% CR steel

12. Hydrostatic test pressure Body :450 PSI Seat:315 PSI

13. Test pressure with air 80 PSI

14. Valve will be supplied with companion standard flanges & fasteners at both the end.

8000006103 47 of 101

0102 Inlet Line No.03 Outlet Line No.04 Schedule ** S40 ** S4005 Inlet Line I.D. Outlet Line ID * * * *06 PR. REDUCTION PR. REDUCTION07 Regulation DOWN STREAM DOWN STREAM08 Type of Regulator : STD Pilot Op. Globe spring loaded Globe spring loaded09 Body Size Port Size * * * * 10 End Conn : Flgd. Size & Rating * 300# / 600# * 300# /600#11 Facing & Finish RF 125 AARH RF 125 AARH12 Body Material ASTM A216 GR. WCB ASTM A216 GR. WCB13 Trim Material SS 316 SS 31614 Bonnet Type 15 Impulse Connecn. Int. Ext. EXTERNAL EXTERNAL16 Connection Size & Type if External * 3/8" NPTF * 3/8" NPTF17 Material of Diaphgram * Nitrile * Nitrile18 Other Wetted Parts * SS 316 * SS 31619 Soft Seating Material20 ANSI Leakage Class21 Failure Position FC/FO FC/FO22 Solenoid Valve23 I/P Converter24 Filter With Gauge25 Limit Switch/ Proximity Switch26 State27 Flow Liquid_Min Normal / Max 28 Flow Vapour_Min Normal / Max ** ** ** **29 Flow Water_Min Normal / Max30 Inlet Pr._Min Normal / Desn. ** ** ** **31 Outlet Pr._Min Normal / Max ** **32 Delta Pr. Shut Off ** **33 Temp. ° C Oper. Max 65 ** 65 **34 Oper. S.G. Mol. Wt. # # # #35 CP/ CV Compresiblity Factor # # # #36 Flash % Visc. (cP) # #37 Maximum Flow Capacity * *38 PCV Set Point3940 Cv. Min. Cv. Max. * * * * 41 Cv. Nor. Selected Cv. * * * * 42 Predicted Sound Level DBA4344 Actuator * * * *45 Limit Switch * -- * --46 100% Radiography

Notes: **' AS per P& ID ‘#’ Refer Annexure -II

1 * - TO BE FURNISHED BY THE VENDOR.2 SPRING SHALL BE SUITABLE TO ADJUST OUTLET PRESSURE OF SKID. SPRING RANGE SHALL BE FINALLIZED DURING DETAIL ENGINEERING.3 ACCURACY OF REGULATION SHALL BE BETTER THAN ± 2.5% OF THE SET PRESSURE.4 VENDOR SHALL FURNISH THE SIZING CALCULATIONS ALONG WITH THE QUOTE.5 VENDOR SHALL FURNISH SPRING RANGES ALONG WITH OFFER

67 THE SELECTED MODEL SHALL BE OF SPRING OPERATED ( GLOBE TYPE) WITH EN 334 APPROVAL..

Ser

vice

Con

ditio

nsV

alve

D

ata

Line Size

PRESSURE CONTROL VALVES

PCV- ** (Quantity as per P& ID) PCV - ** (Quantity as per P& ID)

4 ( NOTE -2)

CLASS VI CLASS VI

UNITS : Flow > Liquid - m*3/hr , Gas-SCMH, Steam - kg/hr. Pressure -> kg/cm 2(g), Temperature-°C, Level/ Length-> mm

Gen

eral

Val

veO

ptio

ns

Not Required Not Required

Model Nos.

4 ( NOTE -2)

THE SELECTED SIZE & MODEL SHALL BE SUCH THAT THE PRESSURE CONTROL VALVE MUST OPERATE AND CONTROL AT BOTH MIN. AND MAX. FLOW RATE AS INDICATED WITH THE GIVEN PRESSURE CONDITIONS.

Positioner

* *

NATURAL GAS VAPOUR NATURAL GAS VAPOUR

* *

Tag No.

Service

ValveInlet Velcity M/S

Fluid

DATA SHEET OF PRESSURE CONTROL VALVES

DS No: MEC/ 05/E5/DS- PCV

0

MECON LTD. DELHI

Rev.

c:\fateh\pragati\ds\pcv_spring

8000006103 48 of 101

QAP FOR MECHANICAL ITEMS

1. QAP for Flanges & Fittings

2. QAP for Assorted Pipes

3. QAP for PSV

8000006103 49 of 101

Tender No. 05/51/23NB/GAIL/001(i)FORM NO. 11.20(4.4)F-09 REV-0

CONTRACTOR

ORDER NO. & DATE PACKAGE NO. : 05/51/23NB/GAIL/001(i)

SUB-CONTRACTOR PACKAGE NAME : ASSORTED PIPES

ORDER NO. & DATE MR NO. : TS No.:

INSTRUCTIONS FOR FILLING UP : CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :

1. QAP shall be submitted for each of the equipment separately with break up Code Description Code Code Description Code DOCUMENTS:of assembly/sub-assembly & part/component or for group of equipment 1. Visual 18. Amplitude Test 34. Internal Inspection Report D1. Approved GA drawingshaving same specification. 2. Dimensional 19. Sponge Test by Contractor D2. Information and other

2. Use numerical codes as indicated for extent of inspection & tests and 3. Fitment & Alignment 20. Dust/ Water Ingress Test 35. Hardness Test reference drg/ stampedsubmission of test certificates & documents. Additional codes & description 4. Physical Test (Sample) 21. Friction Factor Test 36. Spark Test for Lining drgs released for mfg.for extent of inspection & tests may be added as applicable for the plant 5. Chemical Test (Sample) 22. Adhesion Test 37. Calibration D3. Relevant cataloguesand equipment 6. Ultrasonic Test 23. Performance Test/Characteristic 38. Safety Device Test D4. Bill of matl./Item no./

3. Separate identification number with quantity for equipment shall be 7. Magnetic Particle Test (MPI) Curve 39. Ease of Maintenance Identification indicated wherever equipment having same specifications belonging 8. Radiography Test 24. No Load/ Free Running Test 40. Fire Test (Type Test) D5. Matchmarks detailsto different facilities are grouped together. 9. Dye Penetration Test 25. Load/ Overload Test 41. Charpy V-Notch Test D6. Line/ Layout diagram

4. Weight in kilograms must be indicated under Column-5 for each item. 10. Metallographic Exam. 26. Measurement of Speeds 42. Operational Torque Test D7. Approved erectionEstimated weights may be indicated wherever actual weights are not 11. Welder’s Qualification & 27. Accoustical Test 43. ENP (Electroless Nickel Plating) proceduresavailable. Weld Procedure Test 28. Geometrical Accuracy Execution D8. Unpriced sub P.O. with

12. Approval of Test and Repair 29. Repeatability and Positioning 44. Painting specification and amend-Procedure Accuracy 45. Anti-Static Test ments, if any

ABBREVIATIONS USED : KEY TO SYMBOLS : 13. Heat Treatment 30. Proving Test 46. Hydrostatic Double Block & D9. Calibration Certificate ofCONTR : CONTRACTOR * : MFR/ CONTRACTOR - AS APPLICABLE 14. Pressure Test 31. Surface Preparation Bleed Test all measuring instrumentsMFR : MANUFACTURER ** : TEST TO BE PERFORMED, IF APPLICABLE 15. Leakage Test 32. Manufacturer's Test Certificates 47. Functional Test and gaugesH : HOLD 16. Balancing for bought-out items 48. Pneumatic Double Block & D10. X-Ray ReportsR : REVIEW 17. Vibration Test 33. IBR/ Other Statutory agencies Bleed TestW : WITNESS compliance certificate 49. Proof Test (Type Test)

50. Dielectric Test

Test Certificates & REMARKS/Sl. Identification Quantity Unit Expected Documents to be SAMPLING PLANNo. No. No./M Weight Schedule of submitted to MECON

(MR Item No.) (Kg) Final Inspn. MFR CONTR MECON MFR CONTR TPI

1 3 4 5 7 8 9 10 11 12 13 14 161.0 As per 1,2,4,5,41 - 1,2,14,35 1,2,14,35 1,2,14,35 1,2,4,5,32,34,D9

SOR

QAP NO. REVFor MECON (Stamp & Signature) For CONTRACTOR/ SUB-CONTRACTOR

(Stamp & Signature) SHEET 1 OF 1

PROJECT : UPGRADATION AND AUGMENTATION OF FIRE WATER SYSTEM AND ASSOCIATED WORKS AT VIZAG DT & CHERALAPALLY RT

EQUIPMENT

Q U A L I T Y A S S U R A N C E P L A NF O R

STRUCTURAL AND MECHANICAL

EQUIPMENT DETAILS INSPECTION AND TESTSDescription (with equipment

heading, place of use and briefspecifications)

Assorted Pipes

Acceptance CriteriaStandards/ IS/ BS/ASME/ Norms and

Documents

15MECON's T.S. &

Final Inspection/ Test byManufacturer'sName and Address

Raw Material and In-ProcessStage Inspection

Description

6100 % inspection by MECON's Approved TPI

Relevant Standards mentioned therein

8000006103 50 of 101

Tender No: 05/51/23NB/GAIL/001(i)FORM NO. 11.20(4.4)F-09 REV-0

CONTRACTOR


SUB-CONTRACTOR PACKAGE NAME : Flange & Fitting <16"

ORDER NO. & DATE MR NO. : TS No.:







ABBREVIATIONS USED : KEY TO SYMBOLS : 13. Heat Treatment 30. Proving Test 46. Hydrostatic Double Block & D9. Calibration Certificate ofCONTR : CONTRACTOR * : MFR/ CONTRACTOR - AS APPLICABLE 14. Pressure Test 31. Surface Preparation Bleed Test all measuring instrumentsMFR : MANUFACTURER ** : TEST TO BE PERFORMED, IF APPLICABLE 15. Leakage Test 32. Manufacturer's Test Certificates 47. Functional Test and gaugesH : HOLD 16. Balancing for bought-out items 48. Pneumatic Double Block & D10. X-Ray ReportsR : REVIEW 17. Vibration Test 33. IBR/ Other Statutory agencies Bleed TestW : WITNESS compliance certificate 49. Proof Test (Type Test)

50. Dielectric Test


(MR Item No.) (Kg) Final Inspn. MFR CONTR MECON MFR CONTR MECON

1 3 4 5 7 8 9 10 11 12 13 14 161.0 As per 1,2,4,5, - - 1,2,6 * - 1,2,4,5,6,13,35,41**, 100%

SOR 13,35,41** D9

QAP NO. MEC/23NB/05/21/M/001/QAP-025 REVFor MECON (Stamp & Signature) For CONTRACTOR/ SUB-CONTRACTOR



EQUIPMENT


STRUCTURAL AND MECHANICAL


heading, place of use and briefspecifications)

Flanges & Fittings < 16"


Documents

15MECON's T.S. &

Final Inspection/ Test byManufacturer'sName and Address

Raw Material and In-ProcessStage Inspection

Description

6

Relevant Standards mentioned therein

8000006103 51 of 101

nder No: 05/51/23NB/GAIL/001(i)ORM NO. 11.20(4.4)F-09 REV-0

CONTRACTOR


SUB-CONTRACTOR PACKAGE NAME : PRESSURE SAFETY VALVE

ORDER NO. & DATE MR NO. : SPEC. NO.:







ABBREVIATIONS USED : KEY TO SYMBOLS : 13. Heat Treatment 30. Proving Test 46. Hydrostatic Double Block & D9. Calibration Certificate ofCONTR : CONTRACTOR * : MFR/ CONTRACTOR - AS APPLICABLE 14. Pressure Test 31. Surface Preparation Bleed Test all measuring instrumentsMFR : MANUFACTURER ** : TEST TO BE PERFORMED, IF APPLICABLE 15. Leakage Test 32. Manufacturer's Test Certificates 47. Functional Test and gaugesP : PERFORM : FUNCTIONAL TEST INCLUDES : (1) COLD BENCH 16. Balancing for bought-out items 48. Pneumatic Double Block & D10. X-Ray ReportsR : REVIEW SET PRESSURE TEST (2) SEAT LEAKAGE TEST 17. Vibration Test 33. IBR/ Other Statutory agencies Bleed TestW : WITNESS AND (3) VALVE LIFT TEST. compliance certificate


(MR Item No.) (Kg) Final Inspn. MFR CONTR MECON MFR CONTR MECON

1 3 4 5 7 8 9 10 11 12 13 14 161.0 1,2,3,4, * - 1,2,3,14, - - 1,2,3,4,5,8,14,31, 100%

5,8 31,44,47 32,34,44,47

QAP NO. TO BE ALLOTED BY MECON

QAP NO.:MEC/23NB/05/21/M/001/QAP-056 REVFor MECON (Stamp & Signature) For CONTRACTOR/ SUB-CONTRACTOR 0


Name and AddressRaw Material and In-Process

Stage Inspection


STRUCTURAL AND MECHANICALEQUIPMENT

specifications)

2Pressure Safety Valves


Documents

15MECON's T.S.,


heading, place of use and briefFinal Inspection/ Test byManufacturer's

Description

6


Approved Data Sheet

3.2.3-QAP-psv_GAIL

8000006103 52 of 101

ANNEXURES TO PARTICULAR JOB SPECIFICATION

8000006103 53 of 101

ANNEXURE TO PARTICULAR JOB SPECIFICATION

CONTENTS ANNEXURE-I : CIVIL & STRUCTURAL WORKS

ANNEXURE-II : INSTRUMENTATION WORKS

8000006103 54 of 101

Annexure-I to

Particular Job Specification (CIVIL & STRUCTURAL WORKS)

8000006103 55 of 101

of 10

1.0 CIVIL & STRUCTURAL WORKS I) GENERAL :

The scope of work to be performed under this contract shall include complete civil and steel structural works as per plans, equipment layout, drawings & technical specifications for the Vizag fire protection wall, pump house foundations, pavement and pipe support foundations.

Based on the location and type of the building the scope of work has been given below in Table-1 for Vizag and Table -2 for Cheralapally / Secundrabad : TABLE-1 (Vizag)

Sr. No.

Description Size/Quantity Remark / Reference Drg. No.

1 Dismantling of existing pump foundations, pavement structure, Road, RCC / PCC Flooring, removal of debris and dumping at any lead / length, without damaging the any existing facilities, Electrical and Instrumentation equipments / installations as directed by Engineer in Charge.

2 Dismantling of existing brick work in substructure / superstructure and removal of debris without damaging the any existing facilities as directed by Engineer in charge.

3 Construction of pump foundations, Repair of pavement, Pipe support foundations and other support structures including bitumen painting on faces in contact with earth.

1. Pump foundations (02 Nos.)

2. Pipe support foundations (25 nos.) & Pavement

-- Drg.Nos. MEC/GAIL/05/11/001/STD-III MEC/05/11/STD Terminal/02

4 Construction of fire protection brick wall, with RCC slab including plastering and painting as per enclosed tender purpose drawings.

6 nos. Drg.No. MEC/GAIL/05/11/001/STD/25

5 Repair / Construction of road by providing reinforced Hume pipe (NP-3) as per drawings given in the tender

25 Nos-2 x 300 dia Hume pipe (NP-3) culvert –5 m length

Drg.No. MEC/23NA/05/11/ STD/021

6 Laying of pavior blocks on the sand bed / PCC bed.

7 Repair / Construction of pavement (RCC) by providing M-25 concrete as per specifications and drawings given in the tender

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TABLE-2 (Cheralapally / Secundrabad) Sr. No.

Description Size/Quantity Remark / Reference Drg. No.

1 Dismantling of existing pump foundations, pavement structure, Road, RCC / PCC Flooring, removal of debris and dumping at any lead / length, without damaging the any existing facilities, Electrical and Instrumentation equipments / installations as directed by Engineer in Charge .

2 Dismantling of existing brick work in substructure / superstructure and removal of debris without damaging the any existing facilities as directed by Engineer in charge.

3 Construction of pump foundations, Repair of pavement, Pipe support foundations and other support structures including bitumen painting on faces in contact with earth.

1. Pump foundations (02 Nos.)

2. Pipe support foundations (25 nos.) & Pavement

-- Drg.Nos. MEC/GAIL/05/11/001/STD-III MEC/05/11/STD Terminal/02

4 Construction of fire protection brick wall, with RCC slab including plastering and painting as per enclosed tender purpose drawings.

6 nos. Drg.No. MEC/GAIL/05/11/001/STD/25

5 Repair / Construction of road by providing reinforced hume pipe (NP-3) as per drawings given in the tender

25nos-2 x 300 dia Hume pipe (NP-3) culvert –5 m length

Drg.No. MEC/23NA/05/11/ STD/021

6 Laying of pavior blocks on the sand bed / PCC bed.

7 Repair / Construction of pavement (RCC) by providing M-25 concrete as per specifications and drawings given in the tender

II) SCOPE OF SUPPLY –

Contractor shall procure & supply to site all the materials including cement, reinforcing steel, steel sections/plates, pipes, shuttering materials, chequered plate, mesh, bolts and other accessories, other masonry materials, bitumen/asphalt, admixtures & bonding agents, sealants, pavior block, sand, bricks, stones, water proofing roof materials, boulder, Welding set etc., and any other construction material / item required to complete the civil & structural works.

All costs towards testing/inspection of materials/goods shall be borne by the Contractor. No materials/items shall be supplied by the Owner.

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III) SITE WORK -

Complete construction work including supply of labour, construction materials, construction equipment, survey, tools & tackles, dismantling & modification/strengthening, supervision, testing etc. required to complete all the structures, foundations, roads, drains, pavements, finishes, supply, fabrication, erection of steel structures, painting, including site grading/earthwork in cutting & filling etc. as specified and required to complete the civil & road works in all respect. All enabling works e.g. construction water tank, casting/fabrication yard, electricity, site stores & office, safety and security measures, coordination with other contractors working at site etc. shall be Contractor’s responsibility. Special permits such as ‘Hot Permit”, “Fire Safety Permit”, “permissions for controlled blasting of rock from concerned authorities” etc. to work at terminals shall be contractor’s responsibility.

IV) SCOPE OF WORK The scope of work shall be as per Table-1. Broadly the activities to be performed are listed as below, but not limited to, the following:

a) Dismantling of existing brick structures, pavior blok flooring and existing

foundations, road, structures etc. and clearing the site for the purpose of construction.

b) Excavation for making fire protection wall, pump and pipe support foundations.

c) Earth filling in embankments with available earth for roads/ repair of approach road wherever required including box culverts/ Pipe Culvert.

d) Construction of a 3.0 m high fire protection wall (brick masonary 1:4) with R.C.C. (M-25) slab on roof as per drawing.

e) Construction of pump and pipe support foundations with RCC (M-25) grade of concrete.

f) 150 mm thick RCC (M -25) pavement for all process area, external/internal roads & flooring as shown in architectural drawings.

g) RCC for complete civil works for cable trench including providing inserts, conduits (GI, PVC or HDPE etc.) and PVC coated MS Chequred cover plate/ Pre cast concrete covers as per requirement.

h) Storm water drainage system in RCC/brick drains with connections to main Drain complete civil works as per requirement.

i) 80 mm thick PCC pavior block over sand cushion over ground/on a PCC base (Grade M-10) at locations as specified.

j) Supply, Fabrication and Erection of Mild Steel base plates at foundations. Steel structures required for Valve Operating Platforms and Crossovers.

k) Grouting of all base plates/frames of equipment foundations and structural bases.

l) Providing of all inserts, conduits, pre-cast covers, fixing of free issue items into permanent works etc.

m) Providing of approved quality sand for back filling as per requirement. Construction of leveled floor area by providing brick on edge as per requirement.

n) Providing water proofing to roofs & water tanks as per architectural drawings.

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o) Clearing all construction debris and handing over completed work site. p) Any other work not specifically mentioned but required to make the terminal

functional. q) Making as-built details/drawings on one set of construction drawings and

return to owner.

2.0 PREAMBLE TO SCHEDULE OF QUANTITIES The Preamble to Schedule of Items is an integral part of the schedule of quantities and rates and this is to be considered incorporated into the description of items them selves. The Contractor’s rate for any item of work in the schedule of item shall, unless stated otherwise be held to include the cost of all materials including wastage, conveyance and delivery, unloading, storing, fabrication, all consumable materials, like MS bolts, washer, electrodes, putty, gases, splices paints, tools and plants, power fuel, consumables, all taxes, royalties, other revenue expenses, temporary facilities like roads etc

2.1 DISMANTLING OF CIVIL foundations & STRUCTURAL items

Brief description of major items shall be as follows:

a. Dismantling of PCC/RCC foundations, floor, brick masonary work, road, drain, structural items etc. by using skilled / unskilled manpower and machinery.

b. Ensuring all safety measures and taking permissions from concerned authorities and client prior to dismantling of any existing structure.

c. Disposal of unserviceable and surplus debris to a suitable dumping ground up to any lead with prior permission of dumping from concern authority.

d. Actual work shall be carried out as per certified drawings to be issued to successful tenderer.

Note: i) For all these items actual quantity in CuM / RM/ SqM shall be measured as

per respective S.O.R. items for payment.

2.2 EARTHWORK IN SITE GRADING, EXCAVATION & BACKFILLING FOR PLOT DEVELOPMENT, ETC.


a) Taking pre-work and finished levels. b) Stripping and grubbing the top soil of 150 mm and preparation of sub-grade. c) Excavating excess soil and soft rock if any to develop the plot. d) Backfilling with serviceable earth in layers of 300 mm thickness in controlled

way. e) Watering and compaction up to ‘95% or as per direction of Engineer in charge

of its MDD with mechanical means. f) Disposal of unserviceable and surplus earth/rock to a suitable dumping ground

to any lead. g) Actual work shall be carried out as per certified construction drawings to be

issued to successful tenderer. Note: For all these items only net excavated quantity in CuM shall be measured for

payment.

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2.3 EARTH WORK IN FILLING

Complete earthwork in filling with borrowed earth is included in the scope. Brief description of major items shall be as follows:

a) Taking pre-work and finished levels. b) De-watering of excessive water c) Strutting and shoring to retain the earth. d) Borrowing of approved quality good earth from any lead. e) Filling in layers of 300 mm. f) Waering and compaction up to ‘95% or as per direction of Engineer in charge’

of its MDD with mechanical means.

Note: Payment for item earthwork in filling shall be paid for compacted net volume of filling after deductions of foundations, culverts, etc

2.4 SAND FILLING

Complete sand filling with mixed sand is included in the scope. Brief description of major items shall be as follows:

a) Taking pre-work and finished levels. b) De-watering of excessive water. c) Strutting and shoring to retain the sand if required. d) Providing approved quality good sand (free from dirt, earth lumps, and

weeds) from any lead. e) Filling in layers of 300 mm. f) Watering and compaction up to ‘95% or as per direction of Engineer in

charge’ of its MDD with mechanical means.

Note: Payment for item sand filling shall be paid for compacted net volume of filling in underground structures after deductions of foundations, culverts, etc

2.5 PCC WORK

Providing and laying PCC M-7.5/ M-10 / M-15 in all positions, in foundations, substructure, and superstructure and under floor, etc. (at locations where the same is not included in respective SOR items), complete in all respects as per scope of work, detailed construction drawings, technical specifications and direction of Engineer-in-charge.

Following works shall be inclusive in the rate of PCC item:

a) Earth Work in excavation including back filling (including disposal of surplus earth).

b) Providing shuttering and strutting of all types (If necessary).

PCC M-7.5/ M-10 / M-15 as per drawing & specification including supply of cement, coarse aggregate, fine aggregate and placement of concrete at all levels and depths, all inclusive & testing of materials.

Note: For all these items only net PCC concrete quantity in CuM shall be measured for payment.

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2.6 REINFORCED CEMENT CONCRETE – SUBSTRUCTURE (FOUNDATIONS)


a) Earth Work in excavation including back filling, disposal of surplus earth (wherever required), including bailing out water (where ever required), shoring / strutting etc.

b) 100 thk. PCC M-10 in mud mat. c) Providing shuttering and strutting of all types. d) RCC M25 as per drg. & specification including supply of cement, coarse

aggregate, fine aggregate and placement of concrete at all levels and depths, all inclusive & testing of concrete and other materials.

e) Providing of all inserts, conduits, precast covers, chequered plates, fixing of free issue items into permanent works etc.

f) Grouting of all base plates/frames of equipment foundations and structural bases as per requirement.

g) Application of two coats of hot bitumen on surfaces in contact with soil.

Note: For all these items only net RCC quantity in Cu.M shall be measured for payment

2.7 REINFORCED CEMENT CONCRETE – SUPERSTRUCTURE


a) Providing shuttering and strutting of all types at all levels. b) RCC M25 as per drg. & specification including supply of cement, coarse

aggregate, fine aggregate and placement of concrete at all levels, all inclusive & testing of concrete and other materials.

c) Grouting of all base plates/frames of equipment foundations and structural bases as per requirement.

d) Providing of all inserts, conduits, Railing, precast covers, water tanks, GI fittings, chequered plates, fixing of free issue items into permanent works etc.

Note: For all these items only net RCC quantity in Cu.M shall be measured for payment

2.8 REINFORCEMENT STEEL

a) Supplying, Fabricating and Fixing in position HYSD Steel Reinforcements/

TMT Grade Fe-415 conforming to IS1786-1985 at all levels and positions b) Straightening, Cutting, Bending, Cranking, Binding, Welding, Provision of

necessary Chairs and Spacers for reinforcement bars as per drawing and construction requirements.

c) Preparation of bar bending schedule Drawings and getting the same approved by Site Engineers as directed by EIC.

Note: 1. Rate to include cost of all labour, tools, tackles, equipment, hire charges,

supply of all materials such as steel Reinforcement, binding wire and other minor construction materials, testing etc. all bye works and sundry works complete in all respects..

2. Chairs, laps, spacers, wastage etc. shall be to contractor's account. 3. Only net Reinforcement bars as per approved BBS / as laid at site shall be

considered for payment.

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2.9 BRICK WORK IN SUB -STRUCTURE

Complete works in brick masonry sub structure is included in the scope. Brief description of major civil items shall be as follows:

a) Earth Work in Excavation including back filling. b) Brick work in sub structure (drains, building, boundary wall etc.) with not less

than M-7.5 grade bricks in 1:4 cement sand mortar(in coarse sand). c) 150 thk PCC (M-10) in leveling course. d) DPC 40 mm with cement concrete 1:2:4 as per requirement with water

proofing compound and application of bituminous paint e) 15 mm thk plastering in CM (1:4) (in course sand) on exposed brick surfaces. f) Application of two coats of hot bitumen on surfaces in contact with soil. g) Applying Lime wash / Cement based paint / Weather proof paint / oil bound

distemper/Acrylic paint on plastered faces in super structure as specified in drawings

Note: Only net brick masonry quantity shall be measured for payment purpose

below FGL in fire protection walls and other structures.

The construction of brick work shall be done as per detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on work described above and payment will be made on rate (per CuM) of brickwork done.

2.10 BRICK MASONRYFIRE PROTECTION WALL IN SUPER STRUCTURE

Complete works of brick masonry wall in superstructure including PCC, DPC, is included in the scope.

Brief description of major civil items shall be as follows:

a) 230mm/345mm thick brickwork in wall and 690mmx460mm pillar with not less

than M-7.5 grade bricks in 1:4 cement mortar. b) 15 mm thk plastering in CM (1:4) (in coarse sand) on exposed brick surfaces. c) Painting of exposed wall surface with three coats of cement base /Acrylic

emulsion paint as approved by Engineer-in-charge. d) Expansion joints shall be provided as per drawings. Note: Only net brick masonry in CuM shall be measured for payment purpose.

The construction of brick masonry boundary wall shall be done as per detailed construction drawings to be issued to the successful tenderer.

2.11 BRICK ON EDGE FLOORING- Brief description of major works to be considered in this item is as follows:

a) Earthwork in excavation including back filling upto required level (including

using borrow earth and disposal of surplus earth) b) Filling in layers of 150-mm. thickness in controlled way. c) Watering and compaction up to 95% of modified dry proctor density of soil with

mechanical means.

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d) Providing and laying / fixing bricks over 100 thick sand cushions over well compacted sub grade / PCC as specified.

e) Filling joints between the blocks with fine River sand. f) Making slopes, finishing edges, leaving pockets for pedestals & sleepers g) Actual work shall be carried out as per certified construction drawings to be

issued to successful tenderer.

Note: -

1) Complete civil works for Brick on edge flooring, earth work in excavation, preparation of base i.e., compacted sub grade, 100mm thk. sand filling and compaction, etc. are included in the works & payment shall be made under brick on edge flooring. Only net laid quantity measured in SqM shall be considered for payment purpose.

2) PCC under the Brick on edge flooring wherever specified shall be paid under separate PCC item.

2.12 PAVIOR BLOCK (80 mm THK) PAVEMENTS IN SPECIFIED AREAS

Brief description of major works to be considered in this item is as follows:

a) Earthwork in excavation including back filling upto required level (including

using borrow earth and disposal of surplus earth). b) Filling in layers of 150-mm. thickness in controlled way. c) Watering and compaction up to 95% of modified dry proctor density of soil with

mechanical means. d) Providing and laying / fixing 80 mm thick M-40 Pavior Blocks over 100 thk. sand

cushion over well compacted sub grade / PCC as specified. e) Filling joints between the blocks with fine River sand. f) Making slopes, finishing edges, leaving pockets for pedestals & sleepers g) Actual work shall be carried out as per certified construction drawings to be

issued to successful tenderer.

Note: -

1) Complete civil works for Pavior Block Pavement including, earth work in excavation, preparation of base i.e., compacted sub grade, 100mm thk. sand filling and compaction, etc. are included in the works & payment shall be made under Pavior Block Pavement item. Only net laid quantity measured in SqM shall be considered for payment purpose.

2) PCC under the Pavior Block Pavement wherever specified shall be paid under

separate PCC item.

2.13 PIPE CULVERT WITH 300 DIA NP-3 PIPES

1. Brief earth work / dismantling of existing Road / RCC / PCC pavements including removal of debris making place for constructing the pipe culvert.

2. Encasing and lying of Hume pipes (NP-3) as pre enclosed drawings (M-10).

3. Backfilling of earth and repair of road as per existing specifications of road.

Note :

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1. Complete civil works including dismantling of existing road, providing hume pipes (M-3) and PCC as per given drawings.

2. Payment shall be made as per running meter length of pipe culvert.

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SUPPLY FABRICATION AND ERECTION OF STEEL STRUCTURE 1.0 This Specification shall apply to supply, fabrication and erection of steel structures in

building and general structural work. The steel structures shall consist of but not limited to columns, column bracing, portals, platforms, walkways, stairs, ladders, handrails, chequered Plate/Grating for platforms, chain link fencing and fencing gate etc.

This Specification covers the structural steel work mainly mentioned below. The structural work shall not be limited to the following description but shall be guided by technical/ technological aspects for the total scope of work.

Brief description of major works under the item is as follows:

1.1 Supply, Fabrication and Erection of Miscellaneous steel structural works.

Brief description of major items shall be as follows

a) Supply, Fabrication and erection of canopy, crossovers, platform, Structure for maintenance shed, etc. fabrication from rolled Steel section and built up section conforming to IS:2062 Grade-A and pipes conforming to IS:1161,as per requirement.

b) Painting of steel structure as per specification and drawing c) Crossover, Platform, Pipe and Valve Supports structure shall be fabricated

and erected as per detailed construction drawing to be issued to the successful tenderer

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Annexure-II to

Particular Job Specification (INSTRUMENTATION WORKS)

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GAIL (INDIA) LIMITED New Delhi

FIRE WATER SYSTEM

PARTICULAR JOB SPECIFICATION INSTRUMENTATION WORK

PJS No.: MEC/S/05/E5/GAIL/INST-PJS-01

PREPARED AND ISSUED BY

ELECTRICAL &

INSTRUMENTATION SECTION MECON LIMITED

DELHI - 110 092

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CLIENT: GAIL (I) LTD.

PROJECT: FIRE WATER SYSTEM

PARTICULAR JOB SPECIFICATION FOR INSTRUMENTATION WORK

MECON LIMITED

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INDEX

Sl. No. DESCRIPTION 1.0 INTENT OF THE SPECIFICATION 2.0 SCOPE OF WORK 3.0 PROCESS DESCRIPTION AND ENVIRONMENTAL CONDITIONS 4.0 CODES AND STANDARDS 5.0 BATTERY LIMIT AND EXCLUSIONS 6.0 VENDOR DATA REQUIREMENT 7.0 DESIGN CRITERIA 8.0 INSPECTION AND TESTING 9.0 SPARES 10.0 AS BUILT DRAWINGS AND DOCUMENTS 11.0 DEVIATIONS

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1.0 INTENT OF THE SPECIFICATION

Instrumentation requirements for the Fire Water Systems to be installed at GAIL’s existing plant based on the recommendations of OISD-117 (Oil Industry Safety Directorate) which are now required to be upgraded as per guidelines laid in OISD:226 and PNGRB. Project details will be provided elsewhere in the tender.

2.0 SCOPE OF WORK FOR INSTRUMENTAION : The scope of work pertaining to Instrumentation shall include but not limited to the following:

a) Design, engineering, manufacture, supply, erection, testing & commissioning of completely wired

free standing type Control Panel along with all accessories for as per the specification indicated in the Technical Specification (Data Sheet No. MEC/05/E5/DS-CP-01).

b) Design, engineering, procurement, supply, installation, testing, Calibration & commissioning of all

the Field-mounted Instruments & Control Panel mounted Instruments viz. various Sensors, Transmitters, Gauges, Annunciators, Barriers, Signal Multipliers (SDC) etc. as per attached Instrument Data Sheets.

Major Field Instruments are Pressure Gauges, Pressure Switches, Pressure Transmitters, and Pressure Safety valves, Temperature Gauges, Level Transmitters, Level Gauges, Pressure Control Valve and Air Release Valves etc.

c) Design, engineering, procurement, supply, installation, testing, Calibration & commissioning of LEL

Detection Systems, comprising of 1No. of control unit (to be mounted in the Control Panel) and 12 Nos. (to be installed in the field) + 2 No. (Spare) sensors as per the Technical Specification attached. (Data Sheets No: MEC/05/E5/DS-LEL-01). All necessary cabling & accessories for Interfacing with Micro PLC through serial communication / hard wired cables shall be done. Where existing detectors & panels is adequate, serial communication / hard wired cabling of existing panel to be considered. Details will be provided at the time of detailed engineering.

a) Supply and laying of control, signal, triad cables on main cable trays, perforated trays, trenches

including supply of all required cable glands (explosion proof double compression type) and consumables like ferrules, clamps, PVC tubes, Aluminium / SS tag plates etc., clamping, ferruling, glanding of the cables, termination at both ends, including shield/ drain/ communication wire, providing/fixing of identifying tags and megger testing and loop testing.

b) Supply, installation of Junction Boxes including plugs for unused entries, supply, fabrication and

installation of supports, plugging of unused entries and painting (explosion proof electrical junction boxes for 6 pair/ 12 core cable entry and for 12 pair / 24 core cable entry).

c) Supply of Canopies fabricated out of Powder coated MS for electronic transmitters including supply,

fabrication of support and installation of Canopy with support and reflective painting.

d) Supply, laying and termination of both ends from earth grid to field instruments/ JBs/ Control Panel by 8 SWG G.I. Wire / Strip in tray and conduits as required excluding Earth-Pit preparation.

e) Supply, laying and termination of both ends of 4 sq. mm. PVC insulated armoured copper cable from

earth pit to the barrier earth bus bar in trays/conduits/trenches as required.

f) All cables required for new Deluge Valve, detectors & panels shall be in the scope of contractor.

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g) Handling, transportation from store to site, Erection of free issue Fire Water Pump Panel and associated works, interfacing with client’s PLC, Panel SCADA.

h) Any work for Dismantling of free issued items and reinstallation and commissioning as required.

i) Start up & commissioning of complete terminal instruments, including all labour, test equipments

and other auxiliaries as required, etc., complete in all respects as per specifications/ drawings/ directions of Engineer-in-Charge. All necessary Testing and Commissioning Reports, As-built Drawings etc., shall also be prepared and to be submitted to the GAIL/MECON

j) The scope of work shall also include

- All the necessary work for the completion of the Instrumentation requirements in all respect

for fire water interlocking and control and hookup to client’s SCADA as per the scheme finalized during detailed engineering.

- Arrangement of the inspection of all the items to be supplied as mentioned above at the Manufacture’s works by GAIL/MECON as per approved QAP.

- Submission of all drawings and documents as listed elsewhere in this Bid document.

The scope of work shall also comply with the Instrumentation General Specifications as described elsewhere in the Bid document.

3.0 PROCESS DESCRIPTION AND ENVIRONMENTAL CONDITIONS 3.1 SCADA Facility

Some of the parameters of the Fire water system will be hookup with the existing SCADA system of GAIL. It will be through serial communication or hardwired (will be finalized later & to be communicated during detailed engineering to contractor). The Control system with LEL facilities shall be compatible for hooking up with the existing SCADA System within the define scope. Data to be hooked up to SCADA shall be user selectable at site. The control system shall be able to support SCADA without change in architecture or addition of hardware. A dedicated Terminal Block shall be provided for SCADA Parameters.

3.2 Environmental Conditions The environmental condition to be considered for selection, design, derating of Instrumentation equipment

shall be as follows: Ambient Temperature : 65 0C (Max.)

Relative Humidity : 90 % RH 4.0 GENERAL INSTRUCTION:

i. The Contractor shall be responsible for complete activities involving all subcontractors under him and also instrument sub-contractor (if applicable) works under him for the complete instrument works, as part of his scope.

ii. Scope of work shall be read in conjunction with the Schedule of Rates, drawings, specifications and other documents forming a part of the Contract document.

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iii. In the control room, the contractor's scope shall include laying, tagging and identification of all cables connected between the field and the control room, dressing of the same inside the control room. It is the responsibility of the contractor for proper routing, dressing of cables, terminations in UCP’s, inside the control room and also for loop checking.

iv. Contractor shall quote unit rates for all items covered in the “Schedule of Rates” (SOR).

v. Contractor shall be responsible for co-ordination during installation, testing, calibration, pre commissioning and commissioning with his Mechanical and other sub contractors for proper installation of line mounted instruments like Pressure/Thermal Relief valves, Electro-Hydraulic Control valves etc.

vi. Contractor shall be responsible for coordination with other vendors for all kind of works in side the control room i.e. cable laying, tray erection, if any, and for proper cable terminations and loop checking.

vii. Drawings and Installation Standards enclosed with the tender are only for reference and indicative of general nature for scope of work. Actual installation shall be carried out based on final installation standards, Bill of material and vendor’s drawings / documents issued to site and as per instructions of Engineer-in-Charge.

viii. Instrument items such as tubes, tube fitting, valves & manifold, junction boxes, cables, cable glands, plugs, adapters, pipe and pipe fittings etc., as required for installation & hook-ups of instrument listed under SOR shall be supplied from the attached list of Approved Vendor’s only. Contractor shall take prior approval of make and specification of such items before placement of order.

ix. Sealing of cable entries into the control room after laying and testing of all cables through pipe sleeves by filling with sealing compound.

x. During trial run/start up/commissioning , the contractor shall provide skilled personnel and supervision round the clock at contractor’s cost. Any defect or changes of setting, recalibration, etc., if any during the above activity shall be rectified/done immediately to the satisfaction of engineer-in-charge or his representative. The number and category of the personnel shall be as decided by the engineer-in-charge. The cost of the above is deemed to be included by the contractor in the rate quoted.

xi. Contractor's scope shall include making holes in the RCC for fixing up of supports for instrumentation items, trays etc.

xii. Contractor shall note that elbows (if required) shall be installed on the impulse line wherever required as per instructions of the Engineer-in-Charge even if it is not indicated in the installation standards.

xiii. The field work shall be carried out under strict safety regulations and work permits as laid down by the client. The contractor shall take extreme care regarding safety and all safety gear like helmets; hand gloves, safety belts, spectacles etc. shall have to be provided by the contractor.

xiv. The ferruling for cables shall be done with tag no. of instruments for individual pair. Cross

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ferruling shall be done for cable ferruling in field, control panel and UCP panels as per instruction of the Engineer in charge.

xv. The contractor shall have to assess the actual site conditions/requirements before placement of order for cable/trays as per the actual site condition. Contractor has to prepare a cable routing layout as per actual site requirements from field to existing control room and get the approval before placement of procurement.

xvi. Allowable minimum bending radius of multipair / multicore cable shall be 6 times the outside diameter for unshielded cables and 8 times the outside diameter for shielded cables unless otherwise recommended by the supplier.

xvii. Location and flow direction of on-line instruments shall be checked by the contractor and to be rectified in case of any discrepancy as per the instruction of Engineer-In-Charge

xviii. The cable entry to the Control room shall be through pipe sleeves for all the control rooms, which shall be installed by the contractor. The installation of the pipe sleeves shall be as approved by the Engineer-in-charge. Contractor shall run all cables from field to Control Room. The cables shall run through Tray / Trench / IRC (instrument road crossings) from field to the control room as per Instrument Layout Drawings (to be furnished during execution).

xix. Wherever trenches of longer/ smaller dimension than the maximum dimension identified in the SOR, the rate shall be considered as pro-rata basis for increase/ decrease in floor area change.

xx. Welding/NDT, Charpy V-notch, QA/QC requirement etc. shall be as per Piping Material Specification (PMS), MECON standards & specifications and other requirement attached / mentioned elsewhere in the tender document. Contractor to also note that 100% MPI shall be carried out in the entire socket weld joints in the installation of instruments. The SOR price shall include all the above in the installation of respective instrument/item.

xxi. Welding shall be as per welding standard attached elsewhere in the tender document.

xxii. The methodology of cable supports shall be as follows:-

1. Perforated/Angle/Ladder Trays (Contractor’s supply) for all the cables from the individual instruments to the respective junction boxes.

2. Perforated/Angle/Ladder Trays (Contractor’s supply) or Trenches (Prepared by contractor) as per the layout drawings (and any subsequent site adjustments as deemed necessary by the engineer-in-charge) from the junction boxes to the control room(s), the same supports/routes will have to be used for direct run cables from the individual instruments to the control room.

5.0 BATTERY LIMIT AND EXCLUSIONS 5.1 Power Supply

Uninterrupted power supplies (230 VAC UPS) battery back up will be provided by GAIL However conversion of 230V AC to 24 V DC with dual redundant power supply shall be in Vendor’s scope. The

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supply, Installation, testing and commissioning of 24 VDC power distribution box (PDB) and necessary wiring inside the panel shall be in the scope of the Vendor.

5.2 Exclusions a) Supply & erection of Fire Water Pumps b) Supply & erection of Fire Water lines c) Supply & Erection of Fire Water Tanks & associated piping.

6.0 SPARES 6.1 Commissioning Spares And Consumables Vendor shall include supply of spare parts for commissioning and furnish the complete list. Any extra

commissioning spares and consumables required during commissioning shall be supplied free of cost. 6.2 Special Tools And Tackles

Vendor shall provide a set of special tools and tackles required for calibration, erection, testing and commissioning and maintenance of instrumentation equipment.

7.0 DESIGN CRITERIA

7.1 CODES AND STANDARDS

The following codes and standards (versions/revision valid in the date of order) shall be referred to and made part of this specification ISA, API-RP, BIS, ANSI, ASTM, NEMA, DIN, Indian Explosive act as applicable. Specification and recommendations of IEC, and all other relevant standards and norms as applicable. In addition to above following shall be referred:

a. TAC Fire Protection Manual for Hydrant system – 1998 edition b. IS codes for fire fighting equipments? d. National Fire Prevention codes (NFPA) e. MECON standards & specifications f. Rules for water spray systems (TAC) Specific requirement as specified elsewhere in the documents shall be over- riding the interpretation of the codes as referred above.

Oil Industry Safety Directorate (OISD Standards)

OISD-GDN-115 : Guidelines on Fire Fighting, Equipment and appliances in Petroleum Industry OISD-Standard-118 : Layouts for oil and gas installations OISD-Standard-144 : Design and construction requirements for cross country hydrocarbon pipelines OISD-Standard-214 : Cross Country LPG Pipelines

7.2 Instrumentation & Control shall be provided for safe and efficient operation of the pipeline, terminals, and

tap-off points. Field mounted instruments as well as Panel mounted instruments are envisaged. Panel mounted instruments necessary interface is envisaged in each station including SV stations to connect pipeline /terminal parameters to the SCADA system for remote control and telemeter.

8000006103 73 of 101




MECON LIMITED

Page 8 of 11

7.3 Instrumentation and Control system has been envisaged to ensure optimum performance of the Natural Gas transportation and to achieve safe, reliable and trouble free operation. For this purpose, microprocessor based electronic instruments having 4 – 20 mA DC unified current signal as input/ output have been envisaged. The basic function of the Instrumentation system is to monitor and control of natural gas parameters viz., pressure, temperature, flow, % of LEL, actuated valve status, etc. These functions will be achieved with the help of panel mounted receiver instruments, annunciation lamps, push buttons, etc. in the control room along with equipment/ pipeline mounted sensors, transmitters, gauges, switches, actuated valves, etc. in the field.

7.4 The design shall employ the latest technology of proven capabilities. The selection of equipment shall be

such as to offer flexibility for future modification and expansion without affecting the system reliability. 7.5 All instruments shall be capable of operating for the specified turndown conditions. All instruments unless

otherwise specified, shall be electronic type. However, final control element shall be pneumatically or gas operated.

7.6 All plant safety shutdown and interlocks shall be carried out using electromagnetic relays for fail safe and

reliable shutdown. Control Panel and Relay Panel / Marshalling Rack shall be located in control room. 7.7 All field instruments, junction boxes and cable glands shall be certified for use in hazardous area as per area

classification. The Instrumentation shall be certified intrinsically safe in general, as per IEC-79. However, field switches, solenoid valves shall be certified flameproof for use in classified area as applicable (IS-2148/ IEC-79). Moreover, all field instruments, junction boxes, cable glands and local control panels shall be weather proof to NEMA-4 / IP 55 as per IS:2147 / IEC-529 as a minimum and explosion proof/ flame proof to NEMA-7 or equivalent IS Standard. Junction boxes, cable glands and accessories shall be Weatherproof only when connected to intrinsically safe circuit and NEMA-7 or equivalent IS Standard, when connected to explosion proof instruments / circuits.

7.8 The philosophy of power supplies for Instrumentation purposes are as follows:-

i) 230 V AC 50 HZ. UPS , ii) 230 V AC 50 HZ. Non-UPS iii) 24 V DC

230 V AC 50 Hz. UPS shall be used for main incoming power to control panel. 24 V DC (Dual Redundant) power supply to be used for panel mounted receiver instruments, transmitters, barriers, signal repeaters (SDC) etc. shall be derived from 230 V AC (UPS) power supply as part of control panel . 24 V DC shall also be used for interlock based relay system, solenoid valves LEL detectors. 230 V AC non-UPS shall be used for panel lighting, electrical heat tracing. The UPS and 24 V DC shall be sized to meet the control system / relay based logic system load and other non-UPS loads shall also be sized by Contractor based on the requirement.

7.9 Isolated 230V AC @50 Hz, 24V DC and its distribution within the battery limits including UPS and battery

backup shall be Contractor’s responsibility. AC distribution board and DC distribution board shall be provided in control room with suitable isolator for each feeder.

7.10 All open and close loops shall have an individual MCB in the panel for isolating the field instruments for maintenance (i.e. for field switches, transmitters, SOV, Control Valve etc.)

7.11 The design and installation of instruments shall be generally in accordance with ISA / API recommended

practices and other applicable standards like ASI, IBR etc. Material specifications and practices shall, in general, conform to appropriate ASTM or equivalent standards. All standards, code of practice shall be of the latest edition.

7.12 Instruments and equipments shall be suitable for use in hot, humid and tropical

industrial climate in which corrosive gases and/ or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof, weather proof to NEMA 4 (IP 55)

8000006103 74 of 101




MECON LIMITED

Page 9 of 11

and secure against the ingress of fumes, damages, insects and vermin. All external surfaces shall be suitably treated to provide anti corrosion protection against plant atmosphere.

8.0 INSPECTION & TESTING

Vendor shall submit Quality Assurance Plan (QAP) for all items of Instrumentation equipment for GAIL/MECON approval. Enclosed Vendor list shall be followed. Vendor shall be responsible for all Tests for perfect Integrated Control Panel. Vendor shall arrange all necessary Instruments/accessories assistance required for these tests.

8.1 Acceptance Certificate (AC)

Acceptance Tests shall be conducted at Manufacture’s works during inspection after equipment/sub-system is completely ready for inspection. These shall include testing & calibration etc. of equipment/sub-system. Acceptance Certificate (AC) shall be issued after all the materials received at site.

9.0 AS BUILT DRAWINGS AND DOCUMENTS

Vendor shall incorporate all changes made in the drawings from approval stage to the handing over stage. As-built drawings shall be submitted in requisition of sets (these will be in addition to the sets submitted at the time of approval/ for information and up to commissioning). The drawings to be submitted shall include all the drawings/documents submitted for the approvals, information as also the drawings / documents required for normal operation, trouble shooting, repair, maintenance and testing of equipment /system /installation. Vendor shall submit the following drawings / document/ data in specified number of copies and reproducible prior to submitting the final bill to the GAIL/MECON on handing over the installation to the customer whichever is earlier. i) All drawings / documents submitted to GAIL/ MECON for approval/information. ii) Equipment manufacturing drawings / documents submitted for information GAIL/MECON. iii) Operation and Maintenance Manuals, Vendor shall submit one preliminary O&M manual to

GAIL/MECON for approval. The final manual in bounded volumes shall be supplied before despatch of equipment in specified no. of copies.

iv) Inspection reports, factory and site calibration test reports in bounded volumes. v) As built drawings/documents incorporating all site modifications. vi) List of spares. vii) All the necessary documents required for final testing and commissioning.

Vendor shall give the drawings and documents as follows: (i) Six sets of Prints (ii) One set of Transparency

10.0 DEVIATION The Vendor shall clearly mention in the offer all the deviations from the Technical Specifications, however minor may be. Otherwise, it will be taken for granted that the Vendor includes all the details as mentioned in the Technical Specification though these might not have been specifically mentioned in the offer.

11.0 LIST OF ATTACHMENTS:

Refer the List of Standard Specifications and Standard Drawings enclosed else where in the tender document.

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MECON LIMITED

Page 10 of 11

LIST OF STANDARD SPECIFICATIONS

1. Specification for Installation of Instruments MEC/S/05/26/01, Rev-0 2. Specification for Instrument Tubing MEC/S/05/26/02, Rev-0 3. Specification for Instrument Tube Fittings MEC/S/05/26/04, Rev-0 4. Specification for Instrument Valves and MEC/S/05/26/05, Rev-0 Manifolds 5. Specification for Junction Boxes & Cable MEC/S/05/26/06, Rev-0 Glands 6. Specification for Signal Cable MEC/S/05/26/07, Rev-0 7. General Technical Specification for MEC/S/05/26/08, Rev-0

Instrumentation 8. Specification for Cabling MEC/S/05/E5/21, Rev-0 9. Specification for Earthing MEC/S/05/26/23 A, Rev-0

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MECON LIMITED

Page 11 of 11

LIST OF STANDARD DRAWINGS (Refer as per requirements if included in SOR / Price only) will be provided to successful bidder.

Sl. No. DRAWING No. DESCRIPTION REV.

1 MEC/05/E5/SD/PT/001 INSTALLATION DIAGRAM FOR PRESSURE TRANSMITTER. 0

2 MEC/05/E5/SD/DPG/003 INSTALLATION DIAGRAM FOR DIFERENTIAL PRESSURE GAUGE. 0

3 MEC/05/E5/SD/PG/004 INSTALLATION DIAGRAM FOR PRESSURE GUAGE. 0

4 MEC/05/E5/SD/PS/002 INSTALLATION DIAGRAM FOR PRESSURE SWITCH 0

5 MEC/05/E5/SD/TG-RTD/005 INSTALLATION DIAGRAM FOR TEMPERATURE GUAGE & RTD. 0

6 MEC/05/E5/SD/RTD-TW/006 MOUNTING DETAILS FOR THERMOWELLS (RTD). 0

7 MEC/05/E5/SD/TG-TW/007 MOUNTING DETAILS FOR THERMOWELLS (T G). 0

8 MEC/05/E5/SD/SF-RTD/008 SCHEMATIC DIAGRAM FOR SKIN TEMPRATURE MEASUREMENT SYSTEM. 0

9 MEC/05/E5/SD/JB/009 SUPPORT DETAILS FOR JUNCTION BOXES.

0

10 MEC/05/E5/SD/IS/010 A (Sheet – 1 to 3)

INSTRUMENT SUPPORT SINGLE INSTRUMENT. 0

11 MEC/05/E5/SD/IS/010 B (Sheet – 1 to 3)

INSTRUMENT SUPPORT TWO INSTRUMENTS. 0

12 MEC/05/E5/SD/CY/011 FABRICATED CANOPY FOR INSTRUMENTS. 0

13 MEC/05/E5/SD/CB-LY/012 PERFORATED TRAY SUPPORTS & CABLES CLAMPING DETAILS 0

8000006103 77 of 101



MECON LIMITED DELHI

DATASHEET INDEX

Sl. No.

Data Sheet No. Description

1. MEC/05/E5/DS-PG-01 Pressure Gauges

2. MEC/05/E5/DS-PT-01 Pressure Transmitters

3. MEC/05/E5/DS – CP-01 Control Panel & Accessories

4. MEC/05/E5/DS – SDC-01 Signal Distribution Cards

5. MEC/05/E5/DS – ZB-01 Barrier / Isolators

6. MEC/05/E5/TS/PLC-01 TS for PLC based System

7. MEC/05/E5/DRG/CP Suggestive Panel Arrangement for Control

Panel

8. MEC/05/E5/DS – LEL-01 LEL Detection System

9. MEC/05/E5/DS-LT-01 Level Transmitters

8000006103 78 of 101

CLIENT: GAIL (INDIA) LTD.

FIRE WATER SYSTEM

Data Sheet No.: MEC/05/E5/DS-PG-01

MECON LIMITED DELHI

PRESSURE GAUGES

Units:- Flow : Liquid-T/hr Gas-MMSCMD Steam- kg/hr Pressure-Kg/cm2(G) Temperature- C Level/Length-mm 1 Type Direct Wetted parts material --- 2 Mounting Local Element --- 3 Dial size 150 mm Lower body --- Colour White (Non rusting plastic

with black engraving) Non wetted parts ---

4 Case material Cast aluminium Process connection --- 5 Bezel ring Screwed Size --- 6 Window material Shatter proof glass Rating --- 7 Enclosure IP 55 / NEMA 4 Facing &Finish --- 8 Pressure element Bourdon tube Capillary material --- 9 Element material SS 316 Capillary length --- 10 Socket material SS 316 Flushing & Filling --- 11 Accuracy 1% FSD 16 Over range protection 130% of range 12 Zero adjustment Micrometer pointer (Internal) 17 Blow out protection Required 18 Options

13 Connections ½” NPT (M) a) Snubber Conn. Location Bottom b) Syphon

14 Movement SS 304 c) Gauge saver 15 Diaphragm seal --- d) Liquid filled casing Type --- e) 3 Way Manifold 19 Make & Model *

Tag No. Range Pressure Design

Temp. Fluid Service Options Operating Design

PG – ** * ** ** ** water Pump e

PG – ** * ** ** ** water Line Pressure e

NOTES:

1) ‘*’ Information to be supplied by the Vendor / Contractor.

2) ** As per P&ID..

3) Make of the PG shall be from approved vendor list of Mecon /Client.

4) Quantity shall be as per P&ID / SOR (whichever is higher).

0

Rev. Date By Chkd Appd

8000006103 79 of 101


FIRE WATER SYSTEM Data Sheet No.: MEC/05/E5/DS-PT-01

MECON LIMITED DELHI

PRESSURE TRANSMITTERSUnits:- Flow : Liquid-T/hr Gas-MMSCMD Steam- kg/hr Pressure- Kg/cm2 (G) Temperature- C Level/Length-mm

GENERAL MEASURING UNIT 1 Function Transmit & Indicate 24 Service Pressure

2 Type Electronic Smart P Based

25 Element Diaphragm

3 Case Mfg. Std. 26 Body Material Carbon Steel 4 Mounting Yoke 27 Element Material 316 SS

5 Enclosure

Weather proof to IS2147 Explosion proof to IS2148

28 Process Connections ½” NPT(F)

Enclosure class NEMA 4 & NEMA 7 Process Conn. Locn.

6 Elec. Area Class. Zone-I, Gr.IIA & IIB, T3

29 Diaphragm Seal:-

7 Intrinsically safe Required Type 8 Air supply Wetted Parts Matl. 9 Power supply 24 VDC Other Material 10 Cable entry ½” NPT(F) Process Conn.:- 11 Accuracy + 0.075% of SPAN Size and Rating 12 Repeatability + 0.05% Facing and Finish

TRANSMITTER Capillary Material:-

13 Output 4 – 20 mA DC, Two wire

Armour Flexible

14 Trans. Power supply 24 V DC Armour Flexible

Matl.

CONTROLLER Capillary length, mm

15 Output Flush / Filling Conn.

with plug

16 A/M switch MISCALLANEOUS

No. of positions 30 Over Range Protection

130% of Range

17 Set Point Adj. 31 Options 18 Manual Regulator a) Output Meter W.P. Intr Safe (note 2)

19 Mode b) Mounting Accessories

For 2” pipe mounting

RECORDER c) 3 -Way Manifold Required

20 Chart d) Zero elevn. & suppression

Required

21 Chart Drive 22 Moving Parts Matl. 32 Make & Model * 23 Chart speed

Tag No. Operating Pressure Design Press.

Design Temp.

Range Service Options

Span Set

PT- ** ** ** ** * * water a, b, c, d

NOTES: 1) ‘*’ Information to be supplied by the Vendor / Contractor. 2) Over range protection shall be 130% of maximum static pressure. 3) Local Digital Output meter should indicate the line pressure in Kg/cm2g. 4) Environmental cover to be provided for each transmitter 5) Transmitter shall have zero elevation /suppression for the service specified. 6) Make of the PT shall be from approved vendor list of Mecon /Client. 7) ** As per P&ID. 8) Quantity shall be as per P&ID / SOR (whichever is higher).

0


8000006103 80 of 101

GAIL (INDIA) LTD.

FIRE WATER SYSTEM

TANK LEVEL INDICATORS (FLOAT OPERATED)

DATA SHEET NO.: MEC/05/E5/DS-LT-01 Rev - 0

MECON LIMITED

DELHI

Units : Flow→ Liquid-M3/Hr, Gas → Kg/Hr, Steam→ Kg/Hr, Pressure → Kg/Cm2 G, Temperature → Deg C, Level/ Length → mm

1. TAG NO. LT/LI – 001 / 002 GENERAL 2. TANK NO. T-8001/T-8002 3. SERVICE FIRE WATER TANK / EQUPT. 4. TYPE / MOC STORAGE / CS 5. HEIGHT MTR INTERNAL DIA. MTR NOTE – 5 6. TYPE FLOAT & TAPE (AUTOMATIC TANK LEVEL GAUGE) 7. FUNCTION INDICATING / TRANS. INDICATE & TRANSMIT WITH LOW & HIGH ALARM 8. GAUGE HEAD LOCATION SIDE (GRADE) 9. RANGE NOTE – 5 10. ACCURACY + 2MM 11. NO. OF PULLEYS TWO, AS REQD. (90 DEG.) 12. ELECTRICAL CABLE ENTRY ½’’NPT(F) 13. POWER SUPPLY TO BE PROVIDED BY VENDOR LEVEL GAUGE 14. ENCLOSURE WP TO IP 55/NEMA 4 15. REFER ASSEMBLY DRAWING NO. REF. INSTL. STD/API RP-550 16. CONNECTIONS & RATINGS 1.5" ANSI 150 # RF SERR 17. GAUGE HEAD * 18. SPRING ASSEMBLY 1.5” ANSI 150 # RF SERR 19. TAPE ENTRY * 20. PIPE WORK SIZE SCH. * 21. CABLE ENTRY TO BE PROVIDED BY VENDOR 22. TYPE PTR & SCALE / MECH COUNTER AUTOMATIC TANK LEVEL GAUGE / GAUGE HEAD

COUNTER (5½ DIGIT) INDICATOR 23. COUNTER TYPE MECH. / ELECT.( AT GRADE ) MECHANICAL 24. GRADUATIONS IN CALIBRATED IN M & CM 25. ENCLOSURE IP 55/NEMA 4 26. OUTPUT DIGITAL 27. ENCLOSURE CLASS WP TO IP 55/NEMA 4 TRANSMITTER 28. INTRINSICALLY SAFE NO 29. POWER SUPPLY 24 V DC (FROM CONTROL ROOM) 30. CABLE ENTRY ½’’NPT (F) 31. GAUGE HEAD HOUSING DIE CAST ALUMINIUM / SS-304 32. GAUGE HEAD WETTED PARTS SS – 316 33. FLOAT / DISPLACER SS – 316 MATERIAL 34. TAPE / WIRE SS – 316 35. GUIDE WIRE BOTTOM ANCHOR REQD. GROUTED 36. PULLEY HOUSING PULLEY 37. SPRING ASSY. HOSING SPRING * * 38. PIPE WORK AS PER PMS 39. TAPE BLOCK VALVE YES (NOTE 2) 40. LIQUID SEAL EXPANSION JOIN * 41. ISOLATION GATE VALVE * 42. CALIBRATION CHAMBER - OPTIONS 43. STILL WELL YES (NOTE 1) 44. MOUNTING BRACKETS REQD. 45. OPERATION CHECKER REQD. 46. RECEIVER INDICATOR YES 47. BUILT IN SWITCHES YES 48. - 49. PRESSURE OPER MAX. ATM. 1 SERVICE 50. TEMP. C OPER MAX. / DESIGN AMB 50 / 75 COND. 51. OPERATING S. G. / FLUID DENSITY / 1.0 52. OPERATING VISCOSITY MPA. (CP) 53. AREA CLASSIFICATION SAFE 54. MODEL NUMBER TO BE PROVIDED BY VENDOR 55. SPECIFICATION REMARKS

NOTES: 1. STILL WELL INTERCONNECTING PIPING AND FLANGE TO BE PROVIDED BY VENDOR TO TANK FABRICATOR.

2. BLOCK VALVE END CONNECTION SHALL BE 1.5" ANSI 150 # RF SERATED.

3. FILLED IN DATA SHEETS SHALL BE SUBMITTED FOR APPROVAL.

4. CRANK UP MECHANISM SHALL BE PROVIDED FOR HOSTING FLOAT, FOR MAINTENANCE.

5. TO BE DECIDED DURING DETAILED ENGINEERING (PLEASE REFER PROCESS & MECHANICAL DATA OF THE TANK).

6. * TO BE PROVIDED BY VENDOR

7. FIRE WATER TANK CAPACITY : 2975 CUB. METER

8000006103 81 of 101

MECON LIMITEDDELHI

1 TYPE

2 MOUNTING

3 DIAL 14 ELEMENT TYPE

a. SIZE 15 ELEMENT MATERIAL

b. COLOUR 16 PROCESS CONN.

4 CASE MATERIAL

5 WINDOW MATERIAL 17 DIAPHRAGM SEAL

6 AREA CLASSIFICATION TYPE

7 INTRINICALLY SAFE WETTED PARTS MATERIAL

8 ENCLOSURE OTHER MATERIAL

a. TYPE PROCESS CONNECTION

b. CLASS FACING AND FINISH

SIZE RATING

9 OUTPUT ARMOUR FLEABLE

a. ELECTRICALCONTACTS

ARMOUR MATERIAL

b. QTY. CAPILLARY MATERIAL

c. FORMS CAPILLARY LENGTH

d TYPE 18 OVER RANGE PROTECTION

*

AS PER ELECTRICAL AREA CLASSIFICATION

AS PER ELECTRICAL AREA CLASSIFICATION

IS-2147, NEMA-4 AS MIN.

-

-

-

PRESSURE SWITCH

UNITS : Flow --> Liquid m3/Hr Gas --> M3/Hr Steam --> Kg/Hr Pressure --> Kg/cm2G Temp --> °C Level / Length -->MM

NOTE 1

SS-316

1/2" NPT (F)

DIE. CAST ALUMINIUM WITH EPOXY PAINT

BLIND/PRESSURE/DIRECT

YOKE

-

-

YES

TWO


FIRE WATER SYSTEM Data Sheet No.: MEC/05/E5/DS-PS-01

MICRO SWITCH SNAP ACTION

SPDT

d. TYPE 18 OVER RANGE PROTECTION

e. CONTACT PLATING 19 BLOW OUT PROTECTION

f. RATING VOLT, AMP 20 MOUNTING ACCESSORIES

g. LOAD TYPE 21 OPTIONS

h. CABLE ENTRY a. SNUBBER

i. NO. OF ENTRIES b. GAUGE SAVER

c. AIR FILTER REGULATOR

10 SET PT. ADJ. d. VACCUM PROTECTION

11 DIFF. 22 MAKE

12 ACCURACY

13 REPEATABILITY

SL. NO.

TAG NO. RANGE SET

POINT PRESSURE

DESIGNTEMP.OPER.

TEMPDESIGN

SERVICE

1 PSL-801 * 8.5 19 15 - 25 65 Pumping Station

2 PSH-801 * 9.5 19 15 - 25 65 Pumping Station





NOTES:

1 130% OF RANGE OR MAX. PRESSURE WHICHEVER IS GREATER

2 SET POINT SHOULD BE ADJUSTABLE THROUGHOUT THE RANGE.

3 (*) BY VENDOR

4 TO BE CONFIRM DURING DETAIL ENGG INFRMN REQD IF ANY

5 TAG NOS. AND QUANTITIES SHALL BE AS PER P & ID

SWITZER / EQUIV.

12.0

12.0

0

12.0

NOTE - 1

REQD.

+ 0.5% OF SET POINT

+ 0.5% OF SET POINT

MIN. (FIXED)

INTERNAL WITH INDICATED SCALE

INDUCTIVE

24 VDC, 1A

PRESSUREOPER.

GOLD PLATED

MICRO SWITCH SNAP ACTION

DUAL

1/2" NPT (F)

12.0

12.0

12.0

8000006103 82 of 101

CLIENT: GAIL (INDIA)

LTD.

FIRE WATER SYSTEM

Data Sheet No.: MEC/05/E5/DS-ZB-01

MECON LIMITED

DELHI

0


Page 1 of 3

ISOLATING BARRIERS

SL.NO. DESCRIPTION DETAILS

1. TYPE SHUNT DIODE SAFETY BARRIER

2. APPLICATION INSTRUMENT TYPE (i) 4-20 mA Analog I/P from 2 wire transmitter

(ii) 4-20 mA Analog O/P to I/P Converter

3. HAZARDOUS AREA CLASSIFICATION ZONE-I, GR. I, IIA & IIB, T3

4. APPROVAL AUTHORITY FM/BASEEFA/CSA/SA/CMRS

5. SUPPLY VOLTAGE 24 V DC

6. FUSE RATING *

7. END TO END RESISTANCE *

8. POLARITY *

9. MOUNTING DIN RAIL (BACK OF THE PANEL)

10. OPERATING TEMP -20 C TO 60 C

11. OPEN CIRCUIT VOLTAGE *

12. SHORT CIRCUIT CURRENT *

14. MAKE MTL/P&F

15. MODEL NO *

NOTES:- * --By Vendor

1. QUANTITY TO BE CONSIDERED AS PER SOR / REQUIREMENT OF P & ID (whichever is higher).

2. 20% (OF NOTE-1 QUANTITY) SPARE FOR EACH TYPE SHALL BE INCLUDED.

8000006103 83 of 101


LTD.

FIRE WATER SYSTEM


MECON LIMITED

DELHI

0


Page 2 of 3

ISOLATING BARRIERS



2. APPLICATION INSTRUMENT TYPE (i) Limit switches (SPDT snap action Micro type)

(ii) R/L status of AV-valves

(iii) Push buttons for AV-Valves

(iv) Spares.




6. FUSE RATING *


8. POLARITY *





14. MAKE MTL/P&F

15. MODEL NO *

NOTES:- * --By Vendor



ISOLATING BARRIERS


8000006103 84 of 101


LTD.

FIRE WATER SYSTEM


MECON LIMITED

DELHI

0


Page 3 of 3


2. APPLICATION INSTRUMENT TYPE 4-20 mA Analog I/P from Temperature Transmitter




6. FUSE RATING *


8. POLARITY *





14. MAKE MTL/P&F

15. MODEL NO *

16 Qty. As Reqd.

NOTE:- * --By Vendor



8000006103 85 of 101

CLIENT:GAIL(I)

LTD.

FIRE WATER BSYSTEM

D.S.No.:MEC/05/E5/DS-SDC-01

MECON LIMITED

DELHI

0


SIGNAL DISTRIBUTION CARDS


1. TYPE DUAL OUTPUT CURRENT ISOLATOR

2. INPUT 4-20 mA D.C

3. OUTPUT TWO NOS. 4-20 mA ISOLATED OUTPUTS AS MINIMUM

4. ISOLATION BETWEEN INPUT & OUTPUT, BETWEEN INPUT & OUTPUT WITH POWER SUPPLY, BETWEEN OUTPUT & OUTPUT

5. ACCURACY ± 0.1%

6. POWER SUPPLY 24 V DC

7. TRANSMITTER POWER SUPPLY 24 V DC

8. OUTPUT LOAD DRIVING CAPACITY 750 Ohms MINIMUM FOR EACH OUTPUT


10. MAKE MTL/P&F

11. MODEL NO By Vendor

12. QUANTITY As Reqd.

NOTES:-



8000006103 86 of 101


LTD.

FIRE WATER SYSTEM

SPECIFICATION FOR LEL DETECTION

SYSTEM

D.S. NO. : MEC/ 05/ E5/DS/LEL-01

MECON LIMITED

DELHI

0


Page 1 of 4

SPECIFICATIONS FOR LEL DETECTION SYSTEM

SERVICE : To detect the presence of HYDROCARBON in the various

locations in Terminal area. NO. OF DETECTORS / : Refer Data Sheet enclosed for quantity requirements. COMPOSITION ALARMS : To be available in the respective Control Rooms. RELAY CONTACT FOR : Required EACH CHANNEL RELAY CONTACT FOR : Required GROUPING 1) SENSOR: TYPE : Poison resistant, infrared absorption type for combustible gas

or vapours. (Non-selective) CONSTRUCTION : Explosion proof, SS 316 body with stainless steel flame

arrestors, dust cover, weather proof as per NEMA 4X or IP 65 (NOTE-1).

Sensor element shall be replaceable type / plug in type. Terminal box shall be provided for further cabling. Flying leads shall not be offered. Cable entry shall be ¾” NPT (F) (NOTE-2).

ELECTRICAL : Zone –1, Gr. II A & II B, T3 AREA CLASSIFICATION RANGE : 0 –100 % LEL ACCURACY : ± 1 % of gas reading @ 50% LEL, ± 5 % of gas reading @ >

50% to 100% LEL MOUNTING : Vendor to indicate. ACCESSORIES

8000006103 87 of 101


LTD.

FIRE WATER SYSTEM


SYSTEM


MECON LIMITED

DELHI

0


Page 2 of 4

NOTE 1: Splash guard & weatherproof cap for protection against dust and rain shall be provided. NOTE 2: The junction box shall be weatherproof to IP 55 and certified to Explosion proof. 2) GAS MONITOR / CONTROLLER: TYPE : Solid state electronic, panel mounted plug in modular construction NO. OF CHANNELS : No of Channels shall be as per attached sheet with this specification.

However, single loop integrity shall be maintained by one monitoring card per sensor. Single Channel Monitors shall be offered.

POWER SUPPLY : 24 V DC Monitor / Controller shall supply power to sensor. RANGE AND : Adjustable between 0-100 % LEL METER CALIBRATION INDICATORS : Required 0 –100 % LEL. INDICATOR LIGHTS: Power on by a confidence flash for every 2 seconds. (Separate for each channel) 20 % LEL

40 % LEL Malfunction (malfunction shall include short cut. line breaking, over range and earth fault.)

OTHER FEATURES : a) Dual adjustable set points for gas level alarm.

b) SPDT latching type relay contacts shall be provided for following:

i) 20 % LEL (each channel)

-alarm high (adjustable)

ii) 40 % LEL (each channel)

-alarm very high (adjustable)

iii) Malfunction (common)

c) Relay contacts shall be suitably rated for the specified power

requirements.

d) Reset push button (common)

8000006103 88 of 101


LTD.

FIRE WATER SYSTEM


SYSTEM


MECON LIMITED

DELHI

0


Page 3 of 4

e) Sensor calibration without alarm outputs shall be achieved by

inhibit switch on relevant channel.

F) Minimum 1 no serial port (RS 485) for output to client’s

PLC/SCADA has to be provided with Modbus details.

MOUNTING : Monitors / Controllers shall be supplied mounted in 19” racks with screwed terminals at the back. However 19” racks shall be fully wired-up in ready to use condition. Dummy plates shall be provided on spare channel slots wherever required (20 % spare slot shall be provided wherever applicable).

CALIBRATION : Set of fully equipped calibration gas kit consisting of at least a

cylinder / bottle of calibration gas for minimum 6 months use (of known mixture of air and gas ) , a pressure regulator with gauge , flexible tube / hose , adapter cap (to fit sensing head ) shall be supplied to enable online calibration of LEL detectors.

3. SPECIAL INSTRUCTIONS TO VENDOR FOR LEL DETECTION SYSTEM

i. Vendor to note that the offered instruments shall be suitable for the following ambient

conditions :

i. Temperature Range : 48°C (Max.) ii. Humidity : 99% (Max.)

iii. Rainfall : 1000mm (Max.) ii. Power Supply shall be from the respective control panel to each monitor rack at each

terminal, Power distribution is in the Vendor’s scope. If conversion to DC level is required, the system shall be based on dual redundant power packs.

iii. Vendor shall furnish the statutory certificates of explosion proof for both LEL detector and

the junction boxes along with offer. iv. Vendor to note that the pellister of the detector must be poison resistant to the normally

known pollutants present in a hydrocarbon processing industry including sulphides, SO2, chlorides, dust etc.

v. Mounting details of the LEL detectors shall be furnished.

vi. Adjustable set points shall be provided at the monitors.

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vii. Calibration gas suitable for the calibration of LEL detectors shall be included in the offer.

viii. Mute circuits with acknowledge and reset buttons shall be provided. ix. Detailed configuration diagram showing connection of monitor etc. along with detailed

catalogues, manuals etc. shall be furnished along with offer. x. Time period required between successive calibrations of the LEL detectors shall be

furnished in the offer. xi. Commissioning Spares for all the items shall be included in the offer. The vendor shall

furnish the detailed list of the commissioning spares in the offer NOTE: a) The Vendor shall indicate distance limitation if any between Sensor and Monitor. b) Minimum one no RS-485 port shall be provided in the monitor. c) FLAMMABLE GAS DETECTORS. d) EXPLOSION PROOF JUNCTION BOXES. e) WEATHERPROOF CAP. QUANTITY (Sensors) : As per SOR + 02 NO. (SPARE) MONITORS / CONTROLLERS : 1 Set NO OF CHANNELS : 8 NOS. (With Common Indicating Meter) MONITORING CARDS : As per SOR reqmt. + 02 NO. (SPARE) CALIBRATION KIT : 1 Set. NO. OF SYSTEMS (Sets) : As per project requirements

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SPECIFICATIONS FOR LEL DETECTION SYSTEM

SERVICE : To detect the presence of HYDROCARBON in the various

locations in Terminal area. NO. OF DETECTORS / : Refer Data Sheet enclosed for quantity requirements. COMPOSITION ALARMS : To be available in the respective Control Rooms. RELAY CONTACT FOR : Required EACH CHANNEL RELAY CONTACT FOR : Required GROUPING 1) SENSOR: TYPE : Poison resistant, infrared absorption type for combustible gas

or vapours. (Non-selective) CONSTRUCTION : Explosion proof, SS 316 body with stainless steel flame

arrestors, dust cover, weather proof as per NEMA 4X or IP 65 (NOTE-1).

Sensor element shall be replaceable type / plug in type. Terminal box shall be provided for further cabling. Flying leads shall not be offered. Cable entry shall be ¾” NPT (F) (NOTE-2).

ELECTRICAL : Zone –1, Gr. II A & II B, T3 AREA CLASSIFICATION RANGE : 0 –100 % LEL ACCURACY : ± 1 % of gas reading @ 50% LEL, ± 5 % of gas reading @ >

50% to 100% LEL MOUNTING : Vendor to indicate. ACCESSORIES

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CONTROL PANEL & ACCESSORIES

Data Sheet No.: MEC/05/E5/DS-CP-01

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A: GENERAL Site of Installation 1. Plant and Location : As per P&ID 2. Owner : GAIL (India) Limited. 3. Consultant : MECON LIMITED. 4. Location of control panel : Indoor and accessories 5. Floor : Concrete. 6. Air conditioning : Yes. 7. Control Panels Quantity : One

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B: CONTROL PANEL CONSTRUCTION

1. Type : Self-supported, Free Standing, enclosed cubicle and Non-graphic. 2. Lighting : Required for inside panel with door switch. 3. Ventilation : Required with louvers backed by wirefly screen & fan. Fan Failure

alarm required 4. Doors : Rear Double removable hinged doors with flush pull type handles &

with locking arrangement. 5. Door width : Each max. of 600mm and shall suit width of the panel. Panel width is

indicative only. The sizes shall be sufficient to accommodate the required hardware specified in MR. However the depth and height shall be 800 & 2100 respectively.

6. Cable Entry : Bottom, Cable Glands shall be double compression type for external

armoured cables. All unused entries shall be plugged. 7. Receptacles : Required for 230VAC UPS / NON UPS 8. Painting : The finish shall include sand blasting, grinding, chemical cleaning,

surface finishing by suitable filter and two coats of high grade lacquer with wet sanding between coats. Two coats of paint in panel colour shall be given for Non-glossy high stain finish. Panel face final colour shall be of the following: a) Siemens Grey (RAL 7032) Powder coating b) Panel internal shall have a finish color of Brilliant

White/Siemens Grey(RAL 7032) c) Channel Base shall have a finish color of Black

9. Name Plates : Front of Panel Instrument name plates shall be black laminated

plastic with white core. Nameplate shall be provided on the rear of the panel also.

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C: DIMENSIONS & MATERIAL OF CONSTRUCTION 1. Panel dimension : 800(W) mm x 2100(H) mm x 800(D) mm (Including channel base of

100 mm height). 2. Front Plate : 3.2 mm thick CRCA steel/5.0 mm thick HRCA steel, Welded to

frame 3. Side & Top plates : 2 mm thick CRCA steel, Welded to frame 4. Door panel : 1.6-mm thick CRCA steel. Double side hinged. Concealed Hinges

and Flush pull chrome-plated handles. 5. Cable gland plate : 3 mm thick CRCA steel 6. Anchor Bolt Size : By vendor 7. Channel Base : 100X50X6 MM, MS material 8. Frame base : 50mm50mm6mm MS material 9. Lifting Eye Bolt : Required (4 Nos.) 10. Anti Vibration Pad : Required (15mm thick rubber pad). Note : *Panel shall be electrically isolated from base frame.

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D: WIRING 1. Type : General purpose, Intrinsically safe 2. Wiring details 230 VAC UPS Wiring External to Cabinet : Min. 3x2.5 mm²/copper conductor PVC insulated armoured Inside the cabinet : Min. 19 Strands, 16 AWG copper conductor PVC insulated 240 VAC Wiring (Non UPS) : 3x2.5mm² copper conductor PVC insulated armoured Low Voltage internal : Min. 19 Strands, 16 AWG copper conductor PVC insulated

to cabinet 3. Signal Wiring 3.1 External to Cabinet : 1.0 mm² twin twisted individual shielded overall s shielded with overall drain PVC insulated armoured 3.2 Inside the cabinet : Multi stranded min. 0.5mm² copper conductor PVC insulated twin twisted and shielded. 4. Terminal type : Screw clamp type with Pressure Plate 4.1 Terminal size for signal : Suitable for min. 2.5 mm² size conductor 4.2 Terminal size for power dist. : Suitable for min. 4.0 mm² size conductor and higher as per actual cable sizes. 4.3 Terminal block : Clip-on type 5. Wiring colour code : 5.1 Power Supply : Hot – Red, Neutral - Black, Earth – Green 5.2 DC Wiring : Positive – Red, Negative – Black 5.3 Alarm System : White 5.4 Control & shutdown : Yellow 5.5 Analog signals (IS) : Light blue 5.6 Identification of Cable Termination : Criss – Crossing PVC tube ferruling. 6.0 Dedicated terminal for Scada as per P & Id has to be Provided BULK POWER SUPPLY UNIT 1. Input : 230/110 VAC, 50 Hz.(UPS) 2. Output : 24 VDC 3. Rating : 1 KW Min. (25% spare capacity) 4. Quantity : 2 Nos. for each Panel (Dual Redundant) 5. Make : ELNOVA / APLAB

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E: POWER SUPPLY DISTRIBUTION BOXES FOR PANELS 1. Function : Distribute power to individual instruments 2. Mounting : Mounted at the panel inside 3. Door : Front single door 4. Painting : As per panel painting specifications. 5. Dimensions and material construction 5.1. Box dimension : By vendor. 5.2 Box plate thickness : 3mm hot rolled steel. 6. Cable entry : By vendor 7. Accessories : 600V Grade DPST toggle switches with glass cartridge fuse for individual consumers or Suitable MCBs

8. Special requirements : Switch fuse unit for incoming feeder.

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F: SPECIFICATIONS FOR ACCESSORIES

1. MCB Make : SIEMENS/ L&T/ MDS. Qty. : As required. 2. Lamps

Type : LED ClusteredType Voltage : 24 VDC Make / Model No. : By Vendor Quantity : As reqd.

3. Push Buttons Type : Spring return Contacts : 2 No. + 2 NC Contact Rating : 2A 24V DC Make : ESBEE / SIEMENS/ TEKNIC Color : As per standard Quantity : As reqd. 4. Selector switch

Type : As per functional switches( 3 Position, 4 Pole) Specification : Silver alloy gold plated contacts To military specification with SS shaft dust covers with water Proof covering and contact shall Be made before break type Rating : 10A 230V 50Hz / 2A 24V DC Make : KAYCEE/ SIEMENS/TEKNIC Quantity : As reqd.

5. Relays

Type : Plug in relays Contact Type : Potential free contact

Contact No. : 3 NO. + 3 NC Rating : 24V DC, 5.0 A Make / Model No. : OEN/ OMRON Quantity : As reqd. 6. Space Heater Rating : 60W, 230 V AC with Thermostat. Make : KEC

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LIST OF VENDORS FOR BOUGHT-OUT ITEMS

I) PRESSURE CONTROL VALVE 1) Fisher Xomox Sanmar Ltd. 2) Mil Controls Limited 3) Samson Controls Pvt. Ltd. 4) Forbes Marshall, Pune 5) Instrumentation Ltd. Palghat. 6) L & T 7) Virgo

II) L.E. L DETECTION SYSTEM

1) Crowcon Detection Instruments Ltd 2) Detection Instruments (I) Pvt Ltd 3) Detector Electronics Corporation 4) MSA – Mines safety appliances. 5) Oldham France S.A.

III) CONTROL AND SIGNAL CABLES

1) M/s ASSOCIATED CABLES 2) M/s ASSOCIATED FLEXIBLES 3) M/s DELTON Cables Ltd, India 4) M/s BROOK 5) M/s KEI Industries Ltd INDIA 6) M/s Suyog Electricals Ltd, India 7) M/s Thermo Cables Ltd 8) M/s Udey Pyrocables Pvt Ltd, India

IV) ZENER BARRIERS/ISOLATORS

1) M/s MTL 2) M/s P & F

V) RTDs 1) M/s General Instruments Ltd., Mumbai 2) M/s Nagman Sensors (Pvt.) Ltd. 3) M/s Pyro Electric, Goa

VI) PRESSURE TRANSMITTERS & DIFF PRESSURE TRANSMITTER

1) M/s Fisher Rosemount (Emerson) 2) M/s Yokogawa 3) M/s Fuji 4) M/s Honeywell

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VII) PRESSURE GAUGES, D. P. GAUGES & TEMPERATURES GAUGES

1) M/s AN Instruments Pvt. Ltd., New Delhi 2) M/s General Instruments Ltd., Mumbai 3) M/s WIKA

VIII) SS VALVES, SS TUBE & SS TUBE FITTINGS

1) M/s Swagelok (USA) 2) M/s Parker (USA) 3) M/s Sandvik, Sweden

IX) JUNCTION BOXES AND CABLES GLANDS 1) M/s EX-PROTECTA 2) M/s FLAMEPROOF CONTROL GEARS 3) M/s BALIGA 4) M/s FLEXPRO ELECTRICALS

X) PUSH BUTTONS/LAMPS:

1) L&T 2) SIEMENS

XI) MCB’S:

1) HAVELL’S 2) INDO ASIAN 3) MDS

XII) RELAYS:

1) OEN 2) JYOTI

XIII) POWER SUPPLY UNIT:

1) ELNOVA 2) APLAB

XIV) CONTROL ROOM EQUIPMENT / CONTROL PANEL & ACCESSORIES

1) M/s Keltron Controls Ltd., Kerala 2) M/s RITTAL 3) M/s Pyrotech 4) M/s Positronics Pvt. Ltd. 5) M/s ABB Instruments Ltd., New Delhi 6) M/s Emerson Process Management (I) Pvt. Ltd. 7) M/s Rockwell Automation (I) Ltd., Ghaziabad 8) M/s Siemens Ltd. 9) M/s Tata Honeywell Ltd.

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XV) INDICATORS/CONTROLLERS/RECORDERS

1) M/s ABB 2) M/s YBL 3) M/s EUROTHERN 4) M/s TATA HONEYWELL 5) M/s MASIBUS

XVI) ALARM ANNUNCIATOR

1) PROCON 2) IIC

XVII) PLC

1) M/s Siemens 2) M/s Yokogawa 3) M/s ABB 4) M/s Rockwell 5) M/s GE

XVIII LEVEL TRANSMITTERS cum GAUGES

1) M/s Emerson 2) M/s Yokogawa 3) M/s Fuji 4) M/s Honeywell 5) M/s SB Electronics 6) M/s LEVCON 7) M/s CHEMTROL

Note-1 For procuring bought out items from vendors other than those listed above, the same may be acceptable subject to the following: - a) The vendor/ supplier of bought out item(s) is a regular and reputed

manufacturer/ supplier of said item(s) for intended services and the sizes being offered is in their regular manufacturing/ supply range.

b) The vendor/ supplier should not be in the Holiday list of GAIL. c) Should have supplied at least 50% of required quantity or minimum 1 number

whichever is higher of maximum size and rating of item(s) as required for intended services.

The bidder should enclose documentary evidences i.e. PO copies, Inspection Certificate etc. for the above, along with their bids.

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Note-2 For any other item(s) for which the vendor list is not provided, bidders can supply those item(s) from reputed vendors/ suppliers who have earlier supplied same item(s) for the intended services in earlier projects and the item(s) offered is in their regular manufacturing/ supply range. The bidder is not required to enclose documentary evidences (PO copies, Inspection Certificate etc.) along with their offer, however in case of successful bidder these documents shall be required to be submitted by them within 30 days from date of Placement of Order.

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