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REQUEST FOR PROPOSAL (RFP) FOR

REALISATION OF DELUGE SYSTEMS FOR AUGMENTED FACILITIES AT SLP COMPLEX (ASLP)

SDSC SHAR, SRIHARIKOTA

***

Technical Specifications, Requirements, Terms & Conditions for

Procurement, supply, Fabrication, Erection, Testing & Commissioning of Deluge system for ASLP facilites

February,2020

SATISH DHAWAN SPACE CENTRE Indian Space Research Organization

Department of Space, Government of India Sriharikota 524124

Nellore District, Andhra Pradesh State, India

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CONTENTS

Sl. No.

Description Page No.

1 Introduction 5-12

2 Geographical location and climatic conditions 12-13

3 Summary of work scope 13-14 4 Detailed scope of work 14

5 Codes and standards to be followed for realization 15-16

6 Philosophy followed for realization 15

7 System realization procedure 16-17

7.1 - Scope of Department for system realization 16

8 Free issue material under department scope 17

9 Scope of contractor 17-21

9.1 Procurement & supply 18

9.2 Purchase & supply of materials 18-19 9.3 Onsite fabrication & Erection activities 19 9.4 Inspection 20 9.5 Surveillance inspection by department 20 9.6 Testing and Evaluation (T&E) 20 9.7 Commissioning 20-21

10 Modality of execution of contract 21 11 Delivery schedule 22 I. SECTION – A TERMS AND CONDITIONS FOR BID 1. Terms and conditions for Bids 24

2. Part-I techno – Commercial bid (ENSURE PRICES ARE NOT INDICATED IN PART-I)

24-38

3 Part-II Price bid. (ENSURE PRICES ARE QUOTED FOR ALL THE ITEMS).

38-49

4 Proposal document 50 5 Ambiguity 50 6 Bids Preparation 50-51 7 Bids evaluation 51 8 Commercial terms 52-53 9 Validity of the offer 53

10 Force majeure 53-54 11 Arbitration 54 12 Secrecy clause 54 13 Compliance with security requirements 54 14 Confidentiality and proprietary right protection 54 15 Instructions to the bidder 54-56 16 Terms and conditions 56 17 Exclusion of tenders 56-57 18 Insurance 57 19 Termination for any fault of the contractor 57-58 20 Cancellation in special cases 58 21 Specific requirements 58 22 Unit rates 59 23 Safety 59 24 Transportation & Material Handling 59 25 Evaluation of machinery, man power & consumables 59 26 Medical assistance 60 27 Record of documents, drawings and operation and maintenance manuals 60

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Sl. No.


28 General conditions 60-61 29 Bidder minimum qualification criteria 62 30 Bidder evaluation criteria 63 31 SECTION-B Specification for details of works to be carried out 64-89 II. Realization of deluge system for ASLP facilities, Chapter-1 66-67

1 Fabrication and erection of Carbon Steel (CS) pipes (Butt-welding & Socket Welding, Chapter - 2

68-70

2 Fabrication (Butt-welding & Socket Welding) and erection of Stainless steel pipe (SS304L/316L) TIG Welding and Radiography of Butt-welding weld joints, Chapter -3

71-74

3 Carbon steel and Stainless steel piping system erection works, Chapter – 4

75-79

4 Fabrication and Erection of M.S Structural Steel, Chapter – 5 80-81

5 Providing RCC pipe pedestals, Equipment foundation and related Civil Works, Chapter – 6

82-83

6 Procedure for Application of Wrapping and Coating Materials for CS buried Underground Piping, Chapter -7

84

7 Tubing works for solenoids, actuators, Pressure transmitters, solenoid cubicles & tube tray works, Chapter – 8

85

8 Erection of Equipment (Nitrogen receiver and Nitrogen Accumulator etc.,), Chapter-9

86

9 Third Party Inspection (TPI) scope, Chapter -10 87-89

10 SECTION-C Specifications of the items to be supplied 90-161

1 Mild Steel/Carbon steel pipes Chapter-1 93-94

2 Carbon steel seamless pipes Chapter-2 95-96

3 Carbon steel pipe fittings and flanges Chapter-3 97-100 4 Wafer Type Manual Butterfly Valves Chapter-4 101-102 5 Electro - Pneumatic (EP) Butterfly valves Chapter-5 103-105

6 Carbon steel manual Ball valves Chapter-6 106-108

7 Manual Water monitors Chapter-7 109

7A Remote operated long range water cum foam monitors; Flow rate: 3000lpm @ 7 bar; Fog/Jet nozzle including spares.

Chapter-7A 110-111

8 Deluge valve – Piston Type Chapter-8 112

9 Dry pilot actuator Chapter-9 113

10 Quartzoid bulb detectors(QBDs)/ Pendent type sprinklers with SS protection guard

Chapter-10 114

11 Medium velocity spray nozzles Chapter-11 115

12 Water filters Chapter-12 116-119

13 Specification of Electro Galvanized fasteners Chapter -13 120-121

14 Specification of Electro Galvanized U-clamps Chapter-14 122

15 Paints primer and Final coat paints Chapter-15 123 16 MS structural material Chapter -16 124

17 Miscellaneous items like Anchor fasteners CAF gaskets etc.

Chapter -17 125

18 Seamless Stainless-Steel pipes Chapter -18 126-128

19 SS forged flanges Chapter -19 129-130 20 SS forged Pipe fittings Chapter -20 131-132 21 Stainless steel Manual ball valves Chapter -21 133-134 22 Pressure gauges Chapter -22 135

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Sl. No.


23 SS fasteners Chapter -23 136-137 24 SS U-clamps Chapter -24 138-139 25 SS Spiral wound gaskets Chapter -25 140 26 Pickling and passivation of pipe lines Chapter -26 141-142

27 SS Nitrogen Receivers Chapter - 27 143-150

28 SS Nitrogen Accumulators Chapter - 28 151-155 29 SS Seamless tubes Chapter - 29 156 30 SS Double compression pipe fittings, Check valves Chapter - 30 157 31 GN2 Pressure regulators Chapter - 31 158 32 GN2 Filters Chapter - 32 159 33 Safety relief valves Chapter - 33 160-161 34 Section-D (Formats to be filled by bidder) 162-169 35 Checklist to be filled by the contractor 163-167 36 Bidder minimum qualification criteria 168 37 Evaluation Criteria 169

List of tables Table-1 Schedule of quantities 6-11 Table-2 Part-I Format for Unpriced bid: schedule of quantities 25-37 Table-3 Part-II Format for Price bid : schedule of quantities 39-49

Table-A Details of Specifications of supply items required for water based deluge systems

91

Table-B Details of Specifications of supply items required for GN2 command supply for deluge system

92

List of drawings

Sl. No.

Description of the facility Layout drawing No. P&I Diagram No.

1. Over all layout of ASLP Facilities ASLP/SS/Layout/01 -

2. ISROsene storage and stage filling facility

ASLP/SS/Layout ISROSENE/01

ASLP/SS/ISROsene storage/FWD/01

3. ISROsene stage pressurization facility

Layout ISROSENE DPT/01 ASLP/SS/ISROsene DPT/FWD/01

4. SC120 LOX Storage facility ASLP/SS/Layout/SC-LOFS & NSS/R0

ASLP/SS/SC120/FWD/01

5. Augmentation of Launch pad area (MLP & UT) for ASLP

Layout of piping in UT & ACOUS tower

ASLP/SS/UT & MLP /FWD/01

6. Augmentation of existing LOX storage facility for C32

Layout/CRYO/C32 AUG/R0 ASLP/SS/C32/FWD /01

Equipment drawings Drawing No. 7. Water filter ASLP/SS/filter/01&2 8. GN2 receiver ASLP/SS/GN2 Receiver/01 9. GN2 Accumulator ASLP/SS/GN2 Acc./01

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1. INTRODUCTION

Satish Dhawan Space Centre (SDSC-SHAR), Indian Space Research Organization (ISRO), Department of Space, Government of India, Andhra Pradesh 524124, Nellore District, Andhra Pradesh State, India (hereinafter referred to as “Department”) intends to provide Deluge systems to the newly established and Augumented facilites at Second Launch pad (SLP) Complex,SDSC SHAR viz., Isrosene Storage, ISROsene DPT, SC120 & C32LOX Storage facilities, Mobile Launch Pedestal (MLP) & Umbilical Tower (UT) at SLP complex.

GSLV MKIII launch vehicles consisting of SC120 and SC200 as Semi-Cryo stages & C32 Cryo Upper stage need to be serviced at Second Launch Pad (SLP) of SDSC SHAR, Sriharikota. To meet the above stage servicing requirements, the following facilities are to be realized/augmented at SDSC SHAR. The layout of the facilities is given in the drawing No. ASLP/SS/LAYOUT/01

- ISROsene storage and stage filling facility - ISROsene stage pressurisation facility - SC120 LOX Storage facility - Augmentation of existing LOX storage facility for C32 - Augmentation of Launch pad area (Mobile launch pedestal [MLP] & Umbilical Tower

[UT]).

The piping & flow components related to the above facilities will spread across ISROsene Storage, Stage Pressurization Room & SC120/C32 LOX Storage, Yard, Umbilical Tower (UT) & Mobile Launch Pedestal (MLP) The Department hereby issues the Request for Proposal (RFP) document to the Capable Bidders to carry out the following works.

Sl. No.

Description of the works to be carried out Qty.

1

Realization of Deluge systems for ISROsene storage & ISROsene DPT, SC120 LOX storage, C32 LOX Storage and also fire suppression systems augmentation for launch pad {Umbilical Tower (UT, Jet Deflection Duct (JDD), Mobile launch Pedestal (MLP)} which includes supply of all materials, Piping fabrication, erection, testing, painting & commissioning including third party inspection as per the specifications Section- A to Section-D.

1Lot

(REFER TABLE-1 FOR SCHEDULE OF QUANTITIES FOR WHICH UNIT PRICES SHALL BE QUOTED IN PRICE BID ONLY)

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TABLE-1 SCHEDULE OF QUANTITIES

Sl. No.

Description Units Qty.

1

Carbon steel Butt welding: Butt welding of CS pipes, fittings by GTAW welding process for root and SMAW for subsequent passes, D.P. Test and Radiography (10%) along with weld consumables as per the specification in Section-B/Chapter-2

Inch dia 14500

2

Carbon steel socket welding: Socket welding of CS pipe fittings, slip on flanges etc., by GTAW welding process for root and SMAW for subsequent passes and D.P. Test with weld consumables as per the specification in Section-B/Chapter-2

Inch dia 6000

3

CS piping erection includes Installation of flow components like Butterfly valves, Deluge valves, EP valves, filters with required gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing (Including scaffolding as required), Hydro testing and testing at Max. Operating pressure, painting of pipe lines and tag numbers and commissioning as per the specification in Section-B/Chapter-4

Inch meter

20000

4

Stainless steel Butt welding : Butt welding of SS Pipes, fittings work includes marking, cutting, profiling, aligning, fit up, Tack welding, cleaning, chipping, placement of wind shields and / or weather protection, Root pass, subsequent passes and final pass TIG welding by GTAW process (GTAW welding shall be with 99.99% purity argon gas shielding & purging), D.P. Test and Radiography (10%) with weld consumables as per the specification in Section-B/Chapter-3

Inch dia 2000

5

Stainless Steel pipe Socket Welding : Socket welding of SS pipe fittings, slip on flanges etc. , Root pass, subsequent passes and final pass TIG welding by GTAW process (GTAW welding shall be with 99.99% purity argon gas shielding & purging), D.P. Test with weld consumables as per the specification in Section-B/Chapter-3

Inch dia 1200

6

SS piping erection includes Installation of flow components like Ball valves, filters, check valves with required gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing (Including scaffolding as required), Hydro testing, Pickling & Passivation, cleanliness checks, testing at Max. Operating pressure, painting of pipe lines and tag numbers as per P&I diagram and commissioning as per the specification in Section-B/Chapter-4

Inch meter

1800

7 Supply, Fabrication & erection of structural supports as per the specification in Section-B/Chapter-5

kgs 5000

8 Providing required RCC pipe pedestals/Pipe Trenches for routing Deluge pipe line in the yard as per the specification in Section-B/Chapter-6

Cu.m 50

9 Providing required foundations and grouting of Equipment viz., Nitrogen receivers, filters etc., as per the specification in Section-B/Chapter-6

Cu.m 25

10 Supply of Carbon Steel /Mild steel ERW pipes as per IS 3589 as per the specification in Section-C/Chapter-1 (unit rate shall be inclusive of TPI cost)

10.1 400NB ERW pipe ,Thickness 8mm meter 300 10.2 300NB ERW pipe, Thickness 6.35mm meter 360 10.3 250NB ERW pipe , Thickness 6.35mm meter 500

11 Supply of Carbon steel Seamless pipes as per ASTM-A106Gr.B as per the specification in Section-C/Chapter-2 (unit rate shall be inclusive of TPI cost)

11.1 200NB SEAMLESS PIPE, Sch40 meter 450

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Sl. No.


11.2 150NB SEAMLESS PIPE, Sch40 meter 350 11.3 100NB SEAMLESS PIPE, Sch40 meter 250 11.4 80NB SEAMLESS PIPE, Sch40 meter 250 11.5 50NB SEAMLESS PIPE, Sch40 meter 220 11.6 40NB SEAMLESS PIPE, Sch40 meter 325 11.7 25NB SEAMLESS PIPE, Sch40 meter 200 11.8 15NB SEAMLESS PIPE, Sch40 meter 50

12 Supply of Carbon steel pipe fittings and Flanges as per the specification in Section-C/Chapter-3 (unit rate shall be inclusive of TPI cost)

12.1 400NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 6

12.2 300NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 15 12.3 250NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 20



12.6 100NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 50 12.7 80NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 60


12.9 40NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 65 12.10 25NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 12.11 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 12.12 400NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 12.13 300NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 12.14 250NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 12.15 200NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 10 12.16 150NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 12.17 100NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 12.18 80NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 20 12.19 50NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 12.20 40NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 12.21 25NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 12.22 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 12.23 400NB EQUAL TEE BUTT WELD, Sch40 Nos. 4 12.24 300NB EQUAL TEE BUTT WELD, Sch40 Nos. 10 12.25 250NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 12.26 200NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 12.27 150NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 12.28 100NB EQUAL TEE BUTT WELD, Sch40 Nos. 40 12.29 80NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 12.30 50NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 12.31 40NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 12.32 25NB EQUAL TEE BUTT WELD, Sch40 Nos. 60 12.33 15NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 12.34 400x400x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 12.35 300x300x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 12.36 300x300x200NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 12.37 250X250X200 UNEQUAL TEE BUTT WELD, Sch40 Nos. 8 12.38 250x250x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 5 12.39 200x200x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 10 12.40 200x200x80 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 4

12.41 150x150x100 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15

12.42 100x100x50NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 20

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Sl. No.


12.43 80x80x50 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 30 12.44 50x50x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15 12.45 40x40x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 12.46 25x25x15 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 12.47 400X300 CONCENTRIC REDUCER, Sch40 Nos. 4 12.48 400X250 CONCENTRIC REDUCER, Sch40 Nos. 4 12.49 300X200 CONCENTRIC REDUCER, Sch40 Nos. 4 12.50 300X250 CONCENTRIC REDUCER, Sch40 Nos. 5 12.51 250X200NB CONCENTRIC REDUCER, Sch40 Nos. 10 12.52 200X150 NB CONCENTRIC REDUCER, Sch40 Nos. 10 12.53 150X100 NB CONCENTRIC REDUCER, Sch40 Nos. 30 12.54 100X80 NB CONCENTRIC REDUCER, Sch40 Nos. 20 12.55 100X50 NB CONCENTRIC REDUCER, Sch40 Nos. 20 12.56 80X50 NB CONCENTRIC REDUCER, Sch40 Nos. 30 12.57 50X40 NB CONCENTRIC REDUCER, Sch40 Nos. 10 12.58 50X25 NB CONCENTRIC REDUCER, Sch40 Nos. 40 12.59 40X25 NB CONCENTRIC REDUCER, Sch40 Nos. 40 12.60 25X15 NB CONCENTRIC REDUCER, Sch40 Nos. 30 12.61 40NB THREADEDOLET ,3000# Nos. 30 12.62 25NB THREADEDOLET ,3000# Nos. 50 12.63 20NB THREADEDOLET ,3000# Nos. 200 12.64 15NB THREADEDOLET ,3000# Nos. 400 12.65 50NB SOCKOLET ,3000# Nos. 25 12.66 40NB SOCKOLET ,3000# Nos. 25 12.67 25NB SOCKOLET ,3000# Nos. 40 12.68 15NB SOCKOLET ,3000# Nos. 40 12.69 ONE END NPT THREADED (OET) COUPLING 40NB,3000# Nos. 25 12.70 ONE END NPT THREADED (OET) COUPLING 25NB,3000# Nos. 45 12.71 ONE END NPT THREADED (OET) COUPLING 15NB,3000# Nos. 60 12.72 ONE END NPT THREADED (OET) NIPPLE40NB,SCH80 Nos. 30 12.73 ONE END NPT THREADED (OET) NIPPLE 25NB,SCH80 Nos. 50 12.74 ONE END NPT THREADED (OET) NIPPLE 15NB,SCH80 Nos. 90 12.75 BOTH END NPT THREADED (BET) NIPPLE40NB,SCH80 Nos. 35 12.76 BOTH END NPT THREADED (BET) NIPPLE 25NB,SCH80 Nos. 50 12.77 BOTH END NPT THREADED (BET) NIPPLE 15NB,SCH80 Nos. 90 12.78 600 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 05 12.79 450 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 6 12.80 400 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 12 12.81 350 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 4 12.82 300 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 10 12.83 250 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 30 12.84 200NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 40 12.85 150 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 30 12.86 100 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 45 12.87 80 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 45 12.88 50 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 35 12.89 40 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 20 12.90 25 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 60 12.91 15 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 80 12.92 300 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 2 12.93 250 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 2 12.94 200 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 4 12.95 150 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 6

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Sl. No.


12.96 100 NB BLIND RAISED FACE FLANGE (BLRF), ANSI B16.5,150# Nos. 8 12.97 80 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 18 12.98 50 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 18 12.99 40 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 20

12.100 25 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 20

13 Supply of Manual butterfly valves as per the specification in Section -C / Chapter-4 (unit rate shall be inclusive of TPI cost)

13.1 600 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 13.2 400 NB MANUAL BUTTERFLY VALVE, 150# Nos. 5 13.3 350 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 13.4 300 NB MANUAL BUTTERFLY VALVE, 150# Nos. 10 13.5 250 NB MANUAL BUTTERFLY VALVE, 150# Nos. 20 13.6 200 NB MANUAL BUTTERFLY VALVE, 150# Nos. 20 13.7 150 NB MANUAL BUTTERFLY VALVE, 150# Nos. 15 13.8 100 NB MANUAL BUTTERFLY VALVE, 150# Nos. 10 13.9 80 NB MANUAL BUTTERFLY VALVE, 150# Nos. 30

13.10 50 NB MANUAL BUTTERFLY VALVE, 150# Nos. 30

Supply of spare gear units for the following butterfly valves of sizes as per the specification in Section-C/Chapter-4

13.11 600 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 13.12 400 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 13.13 350 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 13.14 300 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 13.15 250 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 13.16 200 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 13.17 150 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2

14 Supply of CS Manual ball valves as per the specification in Section-C/Chapter-6 (unit rate shall be inclusive of TPI cost)

14.1 40NB MANUAL BALL VALVE FLANGED 150# Nos. 10 14.2 25NB MANUAL BALL VALVE FLANGED 150# Nos. 25 14.3 15NB MANUAL BALL VALVE FLANGED 150# Nos. 25

14.4 25NB MANUAL BALL VALVE SOCKET WELDED 800# Nos. 40

14.5 15NB MANUAL BALL VALVE SOCKET WELDED 800# Nos. 50 14.6 25NB MANUAL BALL VALVE NPT THD 800# Nos. 50 14.7 15NB MANUAL BALL VALVE NPT THD 800# Nos. 50

15 Supply of Electro pneumatic (EP) Butterfly valves as per the specification in Section-C/Chapter-5

15.1 300 NB EP BUTTERFLY VAVE, 150# Nos. 2 15.2 250 NB EP BUTTERFLY VAVE, 150# Nos. 4 15.3 200 NB EP BUTTERFLY VAVE, 150# Nos. 6 15.4 100 NB EP BUTTERFLY VAVE, 150# Nos. 6

Supply of EP Butterfly Valve soft spares kit for above unit as per the specification in Section-C/Chapter-5

15.5 300 NB EP BUTTERFLY VAVE, 150# Sets 2 15.6 250 NB EP BUTTERFLY VAVE, 150# Sets 2 15.7 200 NB EP BUTTERFLY VAVE, 150# Sets 2 15.8 100 NB EP BUTTERFLY VAVE, 150# Sets 2

Supply of EP valve Actuator spares kit for above units as per the specification in Section-C/Chapter-5

15.9 300 NB EP BUTTERFLY VAVE, 150# Sets 2 15.10 250 NB EP BUTTERFLY VAVE, 150# Sets 2 15.11 200 NB EP BUTTERFLY VAVE, 150# Sets 2 15.12 100 NB EP BUTTERFLY VAVE, 150# Sets 2

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Sl. No.


16

Supply of GN2 receiver, Capacity :1000 litres, Operating pressure:10bar as per the specification in Section-C/Chapter-27 and erection of GN2 receiver as per the specification in Section-B/Chapter-9 (unit rate shall be inclusive of TPI cost)

Nos. 3

17

Supply of GN2 Accumulator, Capacity :100 litres, Operating pressure:10bar as per the specification in Section-C/Chapter-28 and erection of GN2 Accumulators as per the specification in Section-B/Chapter-9 (unit rate shall be inclusive of TPI cost)

Nos. 3

18 Supply of Quartziod bulbs detectors (QBDs)/pendent type sprinklers with SS protection guard for Deluge system actuation line, as per the specification in Section-C/Chapter-10

Nos. 250

19 Supply of medium velocity spray nozzles as per the specification in Section-C/Chapter-11

Nos. 400

20 Supply of Deluge Valves as per specifications in Section-C/Chapter-08

20.1 Size:100NB , FLANGED ,150# Nos. 2 20.2 Size: 150NB, FLANGED .150# Nos. 3

21 Supply of Dry pilot actuator for Deluge Valves as per the specification in Section-C/Chapter-09

Nos. 6

22 Supply of pressure regulators in GN2 actuation line as per the specification in Section-C/Chapter-31

Nos. 5

23 Supply of Safety valves in GN2 actuation line as per the specification in Section-C/Chapter-33

Nos. 4

24 Supply of water monitors as per specifications in Section-C/Chapter-07 Nos. 2

25 Supply of water filters for Deluge system as per the specification in Section-C/Chapter-12 and erection of filters as per the specification in Section-B/Chapter-9 (unit rate shall be inclusive of TPI cost)

25.1 Size: 400NB, Mesh size:500 Microns Nos. 1 25.2 Size: 300NB, Mesh size: 500 Microns Nos. 2 25.3 Spare filter elements for filters Size: 400NB, Mesh size:500 Microns Nos. 3 25.4 Spare filter elements for filters Size: 300NB, Mesh size:500 Microns Nos. 2

26 Supply of SS pipe lines for GN2 actuation line of Deluge system. as per the specification in Section-C/Chapter-18 (unit rate shall be inclusive of TPI cost)

26.1 15NB Seamless pipe,SS304L, Sch40 meters 1200

27 Supply of SS Forged Flanges for GN2 actuation line of Deluge system. as per the specification in Section-C/Chapter-19 (unit rate shall be inclusive of TPI cost)

27.1 15NB SLIP-ON RAISED FACE FLANGE (SORF) , 150# Nos. 150 27.2 25NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 27.3 40NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 27.4 50NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10

28 Supply of SS pipe fittings for GN2 actuation line of Deluge system as per the specification in Section-C/Chapter-20 (unit rate shall be inclusive of TPI cost)

28.1 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 100 28.2 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 20 28.3 15NB EQUAL TEE BUTT WELD, Sch40 Nos. 70 28.4 15NB ONE END NPT THREADED (OET) NIPPLE, Sch80 Nos. 75 28.5 15NB ONE END NPT THREADED (OET) COUPLING, 3000# Nos. 110

28.6 15NB EQUAL TEE BOTH ENDS SOCKET WELD WITH NPT (F)THREADED BRANCH, 3000#

Nos. 250

28.7 15NB Cross Butt Weld SCH40 Nos. 60 28.8 Concentric Reducer 50x25 , Sch40 Nos. 10

28.9 Concentric Reducer 50x40 , Sch40 Nos. 10

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29 Supply of SS Manual Ball valves as per the specification in Section-C/Chapter-21 (unit rate shall be inclusive of TPI cost)

29.1 15NB MANUAL BALL VALVE FLANGED, 150# Nos. 45

29.2 15NB MANUAL BALL VALVE SOCKET WELDED, 800# Nos. 25

29.3 15NB MANUAL BALL VALVE NPT THD 800# Nos. 25 30 Supply of Pressure gauges as per the specification in Section-C/Chapter-22

30.1 Pressure gauges Dial size:150mm,Range 0-25bar Nos. 5 30.2 Pressure gauges Dial size:100mm,Range 0-25bar Nos. 15

31 Wrapper coating of CS Buried pipe lines, sizes varying from 150NB to 200NB as per the specification in Section-B/Chapter-07

meters 100


meters 100

33 Bending of pipe lines, Size : 15NB to 25NB (No. of bends) Nos. 30 34 Bending of pipe lines, Size : 40 NB (No. of bends) Nos. 30

35 Supply of SS Tubes Size: ¼” OD: 6.32 mm Thk.0.91mm as per the specification in Section-C/Chapter-29 and erection as per the specification in Section-B/Chapter -8.

meters 250

36 SWAGELOK/PARKER SS Tube fittings and flow components as per the specification in Section-C/Chapter-30

36.1 UNION Male connector 1/4'' NPTx1/4'' OD tube Nos. 60 36.2 UNION Male connector 1/2'' NPTx1/4'' OD tube Nos. 50 36.3 NPT Female connector 1/4'' NPTx1/4'' OD tube Nos. 50 36.4 NPT Female connector 1/2'' NPTx1/4'' OD tube Nos. 50 36.5 UNION Blanking plug 1/4'' OD tube Nos. 20 36.6 UNION Blanking cap 1/4''OD tube Nos. 20 36.7 NPT Front ferrule 1/4'' OD tube Nos. 50 36.8 NPT Back ferrule 1/4'' OD tube Nos. 20 36.9 NPT Nut 1/4'' OD tube Nos. 20

36.10 UNION 1/4'' OD tube Nos. 10 36.11 Check valve 1/2'' NPT (F) Nos. 20

37 Supply of Filters in GN2 actuation line as per the specification in Section-C/Chapter-32

Nos. 5

38 Supply and erection of Tube trays includes cutting, welding, fixing clamps/SS Wires as per Section-B/chapter-8

Kgs 500

39 Remote Operated long-range water cum foam discharge monitor; Make: SKUM; Flow rate: 3000lpm @ 7 bar; fog/Jet Nozzle including spares as per Section-C/Chapter-7A

Sets 1

40 Third Party Inspection (TPI) Cost for the activities as per Section-B/Chapter-10(Number of required visits for TPI agency)

Nos 30

41 Removal of existing CS pipeline of Size: 250NB to 300NB from pedestals/Pipe Trenches/embedment

meters 300

Note:

- The Quantity mentioned is indicative only. The party shall give undertaking to hold the same quoted unit prices for +/- 10% variation of order quantities for each and every item based on detail engineering/site conditions.

- From Sl.No.01 to 09 the quantities may vary based upon site conditions. The payment will be made only for the quantities executed at site.

- If necessary, the Bidders, may visit the SDSC SHAR for understanding the safety system requirements and assessing the site conditions before submitting the bid.

Page | 12

The Bidders shall submit the bids in Two parts viz., (i) Techno-commercial (Un-priced) bid and (ii) Price bid. The Department will initially open the techno-commercial bids and, if necessary, at their own discretion, organize post-bid techno-commercial meeting with the Bidders.

The Department will initially evaluate the techno-commercial bids and shortlist the Suitable Bidders whose techno-commercial bids are in compliance with the RFP specifications. The Department will open the price bids of the technically suitable Bidders only, hold post-bid price discussion, if necessary at their own discretion, and award the Contract based on the technically suitable lowest-priced bid.

The execution period from release of purchase order to final acceptance shall be taken as 12 months. As this Project is of national interest and to be completed within the stipulated period, the Bidders are advised to take utmost care in studying the quantum & nature of work and plan adequate & suitable resources to execute the purchase order within the stipulated period while submitting the bids. This specification document is organized in three sections as follows. Section – A General Terms and Conditions Section – B Technical Specification for works to be carried out at site (Including Detail

Engineering and analysis) Section – C Technical Specification for Supply of items Section – D Formats to be filled by bidder Date of Notification issued by ISRO: As per e procure notification. Last Date of downloading tender Document by tenderer: As per e-procure notification Last date of submission of tender documents in online by tenderer: As per e-procure notification Last date of Bid sealing in online by ISRO: As per notification Last date for giving open authorization in online by tenderer: As per notification

2. GEOGRAPHICAL LOCATION AND CLIMATIC CONDITIONS

Sl.No Description Details a) Owner / Purchaser ISRO, SDSC, SHAR

b) Focal Point Project Director, Augmented Second Launch Pad (ASLP) project

c) Project Title

Establishment of Deluge System for ASLP facilities viz., ISROsene storage & ISROsene DPT and SC120 LOX storage at SECOND LAUNCH PAD, SDSC SHAR Centre, Sriharikota.

d) Plant Location Satish Dhawan Space Centre, SHAR, Sriharikota – 524 124 Nellore Dist. Andhra Pradesh

e) Altitude 4.7123 meters above MSL f) Transportation

Nearest Railway Station

- The actual site is located about 13.0 km from main gate of Sriharikota.

- Sriharikota is 18 km east of Sullurpeta in Nellore Dist. (Sullurupeta is on main rail line from Chennai to Vijayawada)

- Sriharikota is 100 km North of Chennai -

Road Sullurpeta is located on NH-5 from Chennai to Vijayawada.

Air port Nearest airport is Chennai/Tirupati Sea port Nearest seaports are Chennai/ Krishnapatnam.

Page | 13

Sl.No Description Details g) Ambient air temperature

(a) Maximum dry bulb temperature

45.9 Deg. C

(b) Minimum dry bulb temperature

11.8 Deg. C

(c) Design wet bulb temperature for cooling tower design

28.3 Deg. C

h) Relative humidity a) Maximum 100 % ( consider 95 % for design) b) Minimum 15 %

i) Rainfall

Annual average rainfall in a year

1331.3 mm / year

Maximum daily rainfall 240 mm in 24 hours Maximum hourly rainfall 26 mm/ hr. Design intensity 140 mm / hr

Period of rainfall July to December with peak rainfall in October and November.

j) Wind data Basic wind speed 230 KMPH

Cyclone details Place is prone to cyclones during October to December and facilities are to be designed for cyclonic loads

Wind direction Predominantly from South East (*) k) Seismic data Zone Zone III as per IS 1893 – 2002 Coefficient Basic horizontal seismic coefficient 0.16 as per IS:1893

l) Latitude, Longitude 13 º 47’ N, 83º 15’ E (*) m) Atmosphere Saline and highly corrosive.

3. SUMMARY OF WORK SCOPE

Scope of work is the realization of Water based fire suppression systems for the above facilites meeting satutory requirements as per relevant IS Codes, National/ International standards, codes and manuals such as National Fire Protection Association (NFPA) and Oil Industries Safety Directorate (OISD) and ISRO Fire Safety Manual. Realization/augmentation of Water based fire suppression systems from end to end as per the respective Process & Instrumentation diagrams (P&ID) need to be carried out by the contractor in compliance with technical specifications as highlighted in respective annexures. The scope includes supply of all materials, fabrication, erection, testing and commissioning activities at site.

Existing system configuration:

At present to meet the water requirements of fire protection system of SLP complex facilites, dedicated Fire water pump room (FPR) consisting of Nine pumps of 410 m3/hr capacity each with 105m head are connected to Ground level reservoir (GLR) of capacity 2700m3. In addition to the above Two Nos.of Over head tanks (OHTs) of capacity 300 m3 and 42m staging height each are also connected to the deluge system. The deluge system at various facilites in SLP are connected through above ground Carbon steel piping net work to the FPR and OHTs.

Page | 14

To meet the water requirements for the ASLP facilites branch lines of suitable size are to be taken from the Deluge system piping network in SLP complex as per the details given in the layout diagram. (Refer Drawing.ASLP/SS/LAYOUT/01) The new proposed Water based fire suppression systems for the above ASLP facilities is clearly brought out in the following Lay out drawings and P&I diagram. The scope of this contract is for Deluge system piping only.

Sl. No.


1. Over all layout of ASLP Facilities

ASLP/SS/Layout/01 -













4. DETAILED SCOPE OF WORK

Realization of Deluge systems for ISROsene storage & ISROsene DPT, SC120 LOX storage, C32 LOX Storage and also fire water suppression systems augmentation for launch pad {Umbilical tower (UT), Jet deflector duct (JDD), Mobile Launch pedestal (MLP)} which includes supply of all materials, Piping fabrication, erection, testing, painting, & commissioning including third party inspection as per the specifications Section- A to Section-D The scope includes supply, fabrication, erection, testing, commissioning of the following systems as per the schedule given in the Table – 1.

i. Deluge system consisting of Carbon steel (CS) pipe lines and pipe fittings, flow components like Electro pneumatic and manual butterfly valves, Deluge valves, water monitors etc.,

ii. Gaseous Nitrogen (GN2) Actuation line for Deluge system: consisting of Stainless steel (SS304L) pipe lines and pipe fittings, Equipment like SS receivers & accumulators and flow components like SS manual ball valves, check valves, Pressure regulators, safety relief valve etc.,

The scope of work includes interfacing of the newly erected Deluge system with the existing system as per approved drawings. The scope of work also includes excavation, construction of RCC pipe pedestal foundations/grouting for equipment’s and back filling as per site conditions and requirements. Refer Table - I for the schedule of quantities.

Page | 15

5. CODES AND STANDARDS FOLLOWED FOR REALIZATION OF WATER BASED FIRE SUPPRESSION SYSTEMS FOR ASLP FACILITES

The design philosophy for leak/ fire detection system and fire suppression system for ISROsene storage and handling facilites has been prepared based on the ISRO Fire Safety Manual, relevant IS Codes, National/ International standards, codes and manuals such as National Fire Protection Association (NFPA) and Oil Industries Safety Directorate (OISD). The following are the details of the codes and standards followed for Deluge system (Water System): IS 15325 - 2003 Design and Installation of Fixed Automatic High and Medium Velocity Water Spray System. OISD 117 Fire Protection Facilities for Petroleum Depots, Terminals and Pipeline Installations, August 2000. NFPA 15: 2007 Standard for Water Spray Fixed Systems for Fire Protection. ISRO: DOS: SP: 102, Fire Safety Manual, October 2008.

6. PHILOSOPHY FOLLOWED FOR DESIGNING AND REALISATION OF DELUGE SYSTEM.

Based on the relevant IS Codes, National/ International standards, codes and manuals such as National Fire Protection Association (NFPA) and Oil Industries Safety Directorate (OISD) and ISRO Fire Safety Manual following Philosophy is followed for installation of water based Fire suppression systems for ASLP facilites to meet any exengencies and protect operating personnel and property.

Sl. No.

Facility Type of fire suppression system to be

installed

Design density to be considered

lpm /m2

1.

ISROsene Storage and stage filling facility Refer P&I No. ASLP/SS/ISROsene Storage/FWD/01

Deluge system: Modes of activation

- Automatic activation through Deluge valve - Remote activation through EP (Electro–Pneumatic) valve.

- Local operation through Manual valve.

25

2.

ISROsene DPT (Stage pressurization facility) Refer P&I No. ASLP/SS/ISROsene DPT /FWD/01

Deluge system: Modes of activation - Automatic activation through Deluge valve - Remote activation through EP valve - Local operation through Manual valve.

25

3.

SC120/200 & C32LOX Storage and stage filling facility Refer P&I No. ASLP/SS/SC120/FWD/01 & ASLP/SS/C32 /FWD/01

Deluge system: Modes of activation - Automatic activation through Deluge valve - Remote activation through EP valve - Local operation through Manual valve.

10

4. Remote water cum foam water monitors

Modes of activation - Remote activation through EP valve

3000 lpm

Page | 16

6.1 Medium Velocity Water Spray System

Modes of operation: Medium Velocity Water Spray System (MVWSS) for protecting Isrosene storage & Isrosene DPT, SC 120 LOX storage and C32LOX Augmentation facilities against any external fire with the following modes of operation:

Modes of activation

- Automatic activation through Deluge valve. - Remote activation through EP (Electro–Pneumatic) valve. - Local operation through Manual by pass valve.

Water spray nozzles shall be provided to protect the surface area of tanks and road tankers. The arrangement of the spray nozzles shall be in such a way they do not pose any hindrance to the operating personnel during day-to-day operations in the work area as well as protect the equipment during operation of the deluge system. Description of auto actuation of deluge system: Sprinklers (Quartzoid bulb – Temperature rating 68oC) shall be provided around the areas to be protected for detecting the fire and actuating the deluge valve. The entire deluge system shall be provided with necessary flow components like filters, isolation valves, pressure gauges/ transmitters, etc. as per the relevant P&I diagram. Based on pressure drop calculations, the outlet piping of deluge valve is suitably sized to meet the minimum pressure required at the farthest nozzle in the circuit. Deluge system is kept in active mode with source as overhead tank at 4 bar (g) pressure. However whenever needed, pumping system with 10 bar will be operated remotely based on need. The deluge valve selected shall be suiting to this requirement.

6.2 Design Guidelines:

Medium Velocity Water Spray System (MVWSS) are designed based on the following criteria: - The criterion for MVWSS is exposure protection for the entire surface area of the tank or

tanker to be protected at the rate of 25 lpm/sq.m for Isrosene and 10 lpm/sq.m for LOX. - A Minimum Pressure of 1.4bar shall be available at the farthest location of the sprayer. - Provision of water spray nozzle shall be as per the guidelines of IS 15325:2003 ‘Design

and Installation of Fixed Automatic High and Medium velocity Water Spray System’. - For tanker parking areas, the nozzles shall be located suitably to ensure no hindrance to the

movement of the tankers. Also the sprayers shall not be less than 6 mm in orifice size and shall normally have cone angles between 60° and125°.

- Design velocity in water circuit shall be limited to 2 m/sec for yard pipe lines and 4.5 m/s for piping after deluge valve /EP valve.

7. SYSTEM REALIZATION PROCEDURE

Considering the functional requirements of safety system at ASLP facilites at SDSC SHAR- Sriharikota, realization philosophy of Safety systems for ASLP facilities comprises of the following phases:

- Preparation of Isometric & fabrication drawings. - Piping flexibility analysis - Procurement of all pipes, pipe fittings, flow components, process elements. - Site Fabrication and Erection - Testing, commissioning and acceptance.

The scope of the department & contractor as part of facilities realization are brought out clearly in subsequent sections.

Page | 17

7.1 SCOPE OF DEPARTMENT FOR SYSTEM REALIZATION

Towards realization of Safety systems, a brief summary of scope of the department is given below: PRELIMINARY DESIGN: The Department has done the Preliminary Design for safety systems which shall be the input for establishment of safety systems for ASLP facilites:

- Process & Instrumentation Diagrams (P&IDs) for reference - System description (Mechanical & Instrumentation system) - Specification of equipment, materials and services

Upon award of the Contract, the Department will organize a review meeting with the Contractor at their office (Sriharikota), in which the Contractor’s representative(s) shall participate. In the review meeting, Department will provide the basic details considered for generation of Preliminary Design document as part of realization of facilities to the Contractor. 8. FREE-ISSUE MATERIAL (FIM): The Department scope includes supply of following free issue materials for remote operation and health monitoring of deluge system parameters

Sl. No Element description Indicative Quantity,

No’s 01 Pressure transmitters 20 02 Pressure switches 10 03 Solenoid valves 45

Mounting/Integration of these items with the piping circuits is in the scope of contractor as per the approved Process & Instrumentation Diagram. Instrumentation wiring and interfacing with the control system is not in the scope of this contract.

i.Civil works: (department scope)

RCC Pipe pedestals for routing of pipelines as indicated in the layout drawings. (However, if any requirement arises based upon site conditions the contractor shall provide RCC pipe pedestals and pipe trenches as indicated in schedule of Quantities). ii. Electrical Power Supply: Temporary electrical power supply at about 300m from work spot for onsite fabrication activities at free of cost. Necessary junction boxes, safety elements etc. shall be mobilized by the contractor.

iii.Process Fluids:

Process fluids such as potable water, De-mineralized water and GN2 for testing/ commissioning of the facilities will be provided at free of cost.

9. SCOPE OF THE CONTRACTOR

The Scope of the work includes the establishment of Safety systems viz., augmentation of Deluge systems for ISROsene Storage, ISROsene DPT, SC120 & C32 LOX Storage Facility Mobile Launch Pedestal (MLP), Umbilical Tower (UT) and Jet deflector duct(JDD) at Second Launch Pad of SDSC-SHAR. The Contractor shall be responsible for realization of Deluge systems for the ASLP facilities from end to end (including interfacing with existing Fire water source and Pumping systems) as per the respective Process & Instrumentation diagrams towards achieving the overall satisfactory performance of the systems

Page | 18

The Contractor shall review and confirm the Department's specifications presented and clearly delineate any deviation from the specifications laid down with exhaustive reasoning and put up to the approval of the Department. Once accepted, it is the Contractor's responsibility to configure, detail out, procure, install, test and commission the entire system meeting the total functional requirements as per the specifications and conditions stipulated in this document/ contract. The scope of contractor includes the following towards realisation of facilites:

- Deluge system: For ISROSENE Storage, ISROSENE DPT, SC120 LOX Storage and C32-LOX augmentation facilities

The following are in the contract scope:

- Preparation of Isometric Diagrams - Piping Flexibility Analysis. - Preparation of Fabrication drawings and detail engineering. - Procurement and supply of material as per approved specification. - On site Fabrication, Erection, Inspection, Testing & Commissioning - Deputation of Representatives for Joint technical and managerial reviews. - Preparation of final as built drawings. - Engaging any of the following Third party inspection agency and the activities to be

carried out by the TPI are given in SECTION – B, Chapter- 10. o Lloyds Register Industrial Services Pvt Ltd (LRIS) o Det-Norske Veritas (DNV) o Technischer Uberwachungs Verein (TUV) o Buearea Veritas (BV)

- The inspection, test & evaluation and commissioning 9.1 PROCUREMENT AND SUPPLY Procurement and supply for deluge system as per approved specifications shall be carried out as per time schedule given in sl no. 15 The following procurement procedure shall be followed for all the items: - Approval of procurement specifications and vendors list by Department. - Detailed specifications along with catalogues/technical literatures, unpriced purchase

order, quality assurance plan are to be exchanged between Contractor and Department. - Approval from Department regarding deviations with reference to Purchase Order during

manufacturing. - Expediting services with reference to submission of drawings, manufacturing schedules,

supply of material and dispatch. - This phase of work also involves inspection at different levels/stages of fabrication/

production, final testing and acceptance. The following documents shall be furnished after placement of order and prior to arrival of items at site. - Design calculations (if any) (prior to fabrication/production) for the approval of the

Department. - Fabrication drawings subsequent to approval of design calculations by the Department. - Quality assurance plan for the approval by Department and third party inspection agency. - Final inspection, testing and acceptance certificate from third party inspection agency. - Installation, commissioning, operation and maintenance manuals. - Operational procedures of sub-systems and systems for the desired end specifications. - Production master files for each of the fabricated equipment/ items giving the total history

of design, approval, fabrication, inspection and testing.

Page | 19

9.2 PURCHASE & SUPPLY OF MATERIALS:

- All the materials including the items not covered under Department’s scope (except the FIMs listed) are to be purchased by the Contractor.

- It is the responsibility of the Contractor to ensure that specifications of all materials shall be in compliance to department requirement.

- The Brief specification, make / model/brand / probable suppliers list for each and every item are provided. If any change is proposed by the contractor same should be approved by the department. The probable suppliers list is also provided for ready reference. In case of any new supplier is identified the new supplier shall be approved by the Purchaser.

- Purchaser/ Department will involve in all stages of procurement of items starting from specification generation to receipt of items at site including inspection, testing & dispatch.

- The contractor shall follow strictly the instructions provided by the department for the procurement of items.

- The contractor shall intimate regularly the procurement activities and get necessary approval in each & every stage of procurement.

- The unit cost of the items shall be quoted. - Quantity variation of +10% of the items is permitted for each and every item. However,

while initial procurement, the given quantity in the annexure alone is to be procured and supplied. Later if any requirement arises (Due to Detail Engineering), the extra items shall be supplied under this +10% quantity variation clause else this quantity variation clause will not be applicable.

The schedule of quantities based on preliminary design by departnment is as per the TABLE - I

9.3 ONSITE FABRICATION & ERECTION ACTIVITIES:

The Contractor shall be responsible for the following activities as part of onsite erection & commissioning: - Fabrication, erection and testing of piping/equipment as per the procedures stipulated in

RFP. - It is the responsibility of the supplier to depute one experienced supervisor

(Degree/Diploma in Mechanical Engg) with minimum 3-5-year experience in similar Fabrication works & documentation. Also Quality & safety personnel shall be deployed throughout the contract period for coordinating the following works at site irrespective of no. of batches.

- Discussion and Finalization of nature of fabrication works with Department Engineers. - Collection and mobilization of required Pipes/Fittings/Consumables etc. - Co-ordination with Quality Assurance/Site Engineers for fabrication, Deployment of

required manpower and following Safety precautions. - Mobilization of Adequate skilled, semi-skilled manpower like 6G qualified TIG pipe welders,

arc welders, fitter / fabricator, grinders and un-skilled helper gangs. - The purchaser reserves right to Demand for Deployment of multiple batches at a time for

the timely completion of project works. Hence the supplier should have capacity to mobilize required number of batches for successful completion of the work.

- The works done by the Contractor during fabrication, erection & commissioning shall be inspected by the TPI agency.

- The Contractor shall arrange for construction of temporary sheds/ buildings for storing materials, erection equipment, tools & tackles etc. The Contractor’s personnel shall not be permitted to reside inside the Department’s premises after the work. The Contractor shall arrange for transportation, accommodation, food, health care, communication, etc. for their personnel.

- The Department will provide space at free of cost towards for construction of an office room at site.

- The contractor shall follow the safety norms dictated by the safety team of the department during welding, erection & testing.

Page | 20

- The personnel safety shall be taken care by the contractor including the compliance to all statutory and labour regulations.

9.4 INSPECTION:

The Contractor shall be responsible for inspection as per the scope highlighted below: 9.4.1 PRIMARY INSPECTION BY THIRD PARTY INSPECTION (TPI) AGENCY. The primary agency responsible for inspection of the systems/ subsystems/ components/ materials/ services shall be a Third-Party Inspection (TPI) agency who shall be chosen from among the following list:

- Lloyds Register Industrial Services Pvt Ltd (LRIS) - Det-Norske Veritas (DNV) - Technischer Uberwachungs Verein (TUV) - BeaureaVeritas (BV )

In the event of unavailability of any of the aforesaid TPI agencies in a particular location, the Department may, at their own discretion on case-to-case basis, permit engaging alternative TPI agency based on proposal from the Contractor along with the agency’s credential. The TPI agency shall be responsible for: - Review of test packs of bought-out materials at the Sub-vendor’s premise, Material-receipt

(inward), in-process (stage) & pre-delivery (final) inspection during manufacture/ fabrication at the Contractors’/ Sub-contractor’s/ Sub-vendor’s premises and Material-receipt (inward), in-process (stage) & final inspection during fabrication/ erection at the Department’s premise

- However, the Contractor/ Sub-contractor/ Sub-vendor shall prepare Quality Assurance Plan (QAP) giving the detailed scope of inspection and submit to the Department for approval.

9.5 SURVEILLANCE INSPECTION BY DEPARTMENT

Notwithstanding the inspection by TPI agency, the Department, at their own discretion and on surveillance basis, shall have the right to depute their representative(s) to perform material-receipt/ in-process/ final pre-delivery inspection at any phase during fabrication/ manufacture of any system/ subsystem/ component/ material at the Contractor’s/ Sub-contractor’s/ Sub-vendor’s premise as well as during fabrication/ erection at the Department’s site for ascertaining the material and workmanship of the system. The Contractor shall obtain the necessary permission for the Department’s representatives to visit the Sub-contractor’s/ Sub-vendor’s premise. The participation and approval by the Department’s representatives during the inspection/ review shall not absolve the Contractor of their responsibility to comply with the specification/ obligation of the Contract.

9.6 TEST& EVALUATION

On successful completion of final integrated system leak tests, the system shall be subjected to Test & Evaluation (T & E). The T & E plans shall be drawn based on the guidelines given by the Department and to be approved by the Department and third party inspection agency. The approved T & E plan shall be adopted for testing and performance evaluation of the system realized. (By considering the procedures as stipulated in RFP) The Test & Evaluation of the system shall basically consist of independent testing trials.

Page | 21

9.7 COMMISSIONING

After completing the Test and Evaluation of the systems/sub-systems commissioning activities shall be carried out by the contractor with participation of department. The commissioning activities are as follows: - Performance testing of system. - Contractor’s responsibility is limited to participation in trials by deputing his team to ensure

that the work performed by him including the installation shall work to the expected level as per the specifications, standards and procedure stipulated in the contract. All the systems realized by the contractor shall be used and their over all performance to meet the functional requirements specified in the contract will be evaluated.

- It is binding on the contractor that the systems realized shall meet the ASLP facilities safety system requirements specified in total. Deficiencies of the system to meet the requirements/specifications shall have to be rectified at the Contractor’s own cost and their performance shall be re-evaluated and proved.

10. Modality of execution of contract:

1. The contractor as per the scope has to execute procurement & supply, fabrication, erection and commissioning of Safety systems.

2. The contractor has to prepare the isometric drawings and fabrication drawings of the system.

3. As per P& ID, end to end realization, erection & commissioning are to be carried out by the contractor.

4. For the erection of Flow components & pipe lines, the required machineries shall be mobilized by the contractor. Accordingly, the cost shall be quoted. SDSC SHAR has the facility of ‘Material handling’. Based on the availability of machineries, supplier can make use of the facility on chargeable basis.

5. The temporary power supply for fabrication, Potable water, DM water / Nitrogen gas during erection/ commissioning will be provided by the department, free of cost.

6. The contractor has to procure and supply the items (both mechanical / Process) as per the scope. While quoting, the unit rate of the items shall be quoted.

7. The year of manufacture of the entire supply portion shall be within ± 10 months from the date of PO release. Older stock will not be accepted.

8. +10% variation in the quantity is permitted in the contract for each and every item as per site conditions.

9. All the supply portion of the items shall be completed within stipulated period and fabrication, erection and commissioning shall be completed within contract period.

10. Since delivery is the essence of this order, LD @ 0.5% per week or part thereof subject to a maximum of 10% of the order value for the delayed period of supply/scope of work.

11. The contractor shall follow the rules, regulations and Safety norms of the department.

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11. TIME LINE SCHEDULE The overall timeline for realization of systems as per defined scope shall be taken as 12 months from the date of release of purchase order. Split up of the overall schedule for supply and erection is as follows:

Sl. No.

Description of activity Time line

1 Release of purchase order T0

2 Submission of Specification & Technical data sheets of all supply item of deluge System

T0 + 2 weeks

3 Approval of above specifications & Technical data sheets by department

T0 +3 weeks

4 Preparation of ISO metric & fabrication drawings of Deluge system

T0 + 3 weeks

5 Procurement of materials cleared vide SI No:3 T0 + 7 months

6 Submission for approval of Isometric drawings, fabrication drawings.

T0 + 6 weeks

7 Approval of Department for Activity listed in SI.No. 06 T0 + 7 weeks

8 Mobilization of teams for pipe line fabrication preparations T0 + 7 months

9 Completion of Fabrication, Erection & Testing of Deluge system of propellant storages

T0 + 10 months

10 Completion of Test & Evaluation of Deluge system T0 + 11 months

11 Commissioning of Deluge System shall be completed within one month after Confirmation of Site Clearance by Department

Confirmation of Site Clearance by department + 1 Month

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Section – A

Terms & Conditions for bid

Page | 24

1.0 TERMS AND CONDITIONS FOR BIDS

Offers shall be submitted in TWO-PARTS as per the details given below: - Part-I – Techno-commercial Bid - Part-II – Price Bid

2.0 Details to be furnished in Techno-commercial Bid & Price Bid as follows: -

Part-I – Techno-commercial Bid

- The tenderer shall furnish point-wise confirmation for the technical specifications given in the enquiry. However, change of specifications/ deviations (if any) shall be brought out in the offer as deviation summary with detailed justification. Exclusions, if any from scope of supply shall be clearly indicated in the offer.

- Tenderer need to furnish the details related to commercial terms indicating payment terms, details of bank guarantee in case of advance payments & name of Third Party Inspection Agency proposed etc.

- Tenderer shall quote the prices on “FOR-Sriharikota”. - The overall landed cost to SDSC SHAR will be taken as the basis towards finalization of

the purchase order. - The Bidders shall indicate clearly the delivery/time period for supplying the items to SDSC

SHAR.

2.1Bidder need to submit unpriced price bid copy (as highlighted below) indicating the description of all the cost elements considered, without indicating the price. Tenderer shall note that indication of price in the techno-commercial bid shall lead to dis-qualification of bid.

2.1.1 FORMAT OF UN-PRICED PRICE BID:

Sl. No.

Description

Qty

.

Uni

ts

Uni

t co

st (

Incl

udin

g

Tra

nsp

ort

atio

n, &

T

est

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Ap

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Rs.

Se

par

ate

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Fo

rm (

Yes

/No

)

1

Realization of Deluge systems for ISROsene storage & ISROsene DPT, SC120 LOX storage , C32 LOX Storage and also fire suppression systems augmentation for launch pad {Umbilical Tower(UT, Jet Deflection Duct(JDD), Mobile launch Pedestal(MLP)}which includes supply of all materials, Piping fabrication, erection, testing, painting, & commissioning including third party inspection as per the specifications Section- A to Section-D

1 Lot

Unp

rice

d

Unp

rice

d

Unp

rice

d

Ye

s/N

o

Note: - The detailed specification, quantities are enclosed in the Section - B & C of the enclosed

specifications. - The contract will be awarded to technically suitable and overall lowest party only. Since

procurement, supply and work contracts are interlinked splitting of order is not possible. - One Lot consists of the following as defined in table-2:

Page | 25

Schedule of Quantities: Table -2

Sl. No.


Uni

t co

st (

Incl

udin

g T

rans

port

atio

n, &

Tes

ting

C

harg

es)

Rs.

Ap

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able

Tax

in

Rs.

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Carbon steel Butt welding: Butt welding of CS pipes, fittings by GTAW welding process for root and SMAW for subsequent passes, D.P. Test and Radiography (10%) along with weld consumables as per the specification in Section-B/Chapter-2

Inch dia

14500 * * # * Yes/No

2 Carbon steel socket welding: Socket welding of CS pipe fittings, slip on flanges etc., by GTAW welding process for root and SMAW for subsequent passes and D.P. Test with weld consumables as per the specification in Section-B/Chapter-2

Inch dia

6000 * * # * Yes/No

3

CS piping erection includes Installation of flow components like Butterfly valves, Deluge valves, EP valves, filters with required gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing (Including scaffolding required, Hydro testing and testing at Max. Operating pressure, painting of pipe lines and tag numbers and commissioning as per the specification in Section-B/Chapter-4

Inch meter

20000 * * # * Yes/No

4


Inch dia

2000 * * # * Yes/No

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Stainless Steel pipe Socket Welding : Socket welding of SS pipe fittings, slip on flanges etc. , Root pass, subsequent passes and final pass TIG welding by GTAW process (GTAW welding shall be with 99.99% purity argon gas shielding & purging), D.P. Test with weld consumables as per the specification in Section-B/Chapter-3

Inch dia

1200 * * # * Yes/No

6

SS piping erection includes Installation of flow components like Ball valves, filters, check valves with required gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing (Including scaffolding required),Hydro testing, Pickling & Passivation, cleanliness checks, testing at Max. Operating pressure, painting of pipe lines and tag numbers as per P&I diagram and commissioning as per the specification in Section-B/Chapter-4

Inch meter

1800 * * # * Yes/No


kgs 5000 * * # * Yes/No

8 Providing required RCC pipe pedestals/Pipe trenches for routing Deluge pipe line in the yard as per the specification in Section-B/Chapter-6

Cu.m 50 * * # * Yes/No


Cu.m 25 * * # * Yes/No


* * # * Yes/No

10.1 400NB ERW pipe ,Thickness 8mm meter 300 * * # * Yes/No 10.2 300NB ERW pipe, Thickness 6.35mm meter 360 * * # * Yes/No 10.3 250NB ERW pipe , Thickness 6.35mm meter 500 * * # * Yes/No

Page | 27

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* * # * Yes/No

11.1 200NB SEAMLESS PIPE, Sch40 meter 450 * * # * Yes/No 11.2 150NB SEAMLESS PIPE, Sch40 meter 350 * * # * Yes/No 11.3 100NB SEAMLESS PIPE, Sch40 meter 250 * * # * Yes/No 11.4 80NB SEAMLESS PIPE, Sch40 meter 250 * * # * Yes/No 11.5 50NB SEAMLESS PIPE, Sch40 meter 220 * * # * Yes/No 11.6 40NB SEAMLESS PIPE, Sch40 meter 325 * * # * Yes/No 11.7 25NB SEAMLESS PIPE, Sch40 meter 200 * * # * Yes/No 11.8 15NB SEAMLESS PIPE, Sch40 meter 50 * * # * Yes/No


* * # * Yes/No

12.1 400NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 6 * * # * Yes/No 12.2 300NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 15 * * # * Yes/No 12.3 250NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 20 * * # * Yes/No 12.4 200NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 45 * * # * Yes/No 12.5 150NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 45 * * # * Yes/No 12.6 100NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 50 * * # * Yes/No 12.7 80NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 60 * * # * Yes/No 12.8 50NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 75 * * # * Yes/No 12.9 40NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 65 * * # * Yes/No 12.10 25NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 * * # * Yes/No 12.11 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 * * # * Yes/No

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12.12 400NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 * * # * Yes/No 12.13 300NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 * * # * Yes/No 12.14 250NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 * * # * Yes/No 12.15 200NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 10 * * # * Yes/No 12.16 150NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 * * # * Yes/No 12.17 100NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 * * # * Yes/No 12.18 80NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 20 * * # * Yes/No 12.19 50NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 * * # * Yes/No 12.20 40NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 * * # * Yes/No 12.21 25NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 * * # * Yes/No 12.22 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 * * # * Yes/No 12.23 400NB EQUAL TEE BUTT WELD, Sch40 Nos. 4 * * # * Yes/No 12.24 300NB EQUAL TEE BUTT WELD, Sch40 Nos. 10 * * # * Yes/No 12.25 250NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 * * # * Yes/No 12.26 200NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 * * # * Yes/No 12.27 150NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 * * # * Yes/No 12.28 100NB EQUAL TEE BUTT WELD, Sch40 Nos. 40 * * # * Yes/No 12.29 80NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 * * # * Yes/No 12.30 50NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 * * # * Yes/No 12.31 40NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 * * # * Yes/No 12.32 25NB EQUAL TEE BUTT WELD, Sch40 Nos. 60 * * # * Yes/No 12.33 15NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 * * # * Yes/No 12.34 400x400x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 * * # * Yes/No 12.35 300x300x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 * * # * Yes/No

Page | 29

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12.36 300x300x200NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 * * # * Yes/No 12.37 250X250X200 UNEQUAL TEE BUTT WELD, Sch40 Nos. 8 * * # * Yes/No 12.38 250x250x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 5 * * # * Yes/No 12.39 200x200x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 10 * * # * Yes/No 12.40 200x200x80 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 4 * * # * Yes/No

12.41 150x150x100 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15 * * # * Yes/No

12.42 100x100x50NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 20 * * # * Yes/No 12.43 80x80x50 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 30 * * # * Yes/No 12.44 50x50x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15 * * # * Yes/No 12.45 40x40x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 * * # * Yes/No 12.46 25x25x15 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 * * # * Yes/No 12.47 400X300 CONCENTRIC REDUCER, Sch40 Nos. 4 * * # * Yes/No 12.48 400X250 CONCENTRIC REDUCER, Sch40 Nos. 4 * * # * Yes/No 12.49 300X200 CONCENTRIC REDUCER, Sch40 Nos. 4 * * # * Yes/No 12.50 300X250 CONCENTRIC REDUCER, Sch40 Nos. 5 * * # * Yes/No 12.51 250X200NB CONCENTRIC REDUCER, Sch40 Nos. 10 * * # * Yes/No 12.52 200X150 NB CONCENTRIC REDUCER, Sch40 Nos. 10 * * # * Yes/No 12.53 150X100 NB CONCENTRIC REDUCER, Sch40 Nos. 30 * * # * Yes/No 12.54 100X80 NB CONCENTRIC REDUCER, Sch40 Nos. 20 * * # * Yes/No 12.55 100X50 NB CONCENTRIC REDUCER, Sch40 Nos. 20 * * # * Yes/No 12.56 80X50 NB CONCENTRIC REDUCER, Sch40 Nos. 30 * * # * Yes/No 12.57 50X40 NB CONCENTRIC REDUCER, Sch40 Nos. 10 * * # * Yes/No 12.58 50X25 NB CONCENTRIC REDUCER, Sch40 Nos. 40 * * # * Yes/No 12.59 40X25 NB CONCENTRIC REDUCER, Sch40 Nos. 40 * * # * Yes/No

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12.60 25X15 NB CONCENTRIC REDUCER, Sch40 Nos. 30 * * # * Yes/No 12.61 40NB THREADEDOLET ,3000# Nos. 30 * * # * Yes/No 12.62 25NB THREADEDOLET ,3000# Nos. 50 * * # * Yes/No 12.63 20NB THREADEDOLET ,3000# Nos. 200 * * # * Yes/No 12.64 15NB THREADEDOLET ,3000# Nos. 400 * * # * Yes/No 12.65 50NB SOCKOLET ,3000# Nos. 25 * * # * Yes/No 12.66 40NB SOCKOLET ,3000# Nos. 25 * * # * Yes/No 12.67 25NB SOCKOLET ,3000# Nos. 40 * * # * Yes/No 12.68 15NB SOCKOLET ,3000# Nos. 40 * * # * Yes/No 12.69 ONE END NPT THREADED (OET) COUPLING 40NB,3000# Nos. 25 * * # * Yes/No 12.70 ONE END NPT THREADED (OET) COUPLING 25NB,3000# Nos. 45 * * # * Yes/No 12.71 ONE END NPT THREADED (OET) COUPLING 15NB,3000# Nos. 60 * * # * Yes/No 12.72 ONE END NPT THREADED (OET) NIPPLE40NB,SCH80 Nos. 30 * * # * Yes/No 12.73 ONE END NPT THREADED (OET) NIPPLE 25NB,SCH80 Nos. 50 * * # * Yes/No 12.74 ONE END NPT THREADED (OET) NIPPLE 15NB,SCH80 Nos. 90 * * # * Yes/No 12.75 BOTH END NPT THREADED (BET) NIPPLE40NB,SCH80 Nos. 35 * * # * Yes/No 12.76 BOTH END NPT THREADED (BET) NIPPLE 25NB,SCH80 Nos. 50 * * # * Yes/No 12.77 BOTH END NPT THREADED (BET) NIPPLE 15NB,SCH80 Nos. 90 * * # * Yes/No 12.78 600 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 05 * * # * Yes/No 12.79 450 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 6 * * # * Yes/No 12.80 400 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 12 * * # * Yes/No 12.81 350 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 4 * * # * Yes/No 12.82 300 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 10 * * # * Yes/No 12.83 250 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 30 * * # * Yes/No

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12.84 200NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 40 * * # * Yes/No 12.85 150 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 30 * * # * Yes/No 12.86 100 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 45 * * # * Yes/No 12.87 80 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 45 * * # * Yes/No 12.88 50 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 35 * * # * Yes/No 12.89 40 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 20 * * # * Yes/No 12.90 25 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 60 * * # * Yes/No 12.91 15 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 80 * * # * Yes/No 12.92 300 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 2 * * # * Yes/No 12.93 250 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 2 * * # * Yes/No 12.94 200 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 4 * * # * Yes/No 12.95 150 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 6 * * # * Yes/No 12.96 100 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 8 * * # * Yes/No 12.97 80 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 18 * * # * Yes/No 12.98 50 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 18 * * # * Yes/No 12.99 40 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 20 * * # * Yes/No 12.100 25 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 20 * * # * Yes/No

13 Supply of Manual butterfly valves as per the specification in Section-C/Chapter-4 (unit rate shall be inclusive of TPI cost)

* * # * Yes/No

13.1 600 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 * * # * Yes/No 13.2 400 NB MANUAL BUTTERFLY VALVE, 150# Nos. 5 * * # * Yes/No 13.3 350 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 * * # * Yes/No 13.4 300 NB MANUAL BUTTERFLY VALVE, 150# Nos. 10 * * # * Yes/No 13.5 250 NB MANUAL BUTTERFLY VALVE, 150# Nos. 20 * * # * Yes/No 13.6 200 NB MANUAL BUTTERFLY VALVE, 150# Nos. 20 * * # * Yes/No

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13.7 150 NB MANUAL BUTTERFLY VALVE, 150# Nos. 15 * * # * Yes/No 13.8 100 NB MANUAL BUTTERFLY VALVE, 150# Nos. 10 * * # * Yes/No 13.9 80 NB MANUAL BUTTERFLY VALVE, 150# Nos. 30 * * # * Yes/No 13.10 50 NB MANUAL BUTTERFLY VALVE, 150# Nos. 30 * * # * Yes/No

Supply of spare gear units for the following sizes as per the specification in Section-C/Chapter-4

13.11 600 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 * * # * Yes/No 13.12 400 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 * * # * Yes/No 13.13 350 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 * * # * Yes/No 13.14 300 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 * * # * Yes/No 13.15 250 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 * * # * Yes/No 13.16 200 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 * * # * Yes/No 13.17 150 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 * * # * Yes/No


14.1 40NB MANUAL BALL VALVE FLANGED 150# Nos. 10 * * # * Yes/No 14.2 25NB MANUAL BALL VALVE FLANGED 150# Nos. 25 * * # * Yes/No 14.3 15NB MANUAL BALL VALVE FLANGED 150# Nos. 25 * * # * Yes/No

14.4 25NB MANUAL BALLVALVE SOCKET WELDED 800# Nos. 40 * * # * Yes/No

14.5 15NB MANUAL BALL VALVE SOCKET WELDED 800# Nos. 50 * * # * Yes/No

14.6 25NB MANUAL BALL VALVE NPT THD 800# Nos. 50 * * # * Yes/No

14.7 15NB MANUAL BALL VALVE NPT THD 800#

Nos. 50 * * # * Yes/No

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15.1 300 NB EP BUTTERFLY VAVE, 150# Nos. 2 * * # * Yes/No 15.2 250 NB EP BUTTERFLY VAVE, 150# Nos. 4 * * # * Yes/No 15.3 200 NB EP BUTTERFLY VAVE, 150# Nos. 6 * * # * Yes/No 15.4 100 NB EP BUTTERFLY VAVE, 150# Nos. 6 * * # * Yes/No

Supply of EP Butterfly Valve soft spares repair kit for above unit as per the specification in Section-C/Chapter-5

15.5 300 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No 15.6 250 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No 15.7 200 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No 15.8 100 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No

Supply of EP valve Actuator spares repair kit for above units as per the specification in Section-C/Chapter-5

15.9 300 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No 15.10 250 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No 15.11 200 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No 15.12 100 NB EP BUTTERFLY VAVE, 150# Sets 2 * * # * Yes/No

16 Supply of GN2 receiver, Capacity :1000 litres,Operating pressure:10bar as per the specification in Section-C/Chapter-27 and erection of GN2 receiver as per the specification in Section-B/Chapter-9 (unit rate shall be inclusive of TPI cost)

Nos. 3 * * # * Yes/No

17

Supply of GN2 Accumulator, Capacity :100 litres,Operating pressure:10bar as per the specification in Section-C/Chapter-28 and erection of GN2 Accumulators as per the specification in Section-B/Chapter-9 (unit rate shall be inclusive of TPI cost)

Nos. 3 * * # * Yes/No

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18 Supply of Quartzoid bulbs detectors(QBDs)/pendent type sprinklers with SS protection guard for Deluge system actuation line, as per the specification in Section-C/Chapter-10

Nos. 250 * * # * Yes/No


Nos. 400 * * # * Yes/No

20 Supply of Deluge Valves as per specifications as per the specification in Section-C/Chapter-08

20.1 Size:100NB , FLANGED ,150# Nos. 2 * * # * Yes/No 20.2 Size: 150NB, FLANGED .150# Nos. 3 * * # * Yes/No


Nos. 6 * * # * Yes/No


Nos. 5 * * # * Yes/No


Nos. 4 * * # * Yes/No

24 Supply of water monitors as per specifications in Section-C/Chapter-07 Nos. 2 * * # * Yes/No


25.1 Size: 400NB, Mesh size:500 Microns Nos. 1 * * # * Yes/No 25.2 Size: 300NB, Mesh size: 500 Microns Nos. 2 * * # * Yes/No 25.3 Spare filter elements for filters Size: 400NB, Mesh size:500 Microns Nos. 3 * * # * Yes/No 25.4 Spare filter elements for filters Size: 300NB, Mesh size:500 Microns Nos. 2 * * # * Yes/No


26.1 15NB Pipe Seamless pipe,SS304L, Sch40 meters 1200 * * # * Yes/No

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27.1 15NB SLIP-ON RAISED FACE FLANGE (SORF) , 150# Nos. 150 * * # * Yes/No 27.2 25NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 * * # * Yes/No 27.3 40NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 * * # * Yes/No 27.4 50NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 * * # * Yes/No


28.1 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 100 * * # * Yes/No 28.2 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 20 * * # * Yes/No 28.3 15NB EQUAL TEE BUTT WELD, Sch40 Nos. 70 * * # * Yes/No 28.4 15NB ONE END NPT THREADED (OET) NIPPLE, Sch80 Nos. 75 * * # * Yes/No 28.5 15NB ONE END NPT THREADED (OET) COUPLING, 3000# Nos. 110 * * # * Yes/No


Nos. 250 * * # * Yes/No

28.7 15NB Cross Butt Weld SCH40 Nos. 60 * * # * Yes/No

28.8 Concentric Reducer 50x25 , Sch40 Nos. 10 * * # * Yes/No

28.9 Concentric Reducer 50x40 , Sch40 Nos. 10 * * # * Yes/No


29.1 15NB MANUAL BALL VALVE FLANGED, 150# Nos. 45 * * # * Yes/No

29.2 15NB MANUAL BALL VALVE SOCKET WELDED, 800# Nos. 25 * * # * Yes/No

29.3 15NB MANUAL BALL VALVE NPT THD 800# Nos. 25 * * # * Yes/No

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30 Supply of Pressure gauges as per the specification in Section-C/Chapter-22

30.1 Pressure gauges Dial size:150mm,Range 0-25bar Nos. 5 * * # * Yes/No 30.2 Pressure gauges Dial size:100mm,Range 0-25bar Nos. 15 * * # * Yes/No


meters 100 * * # * Yes/No



33 Bending of pipe lines, Size : 15NB to 25NB (No. of bends) Nos. 30 * * # * Yes/No

34 Bending of pipe lines, Size : 40 NB (No. of bends) Nos. 30 * * # * Yes/No

35 Supply of SS Tubes Size: ¼ ” OD:6.32 mm Thk.0.91mm as per the specification in Section-C/Chapter-29 and erection as per the specification in Section-B/Chapter -8.



36.1 UNION Male connector 1/4'' NPTx1/4'' OD tube Nos. 60 * * # * Yes/No

36.2 UNION Male connector 1/2'' NPTx1/4'' OD tube Nos. 50 * * # * Yes/No

36.3 NPT Female connector 1/4'' NPTx1/4'' OD tube Nos. 50 * * # * Yes/No

36.4 NPT Female connector 1/2'' NPTx1/4'' OD tube Nos. 50 * * # * Yes/No

36.5 UNION Blanking plug 1/4'' OD tube Nos. 20 * * # * Yes/No 36.6 UNION Blanking cap 1/4''OD tube Nos. 20 * * # * Yes/No 36.7 NPT Front ferrule 1/4'' OD tube Nos. 50 * * # * Yes/No 36.8 NPT Back ferrule 1/4'' OD tube Nos. 20 * * # * Yes/No 36.9 NPT Nut 1/4'' OD tube Nos. 20 * * # * Yes/No

Page | 37

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36.10 UNION 1/4'' OD tube Nos. 10 * * # * Yes/No 36.11 Check valve 1/2'' NPT (F) Nos. 20 * * # * Yes/No

37 Supply of Filters in GN2 actuation line as per the specification in Section-C/Chapter-32

Nos. 5 * * # * Yes/No


Kgs 500 * * # * Yes/No

39 Remote Operated long range water cum foam discharge monitor; Make: SKUM; Flow rate: 3000lpm @ 7 bar; fog/Jet Nozzle including spares as per Section-C/Chapter-7A

Sets 1 * * # * Yes/No


Nos 30 * * # * Yes/No



Note: ‘*’Price shall not be mentioned here to be given only in price bid. ‘#’ - Value shall not be mentioned here to be given only in price bid.

Page | 38

2.3 Format to be filled signed and shall be uploaded by the supplier in techno-commercial bid:

Sl.No. Description Yes/

No 1 The scope of work is fully understood by the supplier. 2 Confirm all the specifications and terms & conditions are acceptable

3 Confirm the specification of items to be supplied can be met by the supplier

4 Confirm the supply portions of items are fully considered for quoting as per Section- C. Exclusions if any shall be mentioned clearly.

5 The cost towards the work contracts like piping, fabrication, erection testing and commissioning etc., are considered for quoting as per Section-B

6 The individual item wise cost is quoted. 7 The details like taxes are clearly indicated for each line item.

8 The mobilization charges for men / machineries / materials are considered and they are included in the basic cost.

9 Modality of execution of contract, terms, rules & regulations, general conditions of execution of contract are read and acceptable to all points.

10 Bidder Qualification Criteria and Evaluation criteria formats duly filled and signed.

11 It is noted that the contract will be awarded to Technically suitable and overall lowest party only. Since procurement, supply and work contracts are interlinked, splitting of order is not possible.

Signature of Bidder

3.0 Part-II: Price bid indicating the price.

- Price bid should be submitted by the tenderer in the following format with price break-up. - In view of Two Part Tender, the Offers submitted contrary to above instructions will be

summarily rejected.

Sl. No.

Description

Qty

.

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1

Realization of Deluge systems for ISROsene storage & ISROsene DPT, SC120 LOX storage, C32 LOX Storage and also fire suppression systems augmentation for launch pad {Umbilical Tower (UT, Jet Deflection Duct (JDD), Mobile launch Pedestal (MLP)} which includes supply of all materials, Piping fabrication, erection, testing, painting & commissioning including third party inspection as per the specifications Section- A to Section-D.

01

Lot

Pri

ce V

alu

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o b

e in

dica

ted

Pri

ce V

alu

e t

o b

e in

dica

ted

Pri

ce V

alu

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o b

e in

dica

ted

Note: - The detailed specification, quantities are enclosed in the Section - B & C of the enclosed

specifications. - The contract will be awarded to technically suitable and overall lowest party only. Since

procurement, supply and work contracts are interlinked splitting of order is not possible. One lot consists of the following as defined in Table-3.

Page | 39

The following price details shall be uploaded along with offer:

Schedule of Quantities: Table -3

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1 Carbon steel Butt welding: Butt welding of CS pipes, fittings by GTAW welding process for root and SMAW for subsequent passes, D.P. Test and Radiography (10%) along with weld consumables as per the specification in Section-B/Chapter-2

Inch dia 14500 @ @ $ @

2 Carbon steel socket welding: Socket welding of CS pipe fittings, slip on flanges etc., by GTAW welding process for root and SMAW for subsequent passes and D.P. Test with weld consumables as per the specification in Section-B/Chapter-2

Inch dia 6000 @ @ $ @

3

CS piping erection includes Installation of flow components like Butterfly valves, Deluge valves, EP valves, filters with required gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing(Including scaffolding required), Hydro testing and testing at Max. Operating pressure, painting of pipe lines and tag numbers and commissioning as per the specification in Section-B/Chapter-4

Inch meter

20000 @ @ $ @

4


Inch dia 2000 @ @ $ @

5

Stainless Steel pipe Socket Welding: Socket welding of SS pipe fittings, slip on flanges etc., Root pass, subsequent passes and final pass TIG welding by GTAW process (GTAW welding shall be with 99.99% purity argon gas shielding & purging), D.P. Test with weld consumables as per the specification in Section-B/Chapter-3.

Inch dia 1200 @ @ $ @

Page | 40

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SS piping erection includes Installation of flow components like Ball valves, filters, check valves with required gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing (Including scaffolding required), Hydro testing, Pickling & Passivation, cleanliness checks, testing at Max. Operating pressure, painting of pipe lines and tag numbers as per P&I diagram and commissioning as per the specification in Section-B/Chapter-4

Inch meter

1800 @ @ $ @


kgs 5000 @ @ $ @

8 Providing required RCC pipe pedestals/pipe trenches for routing Deluge pipe line in the yard as per the specification in Section-B/Chapter-6

Cu.m 50 @ @ $ @


Cu.m 25 @ @ $ @


@ @ $ @

10.1 400NB ERW pipe ,Thickness 8mm meter 300 @ @ $ @ 10.2 300NB ERW pipe, Thickness 6.35mm meter 360 @ @ $ @ 10.3 250NB ERW pipe , Thickness 6.35mm meter 500 @ @ $ @


11.1 200NB SEAMLESS PIPE, Sch40 meter 450 @ @ $ @ 11.2 150NB SEAMLESS PIPE, Sch40 meter 350 @ @ $ @ 11.3 100NB SEAMLESS PIPE, Sch40 meter 250 @ @ $ @ 11.4 80NB SEAMLESS PIPE, Sch40 meter 250 @ @ $ @ 11.5 50NB SEAMLESS PIPE, Sch40 meter 220 @ @ $ @ 11.6 40NB SEAMLESS PIPE, Sch40 meter 325 @ @ $ @ 11.7 25NB SEAMLESS PIPE, Sch40 meter 200 @ @ $ @ 11.8 15NB SEAMLESS PIPE, Sch40 meter 50 @ @ $ @

Page | 41

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12.1 400NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 6 @ @ $ @ 12.2 300NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 15 @ @ $ @ 12.3 250NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 20 @ @ $ @ 12.4 200NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 45 @ @ $ @ 12.5 150NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 45 @ @ $ @ 12.6 100NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 50 @ @ $ @ 12.7 80NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 60 @ @ $ @ 12.8 50NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 75 @ @ $ @ 12.9 40NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 65 @ @ $ @

12.10 25NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 @ @ $ @ 12.11 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 @ @ $ @ 12.12 400NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 @ @ $ @ 12.13 300NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 @ @ $ @ 12.14 250NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 @ @ $ @ 12.15 200NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 10 @ @ $ @ 12.16 150NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 @ @ $ @ 12.17 100NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 @ @ $ @ 12.18 80NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 20 @ @ $ @ 12.19 50NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 @ @ $ @ 12.20 40NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 @ @ $ @ 12.21 25NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 @ @ $ @ 12.22 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 @ @ $ @ 12.23 400NB EQUAL TEE BUTT WELD, Sch40 Nos. 4 @ @ $ @ 12.24 300NB EQUAL TEE BUTT WELD, Sch40 Nos. 10 @ @ $ @ 12.25 250NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 @ @ $ @

Page | 42

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12.26 200NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 @ @ $ @ 12.27 150NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 @ @ $ @ 12.28 100NB EQUAL TEE BUTT WELD, Sch40 Nos. 40 @ @ $ @

12.29 80NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 @ @ $ @



12.32 25NB EQUAL TEE BUTT WELD, Sch40 Nos. 60 @ @ $ @ 12.33 15NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 @ @ $ @ 12.34 400x400x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 @ @ $ @ 12.35 300x300x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 @ @ $ @ 12.36 300x300x200NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 @ @ $ @ 12.37 250X250X200 UNEQUAL TEE BUTT WELD, Sch40 Nos. 8 @ @ $ @ 12.38 250x250x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 5 @ @ $ @ 12.39 200x200x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 10 @ @ $ @ 12.40 200x200x80 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 4 @ @ $ @ 12.41 150x150x100 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15 @ @ $ @ 12.42 100x100x50NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 20 @ @ $ @ 12.43 80x80x50 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 30 @ @ $ @ 12.44 50x50x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15 @ @ $ @

12.45 40x40x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 @ @ $ @ 12.46 25x25x15 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 @ @ $ @ 12.47 400X300 CONCENTRIC REDUCER, Sch40 Nos. 4 @ @ $ @ 12.48 400X250 CONCENTRIC REDUCER, Sch40 Nos. 4 @ @ $ @ 12.49 300X200 CONCENTRIC REDUCER, Sch40 Nos. 4 @ @ $ @ 12.50 300X250 CONCENTRIC REDUCER, Sch40 Nos. 5 @ @ $ @

Page | 43

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12.51 250X200NB CONCENTRIC REDUCER, Sch40 Nos. 10 @ @ $ @ 12.52 200X150 NB CONCENTRIC REDUCER, Sch40 Nos. 10 @ @ $ @ 12.53 150X100 NB CONCENTRIC REDUCER, Sch40 Nos. 30 @ @ $ @ 12.54 100X80 NB CONCENTRIC REDUCER, Sch40 Nos. 20 @ @ $ @ 12.55 100X50 NB CONCENTRIC REDUCER, Sch40 Nos. 20 @ @ $ @ 12.56 80X50 NB CONCENTRIC REDUCER, Sch40 Nos. 30 @ @ $ @ 12.57 50X40 NB CONCENTRIC REDUCER, Sch40 Nos. 10 @ @ $ @ 12.58 50X25 NB CONCENTRIC REDUCER, Sch40 Nos. 40 @ @ $ @ 12.59 40X25 NB CONCENTRIC REDUCER, Sch40 Nos. 40 @ @ $ @ 12.60 25X15 NB CONCENTRIC REDUCER, Sch40 Nos. 30 @ @ $ @ 12.61 40NB THREADEDOLET ,3000# Nos. 30 @ @ $ @ 12.62 25NB THREADEDOLET ,3000# Nos. 50 @ @ $ @ 12.63 20NB THREADEDOLET ,3000# Nos. 200 @ @ $ @ 12.64 15NB THREADEDOLET ,3000# Nos. 400 @ @ $ @ 12.65 50NB SOCKOLET ,3000# Nos. 25 @ @ $ @ 12.66 40NB SOCKOLET ,3000# Nos. 25 @ @ $ @ 12.67 25NB SOCKOLET ,3000# Nos. 40 @ @ $ @ 12.68 15NB SOCKOLET ,3000# Nos. 40 @ @ $ @ 12.69 ONE END NPT THREADED (OET) COUPLING 40NB,3000# Nos. 25 @ @ $ @ 12.70 ONE END NPT THREADED (OET) COUPLING 25NB,3000# Nos. 45 @ @ $ @ 12.71 ONE END NPT THREADED (OET) COUPLING 15NB,3000# Nos. 60 @ @ $ @ 12.72 ONE END NPT THREADED (OET) NIPPLE40NB,SCH80 Nos. 30 @ @ $ @ 12.73 ONE END NPT THREADED (OET) NIPPLE 25NB,SCH80 Nos. 50 @ @ $ @ 12.74 ONE END NPT THREADED (OET) NIPPLE 15NB,SCH80 Nos. 90 @ @ $ @ 12.75 BOTH END NPT THREADED (BET) NIPPLE40NB,SCH80 Nos. 35 @ @ $ @ 12.76 BOTH END NPT THREADED (BET) NIPPLE 25NB,SCH80 Nos. 50 @ @ $ @ 12.77 BOTH END NPT THREADED (BET) NIPPLE 15NB,SCH80 Nos. 90 @ @ $ @

Page | 44

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12.78 600 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 05 @ @ $ @ 12.79 450 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 6 @ @ $ @ 12.80 400 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 12 @ @ $ @ 12.81 350 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 4 @ @ $ @ 12.82 300 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 10 @ @ $ @

12.83 250 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 30 @ @ $ @ 12.84 200NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 40 @ @ $ @ 12.85 150 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 30 @ @ $ @ 12.86 100 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 45 @ @ $ @ 12.87 80 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 45 @ @ $ @ 12.88 50 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 35 @ @ $ @ 12.89 40 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 20 @ @ $ @ 12.90 25 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 60 @ @ $ @ 12.91 15 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 80 @ @ $ @ 12.92 300 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 2 @ @ $ @ 12.93 250 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 2 @ @ $ @ 12.94 200 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 4 @ @ $ @ 12.95 150 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 6 @ @ $ @ 12.96 100 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 8 @ @ $ @ 12.97 80 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 18 @ @ $ @ 12.98 50 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 18 @ @ $ @ 12.99 40 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 20 @ @ $ @ 12.100 25 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 20 @ @ $ @

13 Supply of Manual butterfly valves as per the specification in Section-C/Chapter-4 (unit rate shall be inclusive of TPI cost)

13.1 600 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 @ @ $ @ 13.2 400 NB MANUAL BUTTERFLY VALVE, 150# Nos. 5 @ @ $ @

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13.3 350 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 @ @ $ @ 13.4 300 NB MANUAL BUTTERFLY VALVE, 150# Nos. 10 @ @ $ @ 13.5 250 NB MANUAL BUTTERFLY VALVE, 150# Nos. 20 @ @ $ @ 13.6 200 NB MANUAL BUTTERFLY VALVE, 150# Nos. 20 @ @ $ @

13.7 150 NB MANUAL BUTTERFLY VALVE, 150# Nos. 15 @ @ $ @

13.8 100 NB MANUAL BUTTERFLY VALVE, 150# Nos. 10 @ @ $ @ 13.9 80 NB MANUAL BUTTERFLY VALVE, 150# Nos. 30 @ @ $ @

13.10 50 NB MANUAL BUTTERFLY VALVE, 150# Nos. 30 @ @ $ @

Supply of spare gear units for the following sizes as per the specification in Section-C/Chapter-4

13.11 600 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 @ @ $ @ 13.12 400 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 @ @ $ @ 13.13 350 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 @ @ $ @

13.14 300 NB MANUAL BUTTERFLY VALVE, 150# Nos. 1 @ @ $ @ 13.15 250 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 @ @ $ @ 13.16 200 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 @ @ $ @ 13.17 150 NB MANUAL BUTTERFLY VALVE, 150# Nos. 2 @ @ $ @


14.1 40NB MANUAL BALL VALVE FLANGED 150# Nos. 10 @ @ $ @ 14.2 25NB MANUAL BALL VALVE FLANGED 150# Nos. 25 @ @ $ @ 14.3 15NB MANUAL BALL VALVE FLANGED 150# Nos. 25 @ @ $ @ 14.4 25NB MANUAL BALL VALVE SOCKET WELDED 800# Nos. 40 @ @ $ @ 14.5 15NB MANUAL BALL VALVE SOCKET WELDED 800# Nos. 50 @ @ $ @ 14.6 25NB MANUAL BALL VALVE NPT THD 800# Nos. 50 @ @ $ @ 14.7 15NB MANUAL BALL VALVE NPT THD 800# Nos. 50 @ @ $ @

Page | 46

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15.1 300 NB EP BUTTERFLY VAVE, 150# Nos. 2 @ @ $ @ 15.2 250 NB EP BUTTERFLY VAVE, 150# Nos. 4 @ @ $ @ 15.3 200 NB EP BUTTERFLY VAVE, 150# Nos. 6 @ @ $ @ 15.4 100 NB EP BUTTERFLY VAVE, 150# Nos. 6 @ @ $ @

Supply of EP Butterfly Valve soft spares repair kit for above unit as per the specification in Section-C/Chapter-5

15.5 300 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @ 15.6 250 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @

15.7 200 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @ 15.8 100 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @

Supply of EP valve Actuator spares repair kit for above units as per the specification in Section-C/Chapter-5

15.9 300 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @

15.10 250 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @ 15.11 200 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @ 15.12 100 NB EP BUTTERFLY VAVE, 150# Sets 2 @ @ $ @

16 Supply of GN2 receiver, Capacity :1000 litres,Operating pressure:10bar as per the specification in Section-C/Chapter-27 and erection of GN2 receiver as per the specification in Section-B/Chapter-9 (unit rate shall be inclusive of TPI cost)

Nos. 3 @ @ $ @

17 Supply of GN2 Accumulator, Capacity :100 litres,Operating pressure:10bar as per the specification in Section-C/Chapter-28 and erection of GN2 Accumulators as per the specification in Section-B/Chapter-9 (unit rate shall be inclusive of TPI cost)

Nos. 3 @ @ $ @

18 Supply of Quartzoid bulbs detectors(QBDs)/pendent type sprinklers with SS protection guard for Deluge system actuation line, as per the specification in Section-C/Chapter-10

Nos. 250 @ @ $ @

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Nos. 400 @ @ $ @

20 Supply of Deluge Valves as per specifications as per the specification in Section-C/Chapter-08

20.1 Size:100NB , FLANGED ,150# Nos. 2 @ @ $ @ 20.2 Size: 150NB, FLANGED .150# Nos. 3 @ @ $ @


Nos. 6 @ @ $ @


Nos. 5 @ @ $ @


Nos. 4 @ @ $ @

24 Supply of water monitors as per specifications in Section-C/Chapter-07 Nos. 2 @ @ $ @


25.1 Size: 400NB, Mesh size:500 Microns Nos. 1 @ @ $ @ 25.2 Size: 300NB, Mesh size: 500 Microns Nos. 2 @ @ $ @

25.3 Spare filter elements for filters Size: 400NB, Mesh size:500 Microns Nos. 3 @ @ $ @

25.4 Spare filter elements for filters Size: 300NB, Mesh size:500 Microns Nos. 2 @ @ $ @


26.1 15NB Pipe Seamless pipe,SS304L, Sch40 meters 1200 @ @ $ @


27.1 15NB SLIP-ON RAISED FACE FLANGE (SORF) , 150# Nos. 150 @ @ $ @ 27.2 25NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 @ @ $ @ 27.3 40NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 @ @ $ @ 27.4 50NB SLIP-ON RAISED FACE FLANGE (SORF), 150# Nos. 10 @ @ $ @

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28.1 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 100 @ @ $ @

28.2 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 20 @ @ $ @ 28.3 15NB EQUAL TEE BUTT WELD, Sch40 Nos. 70 @ @ $ @ 28.4 15NB ONE END NPT THREADED (OET) NIPPLE, Sch80 Nos. 75 @ @ $ @ 28.5 15NB ONE END NPT THREADED (OET) COUPLING, 3000# Nos. 110 @ @ $ @


Nos. 250 @ @ $ @

28.7 15NB Cross Butt Weld SCH40 Nos. 60 @ @ $ @ 28.8 Concentric Reducer 50x25 Butt weld , Sch40 Nos. 10 @ @ $ @ 28.9 Concentric Reducer 50x40 Butt weld , Sch40 Nos. 10 @ @ $ @


29.1 15NB MANUAL BALL VALVE FLANGED, 150# Nos. 45 @ @ $ @ 29.2 15NB MANUAL BALL VALVE SOCKET WELDED, 800# Nos. 25 @ @ $ @ 29.3 15NB MANUAL BALL VALVE NPT THD 800# Nos. 25 @ @ $ @ 30 Supply of Pressure gauges as per the specification in Section-C/Chapter-22

30.1 Pressure gauges Dial size:150mm,Range 0-25bar Nos. 5 @ @ $ @ 30.2 Pressure gauges Dial size:100mm,Range 0-25bar Nos. 15 @ @ $ @


meters 100 @ @ $ @


meters 100 @ @ $ @

33 Bending of pipe lines, Size : 15NB to 25NB (No. of bends) Nos. 30 @ @ $ @ 34 Bending of pipe lines, Size : 40 NB (No. of bends) Nos. 30 @ @ $ @

35 Supply of SS Tubes Size: ¼” OD: 6.32 mm Thk.0.91mm as per the specification in Section-C/Chapter-29 and erection as per the specification in Section-B/Chapter -8.

meters 250 @ @ $ @

Page | 49

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36.1 UNION Male connector 1/4'' NPTx1/4'' OD tube Nos. 60 @ @ $ @ 36.2 UNION Male connector 1/2'' NPTx1/4'' OD tube Nos. 50 @ @ $ @ 36.3 NPT Female connector 1/4'' NPTx1/4'' OD tube Nos. 50 @ @ $ @ 36.4 NPT Female connector 1/2'' NPTx1/4'' OD tube Nos. 50 @ @ $ @ 36.5 UNION Blanking plug 1/4'' OD tube Nos. 20 @ @ $ @ 36.6 UNION Blanking cap 1/4''OD tube Nos. 20 @ @ $ @ 36.7 NPT Front ferrule 1/4'' OD tube Nos. 50 @ @ $ @ 36.8 NPT Back ferrule 1/4'' OD tube Nos. 20 @ @ $ @ 36.9 NPT Nut 1/4'' OD tube Nos. 20 @ @ $ @

36.10 UNION 1/4'' OD tube Nos. 10 @ @ $ @ 36.11 Check valve 1/2'' NPT (F) Nos. 20 @ @ $ @

37 Supply of Filters in GN2 actuation line as per the specification in Section-C/Chapter-32 Nos. 5 @ @ $ @


Kgs 500 @ @ $ @

39 Remote Operated long range water cum foam discharge monitor; Make: SKUM; Flow rate: 3000lpm @ 7 bar; fog/Jet Nozzle including spares as per Section-C/Chapter-7A

Sets 1 @ @ $ @


Nos. 30 @ @ $ @


meters 300 @ @ $ @

Note: @- Price Value to be indicated

$ - Value to be indicated Note: - The contract will be awarded to technically suitable and overall lowest party only. Since procurement & supply and work contracts are interlinked, splitting

of order is not possible. - From Serial Nos. 1 to 9 quantities may vary as per the site conditions. Payment will be made for the quantities executed at the site.

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4. PROPOSAL DOCUMENT

4.1. Bidder shall sign & stamp each page of the tender document (RFP) as token of his acceptance and submit the same along with his offer.

4.2. Proposal documents shall remain the property of SDSC SHAR and shall not be used for any another purpose without the consent of SDSC SHAR.

4.3. The proposal shall be completely filled in all respects and shall be submitted together with requisite information. Any offer incomplete in any particulars is liable to be rejected.

4.4. The Proposals shall be submitted on-line before the time limit for bid submission specified in the Letter Inviting Bid.

4.5. Supplier shall submit the open authorization on-line with in the time limit specified in the Letter Inviting bid.

4.6. The Proposal will be opened on the date and on the time specified in the Letter Inviting Bid or as soon thereafter as convenient. Proposal not received in time will not be considered.

4.7. Bidders shall set their quotations in firm figures and without variations/additions in the terms of the Proposal documents.

5. AMBIGUITY:

Should there be any ambiguity or doubt as to the meaning of any of the tender clause/condition or if any further information is required, the matter shall be immediately brought to the notice of Head, Purchase & Stores of SDSC SHAR in writing.

6. PREPARATION OF BIDS

6.1 Validity of Offer:

Bid shall remain valid for acceptance for a minimum period of 4 (four) months from the due date of submission of the Bid. The Bidder shall not be entitled during the said period to revoke or revise his Bid or to vary the Bid except and to the extent required by SDSC SHAR in writing. Bid shall be revalidated for extended period as required by SDSC SHAR in writing. In such cases, unless otherwise specified, it is understood that validity is sought and provided without varying either the quoted price or any other terms & conditions of Bid finalized till that time. 6.2 Cost of Bidding: All direct and indirect costs associated with the preparation, submission of bid shall be to Bidder’s account, and SDSC SHAR will in no case be responsible or liable for those costs, regardless of the conduct or outcome of the bid process.

6.3 Applicable Language/ measurements:

The bid and all correspondence incidentals to and concerning the bid shall be in the English Language. For supporting document and printing literature submitted in any other language, an accurate English Translation shall also be submitted. Responsibility for correctness in translation shall lie with the Bidder. All the measurements shall be given in metric system.

6.4 Arrangement of Bid:

The Bid shall be neatly presented on white paper with consecutively numbered pages. It should not contain any terms and conditions, which are not applicable to the Bid. The Bid and all details submitted by the bidder shall be signed and stamped on each page as token of acceptance, by a person legally authorized to enter into agreement on behalf of the Bidder. (Corrections/ alteration, if any, shall also be signed by the same person).

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6.5 Schedule of Prices:

The schedule of prices shall be read in conjunction with all the sections of proposal document SHAR/LS/2019012632.

6.6 Documents Comprising the Bid:

Bids shall be arranged in the following order. - Priced bid shall be filled online in the price bid format. - Schedule of unit prices also to be filled as per price Bid format and no separate document

shall be attached. - Deviations in terms and conditions, assumptions etc. shall be stipulated in format specified

(As per Section-D/ Checklist to be filled by the contractor) in the portal. - SDSC SHAR will not take cognizance of any such statement and may at their discretion

reject such bids.

6.7 BID SUBMISSION - Bids duly filled in by the Bidder should invariably be submitted as stipulated in the Letter

inviting bid. Bids shall be submitted in the following manner. Price Part of the Bid:

- Price bid shall be filled in the on-line ‘price bid’ form of the e-tender only in ISRO e-procurement website “https://eprocure.isro.gov.in”. The cost of items and other prices shall be filled in the respective forms available on-line in the e-portal. Any other terms and conditions given in this part shall not be considered and if insisted upon by the Bidder, bids are liable for rejection.

- SDSC SHAR reserves the right to reject any or all the Bids without assigning any reasons thereof.

7 BID EVALUATION

7.1. During evaluation, SDSC SHAR may request bidder for any clarification on the bid or additional documents.

7.2. Techno-commercial discussion shall be arranged with bidder, if needed. Bidder shall depute his authorized representatives for attending discussions. The representatives attending the discussions shall produce authorization from his organization to attend the discussion and sign minutes of meeting on behalf of his organization if required. The authorized representative must be competent and empowered to settle/decide on all technical and commercial issues.

7.3. Bidder must provide the point-by-point compliance to the technical specifications along with deviations. The tender will be rejected, if the deviations are not acceptable to the department.

7.4. The time schedule for completion is given in the proposal document. Bidder is required to confirm the completion period unconditionally.

7.5. If necessary, to arrive at evaluated prices, wherever applicable, loading on total quoted prices shall be done.

7.6. SDSC SHAR reserves the right to accept a bid other than a lowest and to accept or reject any bid in full or part without assigning any reasons. Such decisions by SDSC SHAR shall bear no liability whatsoever consequent upon such decision.

7.7. The bidder, whose bid is accepted by SDSC SHAR, shall be issued a Letter of Intent (LOI) /Purchase Order (PO) to proceed with the work. Bidder shall confirm acceptance by returning a signed copy of the LOI/PO.

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8. Commercial Terms:

8.1 Taxes:

i. IGST For Inter State: As per the Notification No.47/2017-Integrated Tax (Rate) Dt: 14.11.2017 issued by Ministry of Finance (Dept. of Revenue), SDSC SHAR is eligible to avail reduced rate of IGST @5% for the procurements made by the Dept. of Space (DOS) being a public Funded Research Institution. We will provide IGST exemption certificate. For Intra State: As per Notification No.45/2017- Central Tax (Rate) dated 14.11.2017 and Government of Andhra Pradesh Goods and Service Tax Act, 2017 (Act No.16 of 2017), G.O.MS.No.599, Dated: 12.12.2017 issued by Ministry of Finance (Dept. of Revenue), SDSC SHAR is eligible to avail a reduced rate of CGST/SGST @ 5% for the procurements made by the Dept. of Space (DOS) being a public funded research Institution. We will provide IGST exemption certificate.

ii. Income Tax Income tax at the prevailing rate as applicable and if applicable from time to time shall be deducted from the supplier's bills as per Income Tax Act and a certificate issued (TDS Certificate).

iii. Customs Duty As per notification No.05/2018 Customs dated 25th January, 2018, ISRO is eligible only

for partial exemption of Customs Duty. The reduced rate of CD is 10.775% (CD@5%+Surcharge@10%+IGST@5%). Suppliers are requested to submit their bid by loading these elements wherever, it is applicable. In case of an order, we will issue CD exemption certificate to avail the exemption. The actual amount will be reimbursed against submission of documentary evidence. In case tenderers offering items considering customs duty exemption, they should also indicate the bill of materials and price, separately, with Customs Duty component and terms and conditions thereto. 8.2 Delivery Period: Twelve months (12) from purchase order release date. 8.3 Terms of Payments Our general payment terms are within 30 days after receipt and acceptance of items at purchaser’s Site (SDSC-SHAR Sriharikota) as per the following. No advance payment is envisaged. a) After receipt at SDSC SHAR, Sriharikota:

90% payment will be made pro-rata basis for both supply and erection /fabrication work as applicable. However, the number of bills will be restricted. It will be mentioned at the time of PO placement.

b) After commissioning at SDSC SHAR, Sriharikota: Balance 10% of order value against satisfactory performance of system against performance bank Guarantee.

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8.4 Liquidated Damages (LD): Since delivery is the essence of this order, LD @ 0.5% per week or part thereof subject to a maximum of 10% of the order value for the delayed period of supply/ scope of work. 8.5 Warranty: Warranty for the offered item shall be from the date of installation/acceptance of the item at our site for a minimum period of one year or specified in the tender document. 8.6 Performance Bank Guarantee (PBG): The contractor has to submit a PBG from a Nationalized / Scheduled Bank for 10% of the order value at the time of supply valid till the completion of warranty period plus 60 days towards claim period. OR 10% of the order value shall be hold till the completion of warranty period 8.7 Security Deposit (SD): 10% value of the order shall be deposited with SDSC within 10 days from the date of the Purchase Order towards security deposit in the form of Bank Guarantee towards performance of the Contract valid till completion of the contract period plus sixty days towards claim period. (This will be returned by SDSC immediately on execution of the order satisfactorily as per order terms. If not, the amount will be forfeited).

8.8 Validity of Offer:

The validity of the offers / tenders should be 120 days from the date of opening of the tenders. Tenders shorter than offer validity mentioned above will not be considered for evaluation. 9. As all the scope of work is inter-related, splitting of the order is not possible. Bidder has to quote for all the items listed in the Technical specification (Section- B & C), Schedule of quantities without which the offer will not be considered.

10. Force majeure

For the purpose of the contract, the term “force majeure” shall means strikes, lockouts and other conflicts, acts of an enemy, war hostile blockade, disturbance of the public order, stroke of lightning, fire under thunderstorm, flood explosion and acts of god and government acts beyond the reasonable control of the party claiming force majeure. If due to circumstances of force of majeure, either of the parties to this contract partially of completely unable to fulfil its obligations in accordance with this contract, the said party shall be obligated to immediately inform the other party of occurrence of the circumstances of force majeure in writing. The party claiming force majeure shall also be obligated to keep the other party informed of the events in the process related to the occurrence of the said force majeure circumstances and of the possible degree of non-fulfilment or delay in fulfilment of the obligations in accordance with this contract. All the obligations of the party that invokes the plea of force majeure shall be suspended as long as the said force majeure circumstances continues to exist and not longer, and the said party shall not be regarded as having committed breach or failure, nor shall be held responsible to make compensation for losses suffered by either party. The terms of fulfilment of the obligation shall be duly extended for the period during which the circumstances of force majeure lasts. The fulfilment of the obligations shall be resumed immediately after the cessation of the said circumstances of force majeure. If the said force

54

majeure circumstances last for more than sixty days, parties to this Contract shall discuss and agree upon further action. Should the state of non-fulfilment of obligation under the Contract be more than three (3) months and nothing could be done to make a statement about ceasing of obligations of Contract, within not more than three (3) months either party has the right to cancel the Contract mentioned below. The ownership of all materials, parts and unfinished work paid for by the SDSC SHAR shall vest with the SDSC SHAR or transferred to the SDSC SHAR as soon as they have paid for. The amount of compensation payable/recoverable shall be fixed on the basis of evidence produced by party and acceptable by the purchaser.

11.Arbitration

Except as otherwise specifically provided in the Contract any disputes or differences including those considered as by only one of the parties out of or in connection with this Contract shall be, to the extent possible, settled amicably between the parties. If amicable settlement cannot be reached, then all disputes shall be referred to Director, SDSC SHAR, ISRO, whose decision shall be binding on both the parties. If this contract is terminated for any reasons, the expenses incurred for conduct of the above work are to reckoned to the extent of the work that is carried out which will be settled by the either of the parties to this contract on mutual agreement within 30 days or such extended period from the date of intimation of termination of contract.

12.Secrecy:

The party shall take all reasonable steps necessary to ensure that all persons employed in connection with the Purchase Order have full knowledge of the Official Secrets Act and the regulations framed there under. Any breach of the aforesaid conditions shall entitle the purchaser to cancel the Purchase Order and if necessary to go ahead with the purchase at the risk and cost of the party in addition to any other penal action it may take at its discretion.

13. Compliance with security requirements:

The party shall strictly comply with the security rules & regulations of the purchaser. The party shall complete the required formalities including verification of character & antecedents, of the persons engaged or deployed by him, through police or any other authority.

14. Confidentiality and proprietary right protection:

The party shall be obliged to preserve the confidentiality of the proprietary information received, exchanged between each other during the period of the Contract. Technical documentation published and/or claimed for a patent shall be effected by both the parties only on mutual decisions and approval of both the parties, during the existence of this agreement.

15. Instructions to the Bidder

In case of any conflict/contradiction, the documents shall prevail over one another in the following order:

I. For all commercial, contractual and general conditions, Notice Inviting Tender (NIT).

II. Any contradiction either between various parts of document or in the content of the document itself shall be a matter of clarification to be obtained by the bidder from the purchaser. The purchaser's decision shall be final and binding.

III. The Bidder shall study the specification, visit the site and satisfy himself thoroughly regarding the workability of the proposed Fire protection systems and shall take full responsibility for best quality of material and workmanship, guaranteed operation and smooth performance of

55

all firefighting systems/ equipment & accessories and integrated system as a whole. This technical specification is only guidance to the bidder and hence all the items necessary for safe and satisfactory operation, guaranteed and reliable performance of proposed fire protection systems shall be included in his offer though these might not have been specifically mentioned in the technical specification / schedule of quantities.

IV. The Bidder shall satisfy the department that he possesses the necessary technical experience for design& execution and has at his disposal suitable facilities and crew to ensure that his work shall be of the best quality and workmanship. Necessary particulars in this regard shall be furnished with the offer.

V. Successful Bidder shall obtain approval from department for selecting sub- suppliers and makes for any of the equipment/ parts.

VI. An unpriced copy of the order on the sub-suppliers comprising all detailed specifications and the quantities of the material ordered, bill of material including necessary drawings thereof, shall be sent to department immediately after such order is placed by the successful Bidder.

VII. The purchaser reserves the right of selecting the make/model of equipment, wherever necessary and the supplier shall agree to supply equipment of particular make/model without any cost implication to purchaser.

VIII. Any loss of plant and equipment after receipt at site due to imprudence, negligence and unsuitable treatment and handling on part of the contractor shall have to be replaced by the contractor at his cost.

IX. Any existing services or other property if damaged or demolished during the course of execution either wilfully or negligently, shall be re-done/ re-erected by the bidder at his own cost.

X. The bidder shall take all precaution against damages due to rains or other natural causes and no liability shall lie with the purchaser for any loss on this account.

XI. The approval of drawings and/or inspection by Department and/ or their authorized representative shall not absolve or relieve the bidder from any of his obligation under this contract and they shall be wholly and solely responsible for the satisfactory operation and guaranteed performance of the systems and equipment forming part of the system.

XII. This specification is issued for procurement from indigenous sources only. However, no foreign exchange or import license for importing equipment, components, raw materials or spares will be arranged for or provided by the purchaser. In case the equipment offered involves expenditure in foreign exchange, same shall be arranged and borne by the Bidder.

XIII. Any equipment / material which in any way fails to meet the requirements of the specification will be rejected by the purchaser and such equipment / material shall not be used under the contract. The successful Bidder will be required to promptly furnish new material at his cost without hampering the overall schedule of commissioning of the project.

XIV. Any changes or difficulties which might be encountered during the execution of work or any other problems due to local conditions which are not anticipated / included in the tender document shall fall under full obligations of the successful Bidder. No claim on account of the same and for any ambiguity in any respect will be entertained after placement of order by Purchaser.

XV. The equipment covered in this specification shall conform to the technical specification, general requirements and relevant latest standards / codes in respect of dimensions, size, material, manufacture, inspection, testing, painting, packaging, etc. as applicable.

XVI. All material, dimensional standards, tolerances, process of manufacture and testing procedures shall be in accordance with the latest revision of the standard codes specified in this Tendering Specification. In case where such suitable standards are not mentioned, any acceptable Indian/International Standards shall be adopted with prior approval of purchaser.

XVII. All equipment supplied shall allow access to facilitate connecting up, inspection, maintenance and repair and shall operate satisfactorily under such variations of load, pressure and climatic conditions as may occur during working.

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XVIII. All documents, instructions, name plates etc. shall be written in English language. All weights, dimensions and units shall be in metric system.

XIX. The Bidder shall be responsible for completeness of supplies, work and services to make the system complete and proper operation. Any equipment and material not specifically mentioned in this tendering specification, but required for safe, smooth and efficient operation and guaranteed performance of the Fire Protection system shall be deemed to be included under the scope of work of the Bidder. No claim shall be entertained on this account after placement of Order.

XX. Purchaser reserves the right to reject all or any of the offer fully or partly without assigning any reasons, whatsoever.

XXI. The Bidder shall quote for earliest delivery of the equipment / supplies as well as earliest completion of the entire work.

XXII. The Bidder shall submit the Quality Assurance Plan containing the overall quality management and procedures which he proposes to follow for performing the work during various phases of execution.

XXIII. At the time of award of contract, the detailed Quality Assurance Plan to be followed for execution of the contract will be mutually discussed and agreed to.

XXIV. The sub-contracts for part works can be given for successful completion of project with consensus of purchaser. The total sub-contract of the project is not allowed.

XXV. Materials used and equipment supplied shall be new and the best of their kind and shall comply with the latest revisions of all relevant standards. Manufacturer's certificates shall be furnished by the successful Bidder for the material used.

XXVI. As a minimum requirement, the contractor shall identify a resident engineer / site supervisor to coordinate with department and ensure the quality job completion in specified time.

XXVII. Firefighting systems shall be erected, tested and commissioned as per the standards laid down in this specification. Detailed instructions on such aspects as are not indicated herein shall be as per the latest Indian standards.

XXVIII. Bidder shall clearly indicate the deviations taken from the Tender documents/specifications separately in his offer.

16. Terms & Conditions to Bidder

- Compliance statement to the technical specification given is to be duly signed & stamped and submitted as a part of acceptance.

- Detailed QAP shall be submitted by the party after placement of order. Quality Assurance Plan mutually agreed by successful bidder and purchaser shall be complied. Party shall confirm the broad guidelines mentioned in the technical specification document.

- Deviations, if any, w.r.t technical and commercial terms & conditions shall be clearly brought out and deviation list to be added. If deviations are not listed separately, it will be presumed that the bidder is adhering to all the technical specifications and commercial terms & conditions given in this document.

- Transportation are fully in the scope of supplier and the same shall be borne by the party.

17. Exclusion of Tenders

The following tenders shall be summarily rejected from the procurement process: - Unsolicited tenders from vendors. - The tenders which materially depart from the requirements specified in the tender document or

which contain false information. - The tenders of vendors who have not agreed to furnish Advance Bank Guarantee or

Performance Bank Guarantee. - The validity of the tenders is shorter than the period specified in the tender enquiry. - The tenders received from vendors or their agents or anyone acting on their behalf, who have

promised or given to any official of the Centre/Unit/Department, a gratification in any form, or anything of value, so as to unduly influence the procurement process.

57

- The tenders received from vendors, who, in the opinion of the Centre/Unit, have a conflict of interest materially affecting fair competition.

- The tenders received from Indian agents on behalf of their foreign Principals/OEMs (in cases where the Principals/OEMs also submit their tenders simultaneously for the same item/product in the same tender).

- In case two or more tenders are received from an Indian agent on behalf of more than one foreign Principal/OEM, in the same tender for the same item/product.

- If a firm quote ‘NIL’ charges / consideration, the bid shall be treated as un-responsive and will not be considered.

18. INSURANCE:

- The contractor shall provide, at their own expense, the following insurances from a nationalized/ Government insurance company and endorse the policies in favor of the Department. The Contractor shall seamlessly revalidate the policies until final acceptance of ASLP Facilities Deluge systems realization with additional claim period of 2 months.

- The Contractor shall provide Freight (transportation) insurance for indigenous and imported materials from the Contractor’s/ Sub-contractor’s/ Sub-vendor’s premise to the Department’s site.

- During onsite activities at the Department’s premise, the Contractor shall provide the following insurances: o Workmen compensation policy (Personnel insurance) for the Contractor’s/ Sub-

contractor’s personnel under all categories covering death& accident. o Third-party business liability insurance to cover damage caused by fault of the Contractor

to the Department and/ or third parties. The liability shall be Rs 20 Lakhs for bodily injury applicable to each person and Rs 1 Crore for tangible assets. The Department shall indemnify the Contractor against any further claims.

o Notwithstanding the aforesaid insurance, the Contractor shall be responsible for all the materials/ services including all losses & uninsured losses until final acceptance of realised safety systems for ASLP facilities by the Department.

o Short closure of the contract by the supplier: Due to own reasons if supplier desires to short close the contract, notice of the closure has to be submitted to the department with minimum time of 6 months advance with proper justification and necessary supporting documents. In such cases the Security Deposit submitted by him will be forfeited.

19. Termination for any fault of the contractor

Not withstanding anything elsewhere herein provided and in addition to any other right or remedy of the Department under the condition the contract or otherwise (including the right of the Department to claim compensation for inadequacy in the services), the Department shall be entitled to terminate the contract by written notice at any time during its contract on or after the occurrence of any one or more of the following events/contingencies, namely Default or failure by the Contractor of any of the terms of the Contractor under the contract including but not limited to: - Failure to start the work - Failure to perform the services within the time specified herein or any Department approved

extension thereof. - Disobedience of any order or instruction of the Contract Manager of the Department

affecting the services within the scope of the contract. - Negligence in carrying out the works or carrying out, of work found to be unsatisfactory. - Abandonment of the works or any part thereof. - Substantial suspension of the works or any part thereof for a period or 14 (fourteen) days

or more without the authority of the Contract Manager. - The decision of the Department as to whether any of the events/contingencies hereof

entitling the Department to terminate the contract, has occurred or not shall be final and binding upon the Contractor.

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The notice of termination shall set forth, in addition to a statement of the reason or reasons for terminating the contract, the time(s) and place(s) when the survey and assessment of the work performed under the contract up to the date of termination shall be conducted, for the purpose of determining the final amount(s) due to the Contractor therefore. Short closure of the contract by the supplier: Due to own reasons if supplier desires to short close the contract, notice of the closure has to be submitted to the department with minimum time of 6 months advance with proper justification and necessary supporting documents. In such cases the Security Deposit submitted by him will be forfeited.

20. Cancellation in special cases

Department may at any time cancel this contract by giving written notice with immediate effect in either of the following cases: - If the contractor is adjudged insolvent or if its financial position is such that within the

framework of its national law, legal action leading towards bankruptcy may be taken against it by its creditors or its Govt., or

- If Department has sufficient reason to believe and it is determined through arbitration or through court proceedings, that the contractors has resorted to fraudulent or corrupt practices in connection with its securing or implementation of this contract.

21. Specific Requirements

The delivery and erection of all equipment shall be so scheduled that it shall be possible to commission within due date from the date of award of PO in order to match with the overall commissioning schedule of Project. The delivery date shall be quoted from the date of issue of PO taking into account the time for approval of technical data sheet and specification of bought out items by the Purchaser. The successful Bidder shall guarantee the material delivery and commissioning dates. Progress report shall be submitted by the successful Bidder at regular intervals on a format prescribed by the purchaser giving the status of approval of drawings, ordering position of equipment and other materials ordered, manufactured, fabricated, delivered and erected. After placement of purchase order, the following documents shall be submitted for approval. a) PERT flowchart indicates schedule of work, technical data sheets/Specification of bought

out items b) Fabrication drawings c) Welder qualification, PQR, WPS d) Procedure for qualification of fabricated pipe lines e) Quality assurance plan

22. Unit Rates:

The Bidder shall quote item wise units and unit price and total units and total price of items and materials to be supplied and erected under this specification as per Price Bid format. The rates shall be valid until handing over the systems to purchaser and Bidder shall supply additional quantities, if required for the completion and successful commissioning of the systems on the same rates as quoted. Items not featuring in the BOQ but required for completion of the systems shall be borne by Bidder and shall be deemed to be included in the bidder’s offer. No extra claim for such items shall be entertained after placement of order

23. Safety

1. All equipment shall be complete with approved safety devices wherever a potential hazard exists and with provision for safe access of personnel to and around equipment for operational and maintenance functions. The design shall include not only those usually furnished with elements of machinery but also the additional covers, stairways, ladders,

59

steel structural platforms for operator's control panels handrails, partitions etc. which are necessary for safe operation of the plant.

2. All danger and caution notice boards shall be both in English, Hindi and local languages. 3. When the work is carried out at night with prior approval of purchaser or in the obscure day

light, adequate arrangements for flood lighting in the working area shall be made by Bidder at his own cost and got approved by the Purchaser.

4. The safety posters/regulation for prevention of accidents shall be displayed by the Bidder at appropriate places. Notices and warning signs shall be displayed for all sources of dangers.

5. All electrical drives and equipment must be equipped with safety devices. The safety provisions shall conform to the recognized standards, safety codes and statutory regulations.

6. All safety measures as required to be adopted as per the statutory regulations and the safety rules of the plant shall be strictly followed by the Bidder during the execution of the Contract.

7. Adequate number of first aid boxes as defined in the State Factories Rules shall be provided and maintained at work sites.

8. The vendor shall ensure that the item supplied by them are absolutely safe for use in the stipulated work environment & confirm to applicable safety norms and standards.

9. One safety supervisor shall be posted during the erection activities at site. They shall hold the entire responsibility for the events/activities carried out at site.

24. Transportation & Material Handling:

The contractor shall ensure: 1. Receipt of pipes, pipefittings, flow components etc., transportation to site and leading to

work spot is in the scope of the contractor. 2. Own Transport vehicles required for movement of contract personnel from /to work site

and Gate I / Sullurpeta, including internal movement within site. 3. Relevant derricks, hoists and fixtures for leading and positioning equipment’s on

designated foundations including alignment tools. 4. Department may provide material handling support on chargeable basis subject to

availability.

25. Evaluation of Machinery and Manpower and Consumables:

Machinery and manpower shall be subjected to technical evaluation by the Department Engineer to ascertain their complete suitability / performance for the jobs described above. Based on this evaluation clearance shall be given for taking up the actual job. Work shall be treated as commenced only when the actual welding work is done and as per various technical conditions detailed in this contract.

26. Medical Assistance:

While executing this service contract work, if any of the workers engaged by contract agency is injured, contract agency has to take care of medical treatment.

27. RECORD OF DOCUMENTS, DRAWINGS AND OPERATION AND MAINTENANCE MANUALS

Along with offer: - Checklist to be filled by the contractor (As given in Section-D)

- Format for Bidder Minimum qualification criteria

- Copies of Previous Purchase orders.

- Catalogue/Data sheets of components.

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After placement of order the following documents are to be submitted for approval: - Isometric Diagrams - Fabrication drawings - Detailed Technical specifications of all the items. - Schedule of quantities - PERT chart showing work schedule. - Procedure for work execution. - Quality Assurance Plan (QAP). - Testing and Evaluation Plan. After completion of work during commissioning: - Test & Evaluation documents. - Test certificates of all components of system. - Supplier shall submit three hard copies & one soft copy of all the approved drawings

incorporating any modification / changes made during the execution of CONTRACT. All these drawings shall be marked as 'As Built'.

- Supplier shall submit 3 hard & one soft copy of O&M manual. These manuals should indicate weekly, monthly and yearly maintenance schedule and other instructions necessary for safe maintenance of Safety systems for ASLP facilities.

- Submission of the drawings and manuals shall be a precondition for releasing of any final payment due to Supplier.

28. General Conditions:

- Sriharikota is an island and situated around 100 kms north of Chennai and the work spot (SLP Complex) is located at about 12 kms from main entrance gate. Conveyance for Contractor personnel from and to work spot has to be arranged by the contractor.

- The contractor shall not employ persons below 18 years of age and no female labour shall be employed in dark hours. The contractor shall pay to each person, wages not less than minimum wages specified as per the labour laws.

- Conveyance for contractor personnel from and to work spot has to be arranged by the contractor.

- Department shall decide the hours of work on the site and the contractor shall adhere to it. Department reserves the right to extend working hours beyond office hours including holidays based upon the progress of work to meet the work schedule/target.

- Contractor shall take enough care to ensure to progress the work without any material and personnel damage. It is the sole responsibility of contractor to ensure all safety norms to his personnel during transportation between work spot and Department/Contractor stores, and work in prefabrication area, in storage shed and in yard. Department will not hold responsibility to any mishap to the contractor personnel.

- Department’s permission shall be obtained by contractor for establishing shed/ office with an under taking for construction of shed with non- flammable material and for demolition of the same after completion of work.

- The contractor shall be responsible for the safe storage of radiographic sources of his sub-contractor. Radiographic source shall be stored in a room located at FLP complex, which is about 10km from the work spot. However, the transportation of source from the storage room to the work spot and back shall be the responsibility of the contractor.

- The contractor shall give prior intimation to the Department whenever Radiography is planned, and shall be carried out with necessary approvals only between 18:30 hrs to 06:30 hrs (06:30 PM to 06:30 AM) and the area shall be properly barricaded. However, the contractor can take prior approval from the Department for carrying out Radiography during working hours i.e., from 09:00 hrs. to 17:30 hrs.

- Department will provide electricity required for the job, free of cost. However, all machinery required for above work like welding, grinding, drilling, cutting, etc., has to be arranged by contractor along with necessary Junction boxes, fuses, cables, hoses, etc.,

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- The contractor shall take prior approval from the Department for awarding sub-contract for full/partial works in the contract and the payment for the sub-contractor shall be the responsibility of the contractor.

- The Department reserves the right to pay the sub-contractor directly from the running bills in case if the contractor fails to pay his sub-contractor in the interest of completion of work.

- Contractor has to give an undertaking that they will comply with prevailing safety norms at site put forth by Department. Safety officer shall have full access to contractor’s storage shed. Office at any time for inspection.

- The quantity arrived is indicative only. The party shall give undertaking to hold the same quoted unit prices for the additional quantities of 10% of order quantities if site requirement calls for.

Period of contract: - Twelve (12) months from the date of clearance from department. - Progress review meetings once in a week will be conducted for monitoring the status of

works and the contractor’s site representative need to attend with all relevant inputs. - As all works are inter-related, splitting of order is not possible. Hence, bidder shall quote

for all items of this tender without which offer will not be considered. - Purchaser reserves right to cancel the order at any stage if the performance of the contactor

is not satisfactory and the contractor is not following stipulated Safety/security norms. - Contractor supervisor (Max. two) may be provided with hostel accommodation on

chargeable basis depending on availability. - Contractor has to arrange accommodation for their employment’s outside the island. - The contractor shall clearly indicate deviations if any from indent specifications in the offer;

otherwise, to accept all the terms and conditions put by the department. - Item wise quantity format is only for indicative quantities of various items to be executed.

Payment will be made by department for the actual quantity executed on Pro-Rata basis.

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29. Bidder Minimum Qualification Criteria

The following are the minimum essential criteria to further validate/accept the bid. Vendor is requested to provide all the necessary supporting documents. If any deviation/non-compliances/lack of supporting document bid shall be summarily rejected.

Sl. No.

Description

Vendor Compliance With

Supporting Documents

1

The Bidder should be ISO certified Company/Society/Firm registered in India since last 5 (five) years or more. Company Profile along with documentary evidence of services offered and all relevant enclosures to be submitted.

2

Party should have executed a contract involving supply, erection, testing and commissioning of piping circuit for a value not less than Rs. 4.64 Crores (in the last five years) as a single order (or) atleast two orders of worth Rs. 3.48 Crores each (or) atleast three orders of worth Rs.2.32 Crores each.

3

The bidder should have an annual turnover of Rs. 6.75 Crores on an average in 3 years (Financial year FY 2016-17 & FY 2017-18 & FY 2018-19) in the supply, erection, testing and commissioning of piping system and should have executed similar works between 01-04-2016 and 31-07-2019.

4 PO and Satisfactory Work completion certificate by the end user for the previous executed orders shall be submitted without which offer will not be considered.

5 Audited balance sheet & Profit & Loss A/c is to be submitted (or) Copy of the IT return filed / audited last 3 years financial statements for Financial year FY 2016-17 & FY 2017-18 & FY 2018-19.

6 Vendor must undertake supply, erection, testing and commissioning of piping system as per the specifications and requirements indicated in the RFP.

7 Latest solvency certificate from any Nationalized/Scheduled bank shall be submitted for a value of minimum Rs.230 lakhs. The solvency certificate must have issued after March 2019.

8 Technical compliance to the specifications shall be vetted by the bidder.

9

The firm must provide a self-declaration that there is no complaint/vigilance inquiry against them in any Govt. /Department /PSU and they have not been black listed by any Govt. Department/PSU.

10 The supplier shall mention his welding team details, equipment’s / machineries , facilities if any.

Note: Technical proposal of the bidder, which is not able to substantiate/satisfy the claims made by it with respect to the technical requirements laid down in this RFP, will be summarily rejected. Offers of those bidders taking full scope of the work supply, erection, testing and commissioning of piping circuits as per the requirements indicated in the RFP only will be considered. Signature of Authorized Person with Seal

Administrator

Typewriter

Administrator

Typewriter

Administrator

Typewriter

Administrator

Rectangle

Administrator

Typewriter

Administrator

Typewriter

Administrator

Typewriter

2020

Administrator

Typewriter

Administrator

Typewriter

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30. Evaluation Criteria.

The broad guidelines for evaluation of Bids will be as follows:

Sl. No.

Description Vendor Compliance

1

In respect of Two-Bid system, the technical Bids forwarded by the Bidders will be evaluated by the Department with reference to the technical specifications as mentioned in the RFP. The compliance of Technical Bids would be determined on the basis of the parameters specified in the RFP. The Price Bids of only those Bidders will be opened whose Technical Bids would clear the technical evaluation.

2 During evaluation, SDSC SHAR may request Bidder for any clarification on the bid, additional documents.

3 Bidder must provide the point-by-point compliance to the technical specifications along with deviations. The tender can be rejected if the deviations are not acceptable to the Department.

4 Performance of Bidder on similar nature of works executed/ under execution shall be taken into consideration before selecting the Bidder for opening his price bid.

5 The time schedule for completion is given in the Proposal document. Bidder is required to confirm the completion period unconditionally.

6

SDSC SHAR reserves the right to reject any bid if technically/commercially not meeting the requirement/terms & conditions. Such decisions by the SDSC SHAR shall bear no liability whatsoever consequent upon such decision.

7 Total price inclusive of all taxes, duties, shall be considered for arriving L1 (Overall Lowest) and awarding the contract as per the procedures.

8

If there is a discrepancy between the unit price and the total price that is obtained by multiplying the unit price and quantity, the unit price will prevail and the total price will be corrected. If there is a discrepancy between words and figures, the amount in words will prevail for calculation of price.

9 As all the items within RFP are inter dependent, splitting of the order/WORK is not possible. Hence Technically suitable Overall lowest bidder will be considered.

10 Department reserves the right to inspect the contractor shop floor/premises for evaluation, if required. After evaluating the contractor, decision of the Department is final.

Signature of Authorized Person with Seal

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Section – B

Technical Specifications Of the works

To be carried out at site (Including Detail Engineering and Analysis)

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Sl.No. Specification for works to be carried out Chapter No.

1 Realisation of Deluge System for ASLP facilities Chapter-1

2 Fabrication and erection of Carbon Steel (CS) pipes (Butt-welding & Socket Welding

Chapter -2

3 Fabrication (Butt-welding & Socket Welding) and erection of Stainless steel pipe (SS304L/316L) TIG Welding and Radiography of Butt-welding weld joints

Chapter -3

4 Carbon steel and Stainless steel piping system erection works Chapter -4 5 Fabrication and Erection of M.S Structural Steel Chapter -5

6 Providing RCC pipe pedestals, Equipment foundation and related Civil Works

Chapter -6

7 Procedure for Application of Wrapping and Coating Materials for CS buried Underground Piping

Chapter -7

8 Tubing works for solenoids, actuators, Pressure transmitters, solenoid cubicles & tube tray works

Chapter -8

9 Erection of Equipments (Nitrogen receiver and Nitrogen Accumulator etc.,)

Chapter-9

10 Third Party Inspection (TPI) scope Chapter-10

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Chapter -1. Specifications for Realisation of Deluge System for ASLP facilities

The scope of contractor includes the following towards realization of facilities: Deluge system for ASLP Facilities: Lay out drawings and P & ID reference of ASLP facilities as per preliminary design done by the department are given below:

Sl. No.


1. Over all layout of ASLP Facilities

ASLP/SS/Layout/01 -













The following are in the contract scope: - Preparation of Isometric Diagrams - Preparation of Fabrication drawings - Preparation of integrated and individual piping layout. - Bill of Material generation for pipe fittings, pipe flanges, etc. - Preparation of isometric drawings, pipe segment drawings which are to be given to

fabricator. - Preparation of weld joint schedule. - Preparation of drawings for Working platform (for approach to Deluge valves, Water

monitors and Manual valves etc.,) - All deliverables in the form of drawings/documents. - The supplier has to provide the complete set of isometric drawings in AutoCAD 2002 format

and 3 copies of bound document. One soft copy of total drawings also shall be provided. The supplier shall use PDMS, Auto pipe, CEASER-II or equivalent Software packages for the above works.

- Procurement and supply of material as per approved specification. 1. Technical specifications of items in the scope of contract: 1.1 Piping layout: The piping layout showing details like plan, elevation, and sections of various segments of the Deluge system piping plant shall be supplied. Isometric drawings of independent lines showing slope, Bill of Material (BOM), weld joint schedule shall be supplied. The consolidated BOM for complete erection work with weld joint details shall be supplied.

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1.2 Pipe support: The piping support details shall include BOM for structurals and support clamps. Columns and ceilings will be provided with embedment plates for deriving pipe supports. Embedment plate details will be provided. 1.3 Yard piping: Stress analysis / Flexibility analysis to be carried out by using software for yard pipelines. The loads on pipe pedestals shall be confirmed based on the flexibility analysis. Towards this the contractor shall engage expert agency/consultant in case if adequate in-house resources are not available with contractor. 2. Scope of the purchaser: Purchaser will provide the followings:

- Civil building layouts - P & I Diagrams - Equipment specifications - Pipe pedestals details.

General conditions: The complete work will be reviewed by the purchaser at the consultant’s office. Modifications /improvements in the system shall be incorporated in the piping layouts as and when requested.

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Chapter -2. Procedure for Fabrication and erection of Carbon Steel (CS) pipes

(Butt-welding & Socket Welding) 1.1 Fabrication and erection of CS pipelines

This work includes marking, cutting, profiling, aligning, fit up, Tack welding, cleaning, chipping, placement of wind shields and / or weather protection, DP testing of Root & Final Pass (Both Butt and Socket weld types), X- Ray/gamma Ray radiography (for 10% Butt weld joints). For Carbon steel pipes welding shall be by GTAW for root pass. The filler material used shall confirm to F-6 of ASME Section IX (70S2) and subsequent passes by manual metal arc welding (SMAW) with electrodes confirming to AWS classification E 7018. Only qualified welders to a level of 6G as per ASME Sec. IX with proven track record shall be deployed to carry out the welding works. Qualification of welder need to be carried out in the presence of Department engineer suiting to the pipe size / schedule requirements. Fitters /Fabricators/Grinders should be well experienced. Cutting and edge preparation of pipelines and fittings shall be attempted only with exclusive grinders meant for respective material (Carbon steel). Wherever found necessary, mitre bends (4 pieces) shall be fabricated in place of regular elbows / bends. Fillet weld for Branch pipe line with reinforcement pad shall be carried out as per standard procidure where ever applicable. 1.2 Dye-Penetrant Test: All welding joints shall be tested with Dye-Penetrant test after root pass and final pass welding for both Butt welding and Fillet / Socket welds of pipe line joints as per ASME Sec.V. 1.3 Radiography: - All butt-welds shall be subjected to 10% Radiography, Radiographic Examinations as per

ASME sec. V for a sensitivity of 2-2T. - Interpretation of weld joints radiographs shall be done by TPI/department representative as

per relevant codes such as ANSI B 31.3 and ASME-Sec.V - Exclusive radiography machine / Gamma ray source has to be arranged by the contractor. - D2 films shall be used for Gamma Rays and D5 films shall be used for X-rays. Elliptical shots

(double wall double image) may be employed upto 2” size. - The penetrometer used shall conform to ASTM E 1025/ASTM E747 (or) relevant DIN

standards. - Retake due to rejection of Radiograph owing to bad image quality shall at the cost of

contractor. - Radiography shall be carried out by qualified technicians (i.e.) minimum level- I of ISNT/

ASNT and qualification certificates shall be produced with latest renewal to the Department before proceeding with the work.

- Radiography film shall be evaluated and report shall be submitted by Level II ISNT/ ASNT (or) equivalent qualified person. However, TPI/department Engineer will carry out the final Evaluation.

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1.4 Consumables: The consumables such as Filler wires (ER 70S2), electrodes (E 7018 / E 6013), Grinding Wheels, Industrial Gases (Oxygen / Acetylene), Gas cutting set, Argon gas, Dye-Penetrant Test Kit, Argon regulator, Flow Meters, Face shields, Gloves, Wire Brush, Emery cloth, etc., required for the work shall be in the scope of contractor. Details of the consumables are as follows: - Filler Wires: Size 1.6 mm / 2.0 mm / 2.5 mm, Make (Philips / ESAB / Advani). Manufacturers

material test certificates shall be produced for approval. - Electrodes: Size 2.5 mm / 3.15 mm Make (Philips / ESAB / Advani). Manufacturers material

test certificates shall be produced for approval. - Argon Gas cylinder & Oxy / Acetylene cylinders: Grade Commercial, Purity 99.99%,

Cylinder Capacity 50 Ltrs, Make (Praxair / Bhoruka / Inox / BOC) - Dye-Penetrant test Kit Containing cleaner / Penetrant / Developer, Make (Magnaflux /

Check Mate) - Grinding wheels: Make Universal carburandum/ Norton - Oxy- Acetylene cylinders: Capacity: 50 Lit, Pressure 140-150 bar (g)

1.5 Machinery & Man power: Machinery & Man Power required for four independent teams for CS piping works. The teams shall work if required, on three-shift basis based on site requirement to complete the work within the stipulated period.

Requisite machinery like TIG welding machine, arc welding machine, grinders-angle/pencil, gas cutting sets and bench / hand drilling machines and concrete drillers, tube benders, pipe cutting machine & hydro test pump shall be mobilized by the contractor for the above scope of work.

Adequate skilled, semi-skilled manpower like 6G qualified TIG pipe welders, arc welders, fitter /fabricator, grinders, un-skilled helper gangs and site supervisor (Degree/Diploma in Mechanical Engg) with minimum 3-5-year experience in carrying out similar Fabrication works & documentation, and Quality & safety personal shall also be deployed throughout the contract period.

Since the fabrication, erection & commissioning has to be carried out within the stipulated period, the contractor has to engage multiple teams and shall plan work in three shifts if required and also contractor shall engage sufficient numbers of batches to complete the work within the stipulated period of 12 months.

Extra machinery and teams shall be deployed in case of site requirement calls for to meet time schedule within 2-3 days

1.6 Payment basis: For Carbon Steel Butt welded and socket welded joints: Inch dia.

1.7 Carbon steel piping system erection works: (Refer Chapter- 4 for details)

1.7.1 Erection of piping includes doubling of pipes, positioning of completed pipeline segments at required locations as per isometric drawings, piping layouts and instructions of department focal points depending on the site conditions. This work includes alignment of pipes & pipe fittings, maintenance of required slopes, providing necessary U-clamps, Gaskets, fixing of flow components & instruments as per P& I and laying such pipelines over structural pipe supports/ RCC pedestals, in trenches, in Hume pipes etc., with proper supports.

The work also includes integration of such pipelines with equipment including proper clamping of pipes on such supports.

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After the pipe spool pieces’ fabrication &qualification, they are to be assembled with flow components & equipments as per the P & ID. 1.7.2 Erection of flow components: The items procured and supplied by the contractor like Manual valves, EP valves, safety relief valves, pressure gauges, Pressure transmitters etc., are to be assembled with the piping system as per the P & ID. Hence as per P & ID, end to end system is to be made with all the flow components & piping system.

1.8 Pipe bending works: As per site conditions the Pipe lines of size 15NB to 40NB can be bent using standard pipe bending machines. Hence required machinery is in the scope of supplier.

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Chapter - 3. Procedure for Fabrication (Butt-welding & Socket Welding) and erection of Stainless steel

pipe (SS304L/316L) TIG Welding and Radiography of Butt-welding weld joints 1.This work includes marking, cutting, profiling, aligning, fit up, Tack welding, cleaning, chipping, placement of wind shields and / or weather protection, DP testing of Root & Final Pass (Both Butt and Socket weld types),X- Ray/gamma Ray radiography (for 10% Butt weld joints). Fabrication of Stainless steel piping by butt welding / socket welding.

- All butt weld joints are 100% radiographed. (X ray 2-2T) - Welding consumables, men & machineries are in the scope of supplier.

2.1. The work covers stainless steel welding of SS 304/304L/316/316L butt/socket. 2.2. The scope of welding of joints includes all associated works with making each joint including marking, cutting, profiling, aligning, fit up, Tack welding, cleaning, chipping, placement of wind shields and / or weather protection, root and Final welding. 2.3. Argon Gas TIG welding is to be adopted for root pass and subsequent passes. DP test of welds need to be carried out for each weld joint for root, subsequent and final pass. The purity of Argon Gas used for TIG welding and purging should be of 99.99%. Cleaning of all welds with SS wire brush for stainless steel materials. 2.4. Only Qualified welder to a Level of 6G as per ASME Sec. IX, will be permitted for carrying out the welding work. Qualification of welder need to be carried out in the presence of Department representative suiting to the pipe size/schedule requirements. The welder qualification has to be carried out at Sriharikota only. The Fitters / Fabricators / Grinders should be of well experienced persons. 2.5. It is the responsibility of the supplier to produce sound weld joints. If any, defective welds are noticed during radiography film review, they have to be rectified by the contractor. 2.6. Dye-Penetrant Test: All welding joints shall be tested with Dye-penetrant test after root pass and final pass welding for both Butt welding and Fillet / Socket welds as per ASME Sec. V. 2.7 SCOPE OF THE SUPPLIER: 2.7.1 Machinery & Man Power required for two independent teams for SS piping works. The teams shall work if required, on three-shift basis based on site requirement to complete the work within the stipulated period. Requisite machinery like TIG welding machine, arc welding machine, grinders-angle/pencil, gas cutting sets and bench / hand drilling machines and concrete drillers, tube benders, pipe cutting machine & hydro test pump shall be mobilized by the contractor for the above scope of work. Adequate skilled, semi-skilled manpower like 6G qualified TIG pipe welders, arc welders, fitter / fabricator, grinders, un-skilled helper gangs and site supervisor (Degree/Diploma in Mechanical Engg) with minimum 3-5-year experience in carrying out similar Fabrication works & documentation, and Quality & safety personal shall also be deployed throughout the contract period.

Since the fabrication, erection & commissioning has to be carried out within the stipulated period, the contractor has to engage multiple teams and shall plan work in three shifts if required and also contractor shall engage sufficient numbers of batches to complete the work within the stipulated period of 12 months.

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Extra machinery and teams shall be deployed in case of site requirement calls for to meet time schedule within 2-3 days

One welding team includes 6G qualified pipe welder (1 no), Fitter/Fabricator (1 no), Grinder (1 no) & helper (1 no). 2.7.2 The machineries like TIG welding machine (Portable) with accessories, Grinding machine, welding electrodes are in the scope of supplier. 2.7.3 Consumables: The consumables such as SS Filler wires (ER SS 308 L / 316 L), Grinding Wheels, Industrial Gases (Oxygen / Acetylene), Gas cutting set, Argon gas, Dye-Penetrant Test Kit, Argon regulator, Flow Meters, Face shields, Gloves, SS Wire Brush, SS alignment shim plates of various sizes, Emery cloth, etc., - SS Filler Wires: Size 1.6 mm / 2.0 mm / 2.5 mm, Make (Philips / ESAB / Advani).

Manufacturers material test certificates shall be produced for approval. - Electrodes for Structurals: Size 2.5 mm / 3.15 mm, Make (Philips / ESAB / Advani).

Manufacturers material test certificates shall be produced for approval. - Argon Gas cylinder & Oxy / Acetylene cylinders: Grade Commercial, Purity 99.99%,

Cylinder Capacity 50 Ltrs, Make (Praxair / Bhoruka / Inox / BOC) - Dye-Penetrant Test Kit Containing cleaner / Penetrant / Developer, Make (Magnaflux /

Check Mate) 2.7.4 Deployment of supervisor: - It is the responsibility of the supplier to depute one experienced supervisor for coordinating

the following works at site irrespective of no. of batches. - Discussion and Finalization of nature of fabrication works with Department Engineers. - Collection and mobilization of required Pipes/Fittings/Consumables etc. - Co-ordination with Quality Assurance/Site Engineers for fabrication, Deployment of required

manpower and following Safety precautions 2.7.5 Deployment of manpower and Machinery:

Adequate skilled, semi-skilled manpower like 6G qualified TIG pipe welders, arc welders, fitter / fabricator, grinders, un-skilled helper gangs and site supervisor (Degree/Diploma in Mechanical Engg) with minimum 3-5-year experience in carrying out similar Fabrication works & documentation, and Quality & safety personal shall also be deployed throughout the contract period.

The purchaser reserves right to Demand for Deployment of multiple batches at a time

for the timely completion of project works. Hence the supplier should have capacity to mobilize required number of batches for successful completion of the work. 2.7.6 Mobilization: The supplier has to mobilize men and machinery including internal mobilization during works by his own arrangement. 2.7.7 Qualification of Butt-Weld Joints: All butt-welds shall be subjected to 100% Radiographic Examination as per ASME Section-V for a sensitivity of 2-2T. All shop welded joints, and in-situ joints shall be radiographed by using X-Ray/Gama-Ray. Interpretation of weld joints radiographs shall be done by Department Engineers as per relevant construction codes such ANSI B 31.3 and ASME-Sec-V.

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2.7.8 Evaluation of Machinery and Manpower: Machinery and manpower shall be subjected to Technical Evaluation by the Department Engineer to ascertain their complete suitability /performance for the jobs described above. Based on this Evaluation clearance shall be given for taking up the actual job. 3. Radiography works: - The Radiography is required to be carried out in stainless steel pipe lines/fittings joints in

storages, yard, and umbilical tower. The thickness range from 1mm to 10mm. The type of weld joints are pipe to pipe, pipe to fittings, fittings to fittings, etc. Gamma-ray technique shall be followed

- Image quality (sensitivity) level required for Radiography shall be at least 2% (2-2T) for both X-ray and gamma-ray.

- The Evaluation of Radiography shall be in accordance with ASME Sec-V boiler and pressure vessel code.

- The penetrometer used shall confirm to ASTM E 1025/ASTM E747 (or) relevant DIN standards.

- The Radiography film grades of D5 (Agfagevaret) / NDT –55(DuPont) and size 5” X 3” shall be used for both X-ray and gamma-ray for pipe line joints.

- Safety code IS 258 is to be strictly followed while carrying – out Radiography. 3.1. Scope of the Radiography works: - - Mobilization of men and machinery such as X-ray machines, gamma ray source,

penetrometer, screens, Films, developing chemicals, Radiation sign boards, warning Lamps, red flags, survey meter etc. required to carry out Radiography.

- Radiography film processing facility need to be established by the contractor. Alternatively based on availability the existing facilities shall be spared dully authorized by the department based on the request from the supplier.

- Repeat radiography due to rejection of Radiograph owing to bad image quality shall be at the cost of contractor.

- Radiography shall be carried out by qualified technicians (i.e.) minimum level-I of ISNT/ASNT and qualification certificates shall be produced with latest renewal to the department before proceeding to the work.

- For handling Gamma – ray source, the radiographer has to posses valid certificate issued by BARC.

- Necessary clearance has to be obtained from concerned authorities (DAE /BARC) for moving Gamma ray source from the contactor’s work place to Sriharikota, before every visit to Sriharikota.

- Radiography film shall be evaluated and report shall be submitted by Level II ISNT/ASNT (or) equivalent qualified person/TPI/ Department engineer.

- Radiography shall be carried out during night time only. - The Radiographer’s who are going to be engaged to carry out the radiography work should

have insurance coverage.

4.0 Erection of Stainless steel pipe lines (Refer chapter - 4 for details) 4.1 Erection of piping includes doubling of pipes, positioning of completed pipeline segments at required locations as per isometric drawings, piping layouts and instructions of department focal points depending on the site conditions. - This work includes alignment of pipes & pipe fittings, maintenance of required slopes,

providing necessary U-clamps, Gaskets, fixing of flow components & instruments as per P& I and laying such pipelines over structural pipe supports/ RCC pedestals, in trenches, in Hume pipes etc., with proper supports.

- The work also includes integration of such pipelines with equipment including proper clamping of pipes on such supports.

- After the pipe spool pieces fabrication &qualification, they are to be assembled with flow components & equipments as per the P & ID.

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Erection of flow components: The items procured and supplied by the contractor like Manual valves, EP valves, safety relief valves, pressure gauges, Pressure transmitters etc., are to be assembled with the piping system as per the P & ID. Hence as per P & ID, end to end system is to be made with all the flow components & piping system. 5.0 Pipe bending works: As per site conditions the Pipe lines of size 15NB to 40NB can be bent using standard pipe bending machines as per site conditions. Hence required machinery is in the scope of supplier.

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Chapter - 4 Procedure for Carbon steel and Stainless steel piping system erection works:

I. CS piping erection includes Installation of flow components like Butterfly valves, Deluge valves, EP valves, filters with required CAF gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing, Hydrotesting and testing at Max. Operating pressure, painting of pipe lines and tag numbers and commissioning. As per the details given below point III to point VI. Erection of piping includes doubling of pipes, positioning of completed pipeline segments at required locations as per isometric drawings, piping layouts and instructions of department focal points depending on the site conditions. II.SS piping erection includes Installation of flow components like Ball valves, filters, Pressure regulators, SRV’s, check valves with required SS Spiral wound metallic gaskets and mounting of Instruments like pressure gauges, Pressure switches, pressure transmitters etc., as per P&I diagram. Erection work also includes providing supports from pedestals and also from concrete wall by using anchor fasteners where ever required, U-clamp fixing, Hydrotesting, Pickling –Passivation, cleanliness checks, testing at Max. Operating pressure, painting of pipe lines and tag numbers as per P&I diagram and commissioning as per the details given below point III to point VI... III. Erection of piping includes doubling of pipes, positioning of completed pipeline segments at required locations as per isometric drawings (Approximate Elevation of pipe lines in ISROSENE storage and SC120 LOX facility is 8m and in Launch pad JDD area is 11m, considering this necessary scaffolding to be provided to carrying out erection work), piping layouts and instructions of department focal points depending on the site conditions. IV. This work includes alignment of pipes & pipe fittings, maintenance of required slopes, providing necessary U-clamps, Gaskets, fixing of flow components & instruments as per P& I and laying such pipelines over structural pipe supports/ RCC pedestals, in trenches, in Hume pipes etc., with proper supports. V. The work also includes integration of such pipelines with equipment including proper clamping of pipes on such supports . VI. After the pipe spool pieces fabrication &qualification, they are to be assembled with flow components & equipments as per the P & ID. 1.0 Erection of flow components: The items procured and supplied by the contractor like Manual valves, EP valves, safety relief valves, pressure gauges, Pressure transmitters etc., are to be assembled with the piping system as per the P & ID. Hence as per P & ID, end to end system is to be made with all the flow components & piping system. 2.0 Hydro testing of welded pipe lengths & Commissioning Scope of work: - Hydro testing of welded pipe lengths / spool pieces with pipe fittings and flanges. - Assembly of flow components/ pipe spools with gaskets - Commissioning of the system including dew point checks, leak checks.

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Hydro testing on completed piping segments: Hydrostatic / Pneumatic leak checks on completed piping segments shall be carried out at defined pressure rating as informed by the department personnel. Hydrostatic test shall be carried out with potable water for CS pipe lines and DM water for SS Pipe lines (water will be free issue by Department). The items required for hydro test like hydro test pump, calibrated pressure gauges, blinds etc are in the scope of supplier. Sequence of Testing for CS Pipelines: - Flushing of piping segments with potable water. - Hydro test as per department specified pressures.(18bar for deluge system pipe lines)) - Flushing of all circuits with portable water. - Replacement of test gaskets with actual gaskets (in the scope of the supplier). - Cleanliness check of fluid circuits. - Leak test of the total system as an integrated system ready for process functional checks

at operating conditions. (12bar for deluge system pipe lines) Sequence of Testing for SS Pipelines: - Flushing of piping segments with DM water. - Hydro test as per department specified pressures. - Flushing of all circuits with DM water. - Replacement of test gaskets with actual gaskets. - Purging of all circuits with dry / N2 gas with requisite dew point. - Cleanliness check of fluid circuits. - Pneumatic leak test of the total system as an integrated system ready for process

functional checks at operating conditions. Commissioning of the system: - The total system shall be commissioned end to end to meet the purchaser’s requirement. - Commissioning includes assembly of flow components with gaskets. The joints shall be

tightened by SS studs for stainless steel MOC components and CS studs for carbon steel MOC components with required torque.

- The total system shall be leak checked with N2 gas at operating pressure condition. - All the flow components shall be functional tested. - After the satisfactory performance of leak testing & flow components testing, the system will

be subjected to actual working fluid. - The total system is subjected to test & evaluation as per department procedure. Supplier

also shall involve during such activities. - The system will be declared as commissioned after performance testing of the integrated

system. 3.0 Specification for Pickling & passivation (for SS Pipe lines only) A. Pickling: This is carried out after mechanical cleaning and degreasing operations to remove all the rusts and scales. Pickling is carried out with a solution containing Hydrofluoric acid and Nitric acid. The composition of the pickling solution and duration of pickling are adjusted after trial test on a sample piece to remove uniformly less than 25 microns thick material. The composition is as follows: HNO3 - 15 to 20% by volume HF - 2 to 5% by volume DM Water - Balance Temperature - Ambient Duration - 2 hours - After pickling, rinsing with ordinary potable water until all the acid traces are removed. - The bath solution has to be changed if the level of Iron in the bath reaches 8 grams/litre. B. Passivation: This is done after the pickling operation, a solution having the following specifications shall be used. HNO3 - 25% by volume DM Water - 75% by volume Temperature - Ambient

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Duration of the passivation should be minimum 2 hours. The bath solution has to be analyzed frequently and the bath replenished if the level of iron exceeds 5 g/liter. Finally rinsing with demineralized water (conductivity less than 10 micro siemens/cm) is carried out till final rinse water PH is between 6.5 to 7.5 to minimize staining. C. Checking of chemicals used for pickling & Passivation Test for acid after pickling and passivation:

a) After rinsing with water/DM water, the washings shall be checked with methyl orange indicator until the colour becomes golden yellow. A red colour shows the presence of acid and rinsing shall be continued.

b) Test for fluoride: This shall be done using Zirconium Oxy Chloride solution using Xylenol Orange as indicator. The bleaching of Zirconium Xylenol orange complex will indicates the presence of fluoride.

c) Determination of acid concentration: Pipette out 25 ml of pickling or passivation bath solution into 100 ml flask. Dilute to 100 ml with distilled water, pipette 20 ml of this solution into 250 ml flask and dilute to 100 ml with distilled water. Add 2/3 drops of methyl orange indicator and Titrate against N/2 NaOH contained in a burette. Take reading when colour change from (red to yellow) (pink to yellow). Percentage of acid = No. of ml X 0.67

d) Estimation of iron: Pipette out 10 ml of solution into a flask and dilute it to 100 ml with distilled water. Pipette 10 ml of dilute solution into flask and add 10 ml of 50% Sulphuric acid.

Titrate against N/10 KMNO4 solution till the pink colour persists for about 15 seconds.

Percentage of iron = No. of ml of N/10 KMNO4 X 0.56

e) Inspection after cleaning for the presence of free iron: i) Copper Sulphate Test ii) Ferroxyl test For all testing, the contractor shall establish a small laboratory facility on his own and all chemicals purchased by the contractor will be subjected to the approval of inspection agency. D. Drying: The drying is done on GN2receivers and Accumulators as well as piping to remove water and this is done as given below: Oil free compressed air dew point less than -40 Deg. C is used to purge initially. Purging with dry Nitrogen having Dew point less than -40 Deg. C and free from oil and greases (less than 10 PPM at 60 Deg. C till the moisture level at the exit comes to the inlet concentration value. E. Sealing: After drying, the GN2 pipes/equipment should be sealed so that ambient moisture never enters inside. The pipes/equipments are to be pressurized to 0.5 bar with dry N2 gas at

-40o C dew point Temperature. F. General conditions: The pipelines after welding & radiography/hydro test will be subjected to pickling & passivation. The spool pieces / yard length pipe lines will be subjected to pickling & passivation. The spool pieces shall be pickled & passivated by holding method whereas the yard length line shall be pickled & passivated by holding & circulation method. The external & internal surface of the weld joints of the pipe lines are to be pickled & passivated. The chemicals, pump, PVC hoses, testing equipment’s, plastic drums are in the scope of supplier 4.0 Painting works A. Scope of work:

- Painting of equipment’s& pipe lines. - Painting of structural items & hand rails - Tag numbering of flow components - Painting of pipe line numbers / designation

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B. Painting of all equipments/pipe lines: - The paints to be applied are special type (epoxy paints) i.e. two component paints. Both the

components (3:1 ratio) are to be mixed and applied immediately on mixing. All the surfaces shall be applied with one coat of primer & one coat of finish coat.

- In order to protect the surface of the pipe lines and equipments from rust and dry coastal saline weather, application of primer and finish coat paint shall be carried out.

- The metal surface shall be cleaned thoroughly for surface preparation with Carbon steel /Stainless Steel brushes as applicable.

- A high build epoxy primer suitable for Stainless Steel surface of 120 +/- 10 micron Dry Film Thickness (DFT) followed by a finish coat of aliphatic/polyurethane finish paint of 40 microns DFT shall be applied so that the total DFT achieved will be 150 +/- 10 microns.

- The tag numbering of pipelines and flow components shall be written at appropriate places as per P & I diagram.

- All paints and necessary consumables fall under the scope of the contractor. - For equipments (GN2 Receivers and Accumulators) spray painting shall be employed. The

spary gun is in the scope of supplier. The source of Air will be provided by the department. C Painting of Structures/platforms/hand rails/cable trays: Painting of MS pipe Supports/Structures, platforms and cable tray work includes surface preparation, mixing and application of paints. Primer & Final coat as per required thickness. All paints and necessary consumables fall under the scope of the contractor. Painting Scheme shall be followed given below:

Epoxy mastic coating : 120 - 130 microns Aliphatic Polyurethane : 30 - 40 microns Total Dry film thickness : 150 +/- 10 microns

Colour scheme: The colour code scheme for liquid lines, N2 gas lines, vapour lines, etc will be provided by purchaser at the time of painting works and in general as per relevant Indian standards and which will be applicable for final coat. Tag numbering / Pipe line numbering: Numbers are to be painted on the pipelines using white synthetic enamel paint on a black back ground painted surface as follows: Height, width & thickness of letters/numbers are 25, 50 & 5 mm respectively. One set consists of numbering with white enamel on a black background. Black background is to be painted prior to numbering with stencils.

1234-QD-SK-50-D1C 50/35/15

ABCD - 456 7 50/35/15

300/200

500/350

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General conditions: - Experienced painters shall be employed. - Spray painting / manual brush mode painting shall be employed. - While painting uniform DFT shall be maintained. - The brushes, waste/ cotton cloths, spray gun are in the scope of supplier. - Paint / Thinner should not be wasted. - Tag numbering / pipe line numbers will be provided at the time of painting works.

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Chapter - 5. Procedure for Fabrication and Erection of M.S Structural Steel

The scope includes the MS structural steel supply, fabrication, assembly and installation of all types and size of structures like truss/frame works structural supports, base plates Working platforms, hand rails, pipe supports and cable tray works and any other type structures as per the design. It also includes supply of foundation bolts, Hilti anchor bolts, studs/ bolts & fabrication, cutting, drilling, welding, assembly, installation, fixing of bolts and providing necessary torque after installations and adjustment of the structures according to the requirements at specified locations. There shall be no limitation to the number of welds or drillings to be carried out per kilogram of the structural works. The work includes pipeline supports at ISROsene storage, DPT, UT, ACOSS, Tower, SC120LOX etc., 8m height pipe rack for routing of pipes as per the piping layout, Elevated platforms with staircase for all the monitors, elevated platforms with staircase for foam concentrate storage tank, cross over platforms for pipelines & platforms for Manual valves, sheds for deluge valves and foam skid etc., at the tentative locations shown in layout drawing. Structural Sections : Material shall conform to IS 2062 Grade E 275BR. Base Plates : Material shall conform to IS 2062 Grade E 275BR. Chequered plates : Material shall conform to IS 2062 Grade E 250 A and requirement for chequered plates shall conform to IS3502. Foundation Bolts : Conforming to IS 5624, including washer and hexagon nut conforming to IS 1360 (Part3). Studs : Material of full threaded Studs shall conform to ASTM A193 GR.B7and hexagonal nut shall conform to ASTM A194 GR.2H. - The dimension of studs and nuts shall conform to IS 1367. Flat washers shall suit to

corresponding stud size. One set shall contain a stud, two nuts and two washers. - All fasteners shall be surface treated (Hot dip galvanized/ Teflon coated) for corrosion

resistant. 1.0 Specification for MS Fabrication: 1.1 Fabrication of MS pipe supports, structural platforms, cable trays shall be carried out by means SMAW welding with arc electrodes of AWS E 7018. 1.2 Drilling and anchoring of pipe supports on floor & wall, welding on wall / floor / roof embedment shall be carried out wherever required and after completing the erection and testing of the piping and equipments. 1.3 The procurement of MS structural materials like angles, channels, cable trays etc., is in the scope of the contractor which is already mentioned in the supply portion of the tender. 1.4All necessary handling, transportation, measuring, cutting, drilling, fabrication are to be carried out by the Contractor. 1.5 Electrodes for Structurals: Size 2.5 mm/3.15 mm, Make (Philips/ESAB/Advani). 2.0 General conditions: 2.1 Separate ARC welding teams should be available for carrying out the structural fabrication works. 2.2 Experienced welder, fitter and helpers should be available in each team.

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2.3 The machineries, grinding wheel/ cutting wheel, drilling machines are in the scope of the supplier and they should be in good conditions. The machineries and consumable will be evaluated by the purchaser before actual use for fabrication works. Gas cutting set & arc welding machine with accessories are in the scope of supplier. 2.4 The supplier has to provide multiple teams based on the requirement to complete the project in time else penalty clause will be imposed.

S.No Description

Qty

1 MS structural fabrication works ; Fabrication of (Arc welding) of platforms, pipe supports & hand rails and anchoring works

5 ton

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Chapter – 6 Procedure for providing RCC pipe pedestals, Equipment foundation and related Civil

Works The scope of work shall include foundations for pipe supports and structural supports which are not provided by the department. It also includes supply of steel reinforcement rods, binding wires, cement, sand, granite stone aggregate, gravel, cement concrete interlocking paver block etc. and the work includes excavations of earth for making foundations of structures and equipment. The typical works under this heading include the following: a. Excavation of earth, leveling for laying the pipelines, providing RCC pipe Pedestals. b. Filling of earth after construction of pipe pedestals. c. Pedestals with foundation bolts/Embedment plates for deluge sheds/ equipment, pipe supports and elevated structuralplatforms. d. Grouting of equipment, pipe supports, structural works by PCC/RCC. The composition shall be as follows:

PCC - Cement: Sand:Gravel = 1:4:8 RCC - Cement: Sand:Gravel = 1:1.5:3 Plastering - Cement:Sand = 1:5

Sequence to be followed for Construction of RCC pipe pedestals, Equipment foundation of works:

1 Earth work: Earthwork in excavation for Thrust blocks and valve chambers and Trenches for pipelines

in all kinds of soils including dressing of sides, ramming of bottom prior to laying of pipelines and back filling and leveling after completion of Pipeline testing.

2 Shuttering:

Providing rigid and water tight centering and shuttering using best quality wood/ plywood/ steel forms and centering with steel props, acorn tubes etc., including strutting, propping, bracing, staging etc., complete for all RCC items fixed in position as required including labour for careful removal of form work etc.,

3 RCC:

Providing & laying in position machine batched, machine mixed and machine vibrated design mix cement concrete of specified grade for reinforced cement concrete structural elements, using graded hard granite stone aggregates of maximum 20mm nominal (downgraded) size obtained from approved quarry including fine aggregates conforming to latest IS 383 and cement all as per approved design mix proportions conforming to latest IS 10262 with minimum cement content for durability and plasticizer including supplying and providing concrete cover blocks etc., which shall be followed as per latest IS456-2000 including mixing, transporting, placing, vibrating, compaction, finishing to required levels, curing etc., as per approved Drawing.

4 Reinforcement:

Steel reinforcement with high yield strength deformed bars of SAIL/RINL/TATA or equivalent approved brands for all R.C.C items including decoying, cutting, hooking, bending, cranking, fabricating to required shape, placing in position and tying the system with soft drawn annealed binding wire of diameter not less than 1.00mm with 2 strands etc., complete all as per specifications.

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5 Plastering: Water proof cement plastering of thickness as specified below in cement mortar 1:3 (1

cement : 3 coarse sand) mixed with approved water proofing compound such as ROFFE HYPROOF manufactured by M/s Ruffle Construction Chemicals Pvt. Ltd. at 140ml per bag of cement or CONPLAST X 421 IC of Forsook Chemicals Ltd. at 130ml per bag of cement or equivalent approved make as per manufacturers specifications including curing complete for Internal surfaces and projected portion from ground level for external surface.

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Chapter - 7.

Procedure for Application of Wrapping and Coating Materials for CS buried Underground Piping

The scope of work includes supply of synthetic primer coating, type B conforming to IS 9912/AWWA C203, 4mm thick coal tar based anticorrosion tape conforming to IS 15337/AWWA C203 and the application of underground pipes coating and wrapping shall be done according to code of practice IS 10221. The pipe surface shall be degreased and the rusts shall be cleaned by means of blast cleaning before applying paints. The minimum acceptable standard of blast cleaning shall SA 2.5 as per Swedish Standard SIS-05-5900-1967 or equivalent. Priming shall be done within 4 hours of completion of cleaning. One coat of synthetic primer shall be applied on pipes immediately after cleaning either by brush or spray. The primer shall be allowed to become touch dry prior to wrapping the tape. Before wrapping the coal tar based anticorrosion tape to the pipe, the primer-coated pipe shall be gently heated by a run of LPG torch or suitable heat source. The tape shall be wrapped either by spiral or circumferential method to the pipe and there shall be a minimum of 12.5 mm overlap per single wrap. Over the weld joints, after necessary inspections, the procedure for coating and wrapping shall be of a bare pipe. Overlap on each side of weld joint shall be a minimum of 50 mm. In wrapping application, care shall be taken that there are no air pockets or bubbles beneath tape and tape shall be in intimate contact with the primedsteel. After wrapper coating the coated portion shall be tested with Haliday tester.

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Chapter – 8

Tubing works for solenoids, actuators, Pressure transmitters, solenoid cubicles & tube tray works

Scope of work: - Command gas (N2) supply tubing for electro pneumatic (EP) valves between actuators

and solenoids. - Command gas supply tubing between solenoids & N2 header - Command gas supply tubing for control valves. - Tubing for Pressure transmitter (process instrument) between process pipe & instrument. - Tube tray fabrication, bunching of tubes with SS wire/clamps. Works involved: For electro pneumatic valves: - The tubing works involves cutting, bending, edge preparation without burrs and with ferrule

fittings, the tubes shall be interfaced. The tubing works shall be carried out between actuators, solenoids & command gas header pipe lines. - The solenoid valves are kept in a separate enclosure called cubicles. From the command

gas line header to solenoid valves and from solenoid outlet to actuators of EP valves, tubing works to be carried out. Inside the solenoid cubicles, solenoid valves (13 nos) will be fixed and tubing works shall be made for command gas supply with interface adopters.

- The actuators and solenoids are kept apart. - The tubes shall be interfaced with actuators/ solenoids with suitable interface ferrule fitting

adopters/ compression tube fittings. - The tube & tube shall be interfaced using the union ferrule fittings. - Wherever unions are used the union joint shall be projected above the tube tray for easy

leak check & maintenance. - For each solenoid cubicle entry one filter also is to be assembled.

For Pressure Transmitters, Pressure switches: For the pressure transmitter tubing, the tapping is taken from the process pipe. From the process pipe to PT instrument, tubing is to be carried out similar to EP valves. Tray related works: - Tubes are to be laid neatly via the trays between actuators & solenoid cubicles. - The trays are to be cut/ welded / fabricated for the same. - The tubes are to be bunched together by means of SS clamp / SS wire. (GI wires, MS

clamps shall not be employed which lead to pitting corrosion of tubes)

Schedule of tubing works S.no Description Qty

1 Tubing works for EP valves (GN2 command supply form solenoid valve cubicle), Process instruments viz., Pressure transmitters , Pressure switches etc., Tube size : 6mm

250m

2 Tube tray welding, cutting , fixing including clamps/ SS wires 500 kg

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Chapter-9. Erection of Equipments (Filters,Nitrogen receiver and Nitrogen Accumulator )

1. Scope of works: Erection of equipment’s viz., Nitrogen receiver and Nitrogen Accumulator etc., and Grouting with grout cement and providing Aluminum strip for earthing of equipment (25 x 3mm thick). 2. Erection of tanks / Pressure vessels: Details of tanks to be erected:

Sl.No

Description Capacity/ Size MAWP bar

Qty, Nos

1 GN2 Receiver for Deluge system 1000 Liters 10 3 2 GN2 Accumulator for Deluge system 100 litres 10 3 3 Filter Housings 400NB 10 1 4 Filter Housings 300NB 10 1

- If any of the equipment gets damaged during erection, the cost of rectification / replacement shall be recovered from the contractor.

- The alignments, slopes and elevations of receivers are as per purchaser’s requirement. - The contactor has to provide the details of the foundations/pedestals required. Wherever

foundations / pedestals could not be provided, the supplier has to provide the required pedestals to the department.

- After erection of the equipment the supplier has to grout the equipment using grout cement. - GN2 Receiver shall be earthed through Aluminum conductors of size 25mm (width) X 3mm

(thick) as required at site. Approximate length of strip required 200m. General conditions: Transportation & Material Handling: The necessary items for erection of equipments like wood logs, temporary structures, riggers, tools and tackles, wire ropes, D-shackles, cranes are in the scope of supplier. However, department may provide the material handling support on chargeable basis subject to availability. The approximate dept rates at present are:

Material Handling systems Rates per hour (Approx.) 130 T Crane Rs.14000/hr TL crane (10T) Rs 2500 /hr Hydra (10T) Rs.1400 /hr Gold Hoffer Trailer Rs.1700 /hr Volvo Hauler Rs.1300 /hr Support subject to availability.

The Transport vehicles required for movement of contract personnel from /to work site including internal movement within site is in the scope of contractor only.

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Chapter-10 Third Party Inspection (TPI) scope

The supplier has to employ any of the following TPI for overall certification of the system. - Lloyds Register Industrial Services Pvt Ltd (LRIS) - Det-Norske Veritas (DNV) - Technischer Uberwachungs Verein (TUV) - Beaurea Veritas (BV) Scope of TPI:

A. For CS & SS pipe Fabrication, erection, testing and commissioning works, Sl. No. 01 to

06 of the table - I Unit rate shall be quoted as per the following details.

The details of QAP to be followed by TPI are given in the following Table – A

Sl No Description Number of visits 01. Third party Inspection Cost 30

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A) Scope of TPI for site works at SDSC SHAR

Sl No. Characteristics /Type of Check

Ref. Document Method of Check

Quantum of check

Third party

Purchaser

1 The test packs of the bought-out items / supply portion of the items shall be verified and cleared for usage. However, during manufacturing of the items (like pipes, fittings, GN2 receivers etc.,) if already TPI involved for such items test packs need not be reviewed by the surveyor.

As per PO/ drawing

Visual

100%R R

2 The welder qualification at SDSC SHAR shall be certified by the TPI. The WPS/PQR shall be approved by the TPI.

As per AWS Standard Review

100%R R

3 The erection of static equipment’s, flow components and pipe lines shall be verified by the TPI.

Procedure, alignment, anchoring, fixing, slope maintenance, grouting etc.

Visual 100%W W

4 The weldment Fit-up’s, DP test of Weld Joint Root pass and subsequent passes,

As per standard Visual 10%W W

5 Radiography film review,

As per standard Film evaluation

100%W R

6 Pipe support verification, clamping of pipes, assembly of flow components,

As per standard/Approved

drawings Visual 100%W R

7 Hydro test witnessing As per standard

Pressure hold method

100%W W

8 Pneumatic leak test As per standard

Pressure hold method

100%W W

9 Pickling & passivation of weld joints as applicable for SS piping.

As per standard/Approved Procedure

Visual 10%W R

10 The TPI has to verify and certify for the end to end realization of the system as per P & ID.

Approved drawings Visual 100%W W

89

Sl No. Characteristics /Type of Check

Ref. Document Method of Check

Quantum of check

Third party

Purchaser

11 The TPI shall verify and certify for the assembly of all flow components and process instruments with gaskets in all flange joints and tightening with studs & required torque without leak.

As per standard/Approved Procedure

Visual 100%W R

12 The total boxing up of the system shall be certified by the TPI.

As per approved procedures /Drawings

Visual 100%W R

13 TPI shall participate during commissioning of the system for handing over.


Visual 100%W W

14 Final documentation


Document 100%R R

Legend: R – Review, W – Witness, H – Hold.

B). Scope of TPI for bought out items/ Items under supply scope by contractor. Unit rates quoted for each item shall be inclusive of TPI charges which are in the scope of the supplier.

Sl. No.

Description of the item to be supplied Refer Chapter for

specifications & QAP 1 Carbon steel pipes Chapter-1

2 Carbon steel seamless pipes Chapter-2

3 Carbon steel pipe fittings and flanges Chapter-3

4 Wafer type Manual Butterfly valves Chapter-4

5 Carbon steel manual Ball valves Chapter-6

6 Water filters Chapter-12

7 Seamless Stainless-Steel pipes Chapter -18

8 SS forged flanges Chapter -19

9 SS forged Pipe fittings Chapter-20

10 SS Manual Ball valves Chapter -21

11 SS Nitrogen Receivers Chapter- 27

12 SS Nitrogen Accumulators Chapter- 28

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SECTION-C

Specifications for the items to be supplied

91

TECHNICAL SPECIFICATION OF SUPPLY ITEMS: Specification for scope of supply: Since the scope of work includes supply of items, it is to be noted that the items to be used shall be of the prescribed make/brand(s) only. The brief specifications for each of the items is available in the corresponding sections as indicated in Table-A, and Table -B

Table -A:

Details of Specifications of supply items required for water based deluge systems:

Sl. No.

Description of the item to be supplied

Suppliers / Make Refer Chapter

for specifications

1 Carbon steel pipes MSL/JINDAL/SURYA ROSHINI/RATNAMANI/TATA

Chapter-1

2 Carbon steel seamless pipes MSL/JINDAL/SURYA ROSHINI/RATNAMANI/TATA

Chapter-2

3 Carbon steel pipe fittings and flanges

Sanghvi Forging & engineering ltd/ Sawan engineers pvt ltd/ Rajmani fittings pvt ltd/Rajendra Industrial corporation/RDForge./ Gujarat Infra pipes (p) ltd./Mechwell fittings

Chapter-3

4 Wafer Type Manual Butterfly Valves M/s L&T, M/s Flow Serve (Audco) Chapter-4 5 Electro -Pneumatic (EP) Butterfly valves M/s Metso / M/s Tyco Chapter-5 6 Carbon steel manual Ball valves M/s L&T/ M/s Micro finish/M/s Audco Chapter-6

7 Manual Water monitors M/s Newage, M/s Winco, M/s Shah Bhogilal, M/s AAAG

Chapter-7

8 Remote operated long range water cum foam monitors; Flow rate: 3000lpm @ 7 bar; Fog/Jet nozzle including spares.

Make : SKUM Chapter-7A

9 Deluge valve – Piston Type Make: KIDDE Chapter-8 10 Dry pilot actuator Make:HD Fire Chapter-9

11 Quartzoid bulb detectors (QBDs)/ Pendent type sprinklers with SS protection guard Make: HD Fire/Tyco

Chapter-10

12 Medium velocity spray nozzles Chapter-11

13 Water filters

1.Sakthi-Hitech, Chennai 2.Perfect engineering, Baroda 3.Ultrafilter, Bangalore 4.Mable engineers, Chennai 5.MEFCO,Chennai

Chapter-12

14 Specification of Electro Galvanized fasteners

1.Mechwell fittings, Ahmedabad 2.Tec aero devices, Hyderabad 3.Lee hydraulics, Hyderabad 4.Dabir, Thane 5.VK technical works, Hyderabad 6.Venkatewara Industries, Chennai

Chapter -13

15 Specification of Electro Galvanized U-clamps

Chapter-14

16 Paints primer and Final coat paints Asian paints / Berger paints /CDC Jerlac paints/Nerolac/Grand Polycoats

Chapter-15

17 MS structural material TATA/TISCO/SAIL/JINDAL/VIZAG STEEL

Chapter -16


1.Anchor fasteners : HILTI 2.CAFGaskets: Champian/spitman/uniklinger 3.Wrapper coating: IWL

Chapter -17

92

Table -B:

Details of Specifications of supply items required for GN2 Command supply for deluge station

Sl. No



for specifications

1 Seamless Stainless-Steel pipes Ratnamani metals & tubes ltd./ REMI Edelstahl tubular ltd/ Sandvick-asia/Nuclear fuel complex.

Chapter -18

2 SS forged flanges Sanghvi Forging & engineering ltd/Sawan engineers pvt ltd/Rajmani fittings pvt ltd/Rajendra Industrial corporation/RD Forge./Gujarat Infra pipes (p) ltd./Mechwell fittings

Chapter -19

3 SS forged Pipe fittings Chapter -20

4 Stainless steel Manual ball valves L&T/ Audco/ Microfinish Chapter -21 5. Pressure gauges M/s WIKA/Fiebg/HGURU Chapter -22 6. SS Studs 1.Mechwell fittings, Ahmedabad

2.Tec aero devices, Hyderabad 3.Lee hydraulics, Hyderabad 4.Dabir, Thane 5.VK technical works, Hyderabad 6.Venkatewara Industries, Chennai

Chapter -23

7. SS U-clamps Chapter -24

8. SS Spiral wound gaskets IGP/MIP/ Uniklinger Chapter -25 9.

Pickling and passivation of pipe lines

--- Chapter -26

10. SS Nitrogen Receivers

1. Perfect engineering, Baroda 2. Shakthi hi-tech, Chennai 3. Mabel engineers, Chennai 4. L&T, Mumbai 5. Lloyds, Mumbai 6. Aspick, Chennai 7. Nuberg Engineering, Bharuch

Chapter - 27

11. SS Nitrogen Accumulators Chapter - 28

12. SS Seamless tubes

Ratnamani metals & tubes ltd. REMI Edelstahl tubular ltd Sandvickasia Nuclear fuel complex.

Chapter - 29

13. SS Double compression pipe fittings, Check valves

M/s Parker/ Swagelok Chapter - 30

14. GN2 Pressure regulators IMF,FRANCE(IMFNorgren, Delhi)/Swage lok/ Parker

Chapter - 31

15. GN2 Filters IMF,FRANCE(IMFNorgren, Delhi)/Swage lok/Parker

Chapter - 32

16. Safety relief valves Anderson greenwood Crosby sanmar Chapter - 33

93

CHAPTER -01 SPECIFICATIONS OF CARBON STEEL /MILD STEEL PIPES

Scope of supply: Carbon steel pipes/Mild steel as per the following specifications.

1. Code of Manufacturing & Testing : IS: 3589 2. Method of Manufacture of pipe : ERW

3. Material of construction : Carbon steel pipes confirming to IS: 3589:1991, Gr. Fe410

4. Service fluid : Water 5. Max. Operating pressure : 12 bar 6. Hydrotest pressure : As per standard.

7. i. Finish on Outer Surface : Anticorrosive protective coating for outer surface./Epoxy coating of 120-140 microns

ii. Finish on inner Surface : Epoxy coating of 120-140 microns 8. Tolerances on thickness : As per IS: 3589 9. Length of pipe : Single random length of 5 to 7 m.

10. Marking required on the pipes : Manufacturer’s reference (Pipe Sl. No.), heat /lot number, Code of manufacture, Dimensions of pipe (Size, OD, and Thickness).

11. Ends : As per standard

12 Make of the pipes : MSL/JINDAL/SURYA ROSHINI/RATNAMANI/TATA

Details of pipes required are as follows

GENERAL CONDITIONS: 1. Pipes shall be cleaned and dried before dispatch. 2. Inspection: By Purchaser’s s representative as per Approved QAP(Annexure-1A) 3. Packing: Material shall be suitably stacked /packed to prevent damage during transit. 4. Prices quoted inclusive of all testing charges i.e., Chemical analysis, Mechanical

Test certificate and hydrostatic test certificates as per standard shall be supplied along with dispatch documents.

5. Marking required on pipes: Manufacturer’s reference (Pipe Sl. No.), heat /lot number, Material, Code of manufacture, Dimensions of pipe (Size, OD, and Thickness).

6. Quantity variation: Maximum quantity variation (+/-) 6 meters or one random length in each size.

7. Guarantee: Material supplied shall be guaranteed for 12 months from the date of supply 0r 14 months from the date of commissioning whichever is earlier.

8. Production master file: a. Three copies of production master file shall be supplied with the following details:

i) Dimensional & visual check reports ii) Physical & Chemical Analysis certificates. iii) Final inspection Report/release Note.

Sl. No.

Size NB (mm)

Thickness (mm) Manufacturing

std. Quantity required (m)

1 400 8.0 IS: 3589 300 2 300 6.35 IS: 3589 360 3 250 6.35 IS: 3589 500

94

QUALITY ASSURANCE PLAN FOR INSPECTION OF CS PIPES

Sl. No.

Characteristics / Type of check

Reference Document

Method Of check

Supplier’s QC

Purchaser’s Inspector

Third party inspection

(TPI)

1 Visual &

Dimensional Check IS: 3589 /

Witnessing

H 100%

W 10%

W 10%

2 Chemical analysis -Do- Verification of material test certificates

R 100%

R 100%

R 100%

3

Mechanical tests per each

ingot/parent metal heat no.

-Do- Verification of material test certificates

H 100%

R 100%

R 100%

4 Hydro static test -Do- Witnessing H 100%

W/H 10%

W/H 10%

5 Stamping AS per P.O Perform H

100% W

10% W

10%

6 Issue of Inspection release note (IRN)

Yes

To be given by TPI

Note:

- TPI scope as defined and issue of IRN.

Legend:R- Review, W- Witness, H- Hold.

95

CHAPTER -02 SPECIFICATIONS OF CARBON STEEL SEAMLESS PIPES

Scope of supply: Carbon steel pipes as per the following specifications.

1 Code of Manufacturing & Testing : ASTM-A106Gr.B 2 Type of pipe : Seamless pipes, Sch 40

3 Material of construction : Carbon steel pipes confirming to ASTM-A106Gr.B

4. Service fluid : Water 5. Max. Operating pressure : 12 bar 6. Hydro test pressure : As per ASTM-A106Gr.B

7. Finish : Anticorrosive protective coating for outer surface.

8. Tolerances on thickness : As per ASTM-A106Gr.B 9. Length of pipe : 5 to 7 m.

10. Marking required on the pipes : Manufacturer’s reference (Pipe Sl. No.), heat /lot number, Code of manufacture, Dimensions of pipe (Size, OD, and Thickness).

11. Ends : As per ASTM-A106Gr.B

12 Make of the pipes : MSL/JINDAL/SURYA ROSHINI/RATNAMANI/TATA

Details of pipes required are as follows

Sl. No. Size,NB (mm) Schedule Quantity (m)

1 200 Sch 40 450

2 150 Sch 40 350

3 100 Sch 40 250

4 80 Sch 40 250

5 50 Sch 40 220

6 40 Sch 40 325

7 25 Sch 40 200

8 15 Sch 40 50

GENERAL CONDITIONS: 1. Pipes shall be cleaned and dried before dispatch.

2. Inspection: By Purchaser’s s representative as per Approved QAP

3. Packing: Material shall be suitably stacked /packed to prevent damage during transit.

4. Prices quoted inclusive of all testing charges i.e., Chemical analysis, Mechanical Test certificate and hydrostatic test certificates as per standard shall be supplied along with dispatch documents.

5. Marking required on pipes: Manufacturer’s reference (Pipe Sl. No.), heat /lot number, Material, Code of manufacture, Dimensions of pipe (Size, OD, and Thickness).

6. Quantity variation: Maximum quantity variation (+/-) 6 meters or one random length in each size.

96

7. Guarantee: Material supplied shall be guaranteed for 12 months from the date of supply 0r 14 months from the date of commissioning whichever is earlier.

8. Production master file:

a. Three copies of production master file shall be supplied with the following details:

i) Dimensional & visual check reports ii) Physical & Chemical Analysis certificates. iii) Final inspection Report/release Note.

QUALITY ASSURANCE PLAN FOR INSPECTION OF CS SEAMLESS PIPES

Sl No

Characteristics / Type of check

Reference Document

Method Of check

Supplier’s QC


Third party inspection

(TPI)

1 Visual & Dimensional Check

ASTM-A106Gr.B

Witnessing H

100%

W 10%

W 10%

2 Chemical analysis


R 100%

R 100%

R 100%

3 Mechanical tests per each ingot/parent metal heat no.


H 100%

R 100%

R 100%

4 Hydro static test -Do- Witnessing H

100%

W 10%

W 10%

5 Stamping AS per P.O Perform H

100% W

10% W

10%

6 Issue of Inspection release note(IRN)

Yes

To be given by TPI

Note: - TPI scope as defined and issue of IRN.

Legend: R- Review, W- Witness, H- Hold.

97

CHAPTER -03 SPECIFICATIONS OF CARBON STEEL FITTINGS & FORGED FLANGES

Material: Butt weld fittings: ASTM A 234 WPB(Seamless) Socket weld fittings: ASTM A105 Forged carbon steel Flanges (SLIP-ON RAISED FACE FLANGE (SORF)) and

Blind Flanges with concentric serrations as per ASTM A-105 Pipe Nipples : ASTM A106

1. Dimensions of fittings shall confirm to ANSI standard for Butt welded fittings as per BS16.9 and B16.28. And socket welded fittings shall be as per ANSI B16.11.

2. Dimensions of Flanges shall confirm to ANSI B16.5, 150#. 3. Mechanical, chemical, Micro analysis tests shall be carried out on one sample per heat/lot.

All testing charges shall be included in the quoted price. 4. Sampling for Material testing: One sample from each lot/Heat shall be given for physical,

chemical and micro analysis. 5. All the fittings and flanges shall be inspected and cleared by Purchaser’s representative

prior to dispatch. The readiness of the flanges for our inspection shall be intimated in advance.

6. All Fittings and flanges shall be clearly marked indicating manufacturer’s reference, Dimension, heat/lot number, class rating, Type, Material as applicable.

7. All fittings are to be of Seamless quality. Butt-weld tees shall be of swaged type only. 8. All the External/Internal threaded portions shall be protected with plastic caps to avoid

Damage to the threaded ends. 9. Protective coating: All C.S fittings shall be applied with suitable anti-corrosion coat for

external surface. 10. Dispatch: All C.S fittings shall be neatly packed in wooden boxes to avoid damage due to

transit. 11. Inspections& testing: The following tests shall be as per code:

Sl. No

Type of test By Manufacturer

(100%) By Purchaser

(10%)

Third Party Inspection

(TPI)

1 Verifications of material test certificates for physical and chemical & micro analysis for Forgings.

W

R

R

2 All fittings shall be visually examined for absence of scratches dents, surface irregularities etc.,

w W W

3 Verifications of punched details like Size, class rating, Type, Material and heat number.

W W W

4. Dimensional inspection as per code. W W W

5. Issue of Inspection release note(IRN) Yes

To be given by TPI

Note: - TPI scope as defined and Issue of IRN .

W-WITNESS (PERFORM) R-DOCUMENT REVIEW 12. Production Master file Three copies of production mater file shall be supplied and shall contain the following:

- Dimensional & Visual check reports. - Physical, chemical, Micro analysis reports - Final inspection Report / Release note

98

- All the above reports/Test Results shall be bound neatly Schedule of CS forged Pipe fittings and flanges

Sl. No

DESCRIPTION Units Qty.

1 400NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 6 2 300NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 15 3 250NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 20 4 200NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 45 5 150NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 45 6 100NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 50 7 80NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 60 8 50NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 75 9 40NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 65

10 25NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 11 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 Nos. 40 12 400NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 13 300NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 14 250NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 6 15 200NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 10 16 150NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 17 100NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 15 18 80NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 20 19 50NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 20 40NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 21 25NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 22 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 Nos. 25 23 400NB EQUAL TEE BUTT WELD, Sch40 Nos. 4 24 300NB EQUAL TEE BUTT WELD, Sch40 Nos. 10 25 250NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 26 200NB EQUAL TEE BUTT WELD, Sch40 Nos. 20 27 150NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 28 100NB EQUAL TEE BUTT WELD, Sch40 Nos. 40 29 80NB EQUAL TEE BUTT WELD, Sch40 Nos. 30 30 50NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 31 40NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 32 25NB EQUAL TEE BUTT WELD, Sch40 Nos. 60 33 15NB EQUAL TEE BUTT WELD, Sch40 Nos. 50 34 400x400x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 35 300x300x250NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 36 300x300x200NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 2 37 250X250X200 UNEQUAL TEE BUTT WELD, Sch40 Nos. 8 38 250x250x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 5 39 200x200x150NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 10 40 200x200x80 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 4 41 150x150x100 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15 42 100x100x50NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 20 43 80x80x50 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 30 44 50x50x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 15 45 40x40x25 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 46 25x25x15 NB UNEQUAL TEE BUTT WELD, Sch40 Nos. 40 47 400X300 CONCENTRIC REDUCER, Sch40 Nos. 4 48 400X250 CONCENTRIC REDUCER, Sch40 Nos. 4 49 300X200 CONCENTRIC REDUCER, Sch40 Nos. 4

99

Sl. No


50 300X250 CONCENTRIC REDUCER, Sch40 Nos. 5

51 250X200 NB CONCENTRIC REDUCER, Sch40 Nos. 10










61 40NB THREADEDOLET ,3000# Nos. 30




65 50NB SOCKOLET ,3000# Nos. 25




69 ONE END NPT THREADED (OET) COUPLING 40NB,3000# Nos. 25



72 ONE END NPT THREADED (OET) NIPPLE40NB,SCH80 Nos. 30

73 ONE END NPT THREADED (OET) NIPPLE 25NB,SCH80 Nos. 50

74 ONE END NPT THREADED (OET) NIPPLE 15NB,SCH80 Nos. 90

75 BOTH END NPT THREADED (BET) NIPPLE40NB,SCH80 Nos. 35

76 BOTH END NPT THREADED (BET) NIPPLE 25NB,SCH80 Nos. 50

77 BOTH END NPT THREADED (BET) NIPPLE 15NB,SCH80 Nos. 90

78 600 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 05






84 200NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# Nos. 40

100

Sl. No






89 40 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150#

Nos. 20


Nos. 60


Nos. 80

92 300 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150# Nos. 2

93 250 NB BLIND RAISED FACE FLANGE (BLRF),ANSI B16.5,150#

Nos. 2


Nos. 4


Nos. 6


Nos. 8


Nos. 18


Nos. 18


Nos. 20


Nos. 20

List of Suppliers:

- Sanghvi Forging & engineering ltd

- Sawan engineers pvt ltd

- Rajmani fittings pvt ltd

- Rajendra Industrial corporation

- RD Forge.

- Gujarat Infra pipes (p) ltd.

- Mechwell fittings

101

CHAPTER – 04 SPECIFICATIONS FOR MANUAL BUTTERFLY VALVES (WAFER)

Supply of Wafer Type Butterfly valves as per the following specifications:

Mode of operation:

Hand lever operated for valves up to 150NB Wheel with horizontal worm gear for valves above 150NB.

Technical specifications:

a. Design ,manufacture : BS 5155/AP1 609/BS EN 593 b. Testing code : BS 6755 part I/ EN 12266 PART 1 & 2 c. Make : M/s L&T, M/s Audco/Flow Serve ii. Type : Wafer design, Integral seat, Bubble tight shut off iii. Design class rating : PN 16 iv. End connection : Wafer design suitable for ANSI B 16.5 flanges, 150# Operating pressure : 12 bar

i. Maximum operating pressure for testing of Valves

: As per PN 16 class rating

vii. Material of construction

Body : CI to IS 210 Gr 250 Disc : ASTM A 351 Gr. CF8, Forged quality SS304 Shaft : SS 410 XYLON Coated Seat : Black nitrile Handle/worm gear : CI/GM.

viii. Name plate Tag : SS , Min. 1.5 mm thick to be riveted on body

ix Locking provision for handle/ Wheel

: To be provided for fully open & fully closed position of valve.

Schedule of Manual Butterfly Valves :

Sl. No.

DESCRIPTION Qty. Nos.

1 600 NB MANUAL BUTTERFLY VALVE 2










102

General conditions:

1. Dimensional drawing indicating parts and their material of construction including shall be sent for approval after receipt of order.

2. The scope of inspection as per BS 6755 part I/ EN 12266 PART 1 a). Dimensional verification. b). Witness of shell & seat hydro test.

3. Painting: Outer surface of the valve body, Gear unit & wheel shall be painted with high built epoxy paint (Primer: Minimum 60 Microns and Finish coat: Minimum 40Microns) Total DFT of paint shall be 100 to 120 Microns. Paint Shade: Azure blue

4. SS Tag numbering plates of Size 50mm x15mmx 1.5mm thick shall be riveted on valve body at a prominent location.

5. Spares: Supply includes spare Gear Units 2 Nos for each size. Sl. No.


1 600 NB MANUAL BUTTERFLY VALVE 1 2 400 NB MANUAL BUTTERFLY VALVE 1 3 350 NB MANUAL BUTTERFLY VALVE 1 4 300 NB MANUAL BUTTERFLY VALVE 1 5 250 NB MANUAL BUTTERFLY VALVE 2 6 200 NB MANUAL BUTTERFLY VALVE 2 7 150 NB MANUAL BUTTERFLY VALVE 2

6. QAP for Manufacturer/TPI for Testing & Inspection:

Note: - TPI scope as defined and issue of IRN.

Legend: R- Review W-Witness P-Perform

Sl No

Description of the test

By manufacturer

Purchaser inspection

Third Party Inspection

Scope of inspection for purchaser and TPI

A Raw material identification

Raw material identification

100% R R Review of Material

test certificates B Testing

Shell & seat Hydro test and pneumatic Test

100% W

W 10% subjected to minimum of 1 No each size

C Painting

Paint thickness measurement

100% R R Review of paint DFT measurement report

D Stamping - P P 100% stamping on valve body

E. Issue of Inspection release note(IRN)

Yes

To be given by TPI

103

CHAPTER – 05 SPECIFICATION OF ELECTRO-PNEUMATIC WAFER BUTTERFLY VALVES

A. BUTTERFLY VALVE:

Type :

Wafer body, Normally closed, Eccentric disc, Double offset /triple eccentric design, Pneumatically actuated, operation through solenoid valve

End connection : Wafer body to be fit between RF flanges as per ANSI B16.5, 150#

Design & Manufacturing code : BS 5155/API 609

Testing code : BS 6755/ API 528/API598

Operating Pressure & Temperature : 12 bar (g), 80 Deg C

Design class rating Valve Body Test Pressure rating

: As per ANSI 150 class / PN 16

ΔP across seat for leak tightness : 20 bar (g) Allowable Seat leakage : Bubble tight shut off (ANSI B 16.104 class VI)/API598 Make : M/s Metso /M/s Tyco Material of construction : Body : Carbon steel A 216 WCB/ CI –Gr 250 Disc : Stainless steel as per A 351 CF 8MSCS13A Stem : SS – AISI 410 /SS316/SUS630 Seat & shaft seal : Filled Teflon seats & Teflon shaft seals/RPTFE Fasteners & Washers : SS

Schedule of Size and quantity :

Sl.No. Valve size NB in mm Service/Fluid handled Qty. Nos.

1 100

Raw Water/ Foam Solution

6 2 200 6 3 250 4 4 300 2 B. Pneumatic Actuator

Type : Direct coupled, single acting pneumatic cylinder Suitable for Nitrogen/Air.

Action : Nitrogen/Air supply failure to close Max. Operating Pressure : 8 -10 kg/cm2 Normal Operating pressure : 6 kg/cm2 Nitrogen/Air consumption per operation : To be specified by vendor.

Design Pressure range of the actuator : Lower limit & Upper limit - To be specified by vendor

Max. Operating temp. in º C : 80 degrees Celsius Material of construction

Body : Extruded Aluminum Alloy (To be specified by vendor)

Inter connecting bracket between valve and actuator

: CS/Stainless steel (Preferred)

Fasteners, Tie rods, washers : Stainless steel Support brackets for accessories listed under C : Stainless steel

104

C. Accessories:

1) Limit switch :

Make & Model : To be specified by vendor

Type : 4 x SPDT switch Explosion proof as per NEMA

No. of Indicators : Two numbers of OPEN and two numbers of CLOSE (one set redundant) 4 x SPDT switch

Enclosure : IP – 65 min Voltage / Contact rating : 24 VDC / 1 Amp. Minimum Body material : Aluminum alloy Electrical classification : EE xd IIC T6, IP67 Mounting : Directly on the actuator Electrical conduit : 3/4 “NPT – female threads- with SS plugs.

2) Filter Regulator : Required at inlet side of solenoid valve. (Primary Pressure range: 15-bar max.) Secondary Pressure range: 0-10 bar), 5 microns.

Make & Model : To be specified by vendor Body material : Aluminum / SS 3) Speed Controller

: In built with actuator or externally fitted (Body material: Al/ SS)

Make : To be specified by vendor

4) Quick exhaust valve : Required on Outlet side of actuator (After speed controller)

Body material : Brass /Al. /SS Make : To be specified by vendor End connection : ½” / 3/4 “ NPTF 5) Mufflers for all vent ports : Required Body material : Aluminum/ SS/Brass 6) Lifting lugs for handling : Suitable lifting lugs for handling the unit.

7) Spares and spare parts : As per the following Schedule (List to be given along with offer)

D. Spares for above valves

1. EP Butterfly Valve soft spares repair kit for above unit as per the following details

Sl. No.

Valve size NB in mm Qty. Sets

1 100 2 2 200 2 3 250 2 4 300 2

2. EP valve Actuator spares repair kit for above units as per the following details: Sl. No.

Valve size NB in mm Qty. Sets

1 100 2 2 200 2 3 250 2 4 300 2

105

E. QAP for Manufacturer for Testing & Inspection:

Legend: R- Review W-Witness P-Perform General conditions:

1. Solenoid valve in not in the scope of the supplier. 2. Required SS tubing from Filter regulator (without Solenoid valve) to the speed

Controllers & upto the actuator to be provided with suitable mounting brackets. 3. Operating time of the valve: Opening time: 4-6 Sec., Closing time: 10 -12 Sec. 4. Data sheet of the valve along with drawings of the valve, Actuator & pneumatic circuit

diagrams shall be provided along with the offer. 5. Operation and Maintenance manual along with the list of spares required shall also

be provided along with the offer. 6. Manufacturer’s test certificates shall be provided along with supply.

Sl No

Description of the test

By manufacturer QC

Purchaser inspection

Scope of inspection for purchaser

A Raw material identification

100% R Review of Material test certificates

B Functional test with actuators as per P O/ Approved drwg

. H 100%

W RN-10%

Performance of On/OFF status of valves

C Valve coating / painting Customer P O/ Approved drwgs

Visual inspection

R 100%

D Shell & seat Hydro test and pneumatic Test

100% W

10% subjected to minimum of 1 No each size

E Paint thickness measurement

100% R Review of paint DFT measurement report

F Stamping - P 100% stamping on valve body

G Final Documentation as per P O/ Approved drwg.

100% R Verification of Documents/ Certificates

106

CHAPTER – 06 SPECIFICATIONS FOR CS MANUAL BALL VALVE

Make: M/s L&T/ M/s Micro finish/M/s Audco Detailed specifications of carbon steel ball valves:

Item Description

Detailed specification for C.S Socket weld/

Threaded-NPT(Female)type ball valves

C.S Flanged type ball valves

Type Regular Bore, Three piece, Ball valve

Full Bore, Two piece, Ball valve

End connections Socket weld/Threaded-NPT(Female)

RF Flanged Conforming to ANSI B 16.5, 150#

Class rating & Quantity

800# 150#

Mode of operation Hand Lever Hand Lever Design & Dimension code

BS 5351/ API 6D/BSEN 17292

BS 5351/API 6D/BSEN 17292

Antistatic Device To be provided To be provided Blowout proof stem To be provided To be provided Leakage Class Bubble Tight shut off Bubble Tight shut off

Testing code BS 6755 Part-I / API-598/ BSEN12266 Part I/ ISO 5208

BS 6755 Part-I / API-598/BSEN12266 Part I/ISO 5208

Material of construction: Body Material A 216 Gr. WCB A 216 Gr. WCB Ball Material CF8M/SS 316 CF8M/SS 316 Seat Material PTFE PTFE Seals Graphite/ PTFE Graphite/ PTFE Gland packing, Seals PTFE PTFE

Bolting / Nuts A 193 Gr. B 7/ A 194 Gr. 2H #

A 193 Gr. B 7/ A 194 Gr. 2H #

Valve Castings Radiography Quality Radiography Quality Castings/ Forgings Solution Annealed Solution Annealed # All fasteners, studs, nuts, washers, Hand lever etc. shall be Electro galvanized/ Surface plated for corrosion protection.

SCHEDULE OF CS MANUAL BALL VALVES Sl.no. Description Units Qty.

1 40NB MANUAL BALL VALVE FLANGED 150# Nos. 10 2 25NB MANUAL BALL VALVE FLANGED 150# Nos. 25 3 15NB MANUAL BALLVALVE FLANGED 150# Nos. 25 4 25NB MANUAL BALL VALVE SOCKET WELDED 800# Nos. 40 5 15NB MANUAL BALL VALVE SOCKET WELDED 800# Nos. 50 6 25NB MANUAL BALL VALVE NPT THD 800# Nos. 50 7 15NB MANUAL BALL VALVE NPT THD 800# Nos. 50

107

QUALITY ASSURANCE PLAN FOR C.S MANUAL BALL VALVES

Sl. No

Characteristics / type of check

Ref. Document. Method of

check

Quantum of check Supplier‘s Q.C


TPI

1. Material of construction

Customer P O/ Approved drwg.

Verification of Material test certificates.

R 100%

R 100%

R 100%

2. Radiography Customer P.O Review of radiographs

R 100%

R 100 %

R 100 %

3 Solution annealing

Customer P O/ Approved drgs


R 100%

R 100%

R 100%

4 Dimensional and visual inspection

Customer Approved drwg.

Measurement/ visual

R 100%

R 10 %

R 10 %

5 Valve assembly Customer P O/ Approved drwg.

Bill of material /visual

H 100%

R 10 %

R 10 %

6 Hydro shell / body test

BS 6755 Part -l /API 598/BSEN12266 Part-l/ISO 5208

Testing on RIG

H 100%

W (RN) 10%

W (RN) 10%

7 Hydrostatic seat test


Testing on RIG

H 100%

W(RN)10% W(RN)10%

8 Pneumatic seat test


Testing on RIG

H 100%

W (RN) 10%

W (RN) 10%

9 Valve coating Customer P O/ Approved drwg

Visual inspection

H 100%

R(RN)10% R(RN)10%

10

Valve identification Tagging/labeling on valve/ Protection

Customer P.O Visual H

100%

W (RN) 10%

W (RN) 10%

11 Final documentation

AS per PO Approved drwg

Verification of Documents/ Certificates

H 100%

R 100%

R 100%

12 Inspection release note (IRN)

Yes to

be given by TPI

Note: - TPI scope as defined and Issue of IRN Legend: H-Hold, R-Review, W-Witness, RN-Randomly GENERAL CONDITIONS FOR CS BALL VALVES:

1. No welding shall be attempted on the valve body / parts. 2. The valve offered shall be guaranteed for proper performance for a period of minimum of 18

months form the date of dispatch. 3. The sectional drawings with material of construction of all parts and QAP (Quality Assurance

Plan) shall be sent to purchaser for approval before commencing production. The supplier shall guarantee that the valves supplied shall be exactly as per the approved drawing in all respects.

108

4. All castings (valve body) shall be of radiographic quality. All castings shall be of investment casting. For all the valves, radiography test shall be carried out on one sample selected at random for each size and class. Radiography shall be carried out, one sample selected at random for each size and radiography evaluation reports shall be submitted during inspection of valves.

5. At the time of dispatch of items, 3 sets of production master files comprising the following shall be supplied.

Final Inspection / clearance report. Final drawings Operational and maintenance manual Material test certificates of wetted parts. Part list of spares parts 6. The valves shall be punched with details like, size, class rating, material of construction etc. 7. All castings shall be solution annealed to ASTM A 351 S11.1. 8. All flanged faces shall be Raise Face (RF), serrated. 9. Inspection of valves shall be carried out by the purchaser prior to dispatch at manufacturers

site as per approved QAP. The supplier shall ensure that QAP is strictly followed in all stages of manufacturing, Testing & Inspection. The supplier has to inform the purchaser, the readiness of the materials for inspection well in advance for arranging the purchaser’s representative for inspection at works. The items shall be dispatched only after inspection of the valves completed by the purchaser’s inspection engineers at works and after dispatch clearance given by the purchaser.

10. Ball shall be of solid construction for all sizes. Hollow Ball construction is not acceptable. 11. All valves shall be painted with high epoxy paint with aliphatic polyurethane final coat and

total DFT shall be 150+/- 10µ. Painting shall be carried out after our final inspection. 12. The enclosed checklist shall be duly filled and submit along with offer. Without which the offer

will not be considered.

109

CHAPTER -07 SPECIFICATIONS OF MANUAL WATER MONITORS

1. Super jet Stand post type Manual water monitors Confirming to IS 8442:

a) Discharge: 3500 lpm at 7kg/cm2 b) Pipe & Barrel: 100 NB, CS seamless confirming to ASTMA 106, Gr.B. c) Inlet flange Size: 4” (100NB) Dimensions as per ANSI B 16.5 d) Pipe fittings, Reducers & Bend: ASTM A234 WPB e) Ball bearing swivel joint: Gun metal: IS 318, LTB-2 and SS Ball bearings with brass

locking arrangement. f) Vertical and Horizontal movement:

i) Horizontal 3600 ii) Vertical movement: +800 and -450

g) All steel components shall be Hot – Dip galvanized. h) Nozzle Size: 45 mm bore Aluminum alloy with female threaded inlet. i) Horizontal throw: 60m (at 300 angle in still air) j) Vertical throw: 40m at 70 Degree elevation k) Vent/drain valves of reputed make. l) All bolts, nuts and washers shall be electro galvanized m) All bolts shall have locknuts. n) Painting: With epoxy paint of shade fire red.

Make:

- M/s Newage, - M/s Winco, - M/s Shah Bhogilal, - M/s AAAG

SCHEDULE OF MANUAL WATER MONITORS

Sl. No.


1 100 NB MANUAL WATER MONITORS 02

110

Chapter-7A

Specifications for electrically operated remote Controlled long range water cum foam monitors

Remote Operated Long Range Water Cum Foam Monitor

(MAKE: SKUM only to suit the existing SKUM MAKE control panel /joy stick panel and PLC)

Remote operated long range water cum foam monitor with fog and jet nozzles operated

from Safety consoles by means of existing joy stick panel and through PLC(Which

are at present used for operating Remote controlled FOG/ JET water monitors,

ModelNo.FJM-100 EL)is planned for the area covering SC120SC200 stage.

The monitor shall have transverse mechanism by swivel joints for horizontal and vertical

movement operated by self-locking worm and worm wheel operated geared units. This

shall be equipped with flameproof motors for remote operation and have hand wheels for

manual operation at the field.

The water cum foam monitor’s nozzle shall have the facility to convert the water/foam jet

to fog and vice versa. The system shall be designed so that either water or foam-

water shall be used based on the requirement.

Design Guidelines: Remote operated long range water cum foam monitor shall be designed based on the following criteria:

Flow rate: 3000 lpm per water cum foam monitor. Effective reach (Throw Distance): - The horizontal reach at still air condition for Non-aspirating type/Aspirating type nozzle at 30o nozzle elevation having 7 bar pressure at inlet flange of monitor is 62m. - The vertical reach at still air condition for Non-aspirating type/Aspirating type nozzle having 7 bar pressure at inlet flange of monitor is 36m.(Minimum) when nozzle is tilted at +70 deg in vertical plane.

Detailed specifications:

Sl.No. Item : Remote controlled FOG/JET water monitors.

1 Model : FJM-100 EL (Suitable for water and foam)

2 Make : SKUM

3 Type : Remote maneuverable in vertical and horizontal planes with explosion proof electric motors and explosion proof limit switches.

4 Details of Remote maneuverability

: + 160 deg. Min. in Horizontal plane

- 40 to +70 deg in vertical plane.

5 Max. operating pressure : 12 bar

6 Hydrostatic test pressure : 18 bar

7 Flow rate : 3000 Ipm

111

8 Size : 100 NB

9 End connection : Flanged RF as per ANSI B16.5, 150#

10 Material of construction

:

Turret bends and piping Bearings Water monitor pipe Sealing’s

S.S/ Naval brass Alloy steel S.S/ Naval brass Teflon/Silicon O-Rings

Details of items to be supplied:

General Conditions:

1. Factory QC test certificates shall be provided along with the supply.

Operation and maintenance manual & spares parts list shall be sent along with supply.

Sl.No. Item Description Qty.

1. Remote Operated long-range water cum foam discharge monitor; Make: SKUM; Flow rate: 3000lpm @ 7 bar; fog/Jet Nozzle including spares as per the following details:

1 set

(Consisting of the following

items)

i. FJM-100 EL/MV Ex. ANSI Remote Controlled FOG/JET monitor 1No.

ii. Spare drive motor for the above kit 1No.

iii. Spares kit consisting of O-Rings, seals etc., 2 Nos.

iv. Spare Potentiometer assembly 2 Nos.

112

CHAPTER-08 SPECIFICATION OF DELUGE VALVE

Deluge Valve Along With Trim Kit, Diaphragm Valve and Water Gong

1 Make : Kidde 2 Type : Piston Type

3 Size & Flow rate in Cu.m/hr : 150 NB – 820 Cu.m/hr, 100 NB- 300 Cu.m/ hr

4 Type of Actuation : By Fusing of Q.B. Detector. Remote operated by solenoid valve action

5 End Connection : Flanged end as per ANSI B 16.5, 150 RF Concentric serration

6 Orientation : Vertical 7 Outlet : Horizontal 8 Materials of Construction :

8.1 Body (Housing) : IS. 1865 Gr. 500/7

8.2 Top Cover : 8.3 Side Cover : 8.4 Piston Rod :

G.M (IS 318 LTB-2)

8.5 Piston Seat : 8.6 Piston : 8.7 Valve Seat : 8.8 Valve Disc : 8.9 Guide way : 8.10 Spring : S.S 304 8.11 ‘O’- Ring : Neoprene rubber 8.13 Normal Working Pressure : 12 Kg/ m2

9 Diaphragm Valve size (For Actuation: 15 NB) 10 Test Pressure : 24 Kg/Cm2

11 Quantity : 1. 150 NB size: 3Nos 2. 100 NB size: 2 No

Note: Test certifications shall be provided along with supply.

113

CHAPTER-09 SPECIFICATIONS OF DRY PILOT ACTUATOR (DPA) FOR DELUGE VALVE MODEL H3

SI. NO

Item Description

1. Item: : Dry pilot actuator (DPA) model H1 for deluge valve model H3.

2. Quantity : 6 No’s

3. Material of construction : Stainless steel

4. Maximum working pressure

: 17.5 bar

5. End connection : ½” BSPT

6. Finish : Red-RAL 3001

7. Approval : Part of HDs UL listed deluge trim kit

8. Inspection : Predelivery inspection will be carried out by department

engineers prior to dispatch.

9. Make : HD Fire

10.

Documentation: 10.1- Documents to be submitted along with supplier: Catalogue of DPA model H1 and Technical and service parts list. 10.2- Along with supply: Spare parts list Test certificates Warranty certificates

114

CHAPTER -10 Quartzoid Bulb Detectors (QBDs)/Pendent type sprinklers with SS Protection guards

General Type : Conventional Bulb Type Sprinklers Make : HD Fire/Tyco

Quantity : 250 Nos. (Actual quantity shall vary based on detail engineering).

Mounting Style : Pendant Type Discharge Co-efficient, K : Not less than 70 lpm/bar½at 0.14 MPa Coverage : Standard Coverage Temperature Rating of Bulb : 68oC ± 3oC Temperature Response : Standard Response – 5 mm Glass Bulb Service Medium : Water/GN2 Maximum working pressure : 12bar Factory Hydrostatic Test Pressure

: 35 bar

Min. Operating Pressure

: 0.5 Bar

End Connection : Threaded ½ ” NPT (Male) Protection Guard : SS Material of Construction Body : Bronze/ Brass/ Copper Deflector : Bronze/ Brass / Copper Finish : Chrome Plated Approvals : UL Listed

115

CHAPTER – 11 MEDIUM VELOCITY WATER SPRAY NOZZLES

General Type : Medium Velocity Water Spray Nozzles Mounting Style : Pendant Type Make : HD Fire/Tyco Spray Angle : (Shall vary based on detail engineering). Discharge Co-efficient, K (K-Factor shall vary based on detail engineering). Fluid Medium : Water MAWP : 12 bar End Connection : Threaded ½ ” / ¾” NPT (Male); Material of Construction Body : A351-CF8M (SS) Deflector : ASTM A240 GR 2205 (SS) PIN ASTM-A479 GR 31803 (SS) Approvals UL Listed, FM Approved

Schedule of Quantities:

Sl No K-Factor of Spray Nozzle Quantities (Approx.)

1 135.3 125

2 105.6 45

3 66.9 25

4 59.5 70

5 51.7 40

6 33.80 25

7 26.45 20

8 21.05 40

9 13.15 10

Total Quantity required (Approx.) 400*

*Actual quantity shall vary based on detail engineering

116

CHAPTER - 12

SPECIFICATIONS FOR DESIGN, FABRICATION, INSPECTION, TESTING AND SUPPLY OF FILTERS FOR WATER BASED DELUGE SYSTEM (FIRE PROTECTION SYSTEM)

Basket filter for fire Water Service: - 1.1 Scope of work: Design, fabrication , Inspection and Testing and supply of Basket

filters including filter elements of 500 micron rating to SDSC SHAR as per the following technical specifications.

1.2 Technical Parameters : i) Service medium : Raw water ii) Design parameters:

a) Operating pressure : 12 kg/m2 b) Operating temperature: 60 Deg˚C c) Design pressure: 15kg/m2 d) Test pressure :As per code e) Filtration rating 500 microns f) Pressure loss across the filter at maximum flow At Clean condition: Not more

than 0.1 kg/cm2.At 25% clogged condition: not more than 0.15 kg/cm2 g) Design Standard :- ASME sec VIII DivI-2004 h) Corrosion allowance : 3mm.

iii) Material of Construction:- a) Housing : ASTM A516 Gr.70/A106Gr B b) Top cover : ASTM A 516 Gr.70 c) Element gasket Neoprene/EPDM d) Body gasket : CAF Gr W2 e) Bolts Nuts and washer ( Electro galvanized ) : IS 1367 Gr 10.9 f) Flanges at inlet, outlet, vent and drain : A 105-Forged Carbon steel (RF) and

drilling as per ANSI B 16.5 with concentric serrations. g) Support leg and davit arm : IS 2062 Gr A. h) Filter elements : 3mm thick SS 304/304L sheet with 5MM Φ (dia) holes

enclosed with suitable micron rating wire mesh. 1.3 Quantity: 1) Filter Units (Along with filter elements): As per enclosed Drg: ASLP/SS/Filter/01 & 02

element shall be of removable type.

SI. No.

Diameter of inlet/outlet

Nozzle

No. of filter elements in each filter

Flow rate m3/hr.

Quantity (Nos)

Spare filter elements Nos.

1 400NB 3 750 m3/hr 1 3 2 300NB 2 500 m3/hr 2 2

Note: Minimum thickness of housing, nozzles only indicated in the drawing However if design calls for higher thickness, the same has to be provided by the vendor.

1.4 FABRICATION:

a. For Filter housing: Welding shall be done by GTAW process for root pass and SMAW subsequent passes.

b. For filter elements: Only TIG welding with high purity Argon shielding. i. Welding consumables shall be used as per AWS classification. ii. The welding procedure qualification and welder performance qualification shall be

carried out. Only qualified welders shall be employed for the fabrication. iii. The dye used for Dye-penetrate test shall not have chlorides more than 50 PPM. iv. Any re-work/repair have to be carried out as specified in ASME boiler and pressure

vessel code with the approval of purchaser.

117

1.5 RADIOGRAPHY and DP TESTS:

i. Radiography has to be carried 10% on butt-welded joints. All welds other than butt welds shall be DP tested. The dye used for Dye-penetrant test shall not have chlorides more than 50 PPM (Preferable brands: Magalux/checkmate).

ii. Radiographs have to be carried out using x-ray Source with a sensitivity of 2-2T as per ASME sec V.

iii. All nozzles to shell welds (Root & Final run) shall be examined by DP test.

1.6 HEAT TREATMENT:

Stress relieving of the end domes shall be carried out to relieve stresses caused due to cold working as per code if standards pipe caps are not used.

1.7 NOZZLES: Nozzles shall be provided with forged flanges as indicated in the drawing. Nozzles pipes schedule indicated in the drawing is minimum. However if design calls

for higher thickness, the same has to be provided by the vendor. 1.8 TESTING:

A) Testing of materials: Materials of construction shall be as given in the Drg. Bill of materials All materials used shall be tested as per Code in the Reputed Govt. approved testing labs before fabrication. All the plates proposed to be used for fabrication of fitter, shall be subjected to mechanical, chemical tests in spite of availability of Mill test certificates.

B) HYDRAULIC Pressure Test: i) Hydraulic test is to be conducted on the filter as per code and the same shall be

carried-out in the presence of purchaser. Clean potable water shall be used for hydro testing.

ii) Before hydraulic test the internal surfaces of the filter shall be mechanically cleaned.

1.9 PAINTING: All external surfaces shall be provided with one coat of high build Epoxy mastic primer of 120-130 Microns and two coats of Aliphatic polyurethane paint of 30-40 microns. Total DFT: 150 microns.(Approved makes of paint: CDC Caboline/GoodlasNurolac/Berger)

1.10 NOTES: 1. Supplier shall submit design calculations and fabrication drawings prior for fabrication

for approval 2. QAP is enclosed as Annexure-I for reference. However, detailed quality assurance

plans (QAP) to be prepared prior to fabrication and testing and shall be submitted to the Purchaser for approval. During the course of fabrication, different stages of inspections are to be identified. At every stage, clearance has to be obtained.

3. The fabrication shall be carried out using tested and qualified materials only. 4. All dimensions are in “mm” unless otherwise shown 5. Obstructing insitu supports, gussets etc., non-pressure parts are to be notched suitably. 6. All nozzles bolt holes to straddle vessel main axis unless otherwise shown. 7. All nozzle RF Pads are to be provided with relief tell hole (1 No.-1/4” NPT to 400NB &

2Nos, -1/4” NPT above 400 NB) & tested pneumatically at 1.25 kg/cm (g) using soap solution, before& after hydro test. Such holes shall be plugged after testing.

8. All sharp corners shall be rounded off to smooth radius 9. Metal stamping on rolled surfaces shall be done with a “low stress “stamp. 10. Shell rolling shall be lengthwise only. 11. Welding symbols are as per ASME/AVVS.

118

12. Welding to be done as per approved welding procedure (VVPS & PQR). 13. 100 mm minimum gap between any two weldments shall be maintained.

2.0 GENERAL CONDITIONS:

1. The following documents are to be submitted by the vendor: After placement of order:

The following documents shall be sent for purchaser’s approval

Design calculations.

Fabrication drawings of fitters and fitter elements

Quality Assurance Plan (QAP)

Detailed PERT chart showing all mile stone activities of fabrication, testing, chemical

cleaning etc.,

A. Along with supply:

1. The supplier along with the consignment shall supply three copies of production master

files. Each production master file should contain the following.

Purchaser Order

As built Fabrication drawings

Bill of Materials

Materials Test Certificates

WPS, WPQ, PQR and Welding Layouts

Radiographic reports with sketch

Heat treatment reports, if any

Hydrostatic test certificates

Certificates of clearance

Name plate details.

2. All the above reports/test results shall be bound neatly.

3. One set of soft copy of as-built drawings shall be supplied to the Purchaser.

4. All the testing charges like Radiography, mechanical & chemical testing, etc., shall be

included in the offer.

5. All radiography films pertaining to the fitters shall be supplied to the Purchaser.

List of suppliers:

1. Sakthi-Hitech, Chennai 2. Perfect engineering, Baroda 3. Ultra filter, Bangalore 4. Mable engineers, Chennai 5. Mefco Chennai

119

SCOPE OF INSPECTION: AS PER QAP The Filter should be fabricated under the inspection of Purchaser representative as per QUALITY ASSURANCE PLAN (QAP)

SI. No.

Characteristics/type of check Ref.

Document Method of check

Quantum of check Manufacturer QC

Purchaser TPI

1 Review of fabrication drawings and Design Calculation

As per PO/drawing

Review 100% H 100% H 100% H

2a Raw material identification (pressure parts; plates, pipes & flanges)

As per PO Visual 100% H 100% R 100% R

2b Check test for chemical & mechanical properties

As per PO One

sample per heat

100% H 100% R 100% R

2c Identification of pipes, fittings, flanges, gaskets, filter mesh etc., with physical & chemical test certificates.

As per PO Visual 100% H 100% R 100% R

3 Review of welding procedure & Qualification

AWS Review 100% H 100% R 100% R

4 Dished end circumference, height profile (template matching), thickness, quality heat treatment

ASME sec VIII

Stage Inspection report &

Heat chart

100% H 100% R 100% R

5

Marking, cutting, edge preparation & rolling of shell Dimensional measurement Bevel check profile (template matching) for shell rolling

Approved dwg & ASME

VIII

Visual & dimensio

nal 100% H 100% R 100% R

6 Fit up inspection of pipe with flange, nozzles on shell/ dished end.

Approved drawing

Visual & dimensio

nal 100% H 10% R 10% W

7 Inspection of long seam and circumrenal seam fit up for shell & dished end.

Approved drawing

Visual & dimensio

nal 100% H 10% W 10% W

8 DP test of shell/dish & nozzle joints ASME sec

VIII & V

Review of internal

inspection report

100% H 100% R 10% W/ 100%R

9 Radiographic test of weld seams ASME sec

VIII & V

Visual & dimensio

nal 100% H 100% R 100% W

10 Final dimensional & visual inspection prior to hydro test

Approved drawing

Visual & dimensio

nal 100% H 100% W 100% W

11 Hydrostatic test Approved drawing

Pressure hold

method 100% H 100% W 100% W

12 Cleaning & surface preparation As per P.O. Visual 100% H 100% W 100% W

13 Final stamping

Verification with

approved drawing

Verification

100% H 100% W 100% W


Yes to be given by

TPI Legend: R – Review, W – Witness, H – Hold. Note: TPI scope as defined and Issue of IRN.

120

CHAPTER -13 SPECIFICATION FOR CS ELECTRO- GALVANISED FASTENERS:

Supply of Electro-Galvanized Carbon Steel Studs with two Nos. of Hexagonal nuts and two Nos. of 1.75 mm thick washers up to M12 size, 2 mm thick washers for M16 size & 3 mm thick washers for M18 & above (one set containing 1 No. of stud + 2 Nos. of Hexagonal nuts +2 Nos. of washers). These Studs are required for flanged joints in piping and for Installing wafer type butterfly valves between flanges as per the details given below. Material of construction:

Material: IS 1367, Class 4.6, Nut/ lock nut: IS 1363; Washer: Carbon steel- Electro Galvanized, Dimension: IS 1364

General conditions:

1. Pre-delivery inspection will be carried out by our department Engineers. The readiness of item should be intimated well in advance. The inspection shall be carried out as per the enclosed Quality Assurance plan.

2. Chemical composition certificates and mechanical properties certificates shall be furnished from government –approved laboratory for samples chosen by our inspection engineer. (One sample will be chosen from each lot/heat for Chemical and mechanical testing. Minimum 3 nos. of samples will be selected for testing.)

3. Threads of studs shall be made by thread rolling Machine only to have better finish and strength.

4. Purchaser reserves right to inspect the material at any stage and reject the material if it is not meeting the specification.

5. Purchaser clears the material for dispatch only after review of the test results. In case, the results are not satisfactory, purchaser reserves right to reject the material.

6. All carbon Steel Fasteners shall by Electro galvanized. 7. All the items shall be packed in wooden boxes while despatch to avoid thread damage. 8. All material & test certificates shall be supplied along with consignment. 9. All nuts shall be made forged / machined from bar stock. Cast nuts are

not acceptable.

Quality assurance plan as indicated below

QUALITY ASSURANCE PLAN (QAP)

Sl. No

Type of Check Method

of Check Method of Check

Quantum of Check Suppliers

QC Purchaser

1. Dimensional and visual inspection

As per code

Measurement and Visual Inspection

100% H 10% RN

2. Chemical analysis and mechanical testing

Review of Test Certificates

100% R 100% R*

3. Final Document As per P.O

Verification of certificates

100% H 100% R

R-Review RN-Randomly H-Hold

121

The minimum quantity of Studs, nuts with lock nuts and washers required for following flanged joints in piping and for Installing wafer type butterfly valves between flanges as per the details given below:

Sl.No. Description Qty.

Nos.(Approx.) I. FLANGES JOINTS 1 600 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 7 2 450 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 8 3 400 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 15 4 350 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 5 5 300 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 12 6 250 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 35 7 200NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 45 8 150 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 35 9 100 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 50

10 80 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 50 11 50 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 40 12 40 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 25 13 25 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 65 14 15 NB SLIP-ON RAISED FACE FLANGE (SORF),ANSI B16.5,150# 90 15 300 NB BLRF,ANSI B16.5,150# 4 16 250 NB BLRF,ANSI B16.5,150# 4 17 200 NB BLRF,ANSI B16.5,150# 6 18 150 NB BLRF,ANSI B16.5,150# 8 19 100 NB BLRF,ANSI B16.5,150# 10 20 80 NB BLRF,ANSI B16.5,150# 20 21 50 NB BLRF,ANSI B16.5,150# 20 22 40 NB BLRF,ANSI B16.5,150# 20 23 25 NB BLRF,ANSI B16.5,150# 20

List of Suppliers:

1. Mechwell fittings, Ahmedabad 2. Tec aero devices, Hyderabad 3. Lee hydraulics, Hyderabad 4. Dabir, Thane 5. VK technical works, Hyderabad 6. Venkatewara Industries, Chennai

II. MANUAL BUTTERFLY VALVES 1 600 NB MANUAL VALVE 4 2 400 NB MANUAL VALVE 6 3 350 NB MANUAL VALVE 2 4 300 NB MANUAL VALVE 10 5 250 NB MANUAL VALVE 20 6 200 NB MANUAL VALVE 20 7 150 NB MANUAL VALVE 15 8 100 NB MANUAL VALVE 10 9 80 NB MANUAL VALVE 30

10 50 NB MANUAL VALVE 30 III. EP BUTTERFLY VALVES 1 100 NB EP BUTTERFLY VALVES 8 3 200 NB EP BUTTERFLY VALVES 8 4 250 NB EP BUTTERFLY VALVES 7 5 300 NB EP BUTTERFLY VALVES 5

122

CHAPTER -14 SPECIFICATIONS FOR ELECTRO GALVANISED U–CLAMPS

Supply of Electro Galvanized U-Clamps with 2 nuts, 2 lock nuts &2 washers as per the following specifications.

U-Clamp (Round bar as per IS-1732) Nut/Lock Nut as per IS: 1363 Washers as per IS: 5369 Threading and Electro galvanization as per IS: 1364/IS: 1367)

General conditions: 1. Chemical composition certificates and mechanical properties certificates shall be furnished from

government approved laboratory shall be furnished for samples chosen by inspection engineer. 2. Threads of U- clamps shall be made by thread rolling Machine only to have better finish and

strength. 3. All Carbon Steel U –Clamps Fasteners shall be Electro galvanized. 4. All the items shall be packed in wooden boxes while despatch to avoid thread damage.


Sl. No

Type of Check

Method of Check Method of Check

Checked by Suppliers QC

Purchaser

1. Dimensional/Visual inspection

i) U- Clamp (Round bar as per IS-1732) ii) Nut/lock Nut as per IS-1363 iii) Threading and Electro g

Measurement and Visual Inspection

100% H 10% RN

2.

Chemical analysis and mechanical testing

Chemical composition certificates and mechanical properties certificates shall be furnished from government approved laboratory shall be furnished for 10 samples chosen by our inspection.

Review of Test certificates

100% R 100% R*

LEGEND: R-Review RN-Randomly H-Hold Adequate Electro Galvanized U-Clamps with 2 nuts, 2 lock nuts &2 washers required for following pipe lines:

List of Suppliers:


Details of pipes for which U-clamps/Structural Support are required Sl. No. Size,NB (mm) Schedule Quantity (m)

1 400 8.0 300 2 300 6.35 360 3 250 6.35 500 4 200 Sch 40 450 5 150 Sch 40 350 6 100 Sch 40 250 7 80 Sch 40 250 8 50 Sch 40 220 9 40 Sch 40 325

10 25 Sch 40 200 11 15 Sch 40 50

123

CHAPTER -15

SPECIFICATIONS OF PAINTS PRIMER AND FINAL COAT PAINTS Brands/Make : Asian paints / Berger paints /CDC Jerlac paints/Nerolac/Grand Polycoats Quantity required : Suitable quantity required for the erected pipe lines and flow components. Painting of MS structural’s / CS Pipelines (Primer coat): Painting of MS Structural, CS piping work includes surface preparation, Mixing and application of paints. Primer & Final coat as per required thickness. Primer paint shall be Aluminum-IS 235, Finish paint shall be light grey IS631. Painting Scheme shall be followed given below: Epoxy mastic coating : 120 - 130 microns Aliphatic Polyurethane : 30 - 40 microns Total Dry film thickness : 150 +/- 10 microns A. HIGH BUILT EPOXY COATINGS (Primer): This primer paint shall confirm the following requirements: High performance general maintenance coating for new or old MS material. Self-priming topcoat over most existing coatings. Can be over coated with wide range of topcoats. 125 microns or more in a single coat. Two component, catalyst cured. Minimum theoretical coverage rate of 32 Sq.M/ Litre at 25 Microns DFT. Volume solid (Volume) 80%. Mixing ratio 3:1.

1 High Build Aluminum Epoxy primer.(Suitable for CS surface) 2 High Build Epoxy primer (Suitable for SS primer)

B. ALIPHATICPOLYURETHANE PAINTS (Finish): These finish paints shall confirm to the following requirements: Catalyst isocynade. High gloss finishes. Gloss & color retentive upon prolonged exterior exposure. Suitable as an exterior finish coat over an inorganic primer and inhibitive polyamide epoxy

intermediate coat. Hard, tough, flexible & abrasion resistance. Minimum theoretical coverage rate of 17 Sq.M / Litre at 25 Micron DFT. Mixing ratio 3:1. Paint application method is by brush. Color shade shall be as per IS-05. General conditions: The primer & finish coat part life / self-life shall be 12 months. Ordering quantity variation shall be 4 liters. Scope of inspection: - Viscosity of the paint. - Volume solid test - Coverage rate of the paint as per the specification. - Before dispatch the supplier has to inform for inspection.

Sl.No. Shade Colour Shade No. As per IS -5

1. Fire Red IS-536 2. Grey IS-631 3. Azure blue IS-104 4. Brilliant Green IS-221

124

CHAPER -16 MS STRUCTURAL ITEMS

General conditions of supply:

1. The items to be supplied shall confirm to IS 2062 and IS 1852.

2. The materials shall be free from scratches, pin holes, corrosive layer, material defects,

etc. The latest stock items shall be supplied.

3. The commercial leading brands like TISCO, SAIL, VIZAG steel only to be supplied.

4. The items shall be inspected at supplier’s premises before dispatch. Hence supplier has

to inform us for pre-delivery inspection.

5. The confirmatory material test certificates shall be provided along with the materials/at

the time of inspection.

6. The actual requirement shall be as per details engineering requirement.

Make / Brands: TATA/TISCO/SAIL/JINDAL/VIZAG STEEL

125

CHAPTER -17

SPECIFICATIONS FOR SUPPLY OF MISCELLANEOUS ITEMS.

1. Supply of Electro galvanized Anchor fasteners: Drilling and bolting as defined in the approved drawings. Drilling and anchoring of pipe supports, hangers and other wall / floor / embedment shall be carried out as required. Size of anchor fasteners required M12X150mm long, depending upon the site conditions. (Approximate quantity will be about 200 Nos.)

2. Supply of Gaskets (Champion/ Spittman) as per IS 2712 to suit above mentioned flanges of material CAF Gr. W2 for flanged joints thickness 3mm.

3. Supply of Wrapper Coating Material: Multi-layer wrapper-coating tapes as per AWWA C203. Make: IWL (4 mm thick). Make: IWL

126

CHAPTER -18

SPECIFICATION FOR SUPPLY OF SEAMLESS STAINLESS-STEEL PIPES Make: Ratnamani metals & tubes ltd./REMI Edelstahl tubular ltd/Sandvikasia/Nuclear fuel complex. 1. Manufacturing Standard: ASTM A312 TP. 2. Manufacturing Process: Seamless, Cold Pilgered (100%). 3. Material of construction: SS304L /SS316L. 4. Edge preparation: As per ANSI B 16.25. 5. Length: 5 to 7 m. 6. Dimensional tolerance: As per ANSI B 36.19 7. Straightness: Shall be +/- 3 mm over a length of 3 m. 8. Testing:

a) All pipes shall be tested hydrostatically as per ASTM A530. b) All pipes shall be visually examined for absence of scratches, dents, surface

Irregularities, etc. c) Detailed chemical analysis & IGC test as per ASTM A262 Practice-E shall be carried

out on one sample per each heat (ladle)/per lot for raw material. However after final production minimum one sample for each size of pipe and material shall be tested to confirm chemical composition & IGC. Test certificates shall be produced during inspection.

d) Minimum one test specimen from each heat (ladle)/lot for each size of pipe and material shall be carried out mechanical testing like UTS, yield & percentage of elongation as per ASTM A370 during raw material and after final production. All the test certificates shall be produced during inspection.

Note: For Mother hallows /raw material MIL certificates to be provided consisting of Chemical, Mechanical and IGC Tests. Chemical, Mechanical, IGC & Microstructure examination shall be carried out in government approved laboratory.

9. All the pipes shall be tested by ultrasonic Test as per Practice ASTM E-213. 10. All pipes shall be manufactured by cold Pilgering process only. Smooth finish cold

drawn/ hot finished pipes are not acceptable. 11. All pipes shall be pickled and passivated as per ASTM A380 both inside & outside

Surfaces. 12. The source of raw material (mother hollows) for cold pilgering shall be procured from the

following suppliers. Mother pipe schedules should be one order higher in terms of size & schedule. a) M/s Nippon /Sanyo/Sumitomo, Japan. b) M/s Sandvik Asia Ltd, India. c) M/s DK Corporation, Korea.

13. Cold Pilgering is to be taken up after acceptance of raw material by SDSC-SHAR. 14. Cold pilgered pipes shall be solution annealed. 15. Heat treatment charts shall be submitted for purchaser & TPI for review and Clearance. 16. Third Party Inspection (TPI) shall be engaged by the supplier. TPI Can be of DNV/LIOYDS/

BVIS/TUV. Scope of third-party inspection is as per QAP. GENERAL CONDITIONS:

a) Pipes shall be cleaned and dried before dispatch. Ends shall be protected with suitable plastic caps to avoid entry of dust, water and foreign materials during storage and transportation.

b) Inspection: By purchaser’s representative and TPI as per approved QAP. c) Packing: Material shall be wrapped in polythene sheet and packed in a wooden box as

seaworthy package. d) Test certificate for chemical analysis, Mechanical, Microstructure examination, IGC test

and hydrostatic test shall be supplied along with dispatch documents.

127

e) MARKING: All pipes shall be clearly marked on three places of each pipe indicating manufacturer’s reference, material grade, dimensions, heat /Lot number.

f) Allowable Variation in quantity: one length of pipe. g) Production master file: Three copies of production master file shall be supplied and shall

contain the following: Dimensional and visual check reports Raw material test certificates. Mechanical, chemical, IGC and Microstructure examination Test reports. Heat treatment charts. Hydro test reports Ultrasonic test reports.

All the above reports / test results shall be bound neatly.

Sl. No

Size (NB) Schedule MOC Qty (meters)

1 15 40 304L 1200


Sl. No:

Characteristics/ Type of check

Reference documents

Method of check

Supplier’s QC

TPI scope


1 Identification of raw material for production with MIL certificate

------ Identification & review

H 100%

W 100%

W 10%

2

Review of chemical, mechanical & IGC certificates for mother pipes

As per standard

Review H

100% W

100% WR 10%

3 Verification of cold pilgering process

------ Witnessing H

100% W

100% W

10%

4 Verification of heat treatment process

NA Witnessing H

100% W

10% W

10%

5 Visual & Dimensional check

As per ANSI B 36.19

witnessing H

100% W

10% W

10%

6 Sample selection after final production for each size

As per PO Visual W

100% W

100% W

10%

7 Chemical analysis (One sample per each heat)

As per ASTM A312 TP

304L/316L

Verification of material

test certificates

H

100%

R

100%

R 100%

8 Microstructure examination

ASTM E112 Verification H

100% R

100% R

100%

9 IGC test (One sample per each heat/ lot & for each size and material)

As per ASTM A262 practice

E Verification

H 100%

R 100%

R 100%

10 Ultrasonic test on finished pipes

As per ASTM E213/

ASME sec V Witnessing

H 100%

W 100%

W 10%

128

Note: - TPI scope as defined and Issue of IRN

Legend: R – Review, RN – Randomly, W-Witnessing

Sl. No:

Characteristics/ Type of check

Reference documents

Method of check

Supplier’s QC

TPI scope


11 Physical & Mechanical test (One sample per lot/heat)

As per ASTM 370

Witnessing

H 100%

W 100%

W 10%

12 Hydrostatic test As per ASTM

A 530 Witnessing

H 100%

W 10%

W 10%

13 Pickling and Passivation As per ASTM

A380 Witnessing

H 100%

W 10%

W 10%

14 Issue of inspection release note (IRN)

Yes to be

given by TPI

129

CHAPTER -19 SPECIFICATIONS OF STAINLESS-STEEL FORGED FLANGES

Material of Construction: Forged Stainless-steel Flanges, as per ASTM A 182 F 304 L/316L Item : SLIP ON RAISED FACE (SORF) Flanges with concentric serrations. Schedule of quantities:

S.No. Size (NB) Class rating #

MOC Qty (No.)

1 15NB SLIP-ON RAISED FACE FLANGE

(SORF) 150 304L 150


(SORF) 150 304L 10


(SORF) 150 304L 10


(SORF) 150 304L 10

1. All Flanges shall conform to ANSI B 16.5, serrated raised face. Weld neck flanges shall be suitable for Welding of pipe confirms to ANSI B 36.19. Edge preparation shall be as per ANSI B16.25.

2. Flanges shall be of forged quality and made of ASTM A 182 F 3O4L. The details of size, material, the schedule for the WNRF flanges and quantity are given.

3. Detailed Chemical analysis as per ANSI, mechanical testing as per ASTM-A370 and IGC test as per A262 Practice-E shall be carried out on raw materials & finished products, one per heat/lot number.

4. Test certificates shall be produced during inspection. All testing charges shall be included in the quoted price.

5. Material supplied should be guaranteed for 12 months from the date of supply. 6. All material shall be Pickled and Passivated as per ASTM A380. 7. Purchaser reserves the right to inspect the material at any stage. 8. Supplier has to inform the purchaser well in advance regarding the readiness of material. 9. Packing: All flanges shall be closed properly with plastic caps to avoid damage of edges and

raised face during transit. The cost of the same shall be included in the offer. Material shall be wrapped in polythene sheet and packed in a wooden box as seaworthy package.

10. Acceptance for part order to be confirmed by the supplier. 11. MARKING : All flanges shall be clearly marked indicating the following

Manufacturer’s reference (i.e. Trade name) Nominal Pipe Size Pressure Rating (Class #) Face Designation (including Schedule in case of WNRF flanges) Material Grade Designation Heat treatment and Lot number

12. Inspection shall be carried out by Purchaser’s Representative at supplier’s premises and the dispatch clearance will be given only after satisfactory completion of inspection.

13. Production Master file Three copies of production mater file shall be supplied along with items and shall contain the following.

Dimensional & Visual check reports. Material, chemical, IGC reports. Final inspection Report/Release note All the above reports/Test Results shall be bound neatly

130

Quality Assurance Plan for flanges (QAP)

Sl. No.


Ref. Document

Method of check

(verification)

Quantum of inspection Supplier’s QC

Purchaser’s QC

TPI

1

Identification of raw material with $MIL test certificates (chemical, Mechanical)

As per P.O Verification of certificates

100% H 100% R 100% R

2 Mechanical testing of raw material per Heat/Lot

ASTM-A182F

Review of test certificates

100% R 100% R 100% R

3 Chemical analysis of raw material per Heat/Lot

ANSI-316L/304L

Verification of material test certificates

100% R 100% R 100% R

4

IGC testing one sample per heat number/Lot Number on raw material

ASTM-A262 Practice - E


100% R 100% R 100% R

On finished product


As per PO Measurement & Visual inspection

100% H 10% W at random

10% W at random

6

Chemical analysis of finished product per Size/Heat No. (Minimum number of samples : 08 no’s)

ANSI-316L/304L


100% R 100% R 100% R

7 Mechanical testing per Heat/Lot (For size ≥50NB) @

ASTM-A182F

Review of test certificates

100% R 100% R 100% R

8

IGC testing one sample per heat number/Lot Number &microstructure examination

ASTM-A262 Practice – E/ASTM E112


100% R 100% R 100% R

9 Final Documentation As per P.O Verification of Documents/ Certificates

100% R 100% R 100% R


Yes to be given by TPI

Legend: R-Review, W-Witness, H-Hold $-Supplier shall procure the raw material with MIL test certificate traceability.

@- Sample used for finished product testing is considered in the indent quantity and tested sample to be sent along with the consignment.

Note: - TPI scope as defined and Issue of IRN List of suppliers:

1. Sanghvi Forging & engineering ltd 2. Sawan engineers pvt ltd 3. Rajmani fittings pvt ltd 4. Rajendra Industrial corporation 5. RD Forge. 6. Gujarat Infra pipes (p) ltd. 7. Mechwell Fittings

131

CHAPTER -20 SPECIFICATIONS OF STAINLESS-STEEL FORGED FITTINGS

A. Butt weld fittings: 1) Fittings with Butt-Weld ends, are to be made from pipes, minimum one order higher

thickness schedule pipes shall be used as base material However, the edge preparation of fittings shall as per ANSI B16.25.

2) Material of construction: ASTM A 403 Gr. WPS 304L. 3) All fittings shall be of seamless quality. Butt-Weld Tees shall be of swaged type only.

Welded construction is not acceptable. 4) Dimension as per ANSI B16.9, B16.28 Edge preparation as per ANSI B16.25. The details of the pipe fittings like size, material, class rating, schedule& quantity are given in the table below. B. Socket weld & threaded fittings:

1) All fittings shall be of Forged quality. Welded construction is not acceptable. 2) Material of construction: ASTM A 182 F304L 3) Dimension as per ANSI B 16.11 4) All threads shall be NPT Type.

C. Pipe nipples: 1) All pipe nipples shall be from seamless pipe only. Welded pipes are not acceptable. 2) Material of construction: ASTM A 312 TP 304L 3) All threads shall be NPT Type.

General conditions: 1. All the Finished Product materials shall be tested for Chemical composition, Micro

Structure examination, Mechanical tests (Strength, hardness & % of elongation) as per standard. IGC test shall be conducted as per ASTM standard A262 Practice-E as per QAP.

2. The cost for chemical, MICRO-structure examination, mechanical & IGC test shall be included in the offer itself.

Samples for testing of all types of fittings, material & lot numbers will be selected by Purchaser during inspection.

The purchaser will witness random samples for MICRO-structure examination during PDI; all other test reports shall be reviewed later.

All the tests shall be carried out by NABL approved laboratory. If any of the finished product testing is not possible due to size constraint then

alternative plan will be finalized during inspection. 3. Sampling for Material testing: One sample from each lot/Heat shall be given for physical,

Chemical and IGC Tests. 4. Dimensions of fittings shall conform to ANSI standard and material construction of

Shall confirm to ASTM. 5. All the fittings shall be inspected and cleared by Purchaser’s Representative prior to

Dispatch strictly as per QAP. The readiness of the flanges for our inspection shall be intimated in advance.

6. All fittings shall be solution Annealed as per code. 7. All fittings shall be pickled and passivated as per ASTM A380. 8. All fittings shall be chemically etched with details like, size, class, rating, type, material and

heat number. 9. All the External/Internal threaded portions shall be protected with plastic caps to avoid

Damage to the threaded ends. 10. Three samples will be selected randomly from the butt-welding fittings by purchaser’s

representative at the time of inspection for carrying radiography as per ASME Sec V, (2-2T sensitivity) and Ultrasonic testing as per ASTM E213/E435. All testing charges shall be included in the offer.

11. The supplier of SS pipe fittings should be a manufacturer. Traders are not allowed to quote. 12. Production Master File three copies of production master file shall be supplied and shall

contain the following. Dimensional & Visual check reports.

132

All Material Analysis reports & heat treatment charts IGC & Micro analysis Reports. Final inspection Report / Release note All the above reports/Test Results shall be bound neatly.


Sl. No

Description Reference Document

Supplier

Purchaser

TPI

1 Verification of Raw material Mil test Certificates

As per PO 100 %H 100%R 100%R

2 Selection of Samples (Finished product) for Chemical, Mechanical, IGC & Microstructure examination

As per PO 100 %W 100%W 100%W

3

Verification of Chemical composition, Mechanical test reports (Strength, Hardness & % of Elongation)

As per PO 100 %H 100%R 100%R

4 Verification of IGC test results ASTM A262 Practice-E

100 %H 100%R 100%R

5 Verification of Micro structure examination reports

As per Std 100 %H 100%R/W 100%R/W

6 Visual inspection As per P.O 100%W 10% W 10% W 7 Dimensional inspection As per P.O 100%W 10% W 10% W

8 Verification of etching of Symbol, size, Class rating, type, material and Heat/Lot number.

As per P.O 100%W 10% W 10% W

9 Final documentation As per P.O 100%H 100% R 100% R

10 Issue of Inspection release note (IRN) To be given

by TPI Note: - TPI scope as defined and Issue of IRN Note: For Sl. No 3, 4 & 5, Manufacturer shall test at least one sample from each type of material, each type of fitting and each lot number. The purchaser representative will select all the samples at the time of PDI. Legend: R-Review, W-Witness, Hold-H Sl No

Description Qty (No)

1 15NB ELBOW 90 DEGREES BUTT WELD, Sch40 100 2 15NB ELBOW 45 DEGREES BUTT WELD, Sch40 20 3 15NB EQUAL TEE BUTT WELD, Sch40 70 4 15NB ONE END NPT THREADED (OET) NIPPLE, Sch80 75 5 15NB ONE END NPT THREADED (OET) COUPLING, 3000# 110

6 15NB EQUAL TEE BOTH ENDS SOCKET WELD WITH NPT (F)THREADED BRANCH, 3000#

250

7 15NB Cross Butt Weld SCH40 60 8 Concentric Reducer 50x 25, Sch40 10

9 Concentric Reducer 50x 40, Sch40 10

List of suppliers: 1. Sanghvi Forging & engineering ltd 5. RD Forge. 2. Sawan engineers pvt ltd 6. Gujarat Infra pipes (p) ltd. 3. Rajmani fittings pvt ltd 7. Mechwell Fittings 4. Rajendra Industrial corporation

133

CHAPTER - 21 SPECIFICATIONS FOR SUPPLY OF SS MANUAL BALL VALVES:

Make: L&T/AUDCO/Microfinish Specification:

Item Description

Detailed Specification for S.S Socket weld/ Threaded-NPT(Female)type ball valves

S.S Flanged type ball valves

Type Regular Bore (Full bore/port), Three piece Ball valve

Full bore, One/Two piece Ball valve

End connections Socket Weld (SW)/Threaded (NPT-Female)Conforming to ANSI B16.11

RF Flanged confirming to ANSI B16.5, 150#

Class rating 800# 150# Face to face dimensions

As per BS5351/ANSI B 16.10/ ANSI B 16.34/

As per ANSI B 16.10

Mode of operation Hand Lever Hand Lever Design code BS5351/ISO 17292 BS5351/ISO 17292 Antistatic Device To be provided To be provided Blowout proof stem To be provided To be provided

Fire safe - BS 6755 Part –ll/API 607/ BS-EN-ISO 12266

Leakage Class As per ANSI B16.104 Class VI/ FCI 70.2 -100% Bubble Tight shut off/ Zero Leak

As per ANSI B16.104 Class VI/ FCI70.2 -100% Bubble Tight shut off/ Zero leak

Testing code BS 6755 Part -l /API 598/BS-EN-ISO12266 Part-l/ ISO 5208

BS 6755 Part -l /API 598/BS-EN-ISO12266 Part-l/ISO 5208

Material of Construction Body and Ball Material

CF8M / SS316L CF8M / SS316

Seat Material PTFE /RPTFE PTFE /RPTFE Stem , Stem bush, Stem nuts, Spacer Material

SS 316 SS 316

Lever material SS304 SS304

Body seal/Gasket Graphite/PTFE/RPTFE Graphite/PTFE/RPTFE

Stem seal: Stem packing/0-ring

Graphite/PTFE/RPTFE Graphite/PTFE/RPTFE

Bolting / Nuts A 193 Gr. B8M/A 194 Gr 8M A 193 Gr. B8M/A 194 Gr 8M

Valve Castings Radiography Quality Radiography Quality

Castings/ Forgings Solution Annealed Solution Annealed

SCHEDULE FOR SS MANUAL BALL VALVES Sl. No.

Description Qty. Units

1

Supply of Regular Bore (Full port) Ball valve, Class 800#, Three-piece design, Socket weld Ball valve, Stainless steel Body to ASTM A 351 Gr CF 8M, Ball: SS316 /ASTM A 351 Gr CF 8M, Seats PTFE, Size: 15 NB with PTFE encapsulated Viton/Teflon/Graphoil stem seals as per specifications ( Make: L&T/ Audco/ Microfinish)

25 Nos.

134

Sl. No.

Description Qty. Units

2

Supply of Regular Bore(Full port) Ball valve ,Class 800#, Three piece design, Threaded - NPT(F) Ball valve, Stainless steel Body to ASTM A 351 Gr CF 8M, Ball: SS316/ ASTM A 351 Gr CF 8M, Seats PTFE, Size: 15 NB with PTFE encapsulated Viton/Teflon/Graphoil stem seals as per specifications ( Make: L&T/ Audco/Microfinish)

25 Nos.

3

Supply of Full Bore Ball valve, Stainless steel Body to ASTM A 351 Gr CF 8M, Ball: SS316/ ASTM A 351 Gr CF 8M, Seats PTFE and graphite seal, Fire safe and anti-static design, Flanged ends as per ANSI B16.5, Class :150, Size: 15NB with PTFE encapsulated Viton/Teflon/Graphoil stem seals as per specifications. ( Make: L&T/ Audco/Microfinish)

45 Nos.

QAP FOR SS BALL VALVES

Sl. No.


Ref. Document. Method of check

Quantum of check

Supplier’s Q.C

Purchaser’s inspection

TPI

1 Material of construction Customer P O/ Approved drgs.


R 100%

R 100%

R 100%

2 Solution annealing Customer P O/ Approved drgs


R 100%

R 100%

R 100%


Customer Approved drgs.

Measurement/ visual

R 100%

R 10 %

R 10 %

4 Valve assembly Customer P O/ Approved drgs.

Bill of material / visual

H 100%

R 10 %

R 10 %

5 Hydro shell / body test BS 6755 Part -l / API 598 / BS-EN-ISO-12266 Part-l/ISO 5208/Specs/ Approved drawings.

Testing on RIG H 100%

W (RN) 10%

W (RN) 10%

6 Hydrostatic seat test Testing on RIG H 100%

W (RN) 10%

W (RN) 10%

7 Pneumatic seat test Testing on RIG H 100%

W (RN) 10%

W (RN) 10%

8 Valve coating / painting Customer P O/ Approved drgs

Visual inspection

H 100%

R (RN) 10%

R (RN) 10%

9 Valve identification Tagging/labeling on alve/Protection

Customer P.O Visual H 100%

W (RN) 10%

W (RN) 10%

10 Final doc umentation

AS per PO Approved drgs

Verification of Documents/ Certificates

H 100%

R 100%

R 100%


Yes to be given by TPI

Note: - TPI scope as defined and Issue of IRN - Legend: H-Hold, R-Review, W-Witness, RN-Randomly

135

CHAPTER -22 SPECIFICATIONS FOR SUPPLY OF PRESSURE GAUGES:

Make: M/s WIKA/Fiebg/HGURU 1. Type : Bourdon tube with blow out disc, laminated safety glass

window.

2. Manufacturing Standard : EN 837-1

3. Sensing element : Bourdon tube.

4. Dial colour : White.

5. Material : Bezel & Casing – SS 304/316, Bourdon tube - SS1.4571 (316Ti).

6. Pressure Scale : Bar.

7. Enclosure class : IP 65.

8. Over range protection : 130 % of span.

9. Window : Laminated safety glass.

10. Pressure Range , Dial size and quality : 0 - 25 bar, Dial 100 mm

Sl. No. Description Qty. Units

1. Supply of Pressure gauges, Dial 150 mm, bourdon type, metal body Range: 0-25 bar, Glycerine filled (WIKA/Fiebig/HGURU)

05 Nos.

2. Supply of Pressure gauges, Dial 100 mm, bourdon type, metal body Range: 0-25 bar(WIKA/Fiebg/HGURU)

15 Nos.

136

CHAPTER – 23 SPECIFICATIONS OF SS STUDS

1. Stainless Steel fully threaded studs with two numbers of hexagonal nuts and two numbers of washers (one set consists of 1 no of stud + 2 no’s of nuts + 2 no’s of washers).

Studs and nuts shall be confirm as follows:

Studs : ASTM A 193 Gr.B8M Nuts : ASTM A 194 Gr.8M Washers : SS 316 (1.5 mm thick up to M12, 2 mm thick up to M16 and 3

mm for larger sizes).

2. The process of manufacture of studs shall be as given below:

Receipt of rolled rods of required size and quantity. Cutting to required lengths. Solution Annealing as per standards Samples for Chemical, Mechanical and IGC test drawn (To be drawn by purchaser’s

representative). Cylindrical grinding to achieve required dimensions. Thread rolling Pickling and Passivation followed by thorough washing with DM water. Checking with nuts. Purchaser’s Representative will draw samples for Chemical Test from finished

products.

3. All threads shall be made by Thread rolling method only. Threading by machining is not allowed All Nuts shall be of forged quality, Cast nuts will not be acceptable. Nuts shall be tested as per standard specified.

4. Material tests shall be conducted as per code specified. Chemical & physical tests and IGC tests shall be carried out in Government recognized laboratories only. Minimum of one specimen shall be drawn from each heat and each size as per QAP. Testing charges will be paid at actual against documentary proof. All Test Certificates shall be furnished to the purchaser.

5. The pitch of the threads shall be standard. 6. All bolts, nuts and washers shall be pickled by dipping in the acid solution of 20% of Nitric

acid, 2% Hydrofluoric acid in balance water for about 2 hours and passivated by dipping in the acid solution of 25% Nitric acid in DM water.

Suppliers list: 1. Venkatewara Industries, Chennai 2. Mechwell fittings , Ahmedabad 3. Tec aero devices, Hyderabad 4. Lee hydraulics, Hyderabad 5. Dabir, Thane 6. VK technical works, Hyderabad

137

QUALITY ASSURANCE PLAN

S.

No.

Characteristics/ Type of Check

Ref. Document

Method of Check Quantum of Check

Manufacturer’s QC

Department Representative

Raw material analysis

1.

Mechanical Testing (Number of Samples : SIX)

ASTM A 193 Gr. B8M


100%R

Sample Selection &

Review of Test Reports

2. Chemical Analysis (Number of Samples : SIX)

ASTM A 193 Gr. B8M


certificates 100%R

3. I.G.C Test (Number of Samples : SIX )

ASTM A262 Practice-E


W & R

Note : The supplier has to obtain clearance from purchaser, to commence production based on test reports

After manufacturing studs

4. Dimensional and Visual Inspection of Studs & Nuts

As per PO Measurement and Visual Inspection 100% H 10% RN

Note: The Studs/Nuts are to be packed and sealed in the presence of Purchaser’s Representative, after selecting samples for final chemical analysis.

After physical Inspection of Studs / Nuts

5.

Chemical Analysis of Nuts (Number of samples: Two)

ASTM A194 Gr.8M


certificates 100% H

Sample Selection &


6.

Final Chemical Analysis of SS Studs (Number of Samples: Two)

ASTM A 193 Gr.

B8M


certificates 100% H

Sample Selection &


Note: Dispatch clearance will be given by Purchaser’s Representative after the review of Final Chemical Analysis reports.

1. The Studs/Nuts are to be dispatched in as assembled condition. Legend: R-Review, W- Witness, RN- Randomly, H-Hold The minimum quantity Studs, nuts with lock nuts and washers required for following flanged joints in piping:

Sl. No.

Size (NB) Class rating

# MOC Qty (No.)

1 15NB SLIP-ON RAISED FACE FLANGE (SORF) 150 304L 150 2 25NB SLIP-ON RAISED FACE FLANGE (SORF) 150 304L 10 3 40NB SLIP-ON RAISED FACE FLANGE (SORF) 150 304L 10 4 50NB SLIP-ON RAISED FACE FLANGE (SORF) 150 304L 10

138

CHAPTER -24 SPECIFICATION FOR SS U- CLAMPS

Supply of SS U-clamps (partially threaded) with four Nos. of hexagonal nuts, four Nos. of 1.5 thick plain washers and one No. of 2 mm thick shim plate.

1. Material of Construction: U-Clamps & Nuts - Gr ASTM A 193 Gr. B8 SS 304 Washers& shim plate - SS 304 2. Threads of U-clamps shall be made by Thread rolling only without burrs to have a better finish and strength. 3. All the U-clamps and nuts shall be pickled and passivated as per standard procedure ASTM-

A380. The final finish of items shall be bright finish. 4. Clamps thread ends shall be made as per IS 1368 and thread dimensions shall be as per IS

4218 5. TESTING: Chemical and Mechanical analysis:

After fabrication, U-clamps, nuts, washer and shim plate shall be tested for mechanical and chemical properties (one number of samples in each size and each heat number of the U-clamp set) in a Government approved laboratory.

The sample will be picked up from the inspected lot and it will go for the testing Chemical test by spectra analysis -No of samples -5nos Mechanical test – Tensile test -No of samples -05 nos Proof loading test for Nut - No of samples -05 nos Machining charges for Mechanical test- No of samples-05 Total testing charges should be quoted in their offer itself.

6. INSPECTION: Manufacture shall strictly adhere / follow QAP and necessary records shall be made

available at the time of inspection. All nuts shall be made forged/machined from bar stock only. Each clamp shall be supplied with assembled condition, i.e 4 Nos of plain washer and

4 Nos of nuts in the clamp with shim plate. QUALITY ASSURANCE PLAN (QAP):

Sl. No.

Characteristic/ Type of Check

Ref. Document Method of check

Quantum of check

Manufacturer’s QC

Department Representati

ve

1. Dimensions and Visual inspection

As per Purchase order

Measurement and Visual inspection

100% H 10% W

2. Mechanical Testing ASTM A193

Gr.B8 ASTM A194 Gr.8

Review of Test certificates

100%R 100%R

3. Chemical analysis ASTM A193

Gr.B8 ASTM A194 Gr.8

Verification of material certificates

100%R 100%R

4. Final Documentation

As per P.O Verification of Documents / Certificates

100%H 100%R

LEGEND: R-Review, W-Witness, H-Hold.

139

Sl. No.

DESCRIPTION OF PIPE LINE FOR WHICH U –CLAMPS TO BE PROVIDED

Qty. meters

1 15NB Pipe Seamless pipe,SS304L,SCH40 1200

Suppliers list:

1. Venkatewara Industries, Chennai. 2. Mechwell fittings , Ahmedabad. 3. Tec aero devices, Hyderabad. 4. Lee hydraulics, Hyderabad. 5. Dabir, Thane. 6. VK technical works, Hyderabad.

Medium series standard U clamps with shim plate 7 lock nuts

140

CHAPTER -25 SPECIFICATION FOR SS SPIRAL WOUND TEFLON GASKETS WITH SS INNER & OUTER

RINGS MAKE: IGP/MIP/ UNIKLINGER 1. The gasket shall confirm to API 601 standard. 2. The thickness of the inner & outer rings shall be 3mm and that of gasket shall be 4.5mm.

The SS spiral rings should not be projected beyond the Teflon rings. The Teflon ring thickness of 0.25 mm extra is required top & bottom so that the total thickness of gasket will be 5 mm.

3. The material of the rings (inner & outer) shall be 316L. 4. All the gaskets are to suit flanges of ANSI B 16.5 RF Standard, wherever specified. 5. Inspection & testing shall be carried-out as per code specified for dimensional, material

tests, leak tightness, compressibility, seal-ability test etc., 6. Cut edges of gaskets shall be neat & burr free

General conditions: 1. All items shall be inspected and cleared by Purchaser/Engineer before dispatch. 2. Readiness of items for inspection shall be intimated to the purchase well in advance. 3. All the inspection and Test Certificates shall be furnished to the Purchaser. 4. The size, class rating, material of gaskets shall be marked on the ring wherever possible

and others are to be tagged. 5. All gaskets suitably packed so that they don’t get damaged during handling & transport.

The minimum quantity of SS spiral wound Gaskets to be supplied to suit the flanges of the following sizes.

S.No. Size (NB) Class rating # MOC Qty (No.)

1 15NB SLIP-ON RAISED FACE FLANGE (SORF) 150# 304L 150

2 25NB SLIP-ON RAISED FACE FLANGE (SORF)

150# 304L 10


150# 304L 10


150# 304L 10

Note: * The supplier to consider the cost of the SS spiral wound gaskets along with SS piping erection.

141

CHAPTER -26 SPECIFICATIONS FOR PICKLING & PASSIVATION

1. Pickling: This is carried out after mechanical cleaning and degreasing operations to remove all the rusts and scales. Pickling is carried out with a solution containing Hydrofluoric acid and Nitric acid. The composition of the pickling solution and duration of pickling are adjusted after trial test on a sample piece to remove uniformly less than 25 microns thick material. The composition is as follows:

a) HNO3 - 15 to 20% by volume b) HF - 2 to 5% by volume c) DM Water - Balance d) Temperature - Ambient e) Duration - 2 hours

After pickling, rinsing with ordinary potable water until all the acid traces are removed. The bath solution has to be changed if the level of Iron in the bath reaches 8 grams/liter.

2. Passivation :This is done after the pickling operation, a solution having the following specifications shall be used.

a) HNO3 - 25% by volume b) DM Water - 75% by volume c) Temperature - Ambient

Duration of the passivation should be minimum 2 hours. The bath solution has to be analyzed frequently and the bath replenished if the level of iron exceed 5 g/liter. Finally rinsing with demineralised water (conductivity less than 10 micro siemens/cm) is carried out till final rinse water PH is between 6.5 to 7.5 to minimize staining.

3. Checking of chemicals used for pickling & Passivation

a) Test for acid after pickling and passivation: After rinsing with water/DM water, the washings shall be checked with methyl orange indicator until the colour becomes golden yellow. A red colour shows the presence of acid and rinsing shall be continued.

b) Test for fluoride: This shall be done using Zirconium Oxy Chloride solution using Xylenol Orange as indicator. The bleaching of Zirconium Xylenol orange complex will indicates the presence of fluoride.

c) Determination of acid concentration: Pipette out 25 ml of pickling or passivation bath solution into 100 ml flask. Dilute to 100 ml with distilled water, pipette 20 ml of this solution into 250 ml flask and dilute to 100 ml with distilled water. Add 2/3 drops of methyl orange indicator and Titrate against N/2 NaOH contained in a burette. Take reading when colour change from (red to yellow) (pink to yellow).Percentage of acid = No. of ml X 0.67.

d) Estimation of iron: Pipette out 10 ml of solution into a flask and dilute it to 100 ml with distilled water. Pipette 10 ml of dilute solution into flask and add 10 ml of 50% Sulphuric acid.Titrate against N/10 KMNO4 solution till the pink colour persists for about 15

seconds. Percentage of iron = No. of ml of N/10 KMNO4 X 0.56.

e) Inspection after cleaning for the presence of free iron:

i. Copper Sulphate Test.

ii. Ferroxyl test

For all testing, the contractor shall establish a small laboratory facility on his own and all chemicals purchased by the contractor will be subjected to the approval of inspection agency.

142

4. Drying :The drying is done on Tanks as well as piping to remove water and this is done as given below: Oil free compressed air dew point less than -40 Deg. C is used to purge initially. Purging with dry Nitrogen having Dew point less than -40 Deg. C and free from oil and greases (less than 10 PPM at 60 Deg. C till the moisture level at the exit comes to the inlet concentration value.

5. Sealing :After drying, the pipes/equipments/tanks/pumps should be sealed so that ambient moisture never enters inside. The pipes/equipments/tanks/pumps tanks are to be

pressurized to 0.5 bar with dry N2 gas at -40o C dew point Temperature.

General conditions:

1. The pipelines after welding & radiography/hydro test will be subjected to pickling & passivation.

2. The spool pieces / yard length pipe lines will be subjected to pickling & passivation. The spool pieces shall be pickled & passivated by holding method whereas the yard length line shall be pickled & passivated by holding & circulation method.

3. The external & internal surface of the weld joints of the pipe lines are to be pickled & passivated.

4. The chemicals, pump, PVC hoses , testing equipments , plastic drums are in the scope of supplier

143

Chapter- 27 DESIGN,FABRICATION, INSPECTION, TESTING AND SUPPLY OF STAINLESS STEEL

NITROGEN RECEIVERS PART - I TECHNICAL SPECIFICATION:

1. GENERAL The stainless steel GN2 receivers are meant for storing gaseous nitrogen gas, meant for Deluge system requirements. The detailed specifications are given in the articles described below and drawings enclosed.

- Over all dimensions and internal details shall be as per the drawings enclosed. Drg. No. ASLP/SS/GN2 RECEIVER /01 (For GN2 receiver of Cap. 1 cu.m).

- The supplier has to design the vessel as per ASME SEC.VIII-DIV-1 latest edition.

2. SCOPE OF WORK Design, Supply of Materials, Fabrication, Inspection, testing and Supply of GN2 receivers to SDSC, SHAR as per the details given below:

A. Design Parameters for GN2 RECEIVER : i. Type: Vertical, cylindrical with dished ends.1m3– 3 Nos. (GN2 Receiver). ii. Service:

a) Medium : Nitrogen gas b) Operating Pressure : 10bar. c) Design pressure : 12.5bar. d) Operating Temperature: 50 Deg .C.

iii. Design standard: ASME SEC.VIII-DIV-1, Latest edition up to year 2004 (up to

march). iv. Testing:

a) Hydro test Pressure : As per code. b) Pneumatic Leak Test : 6 bar

v. Fabrication Process:

a) Welding 100% by TIG with pure argon purging. b) Full Radiography of Butt joints. c) Solution annealing of dished ends. d) Total vessel stress relieving after fabrication. e) Pickling & Passivation of internal and external. f) Surfaces as per approved procedure.

g) Approval: Approval by Purchaser for

1) Design calculations and fabrication drawing prior to commencement of work. 2) Dispatch document prior to dispatch.

The Supplier shall design the GN2 receivers and prepare detailed Fabrication Drawings, the Design calculations and Drawings shall be sent to the Purchaser for approval.

vi. Fabrication shall be taken up only after the approval from the third party/

purchaser.

vii. Material of Construction: SA 240 Gr 304L/316LThe fabrication shall be carried out using tested and qualified materials only.

- All raw materials shall be new and properly identified and stamped by TPIA after review of original Mill test Reports.

- Plates shall be procured with suitable sizes to minimize weldment and preferably with 100% UT done at plate manufacturer site under TPIA.

144

viii. Nozzles: a) All the nozzles pipes shall be of seamless type and schedule shall be as per

drawings. b) The nozzles shall be provided on to the tank as shown in the drawing. All the nozzle

flanges are WNRF (serrated face) of SS forged quality & shall conform to ANSI B 16.5.

c) All the nozzles shall be provided with blind flanges as per ANSI B 16.5 with necessary SS studs & nuts and SS spiral wound gaskets.

d) Nozzles to be provided for fixing level indicator. ix. Earth Boss: Two numbers of earth boss shall be provided on the supports. x. Name Plate: Tank should have a name plate permanently fixed on support. xi. Lifting lugs shall be provided for each tank.

Note: Name plate shall not be welded to the shell or dish. This is mainly to minimise welding on the pressure parts.

xii. Accessories required: Foundation bolts & Nuts of suitable size (Material: SS).

xiii. Supporting Legs: Shall be design as per IS: 2825 and minimum number of supports as shown in the drawing.

xiv. Third Party Inspection (TPIA): The GN2 receivers shall be fabricated under the inspection of Third Party DNV/LLOYDS.

xv. QAP is enclosed as Annexure-I for reference. However, detailed quality assurance plan to be prepared prior to fabrication and testing and shall be submitted to the Purchaser for approval. During the course of fabrication, different stages of inspection are to be identified. At every stage, clearance has to be obtained

Serial No.

Tank Volume

(m3

Approx.)

Design Pressure,

bar

Design Temperature

(˚C)

Corrosion Allowance

(inclusive of Allowances)

Quantity (No’s)

Shell Thickness

End Dome Thickness

1 1 12.5 70 3mm As per Design Calculations

3

2.0. Design pressures, Tank capacities, shell and Dome Thickness & Allowances and schedule of quantity: Service: GN2.

2.1. WELDING

i) 100% by TIG process, shall be adopted with high purity Argon gas purging and shielding, right from root to final passes for all butt welds (Long seams, ‘C’ seams, nozzles, pipe to flange joints) and all internal and external welds including fillets welds. SMAW is not acceptable.

ii) Welding consumables (filler wire) shall be used as per AWS classification or ER 308L iii) It is recommended to minimize no of cirseam weld joints on the cylindrical portion of the

tank. The shell of tanks shall be fabricated with standard width plates. iv) The welding procedure qualification and welder performance qualification shall be carried

out. Only qualified welders shall be employed for the fabrication of tank. v) The dye used for Dye-penetrant test shall not have chlorides more than 50 PPM. vi) Any re-work / repair have to be carried out as specified in ASME boiler and Pressure

vessel code with the approval of Third party/purchaser.

2.2. RADIOGRAPHY: i) 100% on butt welded joints All welds other than butt welds shall be DP tested. ii) Radiography has to be carried out with X-ray machine with a sensitivity of 2-2T as per

ASTM E-94.

145

2.3. HEAT TREATMENT: i) Solution annealing of the end domes shall be carried out to relieve stresses

caused due to cold working as per code. ii) The total fabricated vessel has to be stress relieved at 420+ 10 Deg. C as per

standard practice (this operation shall be carried out prior to Hydrostatic test). The detailed stress relieving cycle is as given below

. Loading temperature : 300oC (Max.) Rate of heating : 1000C/Hr (Max.) Soaking temp : 420±100C Soaking time : 2 Hrs (Min.) Rate of cooling : 1000C/Hr (Max.) Unloading temperature : Vessel to be air cooled at

Atmospheric conditions after unloading

iii) Solution Annealing of Domes and stress relieving of tank shall be preferably carried out in an electric furnace. If oil furnace is used, the fuel shall be of lower Sulphur content oil like High-speed diesel.

2.4. TESTING:

i) Testing of materials: Materials of construction shall be as given in Art No. 2.9 Bill of Materials Table: 1. All materials used shall be tested as per Code in the Reputed Govt. approved testing labs before fabrication. All the plates proposed to be used for fabrication of Gaseous Nitrogen receivers, shall be subjected to mechanical, chemical and IGC tests as per A-262 Practice-E in spite of availability of Mill test certificates. The plates used for construction of Gaseous Nitrogen receivers shall also be ensured free from any lamination and manufacturing defects by 100% ultrasonic testing as per Practice ASTM A-435. Ferrite number in weldment shall be measured by testing and this shall be within the specified limit of 3% to 12%. Test certificates shall be furnished to purchaser for approval.

ii) Hydraulic Pressure Test:

The Gaseous Nitrogen receivers shall be tested as per ASME Sec VIII, Div-1, Clean potable water with chloride content of less than 25 PPM, shall be used for testing.

iii) Before Hydrotest all the internal surfaces of the tanks shall be mechanically cleaned.

iv) Heat Treatment of entire vessel shall be carried out prior to Hydro test. After the final hydro test the vessel has to be degreased, pickled and passivated & painted as per the procedure given in Annexure-II. The cleaning, pickling and passivation is to be carried out for both inside and outside surfaces of the vessel by filling/swabbing method.

v) Pneumatic Leak Test

After Hydro test the tank shall be tested at 6.0 bar (g) using dry Nitrogen gas with dew point of minus 40 Deg. C or better and leak check with soap solution at all welds and flanged joints.

146

2.5. Material of construction of tanks shall be strictly as given below.

MATERIAL SPECIFICATION Table-1

Sl. No.

Components Material of construction

1. Shell and Dished ends SA 240 GR 304 L/316L 2. Nozzle pipes A 312 TP 304 L/316L (Seamless) 3. Nozzle flanges A 182F 304 L/316L 4. Supports and all RF pads SA 240 GR 304 L/316L 5. Studs and nuts A193GrB8M/A 194 Gr.8M

6. Gaskets SS 304 Spiral wound with Teflon sand witched with SS 304 inner and outer rings

7. Blind flanges A 182 F 304 8. All internals SS 304 L/316L 9. Name plate / bracket SS 304 L

10. Pad plate SA 240 GR 304 L/316L 11. Lifting Lugs SA 240 GR 304 /316L 12. Material Wherever not mentioned SS 304 L/316L 13. Foundation Bolts & Nuts SS 304 /304L/316L

Make/Supplier: - Perfect engineering, Baroda - Shakthi hi-tech, Chennai - Mabel engineers, Chennai

- L &T, Mumbai - Lloyds, Mumbai - Aspick, Chennai - Nuberg Engineering, Bharuch

PART-II GENERAL CONDITIONS 1.0 Monitoring

i) The progress of work during the course of fabrication will be monitored by the Purchaser. Within 15 days of receipt of the order, the fabricator should prepare a detailed PERT chart showing all mile stone activities of fabrication, testing, chemical cleaning etc., and submit to the Purchaser for approval. The approved PERT shall be modified only with the concurrence of the Purchaser.

ii) Submission of drawings and design calculation to the purchaser for approval prior to taking up fabrication.

iii) Supplier shall prepare detailed design calculations and fabrication drawings and submit (Purchaser) and third party inspection agency within one month of placing the order.

iv) The Bidder has to engage DNV/LLOYDS as Third party inspection agency. v) Production Master File

Three copies of production master files shall be supplied by the supplier along with the consignment. Each production master file should contain the following. - Purchaser Order - Design Calculations & Fabrication Drawings (As – built) - Bill of Materials - Materials Test Certificates - WPS, WPQ, PQR and Welding Layouts - Radiographic reports with sketch - Pneumatic and Hydrostatic test certificates - Certificates of clearance - Name plate details. All the above reports / test results shall be bound neatly.

vi) One set of soft copy of as-built drawings shall be supplied to the Purchaser. vii) All radiography films pertaining to the tanks shall be supplied to the Purchaser.

147

ANNEXURE-A SCOPE OF INSPECTION: AS PER QAP the vessel should be fabricated under the inspection of Third party/Purchaser representative as per QAP.


Sl. No.


Ref. Document

Method of check

Quantum of check

Manufacturer QC

Third party

purchaser

1.a

Identification of material with Mill T/C & ultrasonic T/C & witness of Physical, IGC Test and Ultrasonic test for plates.

As per PO Visual 100% H 100% R R

1.b

Identification of material & witness of Physical & IGC Test for pipes, fittings, gaskets, etc.,

As per PO Visual 100% H 100% R R

2 Review of fabrication drawings and Design Calculation

As per PO/ drawing

Material as per design

100% H 100% R R

3 Review of welding procedure & Qualification

AWS Review 100% H 100% R R

4

Checking of root run & final weld by dye Penetrant test (butt welds)

As per PO Visual 100% W 100% R R

5 Marking of nozzle orientation

As per drawing

Location of nozzle

100% W 100% W R

6 Dye Penetrant test on all fillet welds.

As per PO Visual 100% W 100% R R

7 Visual & Dimensional inspection

As per approved drawing

Dimension 100% W 100% W R

8 Shell rolling, long seam & Cir. Seam fit up

As per std Visual 100% W 100% W R

10 Circularity of shells after rolling


11 Forming of dished ends & solution annealing

As per std Visual 100% W 100% W/R

R

12 Fit up of nozzles, saddles and supports and welding


13 Evaluation of radiography films of all butt welds

As per PO Film

evaluation 100% W 100% R R

148

Sl. No.


Ref. Document

Method of check

Quantum of check

Manufacturer QC

Third party

purchaser

14 Stress relieving of total fabricated tank

As per PO Graph 100% W 100% W R

15 Mechanical cleaning and buffing

As per PO Visual 100% W 100% R W/R

16 Hydraulic test as per design code

As per PO Pressure

hold method

100% W 100% W W

17 Pneumatic leak test As per PO Pressure

hold method

100% W 100% W W

18 Picking, passivation and painting

As per PO Visual 100% W R R

19 Filling with dry nitrogen at 0.5 bar (g)

As per PO Gauge reading

100% W R R

20 Stamping of the vessel and issue of certificates

As per PO Visual 100% R 100% W ---

21 Verification of Material test certificates

As per PO Review 100% R 100% R R

22 Production master file As per PO Document 100% R R R


Yes to be given by

TPI

Legend: R – Review, W – Witness, H – Hold. Note: - TPI scope as defined and Issue of IRN.

149

ANNEXURE-B

PROCEDURE FOR PICKLING, PASSIVATION & PAINTING

i) Mechanical Cleaning: All metallic surfaces inside and outside having scales and foreign materials and out

before stress relieving. all welded surfaces have to be cleaned. This can be done by scrubbing with metallic brush (Stainless Steel). The loose scales and powders obtained from the above process can be cleaned by blowing, sucking or washing with water. Mechanical cleaning shall be carried

ii) Degreasing, pickling and passivation shall be carried out as per the following method for the tank after hydro testing.

a) Degreasing :Degreasing has to be done by soaking with hot detergent solution of Lissapol at 60 Deg. to 70 Deg. C for at least 2 hours till satisfaction.

b) Pickling and Passivation (Filling Method or Swabbing Method) Swabbing method using Barium Sulphate as an acid carrier for both inner and outer surfaces of the tanks.

The pickling and passivation is done with barium sulphate as carrier (chloride levels 25 ppm) in the form of paste. For each of pickling and passivation operations, the paste has to be applied on the surface and has to be kept for at least two hours. Paste has to be removed with waste cotton in each operation and finally the surface has to be rinsed with DM water. ii) Checking : All the relevant tests shall be carried out to ensure proper pickling and passivation as per ASTM A 380. iii) Drying : The drying is done to remove water and this is done as given below: Passing dry Nitrogen /Air having dew point less than –40 Deg. C and free from oil and grease (less than 10 PPM) at 60 Deg. C till the moisture level at the exit comes to the inlet concentration value. iv) Sealing: After drying, the tank should be sealed so that ambient moisture never enters inside. The tank is to be pressurized to 0.5 bar with dry Nitrogen Gas at –40 Deg. C dew point or better. iv) Painting After surface preparation, all external unmachined surfaces shall be provided with one coat of

high built epoxy primer 120 to 130 microns DFT. Preferable make: Berger/Bombay paints /CDC/GP.

1. The contractor shall prepare the design calculation, general arrangement drawing, fabrication drawings and Quality Assurance Plan (QAP) and it shall be submitted to the department for approval.

2. Welding of vessel shall be carried out by GTAW process and shall be performed only by welders qualified under section IX of the ASME Boiler and Pressure Vessel Code, using procedures mentioned under Section IX. Welding procedures must be approved and welder must be qualified by TPI agency.

3. All butt welds shall be full penetration welds and shall be 100% radiographed (X-ray, 2% equivalent sensitivity).

4. Saddle supports have to be designed for maximum weight of the tank in fully filled condition.

5. The vessel shall be offered for inspection to Third Party Inspection Agency. Scope of inspection & test plan by TPI agency shall include approval of the design calculation and fabrication drawings prepared by the contractor, review of material test/UT test certificates, witness of DP test, review of radiographic films, witness of filling test, final dimensional check including checkup of internal and external attachments, examine final documents and as built drawings and countersigning the same, issuing of all relevant certificates and final release note.

150

6. Three numbers of production master file shall be submitted by the fabricator along with the supply. It shall contain

a) Approved design calculations b) Approved drawings c) Third party inspection certificates (all certificates cover in their scope of inspection) d) Final release note by third party inspection agency e) Facsimile of stamping f) Guarantee certificate

Make/Supplier: - Perfect engineering, Baroda - Shakthi hi-tech , Chennai - Mabel engineers, Chennai - L &T , Mumbai - Lloyds, Mumbai - Aspick,Chennai - Nuberg Engineering, Bharuch

151

Chapter – 28 FABRICATION, INSPECTION, TESTING AND SUPPLY OF SS N2 GAS ACCUMULATORS

TECHNICAL SPECIFICATION: 1.1 Scope of work:

Fabrication, Inspection, testing and Supply of accumulators to SDSC-SHAR.Accumulators are meant for storing Gaseous Nitrogen at 10Bar.

1.2 Quantity

Sl.No Description Quantity

(Nos)

1 Accumulator of 100litre water capacity Refer Drg. No.ASLP/SS/GN2ACCUMULATOR/01

3

1.3 The Supplier shall design and prepare detailed Fabrication Drawings. Design

calculations and Drawings shall be sent to the Purchaser for approval. Fabrication shall be taken up only after the approval from the third party / purchaser.

1.4 The accumulators shall be fabricated under the inspection of third party (Lloyds/DNV). 1.5 QAP is enclosed for reference. However, detailed quality assurance plan to be followed

during fabrication and testing, shall be submitted to the Purchaser for approval prior to the commencement of fabrication.

1.6 During the course of fabrication, different stages of inspection are to be identified. At every stage, clearance has to be obtained from purchaser/third party.

1.7 The fabrication shall be carried out using tested and qualified materials only. 1.8 Vessel shall be provided with nozzles and supports as indicated in the drawing.

2.0 Vessel type & design: 2.1 Type: Vertical, cylindrical type with shell and end caps on both ends 2.2 Design & Construction code:

i) ASME Boiler and Pressure Vessel code, Sec. VIII Div.1, Latest edition ii) Saddle supports shall be designed as per IS: 2825. iii) Allowable stress:

For the design of pressure parts like shell, dished ends etc., lower allowable stress shall only be considered. The value selected at 50 Deg.C shall be indicated in the design calculations.

2.3 Dimensional details: As per enclosed drawing. 2.4 Thickness of shell & end caps

Sl. No.

Description Thickness in mm (including

Corrosion allowance of 2 mm) 1 Shell thickness 8 mm 2 End cap Thickness (seamless)/Dished 10 mm 3 S.S Nozzle pipes ( seamless) 80S min.

Note: 1)Each end cap shall be made out of a single plate. 2)If the design calls for lower thickness than minimum thickness specified

above, the thickness specified under 2.4 shall be provided. But, if higher thickness is called for by design than the min. specified above, higher thickness shall be provided.

2.5 Raw material:

All raw materials shall be new and properly identified and stamped by Third Party Inspection agency (TPIA) after review of original Mill test reports.

2.6 WELDING 100% by GTAW process, shall be followed with high purity argon gas Purging & shielding, right from root to final passes for all butt welds (long seams, “C” seams,

152

nozzle, pipe to flange joints) and all internal & external welds including fillets welds. SMAW is not acceptable.

Welding consumables (filler wire) shall be used as per AWS classification or ER 308L. The shell of accumulators shall be fabricated with single wide plate only. ERW

pipes are not allowed for shell. The welding procedure qualification and welder performance qualification shall be

carried out. Only qualified welders shall be employed for the fabrication of tank. 2.7 RADIOGRAPHY:

Radiography has to be carried out 100% on butt welded joints including nozzle pipe to WNRF flange joints. All welds other than butt welds shall be DP tested.

Radiographs have to be carried out with X-ray machine with a sensitive of 2-2T as per ASTM E-94.

Weld defects like Tungsten inclusion & porosity is not allowed in the weldments. The dye used for Dye-penetrant test shall not have chlorides more than 50 PPM.

2.8 Any re-work/repair has to be carried out as specified in ASME boiler and pressure

vessel code with the approval of Third party/purchaser. 2.9 HEAT TREATMENT:

iv) Solution annealing of the end domes shall be carried out to relieve stresses caused due to cold working as per code.

v) The total fabricated vessel has to be stress relieved at 420+ 10 Deg. C as per

standard practice (this operation shall be carried out prior to Hydrostatic test). The detailed stress relieving cycle is as given below

. Loading temperature : 300oC (Max.) Rate of heating : 1000C/Hr (Max.) Soaking temp : 420±100C Soaking time : 2 Hrs (Min.) Rate of cooling : 1000C/Hr (Max.) Unloading temperature : Vessel to be air cooled at

Atmospheric conditions after unloading

vi) Solution Annealing of Domes and stress relieving of tank shall be preferably carried out in an electric furnace. If oil furnace is used, the fuel shall be of lower Sulphur content oil like High-speed diesel.

2.10 NOZZLES:

i.All the nozzles pipes shall be of seamless type. The nozzles shall be provided on to the accumulator as shown in the drawing. All the nozzle flanges are weld-neck RF (serrated face) of SS forged quality & shall conform to ANSI B 16.5.

ii.All the nozzles shall be as per design code & a minimum schedule of 80S to be provided so that stiffeners are not called for as per design code.

iii.All the nozzles shall be provided with blind flanges as per ANSI B 16.5 with necessary SS bolts & nuts as per A193/A194 GrB8 and SS304 spiral wound Teflon filled gaskets as per API 601.

2.11 TESTING:

i) Testing of materials: All materials used shall be tested as per Code in the Reputed Govt. approved testing

labs before fabrication. All the plates proposed to be used for fabrication of tank, shall be subjected to mechanical, chemical and IGC tests as per A-262 Practice-E in spite of availability of Mill test certificates. The plates used for construction of tank

153

shall also be ensured free from any lamination and manufacturing defects by 100% ultrasonic testing as per Practice A-435 and witnessed by TPIA.

Ferrite number in plates and weldment shall be measured by testing and this shall

be within the specified limit of 3% to 12% as per standard code. Test certificates shall be furnished to purchaser for approval before fabrication.

2.12 HYDRAULIC PRESSURE TEST:

i) Before hydro test, the internal surfaces of accumulators shall be mechanically cleaned and buffed.

ii) Hydraulic test is to be conducted on the vessel. The test pressure shall be as per design code and it shall be done in the presence of purchaser representative. Clean potable water with chloride content of less than 25 PPM, shall be used for hydro testing.

iii) After the final hydraulic pressure test, the vessel has to be degreased, pickled and passivated & painted as per the procedure given in Annexure-II. The cleaning, pickling and passivation is to be carried out for both inside and outside surfaces of the vessel.

2.13 Pneumatic Leak Test: After Hydro test of vessels, they shall be tested at 3.0 bar (g) using dry Nitrogen gas with dew point of minus 40 Deg. C or better, by applying soap solution at various weld joints.

2.14 Painting:

After completion of all the works, all the accumulators shall be painted with one coat of high built epoxy primer 120 to 130 microns DFT

2.15 Material of construction shall be strictly as given below. Table-1 MATERIAL SPECIFICATION (Table-1)

SNo

Components Material of construction

1. Shell SA 240 GR 304 L

2. Dished ends SA 240 GR 304 L/ ASTM A403WPS 304L

3. Nozzle pipes A312 GR 304 L (Seam less) 4. Nozzle flanges A182 F 304 L 5 Bolts and nuts A193 GrB8M/A194 Gr8M

6 Gaskets SS 304 L spiral wound with Teflon sand witched with SS 304 inner and outer rings.

7 Blind flanges A 182 F 304 8 Name plate / bracket SS 304 L 9 Pad plate SS 304 L 10 Lifting Lugs SA 240 GR 304 11 Wherever not mentioned SS 304 L

PART-II GENERAL CONDITIONS

i) Monitoring The Purchaser will monitor the progress of work during the course of fabrication. ii) Submission of drawings and design calculation to the purchaser for approval prior to

taking up fabrication. iii) Supplier shall prepare detailed design calculations and fabrication drawings and

Submit 3 sets to purchaser within 20 days of placing the order.

iv) Production Master File The supplier along with the consignment shall supply three copies of production master files. Each production master file should contain the following.

154

- Purchaser Order - Design Calculations & Fabrication Drawings (As built) - Bill of Materials - Materials Test Certificates - WPS, WPQ, PQR and Welding Layouts - Radiographic reports with sketch - Pneumatic and Hydrostatic test certificates - Certificates of clearance - Name plate details.

v) One set of soft copy of as-built drawings. All radiography films pertaining to the tanks

shall be supplied to the Purchaser. QUALITY ASSURANCE PLAN

Sl. No.


Ref. Document Method of

check

Quantum of check Manufacturer’s QC

Third party

Purchaser

1.a

Identification of material with Mill T/C & witness of Physical, Chemical, IGC Test Ultrasonic test for plates.

As per PO Visual 100% H 100%

W R/W

1.b

Identification of material & witness of Physical & IGC Test for pipes, fittings etc.

As per PO Visual 100% H 100%

W R/W

2

Review of fabrication drawings and Design Calculation

As per PO/ drawing

Material as per design 100% H

100% R R

3

Review of welding procedure & Qualification

AWS Review 100% H 100%

R R

3a Welder qualification

AWS Review 100%H W R

4

Checking of root run & final weld by dye Penetrant test (butt welds)

As per PO Visual 100% W 100%

R R

4a

Measuring of ferrite number in all weldments

As per PO Checking with meter

100% W R

5 Marking of nozzle orientation

As per drawing Location of

nozzle 100% W

100% W

R

155

Sl. No.


Ref. Document Method of

check

Quantum of check Manufacturer’s QC

Third party

Purchaser

6 Dye Penetrant test on all fillet welds.


R R

7 Visual & Dimensional inspection

As per approved drawing

Dimension 100% W 100%

W W

8 Evaluation of radiography films of all butt welds

As per PO Film

evaluation 100% W

100% R

R

9 Mechanical cleaning and buffing


R W/R

10 *Stress relieving of total fabricated vessel

As per PO Graph 100% W 100%

W W

11 *Hydro test of accumulators as per design code

As per PO Pressure

hold method 100% W

100% W

W

12 *Pneumatic leak test As per PO Pressure

hold method 100% W

100% W

W

13 Picking, passivation and painting

As per PO Visual 100% W R R

14 Filling with dry nitrogen at 0.5 bar (g)

As per PO Gauge reading

100% W R R

15 Painting of the vessels with one coat of Epoxy primer

As per PO DFT 100% W R R

16 Stamping of the vessel and issue of certificates

As per PO Visual 100% R 100%

W ---

17 Verification of Material test certificates

As per PO Review 100% R 100%

R R

18 Production master file As per PO Document 100% R R R


Yes to be

given by TPI

Legend: R – Review, W – Witness, H – Hold. Note: - TPI scope as defined and Issue of IRN - The purchaser reserve right to participate in the Inspection at any stage of

fabrication & the supplier shall intimate the work progress periodically. However, Purchaser will witness the activities as per QAP

List of suppliers:

- Perfect engineering, Baroda - Shakthi hi-tech , Chennai - Mabel engineers, Chennai - L &T , Mumbai - Lloyds, Mumbai - Aspick,Chennai - Nuberg Engineering, Bharuch

156

Chapter-29

TECHNICAL SPECIFICATION FOR SUPPLY OF SEAMLESS STAINLESS STEEL TUBES 1. Standard: ASTM A 269-Seamless 2. Material of Construction: SS 316 3. End Finish: Square cut, smooth & deburred ends 4. Length: 5 to 7 RM –straight 5. Dimensional tolerance: As per ASTM 269 6. Testing:

Raw material testing: Detailed chemical analysis, Tensile testing, Hardness test, flare test & IGC Testing (as per ASTM A 262 practice – E, one sample per heat/ lot No.) Finished material testing: Hydrostatic test as per ASTM A 530 and Eddy current test as per ASTM A 426 shall be carried out on all tubes. Sample will be selected for chemical testing at the time of inspection.

7. All the tubes shall be soft for cold bending at short radius (Rb 80). 8. All tubes should have smooth and bright surface finish as per standard. 9. All tubes shall be pickled and passivated as per ASTM A 380 both inside & outside Surfaces. 10. Tubes shall be cleaned and dried before dispatch. Ends shall be protected with suitable

plastic caps to avoid entry of dust, water and foreign materials during storage and transportation.

11. Inspection : Scope of Inspection includes Dimensional and Visual check – 10% Random Verification of Test certificates (as per Sl.No.7) and factory QC Reports. Witnessing Hydrostatic Testing – 10 % Witnessing Eddy current testing – 10 % Witnessing Bend test as per standard Sample selection for chemical/Lot or heat

12. Prices are inclusive of all testing charges i.e. Chemical, Mechanical IGC and Eddy current testing.

13. Vendor has to inform the purchaser, stage wise material readiness in advance. 14. Packing: Material shall be wrapped in polythene sheet and packed in a wooden box as sea

worthy package. 15. Test certificate for chemical analysis, tensile & IGC tests and hydrostatic test shall be

supplied along with dispatch documents. 16. Material supplied shall be guaranteed for 12 months from the date of supply. 17. Production Master File:

Three copies of production master file shall be supplied and shall contain the following Dimensional and visual check reports. Material analysis reports IGC Reports. Hydro test& Eddy current test report Final inspection report / release note.

All the above reports/test results shall be bound neatly.

List of suppliers: 1. Ratnamani metals & tubes ltd.; 2.REMI Edelstahl tubular ltd 3. Sandvik-Asia 4. Nuclear fuel complex.

s.no Size OD X Thick MOC Qty.

meter 1 ¼ ” 6.32 X 0.91 SS316 250

157

Chapter-30

SPECIFICATIONS FOR SS DOUBLE COMPRESSION PIPE FITTINGS

Make: M/s Parker 1. All the components shall be PARKER/Swagelok make only. Other makes/brands not

acceptable. 2. All the End connection shall be of double compression twin ferrule fittings type and material

of construction shall be SS 316 only. 3. For Fitting & Flow components Material Traceability/confirmatory certificates shall be

provided for all the components mentioning the part number, Heat/Lot number for purchaser review.

4. For Check valves Supplier has to submit 100% - crack pressure and reverse flow test reports meeting the specification as per catalog for purchaser review

5. Each component shall be engraved with make and heat/lot number. Quality Assurance plan (QAP):

S.No Characteristics /

type of check Ref.

Document Method of

check

Quantum of check

Manufacturer’s QC

Department Representative

1

Verification of Material confirmation

reports/ test certificates. Factory test certificates.

As per Catalog specifications as per P.O.

Review of reports

R 100%

R 100%

2

Inspection @ SDSC SHAR 1.100% visual checks 2. Material check ( One sample per Each lot/heat number)

Random material

PMI check

R 100%

W ( PMI-One sample per

Each lot/ heat number/ item)

Legends: T- Test, W-Witness, R-Review

Sl.No. SWAGELOK/PARKER SS Tube fittings and flow components

1 UNION Male connector 1/4'' NPTx1/4'' OD tube Nos. 60 2 UNION Male connector 1/2'' NPTx1/4'' OD tube Nos. 50 3 NPT Female connector 1/4'' NPTx1/4'' OD tube Nos. 50 4 NPT Female connector 1/2'' NPTx1/4'' OD tube Nos. 50 5 UNION Blanking plug 1/4'' OD tube Nos. 20 6 UNION Blanking cap 1/4''OD tube Nos. 20 7 NPT Front ferrule 1/4'' OD tube Nos. 50 8 NPT Back ferrule 1/4'' OD tube Nos. 20 9 NPT Nut 1/4'' OD tube Nos. 20 10 UNION 1/4'' OD tube Nos. 10 11 Check valve 1/2'' NPT (F) Nos. 20

158

CHAPTER – 31 SPECIFICATION OF NITROGEN PRESSURE REGULATOR

Sl. No

Make IMF, FRANCE (IMF Norgren , Delhi)/Swage lok/Parker

1 Type Spring loaded 2 Accuracy of regulator ±2 % of set pressure for its entire inlet range. 3 Max.Operating Pressure 40 bar 4 Max.FlowRate 100Nm3/Hr 5 Outlet pressure range: 0-10 bar, 6 Max.Operating Temp. -50ºC to +60ºC 7 End Connections 1/2”NPT Threaded 8 Pressure Adjustment By hand knob with locking provision 9 Fluid Handled Dry Nitrogen

10 Material of Construction i. Body, Trim, Spring, Valve ASTM A 351 CF8 / A182F304 ii. Seals Reinforced PTFE/ Manufacturer standard iii. 0-Rings Nitrle/ Manufacturer standard iv. Valve Seat Kel – F/Manufacturer standard 11 Quantity 5 Nos.

General conditions:

The supplier shall provide the complete detailed general assembly drawing along with offer for all the items.

The supplier shall submit the offer in adherence with the specifications given. Any deviation or non-conformance shall be clearly spelt out in the offer.

159

Chapter – 32 SPECIFICATION OF NITROGEN FILTERS

Sl. No

Make IMF, FRANCE (IMF Norgren , Delhi)/Swage lok/Parker

1 Type T-type / Inline type 3 Max.Operating Pressure 40 bar 4 Max.FlowRate 100Nm3/Hr 5 Fiter element type & rating SS clothed/Mesh type14 microns 6 Max.Operating Temp. -50ºC to +60ºC 7 End Connections 1/2”NPT Threaded 9 Fluid Handled Dry Nitrogen 10 Material of Construction i. Body & Element SS304L/SS316L ii. Seals Reinforced PTFE/ Manufacturer standard iii. 0-Rings Nitrle/ Manufacturer standard 11 Quantity 5 Nos.

General conditions:

The supplier shall provide the complete detailed general assembly drawing along with offer for all the items.

The supplier shall submit the offer in adherence with the specifications given. Any deviation or nonconformance shall be clearly spelt out in the offer.

160

Chapter -33 SPECIFICATION FOR SAFETY RELIEF VALVE (SRVs)

Make: Anderson greenwood Crosby sanmar SRVs GN2 Pneumatic circuit

Quantity 4 Nos. Nozzle-Full/Semi/modified Full Type :Conventional/Bellows Conventional Bonnet-Open/Closed Closed CONNECTION Size: inlet Outlet 15 NB 25NB Flange Rating 150 # 150# Type of facing RF ASME B16.5 MATERIAL Body and Bonnet A 351 Gr. CF 8M Disc and Nozzle SS304/316/equivalent Resilient Seat Seal -- Guide A297GrHE(SS) Spring SS304/316/INCONELX750/equivalent Studs/Nuts A 320 Gr. B8/A194 Gr. 8 Gasket SS316T/ SS304 Seat / Disc Metal to metal / soft seal ACCESSORIES Cap - Screwed / Bolted Screwed Test Gag Yes BASIS Code ASME. SEC VIII DIV. I Sizing basis API 520 Relieves to -- FLUID DATA UNITS Fluid Nitrogen Required capacity Cu.m/hr 320 Density Kg/m3 Molecular Weight 28 Operating Pressure Bar 5 Set Pressure Bar 5.5 Operating Temperature Deg. C 40 Relieving Temperature Deg. C 40 Back Pressure - Constant Bar Atmospheric Back Pressure - Built Up Bar -- Over pressure/Blowdown % 10 Maximum Relieving Capacity N.Cu.m/hr To be provided as per standard Body test pressure Bar Asper standard

GENERAL CONDITIONS 1. All the safety relief valves shall be supplied as per the data sheet. Supplier shall mention

the standard available as per our specifications. Deviations and recommendations (by the supplier) against our data sheet shall be clearly spelt out in his offer. Supplier shall provide the valve catalogue along with his offer for quick reference.

2. Castings shall be Solution Annealed as per ASTM A351 S11-1. 3. Material of construction for all parts shall be as per data sheet of the valve.

161

4. The supplier shall submit the chemical analysis certificate for the materials specified by the purchaser.

5. Fabrication/GA drawings to be sent to purchaser approval before taking up the production. 6. Following documents to be sent along with consignments.

Detail drawing showing parts and components, dimensions, materials of construction, etc.

Inspection reports. Guarantee certificates for minimum 18 months from the date of supply, or 12 months

from date of commissioning which ever is earlier for safety relief valves.

7. Each valve should be fixed with tag numbers, which contains set pressure, material of construction, type, etc. 8. Manufacturer shall inform the readiness of the items for inspection.

Quality Assurance Plan

S.no. Description Check Supplier’s QC Purchaser’s

scope

1 Seat tightness test as per API-RP-527

Witness 100% 100%

2 Set pressure test Witness 100% 100%

3 Verification of the material test certificates for major components

Review 100% 100%

4 Visual & Dimensional check

Check 100% 100%

5 Shell pneumatic test with air at 100 PSIG

Witness 100% 100%

6 IGC test as per ASTM A 262 practice –E/B

Review 100% 100%

162

Section-D Formats to be filled by bidder

163

CHECKLIST TO BE FILLED BY THE CONTRACTOR The contractor shall confirm the following points. With regard to agreement on the scope defined in the work contract specifications without which the order will not be considered.

Sl. No.

Description Confirmation Yes / No

1

Realization of Deluge systems for ISROsene storage & ISROsene DPT, SC120 LOX storage , C32 LOX Storage and also fire suppression systems augmentation for launch pad {Umbilical Tower(UT, Jet Deflection Duct(JDD), Mobile launch Pedestal(MLP)}which includes supply of all materials, Piping fabrication, erection, testing, painting, & commissioning including third party inspection as per the specifications Section- A to Section-D and table-1 for schedule of quantities.

2 Summary of work scope Sl.No.3.0 is understood and Accepted.

3 Detailed scope of work Sl.No.4.0 is understood and Accepted.

4 Codes and standards to be followed for realization and philosophy followed for realization Sl.No.6 & 7 are understood and Accepted.

5 System realization procedure and scope of Department for system realization is understood Sl.No.07 & 7.1 and accepted.

6 Details of Free issue material under department scope is understood Sl.No.08 and accepted.

7 Scope of contractor Sl.No.9.0, Procurement & supply Sl.No.9.1 & 9.2 are understood and accepted.

8 Onsite fabrication & Erection activities are understood, Sl.No. 9.3. and accepted.

9 Responsibilities of contractor for Inspection as per Sl.No. 9.4 are understood and accepted.

10 Testing and Evaluation (T&E) and commissioning of the system as per Sl.No. 9.6 & 9.7 are understood and accepted.

11 Modality of execution of contract as per Sl.No. 10 is understood and accepted.

12 Delivery schedule/Time line schedule as per Sl.No.11 is understood and accepted.

I. SECTION – A TERMS AND CONDITIONS FOR BID

1. Confirm terms and conditions for Bids are understood Sl.No. 1 and accepted.

2.

Confirm all Details are furnished for Part-I techno – Commercial bid Sl.No.02 (Ensure prices are not indicated in Part-I) and Sl.No.03 Part-II Price bid.(Ensure prices are quoted for all the items).

3 Confirm Proposal document Sl.No. 4. Ensure all points Sl.No.4.1 to 4.7 are followed.

4 Confirm there is no Ambiguity Sl.No. 5

5 Confirm bids are prepared as per Sl.No.06

164

Sl. No.


6 Confirm bids evaluation is understood as per Sl.No.07 and accepted

7 Confirm Commercial terms are understood as per Sl.No.08 and accepted

8 Confirm Validity of the offer is understood Sl.No.09 and accepted

9

As all the scope of work is inter-related, Bidder has to quote for all the items listed in the Technical specification (Section-B & C), Schedule of quantities without which the offer will not be considered. Sl.No.09

10 Confirm Force majeure clause is understood and accepted, Sl.No.10

11 Confirm Arbitration clause is understood and accepted, Sl.No.11

12 Confirm Secrecy clause is understood and accepted, Sl.No.12

13 Conform Compliance with security requirements clause is understood and accepted, Sl.No.13

14 Confirm Confidentiality and proprietary right protection clause is understood and accepted, Sl.No.14

15 Confirm instructions to the bidder are understood and accepted, Sl.No.15

16 Confirm terms and conditions to Bidder are understood and accepted, Sl.No.16

17 Confirm Exclusion of tenders clause is understood and accepted, Sl.No.17

18 Confirm Insurance Clause is understood and accepted, Sl.No.18

19 Confirm termination for any fault of the contractor clause is understood and accepted, Sl.No.19

20 Confirm Cancellation in special cases clause is understood and accepted, Sl.No.20

21 Confirm specific requirements are understood and accepted, Sl.No.21

22 Confirm unit rates clause is understood and accepted, Sl.No.22

23 Confirm Safety clause is understood and accepted, Sl.No.23

24 Confirm Transportation & Material Handling clause is understood and accepted, Sl.No.24

25 Confirm Evaluation of machinery, man power & consumables clause is accepted, Sl.No.25

26 Confirm Medical assistance clause is understood and accepted. Sl.No.26

27 Confirm Record of documents, drawings and operation and maintenance manuals clause is understood and accepted, Sl.No.27

165

Sl. No.


28 Confirm General conditions clause is understood and accepted. Sl.No.28

29 Confirm Bidder minimum qualification criteria is understood and accepted. Sl.No.29

30 Confirm Bidder evaluation criteria clause is understood and accepted. Sl.No.30 II. SECTION-B Specification for details of works to be carried out

1 Specifications for Realisation of Deluge System for ASLP facilities,Chapter-1

2 Fabrication and erection of Carbon Steel (CS) pipes (Butt-welding & Socket Welding, Chapter - 2

3 Fabrication (Butt-welding & Socket Welding) and erection of Stainless steel pipe (SS304L/316L) TIG Welding and Radiography of Butt-welding weld joints, Chapter -3

4 Carbon steel and Stainless steel piping system erection works, Chapter – 4 5 Fabrication and Erection of M.S Structural Steel, Chapter – 5

6 Providing RCC pipe pedestals, Equipment foundation and related Civil Works, Chapter – 6

7 Procedure for Application of Wrapping and Coating Materials for CS buried Underground Piping, Chapter -7

8 Tubing works for solenoids, actuators, Pressure transmitters, solenoid cubicles & tube tray works, Chapter – 8

9 Erection of Equipment (Nitrogen receiver and Nitrogen Accumulator etc.,), Chapter-9

10 Third Party Inspection (TPI) scope, Chapter -10

Sl. No.


Suppliers / Make Refer Chapter for

specifications Confirmation

Yes/No III. SECTION-C Technical Specifications of the items to be supplied

Table-A Details of items to be supplied for water based deluge systems

1 Carbon steel pipes MSL/JINDAL/SURYA ROSHINI/RATNAMANI/TATA

Chapter-1

2 Carbon steel seamless pipes

MSL/JINDAL/SURYA ROSHINI/RATNAMANI/TATA

Chapter-2

3 Carbon steel pipe fittings and flanges

Sanghvi Forging & engineering ltd/ Sawan engineers pvt ltd/ Rajmani fittings pvt ltd/ Rajendra Industrial corporation/ RDForge./ Gujarat Infra pipes (p) ltd./ Mechwell fittings

Chapter-3

4 Wafer Type Manual Butterfly Valves

M/s L&T, M/s Flow Serve (Audco) Chapter-4

5 Electro -Pneumatic (EP) Butterfly valves

M/s Metso / M/s Tyco Chapter-5

6 Carbon steel manual Ball valves

M/s L&T/ M/s Micro finish/M/s Audco Chapter-6

7 Manual Water monitors M/s Newage, M/s Winco, M/s Shah Bhogilal, M/s AAAG

Chapter-7

8

Remote operated long range water cum foam monitors; Flow rate: 3000lpm @ 7 bar; Fog/Jet nozzle including spares.

Make : SKUM Chapter-7A

9 Deluge valve – Piston Type Make: KIDDE Chapter-8 10 Dry pilot actuator Make:HD Fire Chapter-9

166

Sl. No.


Suppliers / Make Refer Chapter for

specifications Confirmation

Yes/No

11

Quartzoid bulb detectors (QBDs)/ Pendent type sprinklers with SS protection guard Make: HD Fire/Tyco

Chapter-10

12 Medium velocity spray nozzles

Chapter-11

13 Water filters

1.Sakthi-Hitech, Chennai 2.Perfect engineering, Baroda 3.Ultrafilter, Bangalore 4.Mable engineers, Chennai 5.MEFCO,Chennai

Chapter-12

14 Specification of Electro Galvanized fasteners


Chapter -13

15 Specification of Electro Galvanized U-clamps

Chapter-14

16 Paints primer and Final coat

paints

Asian paints / Berger paints /CDC Jerlac paints/ Nerolac/Grand Polycoats

Chapter-15

17 MS structural material TATA/TISCO/SAIL/JINDAL/VIZAG STEEL

Chapter -16


1.Anchor fasteners : HILTI 2.CAFGaskets: Champian/spitman/uniklinger 3.Wrapper coating: IWL

Chapter -17

Sl. No



for specifications

Confirmation Yes/No

Table-B Details of items required for GN2 Command supply for deluge station

1 Seamless Stainless-Steel pipes

Ratnamani metals & tubes ltd/ REMI Edelstahl tubular ltd/ Sandvick-asia/ Nuclear fuel complex.

Chapter -18

2 SS forged flanges Sanghvi Forging & engineering ltd/ Sawan engineers pvt ltd/ Rajmani fittings pvt ltd/ Rajendra Industrial corporation/ RD Forge./ Gujarat Infra pipes (p) ltd./ Mechwell fittings

Chapter -19

3 SS forged Pipe fittings Chapter -20

4 Stainless steel Manual ball valves

L&T/ Audco/ Microfinish Chapter -21

5. Pressure gauges M/s WIKA/Fiebg/HGURU Chapter -22 6. SS Studs 1.Mechwell fittings, Ahmedabad

2.Tec aero devices, Hyderabad 3.Lee hydraulics, Hyderabad 4.Dabir, Thane 5.VK technical works, Hyderabad 6.Venkatewara Industries, Chennai

Chapter -23

7. SS U-clamps Chapter -24

167

Sl. No



for specifications

Confirmation Yes/No

8. SS Spiral wound gaskets IGP/MIP/ Uniklinger Chapter -25 9.

Pickling and passivation of pipe lines

--- Chapter -26

10. SS Nitrogen Receivers

Perfect engineering, Baroda Shakthi hi-tech, Chennai Mabel engineers, Chennai L&T, Mumbai Lloyds, Mumbai Aspick, Chennai Nuberg Engineering, Bharuch

Chapter - 27

11. SS Nitrogen Accumulators Chapter - 28

12. SS Seamless tubes

Ratnamani metals & tubes ltd. REMI Edelstahl tubular ltd Sandvickasia Nuclear fuel complex.

Chapter - 29

13. SS Double compression pipe fittings, Check valves

M/s Parker/ Swagelok Chapter - 30

14. GN2 Pressure regulators IMF,FRANCE(IMFNorgren,Delhi)/Swage lok/ Parker

Chapter - 31

15. GN2 Filters IMF,FRANCE(IMFNorgren,Delhi)/ Swage lok/Parker

Chapter - 32

16. Safety relief valves Anderson greenwood Crosby sanmar

Chapter - 33

168

Bidder Minimum Qualification Criteria The following are the minimum essential criteria to further validate/accept the bid. Vendor is requested to provide all the necessary supporting documents. If any deviation/non-compliances/lack of supporting document bid shall be summarily rejected.

Sl.No

Description

Vendor Compliance With

Supporting Documents

1

The Bidder should be ISO certified Company/Society/Firm registered in India since last 5 (five) years or more. Company Profile along with documentary evidence of services offered and all relevant enclosures to be submitted.

2

Party should have executed a contract involving supply, erection, testing and commissioning of piping circuit for a value not less than Rs. 4.64 Crores (in the last five years) as a single order (or) atleast two orders of worth Rs. 3.48 Crores each (or) atleast three orders of worth Rs.2.32 Crores each.

3

The bidder should have an annual turnover of Rs. 6.75 Crores on an average in 3 years (Financial year FY 2016-17 & FY 2017-18 & FY 2018-19) in the supply, erection, testing and commissioning of piping system and should have executed similar works between 01-04-2016 and 31-07-2019.

4 PO and Satisfactory Work completion certificate by the end user for the previous executed orders shall be submitted without which offer will not be considered.

5 Audited balance sheet & Profit & Loss A/c is to be submitted (or) Copy of the IT return filed / audited last 3 years financial statements for Financial year FY 2016-17 & FY 2017-18 & FY 2018-19.

6 Vendor must undertake supply, erection, testing and commissioning of piping system as per the specifications and requirements indicated in the RFP.

7 Latest solvency certificate from any Nationalized/Scheduled bank shall be submitted for a value of minimum Rs.230 lakhs. The solvency certificate must have issued after March 2019.

8 Technical compliance to the specifications shall be vetted by the bidder.

9 The firm must provide a self-declaration that there is no complaint/vigilance inquiry against them in any Govt. /Department /PSU and they have not been black listed by any Govt. Department/PSU.

10 The supplier shall mention his welding team details, equipment’s / machineries , facilities if any

Note: Technical proposal of the bidder, which is not able to substantiate/satisfy the claims made by it with respect to the technical requirements laid down in this RFP, will be summarily rejected. Offers of those bidders taking full scope of the work supply, erection, testing and commissioning of piping circuits as per the requirements indicated in the RFP only will be considered. Signature of Authorized Person with Seal

Administrator

Rectangle

Administrator

Typewriter

2020

Administrator

Typewriter

169

Evaluation Criteria. The broad guidelines for evaluation of Bids will be as follows:

S.No Description Vendor Compliance

1

In respect of Two-Bid system, the technical Bids forwarded by the Bidders will be evaluated by the Department with reference to the technical specifications as mentioned in the RFP. The compliance of Technical Bids would be determined on the basis of the parameters specified in the RFP. The Price Bids of only those Bidders will be opened whose Technical Bids would clear the technical evaluation.

2 During evaluation, SDSC SHAR may request Bidder for any clarification on the bid, additional documents.

3 Bidder must provide the point-by-point compliance to the technical specifications along with deviations. The tender can be rejected if the deviations are not acceptable to the Department.

4 Performance of Bidder on similar nature of works executed/ under execution shall be taken into consideration before selecting the Bidder for opening his price bid.

5 The time schedule for completion is given in the Proposal document. Bidder is required to confirm the completion period unconditionally.

6

SDSC SHAR reserves the right to reject any bid if technically/commercially not meeting the requirement/terms & conditions. Such decisions by the SDSC SHAR shall bear no liability whatsoever consequent upon such decision.

7 Total price inclusive of all taxes, duties, shall be considered for arriving L1 (Overall Lowest) and awarding the contract as per the procedures.

8

If there is a discrepancy between the unit price and the total price that is obtained by multiplying the unit price and quantity, the unit price will prevail and the total price will be corrected. If there is a discrepancy between words and figures, the amount in words will prevail for calculation of price.

9 As all the items within RFP are inter dependent, splitting of the order/WORK is not possible. Hence Overall lowest bidder will be considered

10 Department reserves the right to inspect the contractor shop floor/premises for evaluation, if required. After evaluating the contractor, decision of the Department is final.

Signature of Authorized Person with Seal

� � � � ��