Technical Specifications Package a Vol 1

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CHECK LIST (FOR TECHNICAL PART) TO BE FILLED IN AND SUBMITTED BY BIDDERSALONG WITH TECHNO COMMERCIAL BID

Name of theBidder

Enquiry No.& Date

IS-1-10-2009

Name of thework

KPCL-1X700 MW BELLARY THERMAL POWER STATIONIN PLANT COAL/ASH HANDLING PLANT

SL.NO CLAUSE BHEL REQUIREMENT ACCEPTANCE /

CONFIRMATION BYBIDDER

1 Understanding ofJob

Bidder to confirm that they understood the nature of job, scope of work and tender requirements and theirresponsibilities

2 Site visit andacquiring ofknowledge andinformation about

site conditionsand work involved

Bidder to submit a declaration in a specific confirmingthat they have visited the site and acquired fullknowledge and information about the site conditionsand work involved and will not raise any claim of any

nature due to lack of knowledge of site conditions.

3 Completeness oftender document

Bidder to check and confirm the completeness oftender document. (Discrepancy if any shall be broughtto notice of purchaser/ Engineer before submission ofbid for necessary clarification)

4 TechnicalDeviation

Bidder to confirm that all the requirements as per NIThas been considered in their offer and " No Technicaldeviation" made.

5 List ofequipments, T&P

available

Bidder to submit a list of equipments and T&P'savailable with them for deployment in this job

6 Minimumrequirement ofequipments andT&P's

Bidder to confirm that the minimum requirement ofequipments and T&P's as specified in the tender willbe provided.

7 Program fordeployment ofminimumrequirement ofequipments andT&P's

Bidder to submit the program for deployment of theminimum requirement of equipments and T&P's

8 Minimumrequirement site

management andsupervisory staff

Bidder to confirm that the minimum requirement of sitemanagement and supervisory staff as specified in the

tender will be provided.



BHEL-ISG

Coal/Ash Handling PlantCivil & Structural Works

KPCL1x700 MW BELLARY THERMAL

POWER STATION

Pre-qualification criteriaSpecification No.:

IS-1-10-2009

ISSUED BY – BG 1-A REV NO. 0 DATE OF ISSUE: SHEET 1/1

PRE-QUALIFICATION CRITERIA

Sl No. BHEL Requirement

1

2

3

4

5

6

1

2

The Bidder should have successfully executed the followingworks within last 7 years:

Bidders should have successfully executed Basement typestructures for Wagon Tipplers or Tunnels or Hoppers or industrialbuildings or other underground constructions. All these works shallbe at least 12m below the ground level involving deep excavation,extensive dewatering .

Experience of executing RCC concreting of 30,000 CUM of industrialtype civil works under single/multiple contracts.

Bidders should have successfully executed 3 nos. of RCC silos ofminimum 1000 CUM capacity OR suitable number of Silosamounting to Total capacity of 3000 CUM.

Construction of Silos should have been done using Slip formtechnology.

Bidder should have fabricated and erected around 6000 tons of

structural steel in one single contract.

Minimum Average turnover of INR 200 Cr. during last threeconsecutive financial years.

General RequirementDocumentary evidence such as attested copy of award letter / contract and also completion certificates / performance certificates ofprevious works executed by him giving name and address of clients,value of each of the works done, completion period, date ofcompletion should be submitted by the Bidder

The Bidder shall submit Annual report including Audited AnnualFinancial Reports for last three (3) consecutive financial years insupport of their meeting the stipulated financial requirements. TheBidder shall submit a certificate from Chartered Accountant, showingturn over for the last three (3) consecutive financial years, dulynotarized in support of their financial requirements



BHEL-ISG

Coal Handling PlantCivil & Structural Works

KPCL

1x700 MW BELLARY THERMAL

POWER STATION

Document No.IS-1-10-2009

Sh. -1 / 1 Rev. : R0

PACKAGE A

CHP CIVIL & STRUCTURAL WORKS

SL. NO. DESCRIPTION SECTIONS

1 VOLUME 1A,B,C,D (D1,D2)

,E,F,G,H

2 VOLUME 2 A,B,C,D,E



BHEL-ISG


KPCL


POWER STATION


Sh. -1 / 1 Rev. : R0

VOLUME – 1



BHEL-ISG Technical specificationsfor


KPCL


POWER STATION

CONTENTS VOLUME-1


Sh. -1 / 1 Rev. : R0

SECTION NAME OF SUB-HEAD NUMBER OF PAGES

SECTION –A SCOPE OF WORK 9

SECTION –B SPECIAL CONDITIONS OF CONTRACT 21

SECTION –C TIME OF COMPLETION AND WORK SCHEDULE 1

SECTION –D MINIMUM REQUIREMENT OF EQUIPMENTS

- D1 CIVIL EQUIPMENT LIST 2

-D2 STRUCTURAL EQUIPMENT LIST 2

SECTION – E MANPOWER REQUIREMENT 1

SECTION – F GENERAL CONDITIONS OF CONTRACT 39

SECTION –G HSE 79

SECTION –H PRICE SCHEDULE 7



BHEL-ISG Technical Specificationsfor


KPCL


POWER STATION

VOLUME – 1


Sh. -1 / 1 Rev. : R0

SECTION– A

SCOPE OF WORK






POWER STATION

Scope of WorkVOLUME-1SECTION- A

Document No.

IS-1-10-2009

Sh. A-2 / 8 Rev. : R0

also placing of counter weight blocks in stacker & Reclaimer machines

2.10 Structural steel works for conveyor galleries, trestles, junction towers, crusherhouse superstructures, cable racks , main plant area& any other buildings/ structures mentioned in the drawings.

2.11 Permanently colour coated steel sheeting over roofs / sides properly screwed orlocked to steel structures of conveyor galleries, Transfer Points, crusher house,etc., all as given in volume-2 of technical specifications.

2.12 Sub grade and base preparation with rubble soling, etc. for Plinth protection, areapaving pavements, grade slabs, etc.

2.13 Brick masonry work in cement mortar at all levels.

2.14 Cement plasters, painting, etc., on internal and external walls.

2.15 Steel / aluminum doors, windows and ventilators including glazing, etc. complete.2.16 Painting of str. Steel members, plastered walls, doors, windows, etc.

2.17 All types of floor finishing such as IPS, Ironite, etc.

2.18 Damp proofing and cement / chemical grouting of underground structures.

2.19 Roof water proofing treatment, over / under deck roof insulation,Roof gutters andrain water down comer pipes.

2.20 Plinth protection, garland drains, storm water drains connected to nearestexisting drains / final disposal point, as required.

2.21 All sanitary and sewage fittings and plumbing work for water supply andsewerage.

2.22 Septic tanks, soak pits, sewer lines, inspection chambers, manholes, etc.

2.23 Staircases, walkways, handrails, etc.

2.24 Providing and placement of insert plates, kerb angles, anchor bolts, etc. in RCCmembers including placement of embedment’s supplied free by employer / BHEL and other contractors.

2.25 Cable / pipe trenches and racks. Pipe saddle supports.

2.26 Roads, pavements, drains, drain pits, culverts, etc.






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2.27 Civil works for dust suppression system, Dust extraction system, service water,potable water, cooling water lines etc.

2.28 Surveying, geotechnical investigations, field and laboratory testings, etc., ifnecessary.

2.29 Area clearance, leveling and grading.

3.0 The works covered in the contract shall include supplying of all materials (exceptmaterials free by BHEL and other contractors), labour, tools, plant andequipments, transportation, fabrication, supervision, construction as per drawings

including embedment of bolts, inserts, leaving holes, pockets, grooves, chamfersas shown therein and all incidental items not shown or specified but reasonablyimplied and necessary for satisfactorily completing the project as a whole.

4.0 It is not the intent to specify completely herein all details of design andconstruction of the works covered under this specification. All works shall bedone as per Volume-2- Technical specifications for coal handling system atBellary and as per approved construction drawings and in a manner acceptableto "Engineer”, who shall have the power to reject any work or material which inhis judgment is not in full accordance therewith. In case of any conflictregarding the interpretation of the intent or meaning of the specifications ordrawings, Engineer shall interpret such intent or meaning, which will be final and

binding on the contractor.

5.0 The scope of work shall include detailed engineering for civil and structuralworks ( except for the electrical buildings, DS pump houses, wagon tippler shedand coal storage area) including preparation of fabrication drawings for str. steelworks, submission and obtaining approvals on designs, drawings and otherengineering documents from all the approval authorities involved includingstatutory authorities, where applicable .

6.0 The scope of work also includes attending meetings at Owner / Consultant'soffices ( Project site / Chennai / Delhi / Bangalore ) or at places decided byOwner as and when necessary for review, discussions, co-ordination, etc.

7.0 The scope of work also includes collection and transportation of materialssupplied, if any, by the Owner / Purchaser from his stores located in the plantsite.

8.0 The scope of work includes making all necessary arrangements for access to thestorage yard from the nearest approach roads and further to the actual site ofwork including dewatering, as necessary, and maintenance of the same in order






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to facilitate transportation of machinery and equipment such as cranes, etc.Refurbishment of existing access roads, if necessary, shall also be done byContractor at no extra cost.

9.0 The scope of work also includes checking the adequacy and doing theappropriate modifications in some of the structures of the existing CHP forinterconnection with the new CHP.

10.0 The scope of work shall include all other works not specifically mentioned abovebut necessary for the satisfactory completion of the project as a whole.

11.0 The Contractor shall be fully responsible for arranging all materials to meet

the requirements of the project (except those supplied by the purchaser).Structural steel & reinforcement steel shall be procured only from SAIL/TISCOor approved equivalent.

12.0 STRUCTURE / BUILDING WISE SCOPE OF CIVIL& STRUCTURAL WORKS:12.1 The structures / buildings required for the CHP are described in the Technical

specifications of Volume-2. The plant layout and the flow diagram are alsoappended therein.

12.2 Detailed drawings viz., plant layout, flow diagrams, longitudinal profiles along theconveyor galleries, electro – mechanical and civil assignment GA (GeneralArrangement) drawings will be submitted and got approved by the plantequipment contractor and those drawings shall then be the design reference

base drawings for the Civil & Structural contractor’s detailed engineering.12.3 Tentative basic dimensions for major structures / buildings of the CHP, are

summarized in the tabular statement below for a quick ready reference.






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13.0 BASIC DIMENSIONS OF MAJOR STRUCTURES / BUILDINGS:-

SL.No.

ITEM

U N I T

Q U A N T I T Y

L E N G T H

I N M

W I D T H I N

M H E I G H T I N

M R E F E R A N

C E

A STACKER RECLAIMER1 STACKER & RECLAIMER

FOUNDATION FORCONVEYOR 32

LOT 1

2 STACKER & RECLAIMERFOUNATION FOR CONVEYOR

34

LOT 1

B CRUSHER HOUSE- STAIR

BAY & GRAVITY TAKE UP UNIT TOBE CONSIDERED EXTRA

1 PRIMARY CRUSHER HOUSE LOT 1 35 18 32.52 SECONDARY CRUSHER

HOUSELOT 1 32 18 35

C JUNCTION TOWER –STAIR BAY & GRAVITY TAKE UPUNIT TO BE CONSIDERED EXTRA

1 JUNCTION TOWER: 12 LOT 1 13 10 27




5 JUNCTION TOWER: 16 LOT 1 19.5 18 206 JUNCTION TOWER: 17 LOT 1 15.5 11 177 JUNCTION TOWER: 18 LOT 1 12 12 11.58 JUNCTION TOWER: 19 LOT 1 15 10.5 169 JUNCTION TOWER: 20 LOT 1 23.5 10.5 18.5

10 JUNCTION TOWER: 21 LOT 1 12 9 1211 JUNCTION TOWER: 22 LOT 1 13 10 2012 MODIFICATION JUNCTION

TOWER: JNT 5

LOT 1

D CONVEYOR1 CONVEYOR 13 B LOT 1

2 CONVEYOR 13 C LOT 1

3 CONVEYOR 26 A/B LOT 1

REFER TENDERDRAWINGS

4 CONVEYOR 27 A/B LOT 16 CONVEYOR 28 A/B LOT 1


10 CONVEYOR 30 A/B LOT 111 CONVEYOR 31 LOT 112 CONVEYOR 32 LOT 113 CONVEYOR 33 A/B LOT 114 CONVEYOR 34 A/B LOT 115 CONVEYOR 35 LOT 116 CONVEYOR 36 LOT 1






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REFER TENDERDRAWINGS




21 CONV 14 A/ B EXTN. LOT 1

E UNDERGROUNDTUNNELS

1 U/G TUNNEL- CONV 35 LOT 1 552 U/G TUNNEL- CONV 36 LOT 1 553 U/G TUNNEL- CONV 13 B LOT 1 604 U/G TUNNEL- CONV 13 C LOT 1 60

F EMERGENCY RECLAIMHOPPER(ERH 2)

LOT 1 8 8 -8

G EMERGENCY RECLAIMHOPPER(ERH 3)

LOT 1 8 8 -8

H WAGON TIPPLER (WT4)-CIV& STR WORKS (Except WTShed)

LOT 1

I WAGON TIPPLER (WT5)-CIV& STR WORKS (Except WTShed)

LOT 1

J PENT HOUSE1 PENT HOUSE 35 LOT 1 5.5 5 62 PENT HOUSE 36 LOT 1 5.5 5 63 PENT HOUSE 13 B LOT 1 5.5 8.7 64 PENT HOUSE13 C LOT 1 5.5 8.7 6

K CABLE RACK &

TRESTLE/CABLETRENCHES

LOT 1

L ROADS AND DRAINS 1 ROADS & SHOULDERS –

Bituminous Roads LOT 1

2 DRAINS LOT 1

M DECANTATION TANK LOT 1

N DRAINAGE SYSTEM INTHE COAL STOCKYARD AREA FOR CONV32 & 34-FROMDECANTATION TANK

TO COAL SETTLINGPOND

LOT 1

O COAL SETTLING POND LOT 1

P MISSELANEOUS 1 BULL DOZER SHED LOT 12 LIGHTING MAST NOS. 153 CIVIL WORKS FOR DUST

EXTRACTION SYSTEMLOT 1






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4 CIVIL WORKS FOR YARD

LIGHTING IN COAL STOCKAREA AND TOWER

LOT 1

5 TOILETS AND SEWARAGESYSTEM

LOT 1

6 CIVIL WORKS FOR LAYINGPIPE LINE FORDS/SW/DW/CW

LOT 1

7 CIVIL WORKS FOR LAYINGCABLE IN STOCK YARD ANDOTHER AREAS

LOT 1

9 DISMANTLING WORKS IFANY AS PERSPECIFICATIONS

LOT 1

10 SUPPLYING OF RCC

COUNTER WEIGHTS FORCONVEYOR SYSTEM

LOT 1

11 PLACING OF COUNTERWEIGHTS FOR CONVEYORSYSTEM

LOT 1

12 SUPPLYING OF RCCCOUNTER WEIGHTS FORSTACKER RECLAIMER

LOT 2

13 PLACING OF COUNTERWEIGHTS FOR STACKERRECLAIMER

LOT 2

14 PROVIDING & PLACING OFRCC COUNTER WEIGHTSFOR WAGON TIPPLER

LOT 2

BHEL-SITE OFFICE LOT 1BHEL-COVERED STORE LOT 1

BHEL-OPEN STORE LOT 1

SITE LEVELLING ANDGRADING AS REQUIRED ASSPECIFICATION

LOT 1

Note The dimensions mentioned above are based on the tender drawings which areindicative and minimum. It may vary to any extent during detail engineering.Quoted price by the bidder shall cover for variation if any upto ±15% in thesizes.






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14.0 TERMINAL POINTS:

Terminal points for the coal handling plant shall be as per attached NIT specifications,

and clarifications of KPCL given in VoLume-2.

15.0 LIST OF ENCLOSURES in Volume -2:

Following documents are an integral part of this tender:

1. KPCL BID SPECIFICATIONS

2. KPCL errata to bid specifications

3. KPCL pre-bid queries technical-critical

4. KPCL pre-bid queries technical-non critical

5. Tender drgs.

6. Geo-technical investigation report.

Special Note : Bidder to note “no deviation” from the Errata to bid-specifications, pre-bid

queries technical-critical and non critical in volume 2, shall be applicable unless and until

written approval from customer KPCL/ BHEL has been accorded. Bidder shall submit a signed

copy of BHEL’s tender documents as technical offer along with the technical bid without any

deviations.





KPCL


POWER STATION

VOLUME – 1


Sh. -1 / 1 Rev. : R0

SECTION– B

SPECIAL CONDITIONS OF CONTRACT





KPCL 1x700 MW BELLARY THERMAL POWER

STATION

Special Conditions ofContract

Volume -1Section - B


Sh. B-1 / 21 Rev. : R0

GENERAL SCOPE OF WORK

This tender specification includes detail design, engineering, supply of all materials,construction of all civil, structural & architectural works of Coal Handling plant on lumpsum basis except for the electrical buildings, DS pump houses, wagon tippler shed andcoal stockyard area. The scope of work for the electrical buildings, DS pump houses,wagon tippler shed and coal stockyard area comprises of the supply and construction ofall civil, structural, architectural and finishing works on unit rate basis, detail engineering ofwhich shall be done by BHEL for proper and successful execution of the job for CoalHandling Plant of 1x 700 MW Bellary TPS UNIT 3 , DIST : Bellary.

The detailed scope of work and the technical requirements for the work to be executedunder this specification shall be as per the approved drawings, technical requirementsenclosed in section-H.

The detail scope of work covered in the Section A is not a comprehensive list of items ofwork involved. The detail scope of work may vary considerably depending on the actualrequirements at site as per the requirements of the customer if any.

ALSO INCLUDED IN THE SCOPE:

Unless otherwise specified, the work to be provided by the contractor for the itemsmentioned in the Section H shall include but not be limited to the following:

a) Furnishing all labour, materials, supervision, construction plans, equipment, supplies,

transport to & from the site, fuel, electricity, compressed air, water, transit and storageinsurance and all other incidental items and temporary works not shown on specifiedbut reasonably implied or necessary for the proper completion, maintenance andhanding over the works, except in accordance with the stipulations laid down in thecontract documents and additional stipulations as may be provided by the engineerduring the course of works.

b) Furnishing samples of all materials required by the engineers for testing/inspection andapproval for use in the works as in the technical specification Volume II, section C3(Quality Assurance). The samples may be retained by the engineer for finalincorporation in the works.

c) Furnishing test reports for the products used or intended to be used, if called for in thespecifications or if so desired by the engineer.

d) Giving all notices, paying all fees, taxes etc., in accordance with the general conditionsof contract, that is required for all works including temporary works.

e) Arranging manufacturer’s supervision for items of work done as per manufacturer’sspecifications when so specified.

f) Carrying out required survey and establish levels and coordinates at suitable intervalsfrom existing grid levels and coordinates furnished by the owner established benchmarks, setting out the locations and levels of proposed structures, constructions and






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Sh. B-2 / 21 Rev. : R0

marking of reference pillars and other identifications works etc as required. Thecontractor shall provide the owner/BHEL such an assistance, instruments, machines,

labour and materials as are normally required for examining, measuring and testingany work for quality, weight or quantity of any material used.

g) Providing all incidental items not shown or specified but reasonably implied ornecessary for the successful completion of the work in accordance with contract.

BHEL / ISG is an ISO 9001-2000, ISO 14001-1996 and OHSAS 18001-1999 certifiedcompany. Quality of work to customer’s satisfaction and system requirements is theessence of these certifications. The contractor in all respects will organize his work,systems, environment, process control documentation, tools, plant, inspection, measuringand testing equipments etc., as per instructions of BHEL engineer.

The contractor shall also comply with applicable legislation and regulations with regard to

health, safety and environmental aspects for minimizing risk arising from occupationalhealth, safety hazards, controlling pollution and wastages.

The customer M/s. KPCL and/ or their consultant may depute their representative forchecking and supervision of important stages of work. The contractor shall be required toprovide all facilities for inspection of works at no extra cost to BHEL. Any defect in qualityof work or deviations from drawings/specifications pointed out during such inspection shallbe made good by the contractor in the same way as if pointed out by the BHEL Engineer,without any cost implications to BHEL.

INSTRUCTION TO TENDERERS:

The tenderers are advised to physically visit the site and fully acquaint themselves withsite conditions, transportation routes, various distances and the fact that other contractorswould be working in this area and that their structures are to be protected. The materialbrought and stacked for construction should not make hindrance to other contractors.Necessary precaution and arrangements including sprinkling of water during work asacceptable to BHEL for safety & security for the above have to be made by the contractor.No claim will be entertained by BHEL on ground of lack of knowledge and the contractor’srates shall be deemed to have taken this into account.

The contractor, in the event of this work awarded to him, shall establish an office at siteand keep posted an authorised, responsible officer with valid Power of Attorney for thepurpose of the contract. Any order or instructions of the engineer or his duly authorisedrepresentative, communicated to the contractor’s representative at site office will bedeemed to have been communicated to the contractor at his legal address.

CONTRACTOR’S SUPERVISION:

The contractor shall deploy adequate site supervision personnel. List of minimum






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Sh. B-3 / 21 Rev. : R0

requirement of supervisor personnel is enclosed. Bidder to confirm deployment of abovepersonnel as enclosed. Bidder to confirm deployment of above personals in case of award

of work. Bidder also to confirm & provide additional persons as per site requirement.

If the contractor fails to appoint a suitable engineers as aforesaid, BHEL engineer shallhave full powers to suspend the execution of work and stop payment of any money thatmay have become due until such date as a suitable engineers are appointed and thecontractor shall be held responsible for the delay caused to the work and no extension oftime on this account shall be given to him.

Orders given to the contractor’s engineers shall be considered to have the same force asif they had been given to the contractor himself.

The contractors’ engineers or his agent shall be in attendance at the site during all working

hours and shall superintend the execution of work with such additional assistance in eachgrade as the engineer may consider necessary.

The contractor or their engineers shall attend, when required and without making anyclaim for doing so, either the office of the engineer or the work site to receive instructions.

The BHEL engineer shall have full powers to instruct the contractor to arrange forimmediate termination of services in connection with this contract, of any agent, servant oremployee whose continued employment is, in his opinion, undesirable without assigningany reason.

SUPERVISORY STAFF AND WORKMEN:

The contractor shall deploy all the experienced skilled, semi skilled and unskilled workmenrequired for all the works under this specification. BHEL reserves the right to decide onthe suitability of the workers and other personnel who will be deployed by the contractor.BHEL reserves the right to insist on removal of any employee of the contractor at anytime, if they find him unsuitable and the contractor shall forth with remove him.

The supervisory staff including qualified engineers deployed by the contractor shall ensureproper out-turn of work and discipline on the part of the labour put on the job by thecontractor and in general see that the works are carried out in a safe and proper mannerand in coordination with other labour and staff deployed directly by BHEL or othercontractors of BHEL / BHEL’s client / other agency.

The work shall be executed under the usual conditions like rain, insufficient space,improper approach roads etc., effecting major construction work and in conjunction withnumerous other operations at site. The contractor and his personnel shall cooperate withother personnel/contractor, coordinating his work with others and proceed in a mannerthat shall not delay or hinder the progress of work as a whole.






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Sh. B-4 / 21 Rev. : R0

The contractor’s supervisory staff shall execute the work in the most substantial and

workman like manner in the stipulated time. Accuracy of work and aesthetic finish areessential part of this contract. The contractor shall be responsible to ensure that assemblyand workmanship conform to the dimensions and tolerances given in thedrawings/documents/instructions given by BHEL engineer from time to time.

It is the responsibility of the contractor to engage his workmen in shifts or on overtimebasis for achieving the targets set by BHEL. The contractor’s finally accepted rates shallinclude all these contingencies.

During the course of construction, if the progress is found unsatisfactory, or in the opinionof BHEL, if it is found that the skilled workmen like welder, fitters, technicians etc.deployed are insufficient, BHEL after giving reasonable opportunity to the contractor,

will induct on the work the required workmen in addition to contractor’s workmen toimprove the progress and recover from the contractor’s bills.

If the contractor or his workmen or employees shall break, deface, injure or destroy anypart of a building, road kerb, fence, enclosure, water pipes, cables, drains, electric ortelephone posts or wire, trees or any other property or to any part of erected componentsetc., the contractor shall make the same good at his own expense or in default, BHELmay cause the same to be made good by other workmen or by other means and deductthe expenses (of which BHEL’s decision will be final) from any money due to thecontractor.

The month-wise manpower deployment plan to be submitted to BHEL and is only to

assess the capability as well as understanding of the contractor to execute the work. Itshall be the contractor’s responsibility to deploy the required manpower, for timely andsuccessful completion of the job, to any extent over and above those indicated in theabove deployment plan (including those which are not covered in the plan submitted)without any compensation on this account.

TOOLS AND PLANTS AND MACHINERY / IMTE’s:

Providing of required Tools and plants and machinery for executing the subject work is theresponsibility of Contractor. Minimum requirement of tools and plants and machinery isspecified in section-D of tender document.

In the event of failure of contractor to bring necessary and sufficient T&Ps & Machinery,BHEL will be at liberty to arrange the same at the risk and cost of contractor includingtransportation cost of same from any of BHEL site/place and hire charges as applicableshall be deducted from contractor’s bill. Decision of BHEL in this regard shall be final andbinding on contractor.






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All distribution boards, connecting cables/welding cables, wire ropes, hoses etc., including

temporary air/water/electrical connectors etc., shall have to be arranged by the contractorat his own cost.

The contractor shall engage trained and experienced operators for the operation of T&Psand machinery. BHEL engineer will check their skill and performance before they areallowed to operate the same. However, checking of skills by BHEL does not absolve thecontractor of his responsibilities for proper and safe handling of equipment, consistentgood performance of operators and regular performance evaluation of operators.

The day to day and routine maintenance of T&Ps and machinery should be carried out bycontractor and these shall be maintained in good working condition during the entireperiod of use. T&Ps in defective/damaged condition shall be rectified promptly to the full

satisfaction of BHEL engineer. Contractor shall maintain records for maintenance ofmajor T&Ps which shall be made available for inspection whenever required. In case ofany lapses on the part of the contractor, BHEL at its own discretion get theservicing/repair of equipment done at the risk and cost of the contractor with BHELoverheads.

The contractor shall arrange all spares needed for upkeep of all T&Ps and machinery. Forcranes, contractor shall arrange spares for repair/replacement of filter, batteries, self start,dynamo, gaskets, hoses, oil seals and rubber parts.

The contractor shall permanently deploy with them minimum number of mechanics andskilled workers for undertaking the regular maintenance of tools and plants and machinery

and for increasing / shortening of the crane boom as required. The contractor shall alsoarrange required tools, supports, consumables, illumination etc. for the above purpose.

The contractor shall arrange for consolidation of ground and arrangement ofsleepers/sand bag filling etc. for safe operation / movement of equipment includingcranes/trailers etc. at his cost.

In the event of BHEL arranging T&P’s and Machineries at the cost and risk of contractor,any loss / damage to any part of T&Ps and machineries provided by BHEL shall be to thecontractor’s account and any expenditure on these accounts by BHEL will be recoveredfrom the contractor’s bill in case the contractor fails to make good the loss.

Further it shall be the responsibility of the contractor to take delivery of T&Ps from storesor place of use by other contractor at project site, transport the same to site and returnthe same to BHEL store/place as intimated by BHEL Engineer in project site in goodworking conditions after use.

Contractor shall ensure deployment of serviced and healthy T&Ps including cranes, lifting






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Sh. B-6 / 21 Rev. : R0

tackles, wire ropes, manila ropes, winches and slings etc. History card and maintenancerecords for major T&Ps will be maintained by the contractor and will be made available

to BHEL engineer for inspection as and when required. Identification for such T&Ps willbe done as per BHEL Engineer’s advice.

Contractor shall ensure deployment of reliable and calibrated IMTEs (InspectionMeasuring and Test Equipment). The IMTEs shall have test/calibration certificates fromauthorised / Govt. approved / accredited agencies traceable to National / Internationalstandards. Each IMTE shall have a label indicating calibration status i.e., date ofcalibration, calibration agency and due date for calibration. A list of such instrumentsdeployed by contractor at site with its calibration status is to be submitted to BHELengineer for control.

Retesting / re-calibration shall also be arranged at regular intervals during the period of

use as advised by BHEL Engineer within the contract price. The contractor will also havealternate arrangements for such IMTE so that work does not suffer when the particularinstrument is sent for calibration. Also if any IMTEs not found fit for use, BHEL shallhave the right to stop the use of such item and instruct the contractor to deploy properitem and recall i.e., repeat the readings taken by that instrument, failing which BHELmay deploy IMTEs and retake the readings at contractor's ’cost.

BHEL shall have lien on all T&P, IMTEs and other equipment of the contractor brought tothe site for the purpose of erection, testing and commissioning. BHEL shall continue tohold the lien on all such items throughout the period of contract. No material brought tothe site shall be removed from the site by the contractor and/or his sub-contractors withoutthe prior written approval of the engineer.

The contractor shall submit month-wise T&P deployment plan. It is only to assess thecapability as well as understanding of the contractor to execute the work. However it shallbe the contractor’s responsibility to deploy the required T&Ps, for timely and successfulcompletion of the job, to any extent over and above those indicated in the abovedeployment plan (including those which are not covered in the plan submitted) without anycompensation on this account.

MATERIALSThe contractor shall at his own expenses provide all construction materials required for thework.However BHEL will supply Structural steel & Reinforcement steel free of cost as per

following terms & conditions:

CHP

For CHP, BHEL will supply maximum of 7000 MT of structural steel and maximum of 3500

MT of reinforcement steel.






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Sh. B-7 / 21 Rev. : R0

AHPAll structural & reinforcement steel required for AHP shall be supplied by BHEL free of

cost.

The section-wise details are enclosed as a part of this Section.

All other materials to be provided by the contractor shall be of the best kind in conformitywith the specifications laid down in the contract or as per relevant Indian standards andtechnical specification, if requested by the engineer, furnish proof to the satisfaction ofengineer that the materials so comply as per the quality assurance given in Volume II, ofKPCL technical specifications.

The contractor shall, at his own expenses and without delay, supply to the engineersamples of materials proposed to be used in the works. The engineer shall within seven

days of supply of samples or within such further period as he may require will intimate tothe contractor in writing, whether samples are approved by him or not. If samples are notapproved, the contractor shall forthwith arrange to supply to the engineer for his approvalfresh samples complying with the specifications laid down in the contract. Any delay inapproval of samples (original or fresh ones) shall not make the contractor eligible for anycompensation.

The BHEL engineer shall have full powers for removal of any or all of the materialsbrought to site by the contractor which are not in accordance with the contractspecifications or do not conform in character or quality to samples approved by him. Incase of default on the part of the contractor in removing rejected materials, the engineershall be at liberty to have them removed by other means. The BHEL engineer shall have

full powers to procure other proper material to be substituted for rejected materials and inthe event of the contractor refusing to comply, he may cause the same to be supplied byother means. All costs, which may attend upon such removal and / or substitution, shall beborne by the contractor.

The contractor shall indemnify BHEL, its representatives or employees against any action,claim or proceeding relating to infringement or use of any patent or design or any allegedpatent or design rights and shall pay any royalties or other charges which may be payablein respect of any article or material or part thereof included in the contract. In the event ofany claim being made or action being brought against BHEL or any agent, servant oremployee of BHEL in respect of any such matters as aforesaid, the contractor shallimmediately be notified thereof, provided that such indemnity shall not apply when suchinfringement has taken place in complying with the specific directions issued by BHELbut the contractor shall pay any royalties or other charges payable in respect of anysuch use, the amount so paid being reimbursed to the contractor only if the use wasthe result of any drawings and / or specifications issued after submission of the tender.

The engineer shall be entitled to have tests carried out as specified in the contract for






STATION




Sh. B-9 / 21 Rev. : R0

c) Balance steel shall be returned to BHEL in good condition and in acceptable length /

size as mentioned below.i) Any rolled steel sections other than plates : 1.00 Mtrs (or) longerii) Plates : Minimum width of 0.3 Mtr and length not less than 1.00 Mtrs

d) Quoted price by the contractor shall be deemed to include the above and thepermissible wastages mentioned. No claim whatsoever shall be entertained on accountof wastage and difference in weight as referred to above.

Issue of stores material is subject to availability and the contractor shall not be entitled toany claim or compensation for non supply or delay in the supply under any circumstances.The material will be issued generally during the working hours.

The contractor shall submit proper account of material / material reconciliation statementfor the material drawn by him from stores once in every month along with running accountbill. Failing compliance of this requirement further issue of steel to the contractor may besuspended and no claim of compensation for delay in execution on this account shall beentertained.

Any unused / serviceable quantity of structural steel not returned in good condition &wastages/loss/consumption beyond specified/agreed limits shall be charged at penal rate.

EXECUTION OF WORK

The work shall be executed in a workman like manner and to the entire satisfaction of the

engineer and as per technical specification issued with tender, IS codes, CPWDspecifications as applicable. In case of conflict, the decision of the engineer shall be finaland binding.

The engineer will communicate or confirm his instructions to the contractor in respect ofthe execution of the work in a “Work Site Order Book” maintained at his office and thecontractor shall visit this office daily and shall confirm receipt of such instructions bysigning the relevant entries in this book. Such entries will rank as order or notices inwriting within the intent and meaning of these conditions.

Only BHEL approved make of electrodes will be used. All electrodes shall be heatedand dried in the electric electrode drying oven to the required temperature for theperiod specified by the engineer before these are used in erection work. All weldersshall have electrodes drying portable oven at the work spot. The electrodes brought tosite will have valid manufacturing test certificates. The test certificate will have co-relationwith the lot no. / batch no. given on electrode packets. No electrodes will be allowed tobe used in the absence of above requirement. The thermostat and thermometer ofelectrode drying over will be also calibrated and test certificate from Govt.,






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Sh. B-10 / 21 Rev. : R0

approved/accredited test house traceable to National / International standards will besubmitted to BHEL before putting the over in use. Periodical calibration for the same

shall also be arranged by the contractor within the finally accepted rates.

SETTING OUT :

All the works shall be set out to the true lines, grades and elevation indicated on thedrawing. The contractor shall be responsible to locate and set out the works. Only onegrid reference line and bench mark all be made available for setting out the works underthe contract. This reference lines shall be used as datum for the works under thecontract and the contractor has to establish for his work area at available pointshorizontal and vertical control points. The contractor shall inform BHEL well in advanceof the times and places at which he wishes to do work in the area allotted to him so thatsuitable datum points established by him are checked by BHEL / customer to enable the

contractor to proceed with the works. Any work done without being properly locatedmay be removed and / or dismantled by BHEL / customer at contractors expense.

The contractor shall at his own expense take all proper and responsible precautions topreserve and maintain these datum marks to its true position. In the event of thesemarks being disturbed or obliterated by accident or due to any other cause whatsoever,the same may be deemed necessary placed by BHEL / customer at contractor’sexpenses.

SITE DRAINAGE

All water including sub-soil water which may accumulate on the site during the progress

of the works, including monsoon period shall be removed by the contractor from the siteto the satisfaction of the engineer. All such expenditure on de-watering shall be deemedto be included in quoted rates.

INSPECTION AND STAGE APPROVAL OF THE WORK :

The owner or his duly authorised representative shall have at all reasonable times accessto the contractor’s premises or works and shall have the power to inspect drawings orany portion of the work, examine the materials and workmanship and shall have theauthority to reject any work. This would be implemented through joint inspection by therepresentative of the owner and BHEL / third party appointed by BHEL and in the form of joint protocols without any extra claims and loss of time and amount.

All work embracing more than one process shall be subject to examination andapproval at each stage thereof and the contractor shall give due notice in writing to theengineer when each stage is ready. In default of such notice being received, theengineer shall be entitled to approve the quality and extent thereof at any time he maychoose and in the event of any dispute, the decision of the engineer thereon shall be






STATION




Sh. B-11 / 21 Rev. : R0

final and conclusive.

UNCOVERING AND MAKING GOOD

The contractor shall uncover any part of the works and/or make openings in or throughthe same as the engineer may from time to time direct for his verification and shallreinstate and make good such part to the satisfaction of the engineer. If any such parthas been covered up or put out of view after being approved by the engineer and issubsequently found on uncovering to be executed in accordance with the contract, theexpenses of uncovering and / or making opening in or through reinstating and makinggood the same shall be borne by BHEL. In any other case all such expenses shall beborne by the contractor.

DISCREPANCIES AND ADJUSTMENT OF ERRORS

The several documents forming the contract are to be taken as mutually explanatory ofone another, detailed drawings being followed in preference to small scale drawings andfigures dimensions in preference to scale and special conditions in preference togeneral conditions.

In case of discrepancies between the specification and/or the drawings, the followingorder of preference shall be observed.

a) Description in Scope.b) Special conditions.

c) Technical specifications.d) Drawings.

If there are varying or conflicting provisions made in any one document forming part of thecontract, the engineer shall be the deciding authority with regard to the document.

Any error in description, quantity in schedule of quantities or any omission there from shallnot vitiate the contract or release the contractor from the execution of the whole or anypart of the works comprised there in according to the drawings and specifications or fromany of his obligations under the contract.

If on check there are found to be differences between the rates given by the contractorin words and figures or in the amount worked out by him in the schedule of quantities andgeneral summary, the same shall be adjusted in accordance with the following rules :

a) In the event of discrepancies between description in words and figures quoted by atenderer, the lesser of the two will be treated as valid rate.






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Sh. B-12 / 21 Rev. : R0

b) In the event of an error occurring in the amount column of schedule of quantities as aresult of wrong extension of the unit rate and quantity, the unit rate shall be regarded

as firm and extension shall be amended on the basis of the rate.c) All errors in totalling in the amount column and in carrying forward totals shall be

corrected.d) The totals of various sections of bill of quantities amended shall be carried over to the

general summary and the tendered sum amended accordingly. The tendered sumso altered shall, for the purpose of tender, be substituted for the sum originallytendered and considered for acceptance instead of the original sum quoted by thetenderer. Any rounding of quantities or in sections of bill of quantities or in generalsummary, by the tenderer, shall be ignored.

e) If neither drawing nor specification contain any mention of minor details ofconstruction which in the opinion of the engineer whose decision shall be final andconclusive, are reasonable and obviously and fairly intended for satisfactory

completion of work, such details shall be provided by the contractor without any extracost, as if they were specially mentioned and shall be deemed to be included in thedrawing.

SAFETY CODE :

Besides provision with regard to safety, contractor shall note that explosives shall not beused on the work by contractor except with permission in writing of the engineer and inmanner and to the extent to which he has prescribed. Where explosives are used, thesame shall be stored in a special magazine to be provided by and at the cost of thecontractor who shall be liable for all damages, losses and injury to any person orproperty and shall be responsible for complying with all statutory obligations in these

respect.

The contractor will be responsible for health, safety and environment management at sitefor the construction activities to be carried out by them in accordance with requirementsgiven under section-I of this tender document.

Contractor shall arrange for following provisions of HSE :

1) Contractor has to maintain contact with local hospital having scanning and othermodern medical facilities required during emergency.

2) Contractor has to ensure pre-employment medical check for all staff and workers3) Contractor has to ensure that adequate first aid facilities with trained nurse and

ambulance are available at work site for emergency purpose. This emergency set-upshould include, but not limited to following :

Male nurse (in shifts)Oxygen set upBreathing apparatus






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Sh. B-13 / 21 Rev. : R0

Eye wash facilityStretcher

Trauma blanketMedicines

The ambulance is required to be arranged and maintained at site and for entire contractperiod for subject work by the successful bidder. This emergency facility set up includingambulance, male nurse etc. will be shared by BHEL and its other contractors working atsame project in case of an need at no extra cost to BHEL and its sub-contractors.

NUISANCE

The contractor shall not at any time do, cause or permit any nuisance on site or doanything which shall cause unnecessary disturbance or inconvenience to owners,

tenants or occupiers of other properties near the site and to the public generally.

MATERIAL OBTAINED FROM EXCAVATION :

Materials of any kind obtained from excavation on the site shall remain the property ofBHEL / its client and shall be disposed of as the engineer may direct at no extra cost.

TREASURE, TROVE, FOSSILS ETC.

All fossils, coins, articles of value or antiquity and structures and other remains or thingsof geological or archaeological interest discovered on the site shall be the absoluteproperty of BHEL / BHEL’s client and the contractor shall take reasonable precautions to

prevent his workmen or any other person from removing or damaging any such articleor thing, shall immediately upon discovery and carryout the engineer’s directions as tothe disposal of the same.

PROTECTION OF WORKS

Trees designated by the engineer shall be protected from damage during the course ofthe works and earth level within 1 meter of each such tree shall not be charged.Where necessary, such trees shall be protected by providing temporary fencing.

The contractor shall provide and maintain at his own expense all lights, guards, fencingand watching when and where necessary or required by the engineer for the protectionof the works or for the safety and convenience of those employed on the works or thepublic.

The contractor shall have total responsibility for protecting his works till it is finally takenover by the engineer. No claim will be entertained by the engineer for any damage orloss to the contractor’s works and the contractor shall be responsible for the complete






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Sh. B-14 / 21 Rev. : R0

restoration of the damaged works to its original condition to comply with thespecifications and drawings. Should any such damage to the contractor’s works occur

because of other party not under his supervision or control, the contractor shall makehis claim directly with the party concerned. The contractor shall not cause any delay inthe repair of such damaged works because of any delay in the resolution of suchdisputes. The contractor shall proceed to repair the work immediately and no causethereof will be assigned pending resolution of such disputes.

RECORD FOR MATERIALS CONSUMED

The contractor shall maintain and furnish to the engineer the record of materialsconsumed in the works for each activity. The statement showing the theoretical vis-à-visactual consumption of specified materials, such as structural steel, grouting compound,paint etc. shall be enclosed along with the running bills submitted by the contractor.

Contractor has to also furnish the test results of the materials used in the work as per ISspecifications.

PROTECTION OF EMBEDMENTS, BOLTS ETC.

The contractor shall ensure proper protection to the satisfaction of the engineer, of allbolts, inserts, embedments etc. from weather etc. by greasing, rapping them withgunny bags or canvas or by any other means as directed by engineer. Cost of suchprotections shall be deemed to be included in the rates quoted for the item.

CLEARANCE OF SITE AND REPAIRS

Contractor has to clear the site/area where mechanical and electrical erection work is tobe commenced or in progress. The contractor shall remove construction materials andequipment lying in the vicinity and causing obstruction in the erection work within 24 hrs.notice. In case, he fails to clear the site, this will be done at his risk and cost by BHEL.

QUALITY ASSURANCE

The contractor shall submit the quality document for approval of BHEL and its client asper the specification and requirement given in KPCL,Technical Specification.

The contractor has to establish / arrange at site the field testing facilities for ensuring theproper quality, grade and strength of the materials used in the construction in line withapproved field quality plan / check list . Contractor has to submit detailed report fortesting of all material used etc. All testing shall be done as per IS code specifications / approved quality plan. If further test is required by the engineer to be carried from outsidelaboratory, the cost of the same shall be borne by the contractor.






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Sh. B-15 / 21 Rev. : R0

COMPLETION OF WORK

The works shall be completed to the entire satisfaction of the engineer and in accordancewith the completion schedule as specified in the contract and all unused stores andmaterials, tools, plant, equipment, temporary buildings, site office, labour hutmentsand other things shall be removed and the site and work cleared of rubbish and all wastematerials and delivered up clean and tidy to the satisfaction of the engineer at thecontractor’s expenses.

BHEL shall have power to take over from the contractor from time to time such sectionsof the work as have been completed to the satisfaction of the engineer. Such workhowever shall not be treated as have been completed until the extra works areexecuted to the satisfaction of engineer. The guarantee period shall commence onlyafter handing over of the entire works.

The engineer shall certify to the contractor the date on which the work is completed andthe date thereof.

RECORDS AND MEASUREMENTS

All items having a financial value shall be entered in BHEL measurement book so that acomplete record is obtained of all works performed under the contract.

Lump sum omissions will be entered for deduction. Measurement shall be restricted tothat required to ascertain the financial liability of BHEL under the contract.

Work which fails to be measured in details shall be measured physically without referenceto any local custom that may obtain excepting where it may otherwise be directed in thetender documents. The measurements shall be taken jointly by any person dulyauthorised on the part of BHEL and by the contractor.

The engineer shall give reasonable notice in writing to the contractor of appointment formeasurement.

The contractor shall, without extra charge, provide assistance with appliances andother things necessary for measurement and shall bear all the cost of measurement ofhis work.

Measurement shall be entered in BHEL Measurement Book and signed and dated byboth parties each day at the site on completion of measurement. If the contractor objectsto any of the measurements recorded on behalf of BHEL, a note to that effect will bemade in BHEL Measurement Book or against the item or items objected to and such noteshall be signed and dated by both the parties engaged in taking the measurement.






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Sh. B-16 / 21 Rev. : R0

If, as a result of such objection, it becomes necessary to re-measure the work wholly or inpart the expense of such re-measurement shall be borne by the contractor.

If the contractor’s representative fails to attend when required, the engineer shall havepower to proceed by himself to take measurements and in that case thesemeasurements shall be accepted by the contractor as final.

The contractor shall, once in every month, submit to the engineer details of his claimsfor the work done by him upto and including the previous month which are not coveredby this contract agreement in any of the following respects :

a) Deviation from the items and specifications provided in the contract documentsb) Extra items/new items of workc) Quantities in excess of those provided in the contract schedule

d) Items in respect of which rates have not been settled

METHOD OF MEASUREMENT

Method of measurements shall be as per standard specifications included in the tender.For other items measurements shall be as per relevant IS codes.

DEVIATION

The contractor shall not make any alteration in addition to or omission from the work asdescribed in the tender documents.

COMPLIANCE TO REGULATIONS AND BYELAWS

The contractor shall conform to the provisions of any statute relating to the work andregulations and bylaws of any local authority and of any water and lighting companies orundertaking with whose system the work is proposed to be connected. He shall, beforemaking any variation from the drawings or the specifications that may be necessitated forsuch connections give the engineer, notice specifying the variation proposed to bemade and the reasons therefore and shall not carryout any variation until he has receivedinstructions from the engineer in respect thereof. The contractor shall be bound to giveall notices required by statute, regulations or bye-laws as aforesaid and to pay all feesand taxes payable to any authority in respect thereof.

FACILITIES TO BE PROVIDED BY BHEL / CONTRACTOR

BHEL shall provide free of charge limited open space, for office and storage shed, asand where made available by M/s.KPCL. It is the responsibility of the contractor toconstruct sheds, provide all utilities and dismantle and clear the site after completion ofwork or as and when required, as a part of his scope of work.






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Sh. B-17 / 21 Rev. : R0

Contractor shall be responsible for providing all necessary facilities like residential

accommodation, transport, electricity, water, medical facilities etc. as required undervarious labour laws and statutory rules and regulations framed there under to thepersonnel employed by him.

Construction power supplied by BHEL will be free of cost and in proportion to the powersupplied by the customer for the entire plant. Construction power will be supplied at onepoint within the plant boundary. Further distribution of power shall be done by contractor athis cost. All wiring must comply with local regulations and will be subject to engineer’sinspection and approval before connecting supply.

Provision of distribution lines of power from the central points to the required place withproper distribution boards observing the safety rules laid down by the authorities of the

state shall be done by the contractor, supplying all the materials like cables, distributionboard, switch board, TPN, CBS, ELCBS, MCCBs, Copper, brass clamps, copperconductor, change over switches, pipes etc. at his own cost. If any failure is caused insupply of the power and water, it is the responsibility of the contractor to make alternatearrangements at his cost. The contractor shall adjust his working shift / hoursaccordingly and deploy additional manpower if necessary so as to achieve the targets.

In case of power cuts / load shedding no compensation for idle labour or extension oftime for completion of work will be given to contractor.

Adequate lighting facilities such as flood lamps, hand lamps and area lighting shall bearranged by the contractor at the site of construction, contractor’s material storage area

etc. Quoted rate by the contractor shall be deemed to include cost of all above work.

Contractor has to arrange for construction water from terminal point given by the employerand shall be free of cost. Contractor shall not use any underground water / borewell forthe construction purposeThe contractor should make arrangements for storage and distribution of sufficientquantity of water required for work.

The contractor shall during the progress of the work, provide, erect and maintain at hisown expenses all necessary temporary workshops, stores, consumables, offices etc.required for the proper and efficient execution of the work. The planning, setting anderection of these buildings shall have the approval of the engineer and the contractorshall at all times keep them tidy and in a clean and sanitary condition to the entiresatisfaction of the engineer.

On completion of work or as and when required by BHEL, all the temporary buildings,structures, pipe lines, cables etc. shall be dismantled and leveled and debris shall beremoved as per instruction of BHEL by the contractor at his cost. In the event of his






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Sh. B-18 / 21 Rev. : R0

failure to do so, same will be got done by the engineer and expenses incurred shall berecovered from the contractor along with prevailing overhead. The decision of BHEL

engineer in this regard shall be final.

DEVIATION

The contractor shall not make any alteration in addition to or omission from the work asdescribed in the tender documents except in pursuance of the written instructions of theengineer. No such deviation from the work described in the tender documents shall bevalid unless the same has been specifically confirmed and accepted by the engineer inwriting and incorporated in the contract.

The engineer may deviate, either by way of addition or deduction, from the work so

described, provided that the contract sum be not thereby varied on the whole by morethan the percentage set our in the tender documents. The value of all additions anddeductions shall be added to or deducted from the contract sum. Whenever the engineerintends to exercise such a right his intentions shall specify the deviations which are to bemade, the lumpsum assessment or the proposed basis of payment, the extra timeallowed, if any, and the date for completion of the entire contract. Any objection by thecontractor to any matter concerning the order shall be notified by him in writing to theengineer within seven days from the date of such order, but under no circumstancesshall the work be stopped unless so ordered by the engineer, owing to differences orcontroversy that may arise from such an objection. In the absence of such a notificationof objection by the contractor, he will be deemed to have accepted the order and theconditions stated therein.

VALUATION OF DEVIATIONS :

Rates for deviated items or new items of work shall be as follows :

If the rates for the additional, altered or substituted work are not specifically provided inthe contract for the work, the rates will be derived from the rates for a similar class ofwork as are specified in the contract for the work.

If the rates for the altered, additional or substituted work cannot be determined in themanner specified in above clauses, the rates for such part or parts will be determined bythe engineer on the basis of prevailing market rates when the work was done and thedecision given in this behalf shall be final and binding on the contract. Rate analysis willbe worked on CPWD manual of rate analysis as guidance.

If the rates for the altered, additional or substituted work cannot be determined in themanner specified in above clauses, then the contractor shall within 7 days of the date ofreceipt of order to carry out the work inform the engineer of the rate at which it is his






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Sh. B-19 / 21 Rev. : R0

intention or charge for such class of work, supported by analysis of the rate or ratesclaimed, and the engineer shall determine the rate or rates on the basis of prevailing

market rates and pay the contractor accordingly. However, the engineer, by notice inwriting, will be at liberty to cancel his order to carry out such class of work and arrange tocarry it out in such manner as he may consider advisable. But under no circumstance thecontractor shall suspend the work on the plea of non-settlement of rates falling under theclause or claim any compensation on that account. Elements of profit, overheads,supervision and establishment charges will be taken as 15% over direct cost.

PROGRESS REPORTING

Contractor is required to draw mutually agreed monthly programme in consultation with

BHEL well in advance. Contractor shall ensure achievement of agreed programmeand shall also timely arrange additional resources considered necessary at no extra costto BHEL.

Weekly progress review meetings will be held at site during which actual progress duringthe week vis-à-vis scheduled programme shall be discussed for actions to be taken forachieving targets. The programme for subsequent week shall also be presented bycontractor for discussions. The contractor shall constantly update/revise his workprogramme to meet the over all requirement. All quality problems shall be discussedduring above review meetings. Necessary preventive and corrective action, shall bediscussed and decided upon in such review meetings and shall be implemented by thecontractor in time bound manner so as to eliminate the cause of non-conformities.

The contractor shall submit weekly and monthly progress reports, materials reports,consumables (gases/electrodes) report and other reports as per proforma considerednecessary by the engineer.

The progress report shall indicate the progress achieved against planned, with reasonsindicating delays, if any, and shall give the remedial actions which the contractorintends to take to make good the slippage or lost time, so that further works againproceed as per the original programme and the slippages do not accumulate and effectthe overall programme.

The daily manpower reports shall clearly indicate the manpower deployed, categorywise specifying also the activities in which they are engaged.DRAWING AND DOCUMENTS

The detailed drawings, specifications available with BHEL engineers will form part ofthis tender specification. These documents will be made available to the contractorduring execution of work at site. The contractor will also ensure availability of all






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Sh. B-20 / 21 Rev. : R0

drawings/documents at work place.

Necessary drawings/documents by BHEL to carryout the construction work will befurnished to the contractor by BHEL (except those proposed to be prepared bycontractor, as mentioned in this contract) on loan which shall be returned to BHELengineer at site after completion of work. Contractor shall ensure safe storage andquick retrieval of these documents.

The contractor shall maintain a record of all drawings and documents available with himin a register as per format given by BHEL engineer. Contractor shall ensure use ofpertinent drawings / data/ documents and removal of obsolete ones from work place andreturn to BHEL.

The data furnished in various annexures enclosed with this tender specification are only

approximate and for guidance. However, the change in the design and in the quantitymay occur as is usual in any such large scale of work.

Should any error or ambiguity be discovered in the specification or information thecontractor shall forthwith bring the same to the notice of BHEL before commencementof work. BHEL’s interpretation in such cases shall be final and binding on thecontractor.

Deviation from design dimensions should not exceed permissible limit. The contractorshall not correct or alter any dimension / details, without specific approval of BHEL.

DELAY AND EXTENSION OF TIME

If, in the opinion of the engineer, the work is delayed :

a) by reason of abnormally bad weather, orb) by reason of serious loss or damage by fire, orc) by reason of civil commotion, local combination of workmen, strike or lockout, affecting

any of the trades employed on the work, ord) by delay on the part of the agency or tradesmen engaged by the BHEL in executing

work not forming part of the contract, ore) by reason of any other cause which in the absolute discretion of the engineer is

beyond the contractor’s control, then in any such case, the engineer (or higherauthority) may make fair and reasonable extension in the completion dates of theindividual items of work or the contract as a whole. Such extension which will becommunicated to the contractor by the engineer in writing shall be final and binding onthe contractor. No other claim in this respect for compensation or otherwisehowsoever is admissible. Upon the happening of any such event causing delay, thecontractor shall immediately give notice thereof in writing to the engineer but shallnevertheless use constantly his best endeavour to prevent or make good the delay






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Sh. B-21 / 21 Rev. : R0

and shall do all that may reasonably be required to the satisfaction of the engineer toproceed with the work.

RATE SCHEDULE VARIATION

Contractor shall fully understand description and scope of work before quoting. Thescope of work and responsibility of the contractor as mentioned under thesespecification shall be covered within the quoted / finally accepted rates.

BHEL Site Office:

Tenderer to construct the BHEL- Site office, Covered store and open storage yard withpaved surface and fencing around the open store.



BHEL-ISGTechnical Specifications

for

Coal Handling Plant

Civil & Structural Works

KPCL


POWER STATION

VOLUME – 1


Sh. -1 / 1 Rev. : R0

SECTION– C

TIME OF COMPLETION AND WORK

SCHEDULE





KPCL 1X700 MW BELLARY THERMAL POWER

STATION

Time of Completion andWork Schedule

Volume -1Section - C


Sh. C-1 / 1 Rev. : R0

1.0 TIME OF COMPLETION AND WORK SCHEDULE

1.01 Time is the essence of the contract. Contractor's particular attention isdrawn to the fact that the given time schedule elsewhere in the commercialconditions for completion of this contract is firm and has to be strictly compliedwith.

The Contractor shall within 2 weeks of the date of award of contract,commence work, submit to the Owner for his approval a detailed workschedule along with a detailed PERT network and BAR charts showing howhe proposes to carryout the work at the required rate specifically mentioning

time period as well as date of completion and such approved schedules mustbe strictly adhered to by the Contractor. The Schedules shall be reviewedperiodically to ensure that the completion date will be met and to instituteall corrective steps such as mobilising additional resources in terms oflabour, materials, equipment, tools and plant, night work etc. at no extra costto BHEL to achieve any accelerated progress at any time to the extentrequired to adhere to the completion dates. BHEL reserves the right torevise the work schedule at his discretion in order to keep up to thecompletion date and to suit the project requirements and such alterationsshall not entitle the Contractor to any extra payment.

1.02 The Contractor shall furnish to BHEL with fortnightly progress reports with

coloured photographs in triplicate on the Saturday of every fortnight in thefollowing format:- _________________________________________________________ Item Schedule for Actual Reason for Steps taken

the fortnight Progress shortfall, to make upif any the shortfall

__________________________________________________________

1.03 In the event of the Contractor failing to furnish the fortnightly reports on time asdetailed in above clause, the running payments shall be withheld till submissionof such reports.

1.04 The Contractor shall not construct his stores, office sheds and labour colonyetc without approval of site and demarcation of land from Client, and also thedate of final completion of works shall be considered as the date when theContractor will demolish all his temporary structures for stores, office sheds andlabour colony hutments etc and clear the debris and handover the area inoriginal good condition.




for

Coal Handling Plant


KPCL


POWER STATION

VOLUME – 1


Sh. -1 / 1 Rev. : R0

SECTION– D

MINIMUM REQUIREMENT OF

EQUIPMENTS






STATION

Equipment list for civilworks

Volume -1Section – D-1


Sh. D1-1 / 3 Rev. : R0

MINIMUM REQUIREMENT OF EQUIPMENTS,INSTRUMENTS AND TOOLS ETC.

FOR CIVIL WORKS TO BE PROVIDED BY THE CONTRACTOR.

SL

NO. DESCRIPTIONQTY UNIT

1L&T Poclain CK 90 Excavator

3no

2JCB excavator

2No.

3Vibratory rollers

2Nos.

4Plate vibrators

4 Nos.

5Escort Crane

1No.

6Dumpers

6Nos.

7Tractor with trailer

2Nos.

8Concrete batching plant

1No.

9Transit Mixer

2Nos.

10 Concrete pump 1 Nos.

11Concrete mixer 7/10 Cft operated

1Nos.

12Concrete weigh batchers

1Nos.

13Concrete immersion vibrators

8Nos.

14Air Compressors

2Nos.

15Concrete pressure grouting pumps

2Nos.

16Field testing equipment

lot

17Compression Testing Machine

1No.

18Total station

1No.

19Levelling instruments ( dumpy, laser)

2Nos.

20Steel forms/Plywood

8000Sqm






STATION




Sh. D1-2 / 3 Rev. : R0

21 Steel props/steel spans/steel staging/100 Mt

scaffolding pipes

22Steel couplers for staging pipes

20000Nos.

23Builders Hoists(Electrically operated)

1Nos.

24Jack Hammers

2Nos.

25Pavement breakers

1No.

26Water pumps of various sizes

3Nos.

27Dewatering pumps of different capacities

6Nos.

28Welding transformers

3Nos.

29Water tanker

1No.

30Electrode baking oven-fixed type

1No.

31Electrode baking oven-portable type

1No.

32 Welding accessories as required

33 Portable Grinding machine of various sizes as required

34 Boom Placer Min. 35 m long 1 No.

35 All special tools & equipment as required

36 Fillet weld measuring gauge as required

37 Electronic distance measuring device 1 No.

38 Spring balance 2 Nos.

39 Electric Winches 2 Nos.

40 Spray painting equipments 1

41 Paint thickness measuring instrument 1 No.

42 Drilling machine as required

43 Safety net as required

44 Steel tapes & measuring device as required45 Safety devices for usage at work site as required

46 Portable fire extinguisher as required

47 Noise level indicator 1 No.

48 Air quality monitoring instruments 1 No.

49 Walkie & talkie 3 No.

50 Emergency medical aid kits 1 Nos.






STATION




Sh. D1-3 / 3 Rev. : R0

51

Portable insulated metal site office (cabin) of minimum size 35m length,5 m width,3m height with

required furniture, lighting, ventilation and air

conditioned space and with required doors and

windows aluminium fittings etc.

1 No.

52Portable insulated metal/plastic (sintex or approved

equivalent) toilet of size 5m length,3m width,3m

height with required sanitary fittings

1 No.

53PVC (sintex or approved equivalent) water tank of

3000 litres capacity2 Nos.

54 All other equipments, instruments, tools etc. as required






STATION

Equipment list forstructural works



Sh. D2-1 / 2 Rev. : R0

Minimum requirement of equipments, instruments and tools etc. For structural

and fabrication works to be provided by the contractor.

Sl.No DESCRIPTION QTY UNIT

1 Trucks-20 T capacity 2 No

2 Tractor with Trailer 2 Nos.

3 Tractor with Trailer – 40 feet length 2 Nos.

4 Total station (one second accuracy, digital) 1 No

5 Levelling Instruments (dumpy, laser) 1 Nos.

6 Welding Transformers 8 Nos.

7 Welding rectifier, 600/400 AMS and generator sets 4 Nos.8 Electrode Baking Oven – Fixed Type 3 Nos.

9 Electrode Baking Oven – Portable Type 6 Nos.

10 Welding Accessories As Required

11 Portable Grinding Machine of various sizes As Required

12 All special Tools & equipment As Required

13 Fillet Weld measuring gauge As Required

14 Any other equipments, instruments, tools etc. As Required

15 Escort Crane – 10 T Capacity 3 Nos.

16 Escort Crane – 5 T Capacity 1 Nos.17 Crane 955 – 75 T Capacity –min. 75 M Boom Length 1 Nos.

18 Crane 855 – 40 T Capacity –min. 50 M Boom Length 2 Nos.

19Crane tyre mounted – 10 T Capacity- min.15 M BoomLength

1 Nos.

20 Jib Arm minimum 10 M length 2 Nos.

21 Hydras – 20 T Capacity 2 Nos.

22 Jeep – Car 2 Nos.

23 Diesel power generator of required capacity 3 No.

24 Portable hand held welding generator 3 Nos.

25 Pencil grinding - Nos.

26 Hand grinding-Min. 2.5 m long - Nos.

27 Buffing Tools of required size 5 Nos.

28 Plane and Milling machine --- Required capacity 2 No.

29 Electronic Plumb 10 kg & 20 kg capacity 2 Nos.

30 Illumination Dome lights and general illuminationAs perrequirement






STATION

Equipment list forstructural works



Sh. D2-2 / 2 Rev. : R0

31 Marking tools etc.As perrequirement

32 Grouting pump 2 Nos.

33 Pug cutting machine 2 Nos.

34 Gas cutting sets 7 Nos.

35 Electric Winches 10T,5T, 3T & 1T 3 Nos.

36 Hook Chuck 3 Nos.

37 Chain Pulley Block 3 T to 10 T capacity 3 Nos.

38 Other Erection tools and tacklesAs perrequirement

39 Sand blasting equipment required capacity 1 Sets40 Spray painting equipments required capacity 2 Sets

41 Paint thickness measuring instrument 1 Nos.

42 Torque Wrench 1 Sets

43 Drilling machine --- Radial type required capacity 2 Nos.

44 Drilling machine --- Pillar type required capacity 1 Nos.

45 Drilling machine --- Hand drill required capacity 4 Nos.

46 Lathe machine required capacity 1 Nos.

47 Safety ladder for AC sheet laying required size - Sets

48 Safety net As perrequirement

49 Steel tapes and measuring deviceAs perrequirement

50Personal protective safety equipments for usage at worksite including safety helmets, shoes, goggles etc.

As perrequirement

51 Portable fire extinguisher 4 Nos.

52 Noise level indicator 1 Nos.

53 Air quality monitoring instruments 1 Nos.

54 Walkie and talkie 1 Sets

55 Emergency medical aid kits 2 Nos.

56 Welding quality control equipment such as MPI, LPI.R.T & U.T etc.

As perrequirement

57 Local stress relieving equipmentAs perrequirement

58 Concrete/steel scraper for storage 1000 Nos.

59 Storage yard steel sheets 50 MT




for

Coal Handling Plant


KPCL


POWER STATION

VOLUME – 1


Sh. -1 / 1 Rev. : R0

SECTION– E

MAN POWER REQUIREMENT



BHEL-ISG

Technical Specificationsfor


KPCL

1X700 MW BELLARY THERMAL POWER

STATION

MAN POWER

REQUIREMENT

Volume -1

Section - E


Sh. E-1 / 1 Rev. : R0

List of Minimum Requirement of Supervision Personals at site:

SL.

No.Details Nos.

Min.

Qualification

Min. yr of

Experience

1 Site-In-charge 1 B.Tech (civil) 10

2Engineer-in-charge for CIVILworks

2 B.Tech (civil) 5

3Engineer-in-charge forSTRUCTURAL works

2 B.Tech (civil) 5

4 Civil Supervisors 6 Diploma (civil) 3

5 Structural Supervisors 5 Diploma (civil) 36 Quality Supervisor 1 Diploma (civil) 3

7 Surveyors 2 38 Quality Engineers (civil) 1 5

9Quality Engineers(Structural)

1 5

10Clarical staff for stores &building

3




for

Coal Handling Plant


KPCL


POWER STATION

VOLUME – 1


Sh. -1 / 1 Rev. : R0

SECTION– F

GENERAL CONDITIONS OF CONTRACT



HSE Management System Manual

CCoonnssoolliiddaatteedd SSiittee SSaaf f eettyy PPllaann (includes all Safety Plan documents of ISG)

Bharat Heavy Electricals Limited

Industrial Systems Group

Prof. C.N.R.Rao Circle, Malleswaram,

BANGALORE 560 012

Phone: 080 - 23365096, Fax: 080 - 23562713

Regd. Office: "BHEL House" Siri Fort, New Delhi - 110 049.

Note: All documents issued from 2003 to 2006 are consolidated in this volume.




Table of Contents

DOCUMENT NO. DESCRIPTION

IS/HSE/SSP/01 1. Details of Project

2. Health, Safety and Environment Policy

3. Roles of Site Personnel4. Safety Awareness & Training:

5. Site Safety Inspection:

6. Emergency Preparedness and Response Plan:

7. Electrical Safety Inspection:

8. Transportation and Material Handling Equipment:

9. Erection of equipment:

10. Commissioning of equipment:

11. Use of Personal Protective Equipment (PPE):

12. Housekeeping:

13. Accident Investigation and Reporting:

14. Protection against Fire

15. Protection against Noise

16.Welding Sets

17.Civil / Structural Work

18. FIRE FIGHTING PLAN

19. NOISE STANDARDS

20. List of Applicable Statutory / Regulatory requirements

Checklist / Formats / Guidelines

IS-QII-4-409/010 SAFETY DECLARTION BY SUB-CONTRACTOR

IS:HSE:CL01 CHECK LIST FOR WORKING AT HEIGHT

IS:HSE:CL02 CHECK LIST FOR HOUSE KEEPING

IS:HSE:CL03 CHECK LIST FOR SCAFFOLDING

IS:HSE:CL04 CHECK LIST FOR GENERAL SAFETY INSPECTIONIS:HSE:CL05 CHECK LIST FOR HEAVY MATERIAL HANDLING EQUIPT

INSPN.

IS:HSE:CL06 CHECK LIST FOR ARC WELDING TRANSFORMER

IS:HSE:CL07 CHECK LIST FOR DC ARC WELDING GENERATOR

IS:HSE:CL08 CHECKLIST FOR STAGING

IS/HSE/SSP/02 Hazards Risk & Preventive Measures at Construction Sites.

Dtd. 30.06.06 Guide lines for Resident Managers on Contract Labour, Safety &

Accident Reporting System

Dtd. 30.06.06 List of Relevant Legislations applicable to Various Sites

IS:HSE:AIR:001 Accident (Personal injury / property damage) Report

Annexures

IS-CW-01, Rev.01 Work instructions for Civil Work at Site




IS/HSE/CSSP/O1 CONSOLIDATED SITE SAFETY PLAN

1. Details of Project

1. Name of the Project & Site

2. Job Number

3. Customer

4. Overall Scope of work:

Design / Supply / Installation

Civil

Structural

Mechanical

Electrical & Instrumentation

Others

5. Project Schedule Starting Date:

Completion Date:

6. Erection & Commissioning

Machinery / Tools /

Instruments Required:

7. Sub-Contractor Details Name of the Sub-contractor

Job order No.:

Duration of Completion:

8. Name of BHEL Residence

Manager

Attach Site Organization Chart of BHEL

9. Designated Safety Officer of BHEL

10. Name of Sub-contractorperson in-charge

Attach Site Organization Chart of Sub-contractor

10. Designated Safety Officer of

Sub-contractor





Safety Awareness and consciousness among workers, supervisors and executives is imparted by the

Designated Safety Officer of BHEL / Sub-contractor. This is done by way of following.

• Talk on Safety issues as per Site Safety Plan

• Posters and Notices at prominent places

• Display of warning boards

• Creating awareness and response for emergencies like Fire, Shock, accidents, dangerous

occurrences and on First-aid, Emergency assistance agencies and their contact telephone

numbers etc.

• Use of Personnel Protective Equipment

5. Site Safety Inspection:

Designated Safety Officer will inspect the site on Daily basis• To identify unsafe conditions and unsafe actions by the labourers and bring to the notice of

sub-contractor. The main objective of the Daily Inspection is to rectify the potentiallydangerous situations and avoid occurrence of any incident.

• To suggest suitable remedial action to correct the unsafe conditions / acts.

• To use appropriate checklists IS:HSE:CL01 to CL08 to verify and record the safety

observations.

• To follow the Copy of Safety Manual – Health and Safety Plan for BHEL Power Sector

(07.12.06 copy no. 18) issued on 26.12.06 and available at site.

6. Emergency Preparedness and Response Plan:

• Use the Emergency Preparedness and Response Plan IS/HSE/EPR/01 available at site

together with PS & Customer. • First aid kits are to be kept in the site office or the locations in the vicinity of work place. The

kit is to be maintained. Records of FIRST AID treatment given to be maintained in a register.

• Whoever first notices the accident occurrence shall immediately notify the same to Designated

Safety Officer / Other BHEL executives.

• Determine the area of accident and organize for evacuation of the personnel.

• Organize for sending the injured person to nearby First-aid / Health Center / Hospitals

depending on the emergency.

• In the event of fire organize for extinguishing the fire using the apparatus available and for

major fire notify the local / nearby Fire Station.

7. Electrical Safety Inspection:

• All the electrical distribution system, sub system, relevant protection unit at electricallypowered machines and tools are inspected periodically including earthing at two points, to

avoid electrical shocks.





• Checklist for House keeping -IS:HSE:CL02 and General safety inspection -IS:HSE:CL04, is

used for periodical inspection.

• For safe operation all the Electrical portable tools and devices are connected with Earth

Leakage Circuit Breaker (ELCB) protection at Distribution Board and continuity of earthconnection is to be ensured.

• The ELCBs are tested periodically and records of such tests are maintained.

• After each inspection the filled up check list date wise is to be retained by Resident Manager.

8. Transportation and Material Handling Equipment:

• Checklist of Inspection of Material Handling Equipment - IS:HSE:CL05 shall be used and

records are to be maintained.

9. Erection of equipment:

• The instructions given in Erection Manual IS: EM-1 to IS:EM-5 in FIVE Volumes are to be

followed during erection of equipment. SAFETY MANAGEMENT AT ERECTION SITES is

elaborated in Document No. IS; EM-4/1 (Erection Manual Issued on 24.01.1995).

• Wherever Checklists are provided, the same shall be used and records are to be maintained.

10. Commissioning of equipment:

• The instructions given in Commissioning Manual IS-QCM in SIX Volumes are to be followedduring Commissioning of Standard equipment.


11. Use of Personal Protective Equipment (PPE):

• The PPE in use shall conform to IS or other relevant standard and the same shall be discarded

in case it is damaged or worn out.


• Soft copy of Corporate Personal Protective Equipment (PPE) Safety Manual Document No.

HSE / PPE Dtd 25.08.2006 available at site to be followed.

12. Housekeeping:

• The Housekeeping Checklist IS:HSE:CL02 available in this document shall be followed and

records are to be maintained.

13. Accident Investigation and Reporting:





A. Fire in ordinary combustible (wood,

vegetable, fiber, paper etc.)

B. Fires in flammable liquids, paints, grease,

solvents etc.

C. Fire in gaseous substances under pressure

D. Fire in reactive Chemicals, active metals

E. Fire in electrical equipments.

Chemical extinguishers of soda acid, gas /

expelled water and anti-freeze types and water

buckets.

Chemical extinguishers of Foam, Carbon Dioxide

and Dry powder type and sand buckets.

Chemical Extinguishers of Carbon Dioxide and

Dry Powder Type.

Special type of Dry Powder extinguishers and

sand buckets.

Chemical Extinguishers of Carbon Dioxide and

Dry Powder Type and sand buckets.

Clause 4.1.3.2 One 9 litre Water / Sand Bucket for every 100sq.metre area

Clause 4.1.3.5.1 One no. of Not less than 2 kg, Dry Powder CO2

extinguisher within 15 metres of apparatus for

rooms containing electrical transformers &

switchgear.

Clause 4.1.3.5.2 One no. 5 kg, Dry Powder CO2 extinguisher

within 15 metres of Motors / other Electrical

equipment.

The following example will illustrate the method of determining the number of fire extinguishers

required to give adequate protection for a given property:

Light engineering workshop ( light hazards).

Area: 315m X 112m = 35300 sq.mType of fire:

1. Class A Fire due to normal combustibles

2. Class B Fire due to existence of spray painting process and storage of flammable liquids

3. Class E ire due to two electrical DB and motors

Number of appliances

Basic protection

353 buckets and

59 water type extinguishers

OR

90 Water type extinguishers if buckets are dispensed with.

For Class B fires 2 Water type extinguishers are replaced by 2 Foam Extinguishers.

For Class E fires 6 Dry Powder Extinguishers are provided. Thus the total no. of fire extinguishers are

Water type: 88

Foam type: 2

Dry powder type: 6

TOTAL 96





Reference Standards for Fire Extinguishers:

Sl.No. Standard /

Year

Description

1. IS940 : 1989 Specifications of Portable fire extinguisher, water type (gas cartridge)2. IS2171 : 1999 Specifications of Portable fire extinguisher, Dry powder (Cartridge

type)

3. IS2878 : 1986 Specifications for Fire extinguisher, Carbon Di-oxide Type (Portable &

trolley mounted)

. IS10204 : 2001 Specifications of Portable fire extinguisher, mechanical foam type

5. IS10658 : 1999 Specifications for Higher capacity Dry powder Fire extinguisher

(Trolley mounted)

6. IS13385 : 1992 Specifications for Fire extinguisher, 50 capacity wheel mounted water

type (Gas Cartridge)

7. IS13386 : 1992 Specifications for Fire extinguisher, 50 l capacity, mechanical foam

type

8. FPM / June1995

Fire Protection Manual (Part-I)By Tariff Advisory Committee

19. NOISE STANDARDS

NOISE : (Ambient standard)

Area

Code

Category of Area Limit in dB (A) Leq

Day time (6 AM to 9 PM) Night time (9 PM to 6 AM)

A Industrial area 75 70

B Commercial area 65 55C Residential area 55 45

D Silence Zone 50 40

Silence Zone is defined as area upto 100 metres around such premises as hospitals, educational

institutions and courts.

Source: EPA Notification [G.S.R. 1063(E), DT. 26th

Dec.1989





20. List of Applicable Statutory / Regulatory Requirements:

Sl.No. Standard Applicable or

Not1. Indian Electricity Rules, 1956 Yes/ No

2. The Motor Vehicle Act, 1988 Yes/ No

3. The Central Motor Vehicle Rules, 1989 Yes/ No

4. The Gas Cylinder Rules, 1981 Yes/ No

5. The Environment (Protection) Act, 1986 Yes/ No

6. The Noise Pollution ( Regulation & Control) Rules, 2000 Yes/ No

7. Battery (Management and Handling) Rules, 2000 Yes/ No

8. Ozone Depleting Substances (Regulation and Control)Rules, 2000

Yes/ No

9. The National Environment Tribunal Act, 1995 Yes/ No

10. Pollution Control Act, Rules and Notifications,

September 2001

Yes/ No

11. Pollution Control Law – Environmental Standard forAmbient Air, Automobiles, Fuels, Industries and Noise –

July 2000

Yes/ No

12. CBIP Guidelines Yes/ No

13. Indian Standards as applicable

14. List of Relevant Legislations Applicable to Various Sites

ISG document issued on 30.06.06

Yes / No

15. International Standards as applicable

16. Project Specific Standards as applicable

Note: Refer to register of regulations in the HSE system document

IS/HSE/ROR/E1.1 to E1.6, IS/HSE/WZS/W1, W2, W3 & IS/HSE/SCH/S1





Format IS-HSE-CL01 Page 1 of 2 Rev.0 Date of Issue: 14.02.2003

CHECK LIST FOR WORKING AT HEIGHT

Name of Sub-contractor

Work Order No.

Nature of work

Name of the Project site

Job. No.

Date

Sl.

No.

Check Points Observation Measures

1. Safety Plan is available from Sub-contractor Yes / No Document No.

Dtd.

2. All the workers have been explained safe work

procedure

Yes / No Verify with few

3. Effective communication system have beenestablished and explained to the workers.

Yes / No Type of communication

4. Adequate illumination is ensured Yes / No Good / fair / poor

5. Work area inspected prior to starting of the job. Joint

protocol signed for site clearance.

Yes / No Verify document

6. Area below the work place is cordoned. Yes / No Verify compliance

7. Arrangement made for fastening hand tools. Yes / No Check

8. Workmen provided with bag / box to carry nut, bolts

and hand tools.

Yes / No Check

9. All work plate forms are of adequate strength and

ergonomically suitable

Yes / No Verify

10. Work at more than one elevation at the same segment

is restricted.

Yes / No Check

11. Availability of supervision staff at work place. Yes / No Check

12. Availability of controlled copy of drawing and

document at work place.

Yes / No Verify

ACCESS / EGRESS

1. Walkways provided with handrails, mid rail & toe

guard.

Yes / No

2. All chequered plates, gratings properly welded and

bolted.

Yes / No Verify

3. Are ladders inspected and maintained in good

condition.

Yes / No Verify

4. Are ladders spliced Yes / No Verify

5. Are ladders properly secured to prevent slipping,

sliding or falling

Yes / No Verify

6. Do side rails extended 36” above top of landing Yes / No Verify

7. Are buildup ladders constructed of sound materials. Yes / No Verify

8. Rungs and cleats not over 12” on center. Yes / No Verify






Sl.

No.


4. Welding cable and power cables are routed separatelyto avoid obstruction and tripping hazards. Yes / No Verify

5. Welding cable and power cables are not damaged

one.

Yes / No Verify

6. Floor of electrical booths kept dry. Yes / No Verify

7. Proper grade Rubber mats are placed in front of

Electrical panels

Yes / No Verify

STORES

1. Walkways, entry and exits are kept clear Yes / No Verify

2. Materials placed on racks are safely accessible. Yes / No Verify

3. Compressed gas cylinders are segregated as full or

empty and types of gas.

Yes / No Verify

4. Vertically stored cylinders are secured chained toavoid toppling and horizontal once guarded against

rolling down.

Yes / No Verify

5. Flammable storage areas are isolated from store,

office and work areas.

Yes / No Verify

6. Cement bags are stacked in proper gradient safely. Yes / No Verify

7. Corrosive material (eg. Acids, alkalies) are stored

away from other material and kept on collection trays

to safe guard against accidental leakage.

Yes / No Verify

8. Storing area for lifting tools & tackles, ropes, wire

ropes & Personnel Protection Equipment is dry, clean

& free of corrosive material.

Yes / No Verify

9. Easy accessibility to installed fire extinguishers

ensured in store.

Yes / No Verify

GENERAL

1. Separate scrap yard is allocated for the site. Yes / No Verify

2. Approaches to workstations, offices, stores are well

laid and demarcated.

Yes / No Verify

3. Site roads are kept clear of stacked material for free

& safe vehicular movement.

Yes / No Verify

4. Heavy materials stacking are taken care of to prevent

slips, collapse and rolling.

Yes / No Verify

5. For house keeping at elevated work places refer toChecklist for Working at height - IS:HSE:CL01

Yes / No Verify

Signature of Sub-contractor Supervisor. Signature of BHEL Supervisor






Sl.

No.


board.

15. Is awareness of workmen on the importance of loaddistribution on a given working platform palpable? Yes / No

16. Is there a check for the condition and correct usage of

fittings for scaffolds?

Yes / No

17. Is the width of a working platform properly

maintained according to usage, viz.

• Minimum 600mm for footing only and not for

deposit of material.

• Minimum 800mm for footing and deposit of material.

• Minimum 1050mm when used for heavier loads or

to support higher platforms.

Yes / No

18. Are all the materials stored on the platforms properlysecured or not.

Yes / No

19. Are openings in working platform kept safely

covered / fenced

Yes / No

20. Whether planks are tied using proper binding wires. Yes / No

21. Are mobile scaffolds used on a firm and level

surface?

Yes / No

22. Does the height of mobile scaffold exceed four times

the smaller base dimension?

Yes / No

23. Are all materials stacked on the platform properly

secured while in motion?

Yes / No

24. Is the safety rule “ not to ride on a scaffold while inmotion violated” Yes / No

25. Is there a system of checking for obstructions before

the tower is moved?

Yes / No

26. Are suitable / correct lifting tackle (wire ropes,

chains, shackles) selected for suspension & use.

Yes / No

27. Is there a system for using manila rope / coir rope for

suspension at any place where such rope would be

liable to damage by heat / flames/ sharp edges etc.

Yes / No

28. Are all precautionary measures taken to prevent

contact between arc welding apparatus and

suspension ropes.

Yes / No

29. Is hanging platform secured? Yes / No

30. Is there a provision of anchoring safety belts-

lanyards to be tied to guy ropes?

Yes / No







Sl.

No.


etc. Not OK

3. Demolition from top in a planned manner OK / Not OK

4. Disconnection of electrical cable connection / water /

steam / gas line etc.

OK /

Not OK

5. Removal of debris immediately at a safe place OK /

Not OK

6. Emergency Transport OK /

Not OK

7. Fire extinguishers kept nearby for emergency. OK /

Not OK

BLASTING

1. Blasting record incorporating number of holes made /

type of explosive used / firing pattern & sequence withdate and time of blast.

OK /

Not OK

2. Handling of explosives by licensed blaster. OK /

Not OK

3. Intensity of the charge calculated before use. OK /

Not OK

4. Before drilling presence of unfired explosives checked. Yes / No

5. Blasting is carried out only during lean period (lunch /

night hours)

Yes / No

6. Standard warning signal / all clear signal is ensured

before and after firing.

Yes / No

7. Competent persons equipped with red flags are posted

at possible approaches to stop traffic and by passers.

Yes / No

GROUND SURFACES

1. Ground level, no soft spot OK /

Not OK

2. Footing timber level adequately supported Yes / No

3. No unauthorized entry. Yes / No

SCAFFOLDS

1. Base plate level OK /

Not OK2. Spindle jack vertical OK /

Not OK

3. Standard plumb (vertical tubes), no damage. OK /

Not OK

4. Ledgers level (horizontal tubes) no damage OK /

Not OK






Sl.

No.


5. Diagonal bracing, check secure and non-missing. OK /

Not OK6. Lock pin in place and secure. OK /

Not OK

7. Support from permanent structure. OK /

Not OK

LADDERS

1. Check ladder is placed on level ground OK /

Not OK

2. Position at an angle of 1:4 OK /

Not OK

3. Adequately secured Yes / No

4. No damage, check welds OK / Not OK

5. Extent 4 rungs above stepping off point OK /

Not OK

6. Uniform and proper spacing of rung and no missing

rung.

OK /

Not OK

WORKING PLATFORM

1. Should not be less than 600mm wide OK /

Not OK

2. Guard rails adequate check

• Top rails at least 910mm height

• No gap greater than 470mm

OK /

Not OK

3. Boards free of defects

• No gaps

• Adequate support

• No risk of trips

• Properly secured / tied.

OK /

Not OK

PERSONNEL PROTECTIVE EQUIPMENT

1. Helmet & Footwear worn Yes / No

2. Safety harnesses as required and secured above

shoulder level

Yes / No

3. USE of safety belt while working at height. Yes / No

4. Safety goggles during welding / gas cutting / grinding

etc.

Yes / No

5. Condition / Maintenance of safety appliances Yes / No

6. Use of body guards, gloves etc.






Sl.

No.


11. Job safety analysis for shut-down jobs and its properaction. OK / Not OK

12. Permit to work. Yes / No

HOUSEKEEPING

1. Material stacking and storing OK /

Not OK

2. Working / Moving area clean OK /

Not OK

3. Access / Main Approach / Passages free from

obstacles.

OK /

Not OK

4. Cordoning / covering of pit, vat, machine foundation

etc.

OK /

Not OK5. Displaying of Red Flags / Tape / Light. Yes / No

6. Removal of unwanted materials like excavated earth

debris etc.

Yes / No

FIRE PREVENTION / PROTECTION

1. Combustible material away from source of heat / fire. OK /

Not OK

2. Provision of fire extinguishers and its maintenance. OK /

Not OK

3. “No Smoking” Board / “Caution” Board displayed. OK /

Not OK

4. Stacking / Storing of different type of combustible

materials.

OK /

Not OK

ROAD SAFETY

1. Driving by unauthorized person. Yes / No

2. Loading of material on truck, dumper securely. Yes / No

3. Material falling from vehicle while transporting. Yes / No

4. Speed Limit. Yes / No

5. Transportation of persons by dumper. Yes / No

6. Going up and coming down from moving vehicle. Yes / No

7. Indulging in Horse Play on job. Yes / No

8. Reverse Horn. Yes / No






Sl.

No.


9. Location of Overhead Lines identified and pre-cautions taken. Yes / No

MISCELLANEOUS

1. First Aid Box with proper medicine and its

maintenance.

OK /

Not OK

2. Validity Date of medicine. OK /

Not OK

3. Illumination. OK /

Not OK

4. Safety board and safety promotional materials

i) Posters.

ii) Stickers.

Yes / No

5. Accident Report form. Yes / No

6. Reporting System with Head Quarters. Yes / No

7. Arrangement of drinking water and sanitation. OK /

Not OK

8. Provision of emergency vehicle. Yes / No

9. Telephone Nos. of nearby hospitals displayed at

prominent place

• For Burns

• For Fractures

• For Head Injuries

• General

Yes / No

10. Telephone Nos. of nearby Fire Stations / Police

Stations / Other establishments nearby for emergency

help, displayed at prominent place

Yes / No







CHECK LIST FOR ARC WELDING TRANSFORMER

(Reference Standard IS-1851 – 1975 Specification for Single operated type Arc Welding Transformer)

Test to be done before first use at site and repeated periodically once in 6 months

Name of Sub-contractor

Work Order No.

Nature of work

Name of the Project site

Job. No.

Welding Set make, model and

Capacity

Serial Number

Date of Testing

Sl.

No.

Check Points Measured Value /

Observations

Observation

1. General Condition of the Set OK /

Not OK2. Earthing of Welding Set at Two Places Yes / No

3. Open Circuit Voltage in Volts

(Measure Output voltage with rated input voltage

without loading the set)

OK /

Not OK

4. Physical Inspection, Check Cable, termination,

Insulation , cleanliness, Guard against live parts,

fuse rating and healthiness

OK /

Not OK

5. Insulation Test (IR value in Megohms)

• Primary Terminal

• Secondary Terminal

• Continuity of Coil - Primary

• Continuity of Coil - Secondary

• Use appropriate Meggar

OK /

Not OK

6. Load Test

U= 20 + 0.04 IWhere U is the Load Voltage in Volts

I is the Load Current in Amps.

Check the results as per the above formula.

Results

Accepted /

Rejected

Sl.No. Welding Current Voltage Electrode Size Remarks







8 Rigidity Rigidity of staging as whole shall be verified thoroughly

before allowing for concrete by a team of engineers

concerned and a joint protocol shall be made.

9 Removal of formwork / staging No form work or staging shall be removed beforecompletion of allowed curing and setting time for concrete

and without prior permission from the Engineer in writing.

10 Construction

Loads

Construction loads over temporary staging shall be well with

in DEAD LOAD + LIVE LOAD as per approved staging

design assumptions.

11 Impact Loads Impact load over staging shall not be allowed due to

movement of construction vehicles, concrete conveying

equipment etc. Ready made concrete delivered from

batching plant through chocked pipes shall not be tied tostaging without approval of engineer in charge. Engineer in

charge to verify of condition free flow of pumped concrete

through the pipe without excessive pumping pressure to

avoid any accidental loads over staging pipes etc.

12 Illumination Sufficient illumination below the centering shall ensured for

verification of above check points during night hours &

wherever clear visibility is absent for checking.

13 Curing Excessive ponding of water beyond 25 mm over cast RCC

slab during rains or curing shall not be allowed to avoid

overloading of staging pipes.

14 Workforce/skille

d labours

Separate required skilled work force with fitters & carpenters

etc. shall be kept to attend to above points during concreting.

15 Approach to

workplace

Proper safety ladder or approach stool shall be provided for

access to inspection of staging.

16 Fire hazards Ensure prevention of fire hazards due to welding & electrical

short circuit etc. in the total staging area.

17 Flooding of

water at base of

staging

Ensure required dry conditions are maintained at the base

level of the staging to avoid slippages of wedges with

required pumps & other facilities.

18 Camber Ensure that for beams above 6 m span required camber as

per approved drawings are maintained by adjustment of the

staging props.

Signature of Sub-contractor Supervisor Signature of BHEL Supervisor





Prepared By: M R Thakurta Date: 27.05.2006 Page 1 of 26

Hazards Risk & Preventive Measures at Construction Sites.(SITE SAFETY PLAN – 2)

INDEX

Sl. NO. TITLE OF ACTIVITY Page no.

1. SURVEY / RECEIPT OF MATERIAL AT STORES &

STORAGE

2 / 26

2. MARCHING & PILING 3,4,5 / 26

3. EXCAVATION 6,7 / 26

4. BACK FILLING & SAND COMPACTION 7 / 26

5. CONCRETING / SHUTTERING. 8,9,10 / 26

6. HANDLING OF REINFORCEMENT 11 / 26

7. PRECASTING 12 / 26

8. FABRICATION 13 / 26

9. ERECTION 14,15,16 / 26

10.

ROAD MAKING 17 / 26

11. ROOFWORK 18 / 26

12. WORKING WITH PORTABLE TOOLS 19 / 26

13. HANDLING OF DIESEL 20, 21 / 26

14. SITE TRANSPORTATION 22 / 26

15. WORKING AT HEIGHT 23 / 26

16. WELDING & GAS CUTTING 24, 25 / 26

17. GRINDING 25 / 26

18. FIRE PREVENTION 26 / 26






2. MARCHING & PILING

ACTION BY : Concerned Site Engineer / Supervisor

Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 Fall of material /

slings cut off / fall of

person from same

level

• Use of proper slings and checking adequacy

before use.

• Selection of proper hitch while shifting sleepers.

• Path should be free from interruption.

• Carrying out work by Skilled operator / Signal

man under supervision of knowledgeable

supervisor.

• Use of PPE’s like Safety shoe, helmet, handgloves.

2 Hand injury, head

injury, fall from same

level, struk by, struk against etc.

• Distance must be maintained while inserting the

wooden plank.

• No one shall be entertained under the rig to

insert plank, pouring water, grease etc. while

marching.

• Marching must be done in the presence of

skilled supervisor.

• While shifting the sleepers by the winch

following needs to be ensured:

The correct hitch must be selected

Path should be cleared from barriers

No one should have direct touch with sleepers

Guy rope should be tied to control the swings of

sleepers Safety helmet, shoe, gloves and belt will be tied

by the lifeline on workers shoulder level

Operator should not use loose shirt

3 Toppling of rig • Sleepers should be provided equally on both the

sides and under the eye

• Exact counter weight should be placed at rear

end

• Dumps would be compensated by placing the

wooden pieces over the sleepers / filling with

sand to make the surface level

• Care must be taken while rolling the wire rope

on Ballard for marching straight and returningto a required angle.

4 Fall of person from

height• Safety belt must be used and lifeline be tied at

shoulder level while putting the channel under

the helmet for resting the hammer.






3. EXCAVATION


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 Under ground cables /

HT lines /

Electrocution

• Site clearance and information on location of

specific area be obtained from concerned

customer’s department.

2 Improper shoring /

collapse of trench• Excavate as per the angle of repose of the

particular soil.

• Provide shoring wherever required

• The excavated soil shall be kept at a distance of

more than 5 feet or half of the depth of the

trench, which ever is more from edge. Proper

slope must be given.

• Vehicle movement should not be allowed near

by the edge of the trench. Necessary protectionshould be taken care.

• Cutting should be done from top to bottom.

Under cutting should not be allowed.

• While providing steps for access / egress,

slippery surface must be avoided. Proper ramp

must be provided.

• Work must be done under the control of skilled

supervisor.

3 Ground water seepage

& accumulation• Dewatering to be done before allowing

workmen in or around the pit

• Suitable pump must be used if heavy seepageexists.

4 Personnel falling into

excavated pit• Provide proper sign / warning board

• Use proper means of access. Ladders to be

provided which should be projected (extended)

more than 3 feet from the ground level.

• 3 feet height Barricade be provided near theexcavated area.

• Proper illumination be provided.

• In deep excavation (more than 4 feet), persons

working at slope or bench of the pit should wear

safety belt.

• One ladder should be placed at the pit site all

the times. One ladder for each 100 m length.

5. Material falling into

excavated pit• Store material away from the edge of the pit

( away from the barricade)

• Edge preparation be ensured

• Vehicle movement permitted away from the pit

barricade.






3. EXCAVATION Contd.


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE6 Occupation health

hazards• Water spraying be ensured over the fly ash or

fines for suppression of dust

• Nose / dust mask must be used

• Safety shoe with ankle must be used

• Ensure eye protection using goggles.

4. BACK FILLING & SAND COMPACTION


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE

1 Reversing of vehicle /

personnel injury / toppling of vehicle

• Reversing horn (back gear horn) of each vehicle

should be working

• Driving near to the edge of the excavation beavoided.

• Back view mirror must be fitted and intact in

proper position on each vehicle

• Proper approach to be made to pit, which

required to be backfilled as well as to the source

of backfilling material.

• Proper signaling be ensured while reversing the

vehicle.

• Activities are to be performed under the control

of skilled supervisor.2 Compactors • All the drivers should possess a valid license.

• For mini hand operated compactors, all rotating

parts should be guarded.

• Near by persons should be alerted while

reversing the compactors

• Hand gloves should be used in case of mini

hand operated compactors

• Care must be taken while starting the hand

operated compactors.

3 Excavation area /

toppling of rollers &

compactors

• Area under excavation should be barricaded.

• Warning sign should be displayed.

• Drivers / operators should be advised suitably

• Constant supervision must be provided.

• Repair and maintenance of compactors or

rollers should be done out of compactor area

• Proper illumination be provided.

• JCBs need not go nearer to edge of excavated

area.

• JCB operators must use helmet.






5. CONCRETING / SHUTTERING.


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 Person working at

height / fall from

height

• Make proper platform with handrail

• Use safety belt at height

• Use safety net if necessary

• Use personal protective gears as required

2 Placing of loose

material at top / fall of

material

• Provide toe boards throughout periphery of the

platform

• Avoid gap between platform planks

• Do not place loose materials over or near by the

edge of the platform

• Keep the hand tools in a particular box and thebox should be tied / fixed with the platform.

• Use hand tools by tying with rope to a fixedstructure, so that it does not fall off due to

inadvertent slippage etc.

• Use safety net having smaller mesh size.

• Avoid standing just below the working area.

3 Improper approach

way / fall of person

from height

• Use proper ladder with handrail placed on firm

ground and lashed / fixed both ends of the

ladder

• Make proper landing place

4 Lifting of materials

like shutters, concrete

etc.

• Check wire ropes & brakes of the machines

daily

• Check lifting tools and tackles daily• Proper slinging

• Check the locking system of concrete bucketregularly

5 Noise pollution while

operating vibrator,

compressors, improper

handling of material,

electrocution,

electrical fire etc.

• Use of ear plug or ear muff

• Use of hand gloves

• Electrical connection to be taken through ELCB

• Checking of electrical grounding system

periodically

• Overhead work to be coordinated properly toavoid injury to people working underneath.

• Proper instruction to be given to the workmenby supervisor while working

• Constant supervision must be provided

• Greasing need not be done on running mixermachine

• Carbon dioxide type extinguisher should be

placed nearby DB / SDB






5. CONCRETING / SHUTTERING. Contd.


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE6 Protruding of nails /

injuries, scratch• Protruding nails from the shuttering planks

should be removed before put into the use.

• Nails should not be thrown or spread at site.

• Nails must be kept in proper box.

7 Pouring of concrete

using transit mixer• Reversing horn (back gear horn) of each vehicle

should be working

• Helper should be provided to operate the lever

to unload the concrete and guide the vehicle

while reversing.

• Concrete should not be collected by bond

carrying on hand for making cubes

• Before making move, the helper should check

that nothing is lying / nobody is sleeping under

the tyres

• On daily basis maintenance work shall be

carried out. Maintenance work shall be taken

place after shutdown of engine fully and

informing driver.

• No one should be permitted to sit over the tyre

shield.

• Speed limit permitted at work site must be

followed.

• Hand break and wedge should be placed underthe tyre while parking at site for unloading the

concrete.

• Each and every rotating part of transit mixer

should be guarded properly

• Tyre pressure needs to be checked at regular

interval.

• Mixer fitness test validity to be ensured

• Break efficiency, head lights, reverse horn

coordination should be checked periodically.

• Concreting activity must be done under the

control of skilled supervisor.

8 Defects in wire ropeand its clamping in

mixer chain

• Proper examination by a competent person

before taking in use. Lubricant should be

applied as per norms.

9 Inhaling of exhaust

gases / health injury• Inhaling of exhaust gases coming out of Diesel

mixer may cause diseases so it should be

directed away from the operator.

•






6. HANDLING OF REINFORCEMENT


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 Sharp edge / scratch /

injury• Persons handling reinforcement rod should wear

hand gloves and safety shoes.

• While shifting the lengthy rods, the group of

persons involved in shifting should be of

nominal heights.

• While shifting the rods, the passage clearance

must be ensured.

2 Rod cutting machine /

cutting injury / caught

in rotating parts

• While bending the rod the nearby personsshould be alerted.

• The rotating part of the machine should be

guarded

• Avoid using loose shirts.

• Ensure proper earthing of machine and

connection taken through ELCB.

3 Persons falling from

height / Injury.• Safety belts must be used while handling the

reinforcement at a height of more than 2 meters.

• Safety net to be tied.

• People working underneath area should be

alerted.

4 Tying of

reinforcement bars /

hand puncturing

• Hand gloves should be used.

• Only one person should do this job in one place.

5 Fall of reinforcementrod

• Proper stacking of rods to be done if required tostore at some elevated level

• Required quantity of rod should be shifted to

elevated work spot.

6 Projected edge / Eye

injury• The projected edge of the stacked rods should

be covered.

7 Bending / breaking of

rod• Carbon content in reinforcement to be checked.






8. FABRICATION


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 General • Space should be earmarked for fabrication yard

at least 40 – 50 feet away from a rail track, road

and overhead transmission lines.

• All equipment electrically operated must have

proper earthing and guards in position.

• Electrical supply should be taken through

ELCB.

• The use of rubber gloves or leather gloves in dry

condition is an absolute must, while operating

hand held electric tools.

• Drilling machine , grinding machine should

have safety guard in position.• While unloading structural steel from trailers or

wagons by cranes adequate protection should be

taken to make the trailers or wagons stationary

by putting scotch blocks or wedge on the

wheels.

• No persons should stand under hanging orswinging load area.

• While fabricating heavy structures, adequateprops to be given to avoid toppling of the

component under fabrication.

• Material should not be dumped haphazardly. Itshould be stacked properly in order.

• All the confined space such as tanks, controlequipments etc should be ventilated properly.






9. ERECTION Contd.


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE• Exact determination of sling capacity, sling angle,

factor of safety

• Factor of Safety should be at least 2.5

• Radius of swing should be identified

• A visual check must be done regarding fitness of all

lifting tackles, ropes, slings etc. before every use.

• The common tendency of checking gear meshing,

lubrication, coupling, hole matching etc. by feeling

with a finger must be strictly curbed.

• Selection of bars, rollers, skid etc. should be made

depending the type of equipment to be handled.

• No slings should be overloaded.

• Proper quality of pulley block should be used. In nocase pulley block suitable for fiber rope should be

used for steel wire ropes.

• No person shall walk, stand or work beneath

suspended load.

• During erection only one signaler shall give signals.

However STOP signal should be obeyed whoever

gives.

6 Lifting of structure /

improper hitch / fall of

material

• Correct hitch to be selected respective to the structure

to be lifted

• Sudden jerk should be avoided.• The structural members should be kept in orderly

manner on the ground so that those items do not roll

down while being handled.

• Clear passages should be left for easy handling and

transportation of structures.

• All persons shall stand clear when a crane is sorting

or shifting steel girders or other structural materials.

• While using spanners, reverting hammer etc. at

height should be tied with rope fixed to nearby

structure so that it will not drop in case of slip.

• Care should be taken while lifting loads. Proper tag

line must be used for guiding while lifting loads.

• While positioning a beam of fabricated structure etc.

it shall be so held that the workers hand does not get

jammed against other objects.






9. ERECTION - Contd


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE• Loose bolt, nuts, and tools must be kept in a box

and not on structures. Box must have proper

anchorage.

• Care should be taken to fasten the erected

members properly and secure by guys etc.

wherever necessary.

• Providing packing over sharp edges should

protect ropes and slings.

• Slinging should be carefully done so as toprevent the load from slipping.

• Proper sequence of erection should be followed.

• All electrically operated equipments likegrinding machine, drilling machine, welding

machines etc. must be properly earthed.

• The structural member should be able to taken

out as per sequence of erection without

disturbing the stack. At the same time light

structure should not be stacked below heavy

structural member to avoid damage.

• Safety appliances like safety Helmets, gloves,belts must be used suitably at erection sites.

7 Barrication of working

area / Fatal hit

• Area should be barricaded

• Appoint experienced signalman.






11. ROOF WORK


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 Standing on and

moving above roof

under construction /

Falling and injury

• Fabricate temporary structure / surface of

adequate strength and supported at a number of

points to distribute load.

• If site is dusty, then dust control measure must

be provided to avoid dust deposition on the roof.

• Suitable platform should be furnished with

width of more than 600 mm for moving along

horizontally.

• Cat boards, flat ladder, crawling boards shouldbe used for moving along vertically.

• A safety net or catch platform should be

installed under the roof if it is necessary.• Evacuate all workers under the roof where work

is in progress.

• Suitable precaution board should be displayed

on working spot.

• Guard rails be installed around the roof edge

and roof openings along with toe guard and

middle rail.

• Proper egress and access to be provided to reach

the work spot.

• All roof materials should be stored at ground

level and shifted as per requirements and do notbe stored at elevated work spot. At most care

must be taken while transporting the fragile

material from store to work spot.

• Proper PPEs like suitable clothing, footwear,with non-slip soles safety belts, fall arresting

system (made preferably from rope).

2 Electrocution / Injury • The electricity supply to adjacent overhead

wires should be interrupted or the wire should

be rendered harmless by some other means.

• Proper illumination arrangement must be made.

3 Health • Medical examination would be done to detect

any defects of equilibrium before being engaged

at work.

• Emergency vehicle should be parked at site for

round the clock.

• First aid hospital shall be identified and phonenumber would be displayed at all visible

locality.






13. HANDLING OF DIESEL - Contd.


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE• Wooden, plastic or non-sparking alloy

implements should be used to clean residues from

floor or other surfaces.

• Heat should never be applied to normally empty

vessels as they still contain explosive mixture.

• Empty containers with cap removed should be

crushed and disposed off as rubbish, but not

incinerated.

• The cleaning or repairing of drums on site is notrecommended. They should be returned to the

supplier if they are not to be removed.






14. SITE TRANSPORTATION


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 Site access or routing

at site / accidents• Site entrance should be located in such a way so as

to cause minimum inconveniences to the public or

other road users.

• Suitable warning notice should be displayed at the

convenient locations ( adjacent to overhead lines

or near storage areas or excavated pits etc.)

• Provision of one way system and the avoidance of

vehicle reversal recommended upto a satisfactory

level.

• Protective embankment should be provided at the

all excavated sites particularly at the areas where

lories or dumpers trip into excavations.2 Vehicles & drivers /

Accidents• Fitness of vehicle needs to be checked.

• Driver must possess valid license.

• Tiers condition / Battery condition be checked.

3 Violation of driving

rules / accidents• Drivers must follow the traffic rules and signals.

• Speed limit and sharp bends must be avoided.

• Stop and proceed carefully at unmanned junction

points.

4 Over loading /

Accidents• Over loading causes more wear & tear of tires,

road surfaces and decreasing efficiency of the

moving components of the vehicle.

• It also causes less control on steering, inadequacyof break power, overturning while negotiating

sharp bends.

5 Stacked material /

Accidents• Transport vehicle usually should go to the stacked

material site for loading either manually or by

machine.

• In case of loading by a ladder strong canopy or

cap should be provided for the safety of the driver.

• The engine of the vehicle should not be kept

running during the period of stacking.

• In case of loading or transporting of material such

as built up columns or MS rods which are

projected beyond the vehicle should be provided

with precautionary signs suitable ( Flag or Signal

man), to avoid injuries to the people.

• Human being should not be transported in Truck /

Dumpers / Cranes etc.

• Filled Oxygen and Acetylene cylinders should notbe thrown from vehicle. It must be shifted through

bottom rim.






15. WORKING AT HEIGHT

ACTION BY : Concerned Site Engineer / Supervisor / Site Safety Engineer

Sl.No. HAZARDS / RISK PREVENTIVE MEASURE1 Fall of a person /

injury• Fabricate temporary structure / surface of adequate

strength and supported at a number of points to

distribute load.

• Suitable stable platform should be furnished with

width of more than 600 mm for moving along

horizontally.

• Proper access / egress should be provided.

• Good house keeping should be maintained at

elevated work place.

• PPE like safety belts, fall arresting system should

be incorporated / anchored of lifeline with

permanent structure at a height of person shoulderlevel.

• Guy ropes shall be used for anchoring lifeline of

safety belt to facilitate safe horizontal movement

at height.

• In special circumstances fall arrestor should be

used where usage of safety belt is non-practical.

2 Fall of material /

Injury• Platform should be spacious to allow placement of

material and space for working person.

• Barrication / handrails, toe boards should be

provided if necessary.

• Guard / Safety net is provided suitably forpreventing falling of material from height..

• Overloading on temporary platform is avoided.

• Protect structures against external impact.

• Build and dismantle the structures in accordancewith design.

3 Improper scaffolding • Erected on firm and level ground

• Proper approach should be provided by ladders,

Ramps etc.

• Gangway jalies, which are used to form platform

at top, should be tied firmly.

• Slippery / wet condition over the working platform

should be avoided.

• Safety belt & safety helmet are must for the peoplewho are working on scaffolding platform.






16. WELDING & GAS CUTTING - Contd.


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE• Incase of confined area, forced ventilation shall

be provided.

3 Exposure to spark hot

metal and fumes• The welder shall use apron and Helmet with

weld screen.

• Provide adequate ventilation in the working

area.

4 Continuous working /

Heat Stress• Provide adequate ventilation.

• Continuous working should be avoided.

Adequate interval should be provided.

• Incase of confined area, forced ventilation shall

be provided.

5 • 17. Grinding


Sl.No. HAZARDS / RISK PREVENTIVE MEASURE

1 Contact with grinding

wheel / electric shock • Wheel guard should be placed in proper

position.

• Machine should be earthed properly.

• Frequent checking of power cord and use of

plugs & sockets.

• Proper use of PPEs such as grinders goggles,face shields, safety shoes, hand gloves etc.

• Wheel should be mounted properly on the

suitable grinding machine.

• Grinding machine RPM and wheel RPM should

match.

• Use of safety belt during grinding at heightmore than 2 m.

2 Damage of wheel • Check the expiry date.

3 Cable / cord • Double insulated power cable should be used in

grinding machine.

• Joints in cable should be avoided or protectedproperly.






18. FIRE PREVENTION


Sl.No. Causes of fire PREVENTIVE MEASURE1 Malicious ignition,

careless gas cutting,

welding, smoking,

throwing of lighting

match sticks,

uncontrolled rubbish

burning

Incorrect storage and

careless use of

flammable liquids and

compressed gases.

• Portable extinguishers containing Foam, DCP or

BCF should be used on fire involving

flammable liquids. Such fire extinguishers shall

be conspicuously located.

• Nobody shall be allowed to misuse or horseplay

with this emergency equipment.

• Demonstration on the usage of fire

extinguishers shall be arranged.

• Employees shall be instructed to report all firesimmediately and notify their supervisor about

the discharge of the fire extinguisher and its

need of servicing.• The extinguisher should be readily available for

use and note more than 15 m away from the

area of use.

• Employees, especially those involved in

actually using these liquid must be adequately

trained in the proper use of fire extinguishers.

These employees in case of emergency and for

other measures can use extinguisher in the event

of fire.

• Fencing of loading area like flammable liquid

stores, paint oil storage and material stores( especially timber stacks) should have

prominent displaying of “ NO SMOKING”.






12) If the accident happened to any contract labour, please obtain a letter from

the contractor regarding the accident and forward the same to the customer

after obtaining concurrence from HQ.

13) In case of Fatal Accident to contract labour, local Police shall be informed by

the contractor under intimation to you. A copy of the FIR may be forwarded

to HQ.

14) In case of Fatal Accident to BHEL employee, local Police shall be informed

by the Resident Manager under intimation to HQ.

15) Obtain the concurrence and approval of Business Manager & Head(HR)

before signing any Accident Notice Forms under the Factories Act or

Form EE under Workmen’s Compensation Act, etc. or any other documents

related to the accident.

16) In case of Fatal Accident to contract labour, ensure contractor shall arrange

for postmortem and other formalities and hand over the body to the relatives.

17) In case of major accidents resulting in serious bodily injury or death to

contract labour, Resident Manager shall forward the prescribed Form (

Notice of Accidents or Dangerous Occurences Resulting in Death or Bodily

Injury under the Factories Act Rules of the state in which site is situated )

filled and submitted by the sub-contractor to the Customer for onward

transmission to the Assistant Labour Commissioner and other concerned

Authorities within the prescribed time limit. For example Form 22 under

Chatisgarh Factories Act Rules is applicable to Korba East site and Form 18under Punjab Factories Act Rules is applicable to Lehramohabat site.

18) In case of major accidents resulting in serious bodily injury or death to

BHEL employee, Resident Manager shall fill and submit the prescribed

Form ( Notice of Accidents or Dangerous Occurences Resulting in Death or

Bodily Injury under the Factories Act Rules of the state in which site is

situated ) to the Customer for onward transmission to the Assistant Labour

Commissioner and other concerned Authorities within the prescribed time

limit. For example Form 22 under Chatisgarh Factories Act Rules is

applicable to Korba East site and Form 18 under Punjab Factories Act Rules

is applicable to Lehramohabat site.

19) Contact Resident Manager / HR executive of Power Sector Site at the same

location, if available, and take their assistance, in case if they had already

handled a similar accident case at the same location.

20) Ensure providing of details like age (date of birth), wages of the person met

with an accident and injured or expired to the concerned authorities.






21) Ensure depositing of Workmen’s Compensation amount decided by the

authority under the Workmen’s Compensation Act with the Commissioner

of Workmen’s Compensation by the contractor or their Insurance Company.

22) Inform HQ regarding the payment of Workmen’s Compensation through the

authorities to the dependents of the person expired.

23) Ensure payment of other statutory payments also, if any.

HSE ACCIDENT / INCIDENT REPORTING

24) Strictly comply with section 17.0 of HSE Management System Manual in

respect of Accident / Incident reporting system

25) Submit the Accident / Incident Report format to HQ immediately afteroccurrence of accident.

26) Submit the Accident / Incident Investigation Report format to HQ after

completion of the investigation




IS:HSE:AIR:001 ACCIDENT (PERSONAL INJURY / PROPERTY DAMAGE) REPORT


1. NAME OF SITE:

2. SCOPE OF WORK:

3. ACTIVITY OF AREA:

4. NAME OF CONTRACTOR:

5. NAME & DESIGNATION OFBHEL ACTIVITY INCHARGE:

6. DATE & TIME OF ACCIDENT:

7. DATE RESUMED:

8. NO. OF WORKING DAYS LOST BY

VICTIM (if duty not resumed giveestimated figure):

9. NO. OF MAN HOURS LOST BYOTHERS:

10. PERSONAL DETAILS OF INJURED AND/OR DETAILS OF MATERIALS /

EQUIPMENT / PROPERTY DAMAGED:

NAME: NAME OF MATERIAL/ EQUIPMENT/

PROPERTY:

PERIOD OF EMPLOYMENT:

AGE: SEX: MARRIED / SINGLE:

ESTIMATEDCOST

ACTUAL COST

OCCUPATION: PART OF BODY INJURED NATURE OF

DAMAGE

NATURE OF INJURY

11. AGENCY (OBJECT / EQUP /

SUBSTANCE) MOST RESPONSIBLE

FOR CAUSING ACCIDENT / INJURY / DAMAGE:




IS:HSE:AIR:001 ACCIDENT (PERSONAL INJURY / PROPERTY DAMAGE) REPORT

12. PERSON (NAME & DESIGNATION )

WITH MOST CONTROL OVER

AGENCY (OBJECT / EQUIP/ SUBSTANCE) CAUSING ACCIDENT /

INJURY / DAMAGE:

13. DESCRIBE CLEARLY HOW THE

ACCIDENT OCCURRED (IF SPACE

INSUFFICIENT USE SEPARATESHEET & ATTACH):

ANALYSIS:

14. WHAT ACTS AND/OR CONDITIONSCONTRIBUTED MOST DIRECTLY TO

THIS ACCIDENT?

15. WHAT ARE THE BASIC REASONS

FOR THE EXISTENCE OF THESE

ACTS AND / OR CONDITIONS?

16. WHAT CORRECTIVE ACTIONS HAVE

BEEN TAKEN TO PREVENT

Technical Specifications Package a Vol 1

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