t000003218 filename1 esp tender 2

PMC SERVICES FOR SUPPLY, CONSTRUCTION & INSTALLATION OF 1NO. ELECTROSTATIC PRECIPITATOR FOR CO-BOILER OUTLET

Title : SCHEDULE OF RATES

Doc No: 287197-500-SOR-PRJ-001 Rev: A Page 1 of 8

P:\Andheri\IndiaProject\292794 BPCL KR ESP\07 Project Management\Project Documents\ESP Tender\ESP Tender - SOR (Final).doc

SCHEDULE OF RATES

Bharat Petroleum Corporation Ltd Kochi Refinery, Ambalamugal 682 302 Ernakulam Dist. Kerala.

Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059

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List of Content Page No

1 FORM SP 0 TOTAL LUMPSUM PRICE 4

2 FORM SP I DETAILS OF CENVATABLE EXCISE DUTY 6

3 FORM SP II SERVICE TAX 7

4 FORM SP III INPUT TAX CREDIT UNDER VAT ACT (ITCV) 8





1 FORM SP 0 TOTAL LUMPSUM PRICE Sr. No. Description

Qty. Unit Unit Rate Amount (In Figures)

Amount (In Words)

SUPPLIES : = Qty x Rate

1 Design & Supply of ESP, as per the specification & Scope of Work, including all Materials, Commissioning spares, etc. (including taxes & duties)

1 Lump Sum

2 Supply of 2 years' Operational & Maintenance Spares of the ESP, as per the detailed list furnished by the Vendor (including. taxes & duties) 1 Lump Sum

A TOTAL SUPPLIES (1 + 2)

SERVICES :

3 Erection, Installation, Testing & Commissioning of ESP, including PGTR including all labour, supervision, tools, tackles, etc.(excluding Service tax) 1 Lump Sum

4 Non comprehensive AMC for Two YEers after completion of Defects Liability Period (excluding Service tax)

I 1st Year including Maintenance, Periodic Visits & Emergency Visits 4 Quarterly Lump sum

II 2nd Year including Maintenance, Periodic Visits & Emergency Visits 4 Quarterly Lump Sum





5 Service Tax Payable on 3 & 4 (i) & (ii) on submission of all necessary supporting documents

____%

B TOTAL SERVICES [3 + 4 (i) + 4 (ii) + 5]

GRAND TOTAL (A + B)





2 FORM SP I DETAILS OF CENVATABLE EXCISE DUTY / CVD + SAD Sr. No.

ITEM / MATERIAL Central Excise Tariff / Customs Tariff Chapter

Heading

Central Excise Duty (CED) / CVD+SAD Amount available to owner as CENVAT Credit

INR 1 2 3 4 5 (In Figures) (In Words)

A] Indigenous Items (Central Excise Duty Amount) 1. 2. B] Imported Items (CVD + SAD Amount) 1. 2.

C] Total (A + B)

NOTE: 1. Total of CENVATable Excise duty amount / CVD+SAD indicated in Col. 4 / Col. 5 above shall be deducted from total quoted price for the purpose of evaluation 2. CED/CVD+SAD Amount component, as mentioned in Col. 4/Col. 5 in this FORM shall be considered as mandatory discount and shall be adjusted from all supply bills on pro-rata basis. This CED/CVD+SAD Amount shall be reimbursed to the contractor upon submission of documentary evidence enabling Owner to claim CENVAT credit benefit, subject to the ceiling mentioned in Col. 4/Col. 5 of this FORM. Further such CED/CVD+SAD Amount shall be reimbursed only for the items which are eligible for CENVAT CREDIT benefit as per excise rules and provisions of bidding document. 3. In case of change in Quantity for any of the items during execution, the CENVATable CED/CVD+SAD amount for such items shall be adjusted proportionately.





3 FORM SP II SERVICE TAX

Sr. No.

DESCRIPTION Amount of Taxable Value of Service

(in INR)

Amount of Service Tax Claimed (in INR)

Amount of Service Tax Credit available to the Owner 94% of Col. 4

(In INR) 1 2 3 4 5 6 (In Figures) (In Words)

1. 2. 3.

TOTAL

NOTE: 1. Bidder to note that service tax credit under CENVAT Credit Rules 2004 is available to Owner to the extent of 94% of the Total Service Tax Amount. 2. Amount of service tax credit available to Owner, as mentioned in Col. 5/Col.6 shall be deducted from the total quoted price for the service (including. service tax) for the purpose of evaluation 3. Service Tax billed by the Contractor shall be paid by Owner subject to compliance with clause no. 6.2.3 of SCC. 4. In case of change in the "Final executed value of work", the amount of Service Tax quoted above shall be adjusted proportionately.





4 FORM SP III INPUT TAX CREDIT UNDER VAT ACT (ITCV)

Sr. No.

ITEM / MATERIAL TOTAL KVAT AMOUNT (in INR)

Amount of Input Tax Credit available to owner under KVAT Act (ICTV) 25% of Col. 3

(in INR) 1 2 3 4 5 (In Figures) (In Words)

1. 2. 3.

TOTAL

NOTE: 1. Bidder to note that input tax credit under KVAT Act (ICTV) is available to Owner to the extent of 25% of the Total KVAT Amount only. 2. Amount of input tax credit available to OWNER, as mentioned in Col. 4/Col.5 shall be deducted from the total quoted price for the purpose of evaluation 3. KVAT Amount component, as mentioned in Col. 3 in this FORM shall be considered as mandatory discount and shall be adjusted from all supply bills on pro-rata basis. This KVAT Amount shall be reimbursed to the contractor upon submission of documentary evidence enabling Owner to claim ITCV, subject to the ceiling mentioned in Col. 3 of this FORM. The KVAT amount shall not be payable in case Owner is not able to avail the credit, based on the documentation provided by the contractor. 4. In case of change in Quantity for any of the items during execution, the KVAT amount for such items shall be adjusted proportionately.

PMC SERVICES FOR SUPPLY, CONSTRUCTION & INSTALLATION OF 1 NO. ELECTROSTATIC PRECIPITATOR

FOR CO-BOILER OUTLET Doc No: 287197-500-SP-INT-001 Rev: C Page 1 of 16

P:\Andheri\IndiaProject\292794 BPCL KR ESP\05 Control & Automation\Documents\ESP TENDER\Inst. Specs\FINAL ISSUE

SPECIFICATION

FOR

FIELD INSTRUMENTS

Bharat Petroleum Corporation Ltd Kochi Refinery P.O. Ambalamugal Kochi- 682302, India





List of Content Page No 1 Introduction 4 2 General 4 3 Codes and standards 4

3.1 Deviations to Specification 6

4 Hazardous Area Classification & Environmental Protection 6

5 Pressure Ratings 6

6 Instrument Material Selection Philosophy 7

7 Scope 7

8 General Requirements 8

9 Pressure 8 9.1 Pressure Transmitter 8 9.2 Differential Pressure Transmitter 10 9.3 Pressure instruments application practices 11 9.4 Pressure / Differential Pressure Switch 11 9.5 Pressure Gauges 11

10 Flow Measuring Instruments 12

11 Temperature 12 11.1 Temperature Gauges 12 11.2 Thermocouple 13 11.3 Thermowell 13 11.4 Temperature Transmitter 14

12 Level 15 12.1 Level Gauge 15 12.2 Hopper Level Measurement 15

13 Identification 15

14 Tests 15

15 Shipping 16

16 Approved Vendor List 16




1 Introduction This specification provides the minimum requirements for design, manufacture, supply, transportation /shipment, unloading & storage at site, installation, inspection, testing, calibration and commissioning of Field Instruments for Electrostatic Precipitator at BPCL, KOCHI.

The intent of this document is to define the basis of design and to define the standards and functional requirements for field instrument. This specification is part of PMC Services for Supply, Construction, Installation and Commissioning of one No. Electrostatic Precipitator for Co-Boiler Outlet at BPCL, KOCHI and it shall be read in conjunction with tender document.

The requirements which have not been explicitly identified, but required for the completion and efficient performance of the entire system are in Bidders scope.

Definitions Owner : Bharat Petroleum Corporation Ltd (BPCL). Consultant : Mott MacDonald Consultants (I) Pvt. Ltd. (MMCI) Bidder : Vendor of Electrostatic Precipitator Engineer In-charge

: Means the Resident Engineer or a person acting on behalf of BPCL/MMCI at site

Shall : This is to be understood as a mandatory in relation to the requirements of this document

Should : This is to be understood as a strong recommendation

2 General

It shall be the responsibility of the Bidder to supply all equipment that are in accordance with standards of engineering, design and workmanship, suitable for the intended service as described herein and consistent with generally accepted standards & practices.

3 Codes and standards Instrumentation Specifications and Data sheets shall be compliant with the current edition of

International Codes and Standards listed, specification, guide etc. wherever indicated and applicable, unless indicated otherwise. If the conflict between these standards may exist; in that case most stringent requirements shall be applicable.

ANSI/ASME American National Standards Institute/American Society of Mechanical Engineers.

B 1.20.1 Pipe Threads General Purpose

B 16.5 Pipe Flanges and Flanged Fittings

B 16.20 Metallic Gaskets for pipe Flanges, Ring Joint, Spiral wound and Jacketed.

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ASME PTC 19.2 ASME Performance test codes - supplement on instruments and apparatus, Part 2 pressure measurement

ASME PTC 19.3 ASME Performance test codes - supplement on instruments and apparatus, Part 3 temperature measurement

API American Petroleum Institute

API RP 500 Electrical Area Classification

API RP 551

Process Measurement Instrumentation Part I - Process Control and Instrumentation

German Industrial Standards Organization

DIN 43760 Resistance Temperature Detection

IEC International Electro technical Commission

IEC 189 Instrumentation and signal cables

IEC 60079 Electrical Apparatus for Explosive Gas atmosphere

IEC 60085 Thermal Evaluation and Classification of Electrical Insulation.

IEC 60331 Test for Electric Cables under fire condition-circuit integrity part II fire alone at a flame temp at 750 Deg.C

IEC 60332 Test on bunched wires or cables under fire condition.

IEC 60529 Degree of protection provided by enclosures. (IP code)

IEC 60751 Industrial Platinum Resistance Thermometer Sensors

IEC 61000-4

Electromagnetic compatibility for Industrial Process measurement and control equipment.

IEC 61000-4-2, 61000-4-3 and 61000-4-4 Electromagnetic compatibility requirements

IEC 61508 Functional Safety (Safety Related System)

IEC 61511 Functional Safety, Safety Instrument Systems.

IEEE 518

Guide for installation of electrical equipments to minimize electrical noise inputs to controllers from external sources

IEEE-802.3U TCP / IP communication protocol

IEEE Std 999-1992 IEEE Recommended Practice for Master/Remote Supervisory Control and Data Acquisition (SCADA) Communications. IS Indian Standard

IS-2147 Degree of Protection Provided by Enclosures for Low Voltage Switch gears & Control Gears

IS-2952-1964 Recommendation for Methods of Measurement of liquid flow by means of Orifice Plates & Nozzles.

IS-3624 Specification for pressure and vacuum gauges

IS-5572 Classification of Hazardous area

ISA Instrumentation, Systems and Automation Society

ISA S 5.1 Process Instrumentation Terminology




ISA RP 12.6 Installation of intrinsically safe systems for hazardous (Classified) dust location

ISA S18-1 Alarm Sequence

OISD Oil Industry Safety Directorate

OISD-STD 163 Safety of Control Room for Hydrocarbon Industry

PESO/CCOE & CMRI

PESO/CCOE & CMRI Certifications

Petroleum And Explosives Safety Organisation (PESO)/ Chief Controller of Explosives (CCOE), Nagpur or Director General of Mines Safety (DGMS) in India.

Note:- The above list is suggestive & not exhaustive. Apart from these basic codes any other code referred-to in this document and/or any other related code shall also be followed wherever required.

3.1 Deviations to Specification 3.1.1 The Bidder shall provide an itemised list of any deviations to this specification. These shall be

listed on the compliance sheet with seal & duly signed by his authorised signatory & shall be submitted along with offer.

3.1.2 Where a conflict between standards occurs then the Bidder shall seek a clarification ruling from the Owner. Where a deviation from the standard is required, then the Bidder shall make a formal request with full supporting information.

3.1.3 Only those deviations that are agreed between the Owner and the Bidder will be incorporated into the requisition at the time of order.

4 Hazardous Area Classification & Environmental Protection 4.1 Location of new Electrostatic Precipitator shall be in Safe Area. Environment condition shall

be followed as mentioned elsewhere in the tender document. All field instruments shall be weatherproof to IP 65 minimum.

4.2 Ingress protection / Weather Proof : The Following minimum degree of Protection as per IEC 60529 & IS: 2147 shall apply to all

the Instrumentation equipment. Indoor Instruments/Equipment/Panel - IP 42 Outdoor Instruments/Equipment - IP 65

4.3 In addition to the above, field Instruments located outdoors, exposed to direct sunlight shall be protected with sunshades. All electrical components shall be tropicalized to protect against humidity, moisture and fungal growth by means of hermetically sealed units, protective coating on circuit boards, gold plated edge connectors, etc.

5 Pressure Ratings 5.1 All instruments shall be fully rated to system design pressure as per process details given in the

tender elsewhere. All flange ratings shall be ANSI class as per details given in the tender.




6 Instrument Material Selection Philosophy 6.1 In general, Wetted parts for all Inline instruments shall be of SS 316 material.

6.2 In general, Instrument enclosures shall be of Die Cast Aluminium with copper free or less than 0.4% of copper by mass.

6.3 All Cable Glands shall be of brass with nickel electroplating or SS304 material & Junction Boxes shall be SS 304 or die-cast aluminium material. Cable glands shall be supplied with PVC shroud of appropriate sizes.

6.4 Instrument Sun Sheds shall be provided if it is expose to sunlight.

6.5 All Tubes and Fittings for Hook Up shall be of SS316 or better suitable material.

6.6 All instrument support structural steel shall be of MS.

6.7 Piping Material Specification shall be followed for the selection of valve material.

7 Scope 7.1 The scope covered under this specification document shall include but not be limited to the

following.

7.2 Design, material selection, manufacture, assembly, shop testing, Inspection at manufacturers works shipment, site storage, installation, testing, calibration and commissioning of field instruments.

7.3 All type of field instruments along with accessories required for ESP to meet the efficient and safe performance of equipment.

7.4 Process installation arrangements, Mounting Brackets, Enclosures, Hardware/ fittings, cable glands, plugs, gland reducers/adapters, sun shades etc. as required.

7.5 Necessary spares for the ease of Operation & Maintenance.

7.6 Supply of all consumables like calibration kits etc. required for commissioning and performance testing during appropriate time.

7.7 Bidder shall indicate recommended and mandatory spares list and quote spares.

7.8 Providing all labour, materials and equipment for Testing at shop as required.

7.9 Procurement, Inspection of all other bought out items.

7.10 Inspection at manufacturers work

7.11 Installation, testing, calibration & commissioning

7.12 Documentation




7.13 Inspection at site of total integrated system

7.14 Preparation and submission of drawings/documents for approval/ information to Purchaser / consultant, as per the drawing / document submission schedule.

7.15 submission of Test certificates

7.16 All the scope of supply and services as indicated above but without excluding other necessary components and services not mentioned but necessary to complete the work in all respects stipulated, regardless of any omission in this specification.

8 General Requirements

7.1 All materials required to make the system complete but not specifically mentioned in this specification shall also be deemed to be included.

7.2 All materials supplied under this contract shall be new and unused.

7.3 The Instruments provided shall be reliable and sufficient to meet process requirements specified in enclosed data sheets

7.4 Design of electronic instruments shall be in compliance with the electromagnetic compatibility requirement as per IEC-61000. The transmitter electronics shall be protected against transients introduced by lightening and power supply surges. Transient protection electronics shall be preferably provided in the terminal block. The transient protection shall meet the requirements specified in IEC-60587.

9 Pressure All pressure measuring instrument shall in general follow below specification.

9.1 Pressure Transmitter 9.1.1 As there are chances of catalyst carryover, all Pressure transmitters shall be Remote Seal

Capillary type to avoid impulse tube plugging.

9.1.2 Flange material shall be according to piping class but minimum SS316 & the diaphragm material shall be minimum SS316 or better depending on process requirement. Capillary shall be of minimum SS316 material and shall have SS 304 armouring with PVC covering. Length of capillary shall be 5 Mtrs minimum. Seal fluid shall be suitable for process temperature.

9.1.3 Flange for Remote Seal diaphragm pressure transmitter shall be 2 as per ANSI B 16.5, class 300 minimum.

9.1.4 Transmitters shall be SMART, 2 wire system, 4-20 mA output with HART protocol, 24VDC loop powered capable of delivering rated current signal into external load of 600 ohms and will be generally powered from vendor supplied control panel. Transmitters shall have the capability of online calibration facility having digital communication via open protocol (HART).




9.1.5 All transmitters shall have integral local LCD indicator. For indicating face shatter proof glass shall be used. All transmitters shall have dual compartment.

9.1.6 Pressure transmitter accuracy shall be 0.075%; turndown shall be 100:1.

9.1.7 All transmitter wetted parts in contact with the process fluid shall be SS 316 (min) or better.

9.1.8 The process connection for the pressure transmitter shall be 1/2 NPTF or as per ESP Bidders standard installation.

9.1.9 Cable entry to all instruments shall be NPT.

9.1.10 Over range protection shall be 130% of range or maximum design pressure whichever is higher.

9.1.11 All pressure transmitters shall be capable of withstanding process static pressure without permanent damage or loss of calibration.

9.1.12 Transmitters shall be supplied with 2 Pipe mounted brackets, clamps & suitable fasteners.

9.1.13 All hardware components, metal accessories & fasteners supplied with transmitter shall be corrosion resistant painted.

9.1.14 Following units of measurement shall be applicable to the transmitter, unless indicated specifically otherwise; Transmitter shall be configurable to these units - Engineering Unit. % mmH2O.

9.1.15 It shall be possible to connect the HART configurator /terminal at any location in the transmitter loop without affecting the loop function while communication is going on between transmitter and the configurator /terminal.

9.1.16 All transmitters shall be located outdoors and exposed to direct sunlight. Transmitter shall perform its normal function without any impact of direct sunlight.

9.1.17 Pressure Transmitter shall have external zero and span adjustment with cover plate.

9.1.18 Instrument tags should be permanently attached to the device. If this is not possible, the instrument tag should be fastened to the instrument with stainless steel wire.

9.1.19 Accessories like snubbers for pump discharge applications shall be considered.

9.1.20 Selection of Ranges

The ranges of the instruments shall be selected based on the following philosophy indicated below:

For pressure and vacuum measurements, the maximum operating pressure shall be within 70 to 80% of the maximum scale range.




All suction measurement shall cover the negative pressure range also and all vacuum measurements shall cover the negative pressure as well as the positive pressure.

9.2 Differential Pressure Transmitter 9.2.1 As there are chances of catalyst carryover, all Differential Pressure transmitters shall be

Remote Seal Capillary type to avoid impulse tube plugging.

9.2.2 Flange material shall be according to piping class but minimum SS316 & the diaphragm material shall be minimum SS316 or better depending on process requirement. Capillary shall be of minimum SS316 material and shall have SS 304 armouring with PVC covering. Length of capillary shall be 5 Mtrs minimum. Seal fluid shall be suitable for process temperature.

9.2.3 Flange for Remote Seal diaphragm type differential pressure transmitter shall be 2 as per ANSI B 16.5, class 300 minimum.

9.2.4 Transmitters shall be SMART, 2 wire system, 4-20 mA output with HART protocol, 24VDC loop powered capable of delivering rated current signal into external load of 600 ohms and will be generally powered from vendor supplied control panel. Transmitters shall have the capability of online calibration facility having digital communication via open protocol (HART).

9.2.5 All transmitters shall have integral local LCD indicator. For indicating face shatter proof glass shall be used. All transmitters shall have dual compartment.

9.2.6 For differential pressure measurement, the transmitter shall be able to withstand the full differential pressure on any port of the transmitter without any damage to the sensor and without shift in zero and calibration.

9.2.7 Differential Pressure transmitter accuracy shall be 0.075%; turndown shall be 100:1.

9.2.8 All transmitter wetted parts in contact with the process fluid shall be SS 316 (min) or better.

9.2.9 Differential Pressure Transmitter shall have external zero and span adjustment with cover plate. Instrument tags should be permanently attached to the device. If this is not possible, the instrument tag should be fastened to the instrument with stainless steel wire.

9.2.10 The total response time for monitoring and control of transmitters shall be of 250 millisecond or less.

9.2.11 All differential pressure transmitters shall be capable of withstanding process static pressure without permanent damage or loss of calibration.

9.1.21 Transmitters shall be supplied with 2 Pipe mounted brackets, clamps & suitable fasteners.

9.2.12 Cable entry to all instruments shall be NPT.




9.3 Pressure instruments application practices 9.3.1 The transmitter shall have both, Over-range protection rated as per design pressure and Under-

range protection for full vacuum.

9.3.2 The pressure and differential pressure measuring instruments shall be located above the taps for gas and non condensable and below the taps for liquids and condensable.

9.3.3 Pulsating service installations shall be provided with pulsation dampeners and/or snubbers.

9.4 Pressure / Differential Pressure Switch 9.4.1 As there are chances of catalyst carryover, Pressure Switch shall be Diaphragm seal type with

flange connection of 2, ANSI B 16.5, class 300 minimum. Flange material shall be according to piping class but minimum SS316.

9.4.2 When required as per standard package of ESP for efficient and safe performance of ESP, Pressure or DP Switches shall be considered for checking the choking conditions.

9.4.3 Pressure element shall be diaphragm with adjustable setting.

9.4.4 Switch shall be SPDT/DPDT with 220 V AC / DC, 3 Amp contact rating.

9.5 Pressure Gauges 9.5.1 Pressure gauges shall be ranged such that normal operating range shall be between 30 70% of

scale; except on pulsating service where it shall be restricted to 60 % of scale.

9.5.2 As there are chances of catalyst carryover, all Pressure gauges shall be Direct mounted flange type or Remote seal capillary type.

9.5.3 Flange for Remote Seal diaphragm type or direct mounted flange type pressure gauge shall be 2 as per ANSI B 16.5, class 300 minimum. Flange material shall be according to piping class but minimum SS316.

9.5.4 Pressure gauges shall have 150 mm minimum case size; smaller gauges shall only be used on filter regulators and where they are part of a pneumatic instrument.

9.5.5 Outer casing of Field pressure gauge cases shall be of SS 304.

9.5.6 All gauges shall be provided with indication in black letters on white background. The pressure gauges shall have over range protection of 1.3 times the maximum scale range. Where a gauge is subjected to a greater pressure, a gauge protector shall be used. Gauges shall be solid front with back blow out protection.

9.5.7 All pressure gauges shall be provided with suitable mounting arrangement.

9.5.8 Pressure gauges shall be solid front type with 3mm shatterproof glass for 25 Kg/cm2 and above.




9.5.9 Differential pressure gauges shall be capable of withstanding full line static pressure on either side of the element without damaging or affecting calibration and accuracy.

9.5.10 Where pressure pulsations are present, then glycerine fill shall be applied to pressure gauges.

9.5.11 Bidder to supply all necessary and required accessories for the pressure gauge.

9.5.12 For diaphragm seal gauges, Capillary shall be of minimum SS316 material and shall have SS 304 armouring with PVC covering. Length of capillary shall be 5 Mtrs minimum. Size of capillary shall be selected to ensure that the response time of the gauge shall be less than 5 seconds.

9.5.13 The sealing liquid for diaphragm seal gauges shall be inert liquid, compatible with the process fluid and its temperature.

9.5.14 For diaphragm seal pressure gauges with flanged ends, the diaphragm shall be rated for the maximum allowable pressure of the associated flange.

9.5.15 20 % Spare Pressure gauges shall be provided.

10 Flow Measuring Instruments 10.1 Any type flow meters required for ESP as per Bidders package requirement, detail technical

specification shall be provided by Bidder to Owner/Consultant for their approval.

11 Temperature All temperature measuring instrument shall in general follow below specification.

11.1 Temperature Gauges 11.1.1 For local indication, gas filled actuated dial thermometers shall be used.

11.1.2 Case and capillary compensation shall be used for filled thermal system where required for ambient temperature changes.

11.1.3 In general 150mm dial, all angle temperature gauges shall be used.

11.1.4 Bi-metal temperature gauges shall be of stainless steel construction with a demountable bezel (head ring) complete with heavy plate glass and heat resistant gasket.

11.1.5 The identifying tag number shall be neatly and clearly marked on the back of each thermometer.

11.1.6 The scale plates of the temperature gauges shall be anodized aluminium with white face and black figures.

11.1.7 Flange type Thermowell shall be supplied with the temperature gauge.

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11.1.8 All gauges shall be provided with C indication. Positive temperature range shall be in black numerals on white background.

11.1.9 For locations at which measurement is to be taken precludes a direct mounted thermometer, a gas or liquid filled instrument with an external capillary (SS armour with PVC coated) shall be used.

11.2 Thermocouples .

11.2.1 Thermocouples shall generally be Nickel-Chrome / Nickel-Aluminium (Chromel-Alumel) ANSI Type K (Class 1) suitable for 0-1000 C.

11.2.2 The element shall be a spring loaded assembly, mineral insulated or provided with insulators of porcelain or better with the transition sealed.

11.2.3 The thermocouple sheath shall be 316SS, minimum. Inconel 800 sheath for temperature greater than 600 deg C for non sulphurous atmospheres whereas SS446 shall be considered for sulphurous atmospheres.

11.2.4 The thermocouple head material shall be aluminium alloy, threaded cover and entry shall be inch NPT having separate terminals for connecting the element and the cable. Grounding terminal shall be provided for connecting the shield of the extension cable.

11.2.5 Thermocouples for standard applications shall be selected from the following types:

ISA /ANSI Letter Design.

Type AWG

Temperature Range

K Chromel - Alumel 18 upto 1000 C

R Platinum 87%-Rhodium 13% -Platinum

22 Above 1000 C

11.2.6 Thermocouple material, tolerance and calibration shall be as per ANSI MC96.Thermocouples in air pre heaters shall be straight element type with ceramic insulators installed in a ceramic protection tube.

11.3 Thermowell 11.3.1 Material for Thermowell shall be ANSI type SS 316 minimum or better suitable to process

condition, machined from single bar stock in a tapered configuration, capable of withstanding as a minimum the operating temperature and maximum. Other materials and ratings may be specified as per Piping Material Specification. They shall be suitable for fluid velocities in which they are located and shall have their Wake Frequency checked as prescribed in ASME PTC 19.3.

11.3.2 Thermowell connections to vessel or pipeline shall be 40 NB (1.5) flanged as per ANSI B 16.5 with instrument connection in general. Their flange shall be rated as per piping class, minimum class 300.




11.3.3 Other process connection may be used if flanged process connection is not possible, Bidder to take prior approval from Owner/Consultant before manufacturing.

11.3.4 Thermowells shall be capable of withstanding the maximum design temperature and pressure of the system. The Thermowell flange material shall be selected based on the associated piping class, and shall withstand the associated pressure or temperature rating.

11.3.5 For 4" pipe and smaller, the Thermowell shall be installed in an elbow or tee branch. When this is not feasible, the line shall be swaged to larger size, minimum of 4". For 4" pipe and smaller, the insertion length shall be selected such that the tip of the temperature elements is located in approximately the centre of the pipe.

11.3.6 For pipe sizes larger than 4" or for the vessels, the insertion length specified shall be such that the temperature elements are in the main flow of the pipe or vessel.

11.3.7 Vibration analysis/ wake frequency calculation shall be carried out for all Thermowell where line velocity is higher. If the Thermowell design fails vibration analysis, an alternate design may be used.

11.3.8 Standout (stub end) dimension for all Thermowell should be 200 mm.

11.3.9 Immersion Length of Thermowell shall be selected as follows; Line Sizes Immersion Length 4 280 mm

6 & 8 300 mm 10 350 mm

16 & 18 400 mm 20 500 mm

Above immersion lengths are based on Thermowell nozzle standout of 200 mm (between flange face and inner wall of the pipe). However in case of special application where Thermowell nozzle standout is larger, immersion length shall be increased in proportion with the increase in nozzle standout.

11.4 Temperature Transmitter 11.4.1 Temperature transmitters shall be electronic "SMART" type 2-wire, 24 VDC loop powered

output with HART Protocol and accuracy +/- 0.25 % of URV as a minimum. Field mount temperature transmitter with integral display shall be used in general. Temperature transmitter shall have dual compartment. Display unit & termination assembly shall be isolated. Head mounted transmitters are not acceptable.

11.4.2 All temperature transmitter shall have inbuilt linearising function to produce output linear to temperature range

11.4.3 Temperature transmitter shall be remote mounted type.

11.4.4 TC shall be fixed to a pipe clamp and the wiring tails connected to temperature transmitter.

11.4.5 Required compensating cables shall be supplied by Bidder.

11.4.6 All transmitters shall have local digital readouts in engineering units.

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11.4.7 The response time of smart transmitter shall be of less than 250ms or better.

11.4.8 In the event of failure, the output shall be driven to predefined value or safe value.

11.4.9 Design of electronic instruments shall be in compliance with the electromagnetic compatibility requirement as per IEC-61000.

11.4.10 Temperature transmitter shall be provided with burn out protection. Upscale and downscale protection shall be decided based on the application to ensure fail safe operation for all temperature input devices.

12 Level 12.1 Level Gauge 12.1.1 As per ESP Bidder standard package requirement, suitable Level gauges shall be supplied.

12.2 Hopper Level Measurement 12.2.1 For ESP Hopper Level Measurement, suitable to application, most reliable and proven

instrument shall be used.

12.2.2 Bidder to provide detail technical specification with proven track record along with offer. Previous track record shall be at least for 2 years satisfactory operation of Hoper level instruments for similar application.

12.3 Bidder shall provide detail technical specification for all the instruments which are to be required and supply for efficient performance of ESP.

13 Identification Each instrument shall be provided with an identification plate, with all data clearly and

indelibly stamped on a stainless steel plate, permanently attached to the instrument by means of SS rivets or screws. In addition, a stainless steel tag shall be provided that is permanently attached to the instrument support wherever possible otherwise attached by a chain or wire to the body of the instrument.

14 Tests 14.1 Calibration test with minimum 5 points for both rising / falling of pressure range. (Calibration

shall be carried out under reference conditions traceable to National Standards) 14.2 Hydro test (1.5 times max. Pr.), leak test for flow chamber/ tube wherever required.

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14.3 Material traceability test as per EN 10204. 14.4 For flow meters, Hydrostatic test (pressure shall be as outlet flange ANSI rating for 20

minutes.), leak test shall be as per API 598 standard. 14.5 All tests shall be witnessed by owner/ consultant/ owners appointed third party inspector. 14.6 Radiography shall be as per ASME B 16.34.

15 Shipping

15.1 Instruments or its parts which can be damaged during shipment shall be packed separately in the original manufacturer boxes. All items shall be properly packed, made see worthy and protected from damage during shipment.

15.2 Each package shall be identified with purchase order number and content list in a weather proof envelope.

15.3 All openings shall be sealed & threads shall be protected with suitable caps to prevent damage.

15.4 All flanged openings shall be protected with suitable closures to protect the flange face & instrument.

15.5 All machined surface subject to atmospheric corrosions prior to installation on site shall be treated with easily removable rust preventive

15.6 A desiccant shall be provided to prevent moisture damage due to high humidity.

16 Approved Vendor List

16.1 All filed instruments required for efficient and safe operation of ESP shall be from following approved vendor list.

Sr.No. Instruments Approved Vendor Name General Instruments Pyro Electric 1 Temperature Gauges ANI Forbes Marshall Pyro Electric General Instruments

2 Thermocouple

Detrive Instruments Waree Wika 3 Pressure Gauges Manometer India Pvt. Ltd. Yokogawa Honeywell 4 Transmitters (FT, PT, DPT, TT) Emerson Sherman Instruments (SOR) Indfoss Industires Ltd. 5 Pressure Switches Switzer Instrument Ltd.


Title : Technical Specification for Plain and Reinforced Cement Concrete Works

Doc No: 287197-500-SP-CIV-001 Rev: B Page 1 of 23

P:\Andheri\IndiaProject\292794 BPCL KR ESP\02 Civil\Documents\SPECIFICATIONS

TECHNICAL SPECIFICATION

FOR

PLAIN AND REINFORCED

CEMENT CONCRETE WORKS

Bharat Petroleum Corporation Ltd Kochi Refinery, Ambalamugal 682 302 Ernakulam Dist. Kerala.






List of Content Page No

1 Scope 6

2 Applicable Codes 6

3 Materials 7 3.1 Cement 7 3.2 Aggregates 7 3.3 Water 8 3.4 Brick Aggregates 8 3.5 Reinforcement 8 3.6 Jointing/Sealing Materials 8 3.7 Admixtures 8

4 Storage of Materials 9 4.1 Cement 9 4.2 Aggregates 9 4.3 Reinforcing Steel 9 4.4 Miscellaneous 9

5 Grades of Concrete 9

6 Type of Concrete Mix 10 6.1 General 10 6.2 Nominal Mix Concrete 10 6.3 Design Mix Concrete 11

7 Concrete Mix Proportioning 11 7.1 Free Water Cement Ratio 12 7.2 Consistency 12 7.3 Workability 12 7.4 Durability 13

8 Batching 14

9 Concrete Mixing 14 9.1 General 14





10 Transportation, Placing and Compaction 14 10.1 General 14

10.1.1 Vibrators 15 10.1.2 Transportation 15 10.1.3 Placing and Compaction 15 10.1.4 Items Embedded in Concrete 15

11 Construction Joints 16

12 Expansion Joints / Isolation Joint 16

13 Protection of Freshly Laid Concrete 16

14 Curing 16

15 Field Tests 17 15.1 Workability 17 15.2 Work Tests 17 15.3 Standard Deviation 18 15.4 Acceptance Criteria 18

16 Finishing of Concrete 19 16.1 General 19

17 Form Work 19 17.1 General 19 17.2 Cleaning and Treatment of Formwork 19 17.3 Chamfers and Fillets 19 17.4 Reuse of forms 20 17.5 Removal of Forms/Stripping Time 20

18 Exposed / Architectural Concrete Work 21 18.1 Form Work 21

19 Reinforcement 21 19.2 Straightening, Cutting and Bending 21 19.3 Placing and Fixing 21 19.4 Splicing/Overlapping 22 19.5 Tolerance to Cover 22





20 Grouting 22

21 Clean Up 23





1 Scope This specification establishes the minimum requirements of materials, quality, batching, mix proportioning, transporting, placing, protecting, curing, repairing, finishing & testing etc. of all types of cast-in-situ and precast concrete used in foundations, underground and aboveground structures, floors, pavements etc. Any special requirements as shown or noted on the drawings shall supersede over the provisions of this specifications.

2 Applicable Codes Apart from this specification, construction of plain and reinforced concrete works shall be in accordance with the Indian Standard Code of Practice for "Plain and Reinforced Concrete" IS:456 and other relevant codes mentioned therein.

The following Indian Standards including all amendments and revisions shall be considered as part of this specification.

IS: 269-1989 Specification for Ordinary. Rapid hardening & Low heat Portland cement IS: 383-1970 Specification for Coarse & fine aggregates from natural sources for concrete IS: 432-1982 Specification for mild steel and (Part I & II) medium tensile steel bars and hard

drawn steel wire for concrete reinforcement. IS: 455-1989 Specification for Portland Blast Furnace Slag cement. IS: 456-2000 Code of Practice for Plain and Reinforced Concrete. IS: 516-1959 Methods of Tests for Strength of Concrete. IS: 650-1991 Specification for standard sand for testing of cement. IS: 1139-1966 Specification for hot rolled mild steel and medium tensile steel deformed bars for

concrete reinforcement. IS: 1199-1959 Methods of Sampling and Analysis of Concrete. IS: 1200-1992 Methods of measurement of building works. IS: 1489-1991 Specification for Portland Pozzolona Cement. IS: 1566-1982Specification for plain hard drawn steel wire fabric for concrete reinforcement. IS: 1786-1985 Specification for High Strength Deformed Steel Bars and Wires for

Concrete Reinforcement. IS: 1791-1985Specification for Batch Type Concrete Mixers. IS: 2386-1963 Methods of Test for Aggregates for Concrete: Part 3, Specific gravity, density,

voids, absorption and bulking. IS: 2396(I)-1988 Flakiness index of aggregates IS: 2502-1963 Code of Practice for Bending and Fixing of Bars for Concrete Reinforcement. IS: 2505-1992 Specification for concrete vibrator immersion type. IS: 2645-2002 Specification for integral cement water proofing material.





IS: 2750-1964 Specification for steel scaffolding IS: 2751-1979 Recommended Practice for Welding of Mild Steel Plain and Deformed Bars for

Reinforced Concrete Construction. IS: 2772-1982 Specification for portable swing weigh-batchers for concrete IS: 3696-1987 Safety code for scaffolding and ladders IS: 4014-1967 Code of Practice for steel tubular (Part I & II) Scaffolding IS: 4031-1996 Method of physical tests for hydraulic cement IS: 4926-2003 Ready Mixed Concrete IS: 4990-1993 Specification for plywood for concrete shuttering work IS: 7861 Code of Practice for Extreme Weather Concreting. Part I-1975 Recommended Practice for Hot Weather Concreting. Part II-1981 Recommended Practice for Cold Weather Concreting. IS: 9013-1978 Methods of Making, Curing and Determining Compressive Strength of

Accelerated Cured Concrete Test Specimens. IS: 9103-1999 Specification for Admixtures for Concrete. IS: 9417-1989 Recommendation for Welding Cold Worked Steel Bars for Reinforced Concrete

Construction. IS: 10262-1982 Recommended Guidelines for Concrete Mix Design. IS: 14687-1999 Guidelines for Formwork for Concrete Structures. IS: 12330-1987 Specification for sulphate resisting Portland cement.

IS: 8112-1989 Specification for 43 grade ordinary portland cement.

3 Materials 3.1 Cement

Ordinary Portland Cement shall conform to IS: 269, Portland Blast Furnace Slag Cement shall conform to IS: 455. Use of Portland Pozzolana Cement shall be only with prior approval of the MMCI/BPCL Engineer-in-charge.

3.2 Aggregates Aggregates in general designate both fine and coarse inert materials used in the manufacture of concrete. The fine aggregate is aggregate which passes through 4.75 mm IS Sieve. Coarse aggregate is aggregate most of which is retained on 4.75 mm IS Sieve.

All aggregates shall conform to IS: 383. Fine aggregate shall consist of natural sand, i.e. river or pit sand. Coarse aggregate shall consist of crushed gravel, natural gravel, crushed stone or combination thereof conforming to requirements of grading and physical properties called for. However, bank run gravel shall not be permitted for coarse aggregates.

The fineness modules of sand should be between 2.2 to 3.2 for concrete works.





The maximum size of coarse aggregate shall be 38 mm except for slabs and walls less than 250 mm thick which shall have a maximum size of 19 mm.

Blast furnace slag and manufactured sand shall not be used as aggregates.

3.3 Water Water used for both mixing and curing shall be free from injurious amounts of deleterious materials and shall be of potable quality conforming IS: 456.

3.4 Brick Aggregates The brickbats shall be new bricks well burnt, hard durables, broken to sizes and well graded. It shall be free from dust, earth and any other impurities.

3.5 Reinforcement Reinforcement shall be of tested quality M.S. round rods conforming to IS:432, IRC wire mesh fabric conforming to IS:1566, mild steel and medium tensile steel deformed bars conforming to IS:1139 and cold twisted steel bars conforming to IS:1786 as shown in drawings.

All reinforcement shall be clean, free from grease, oil, paint, loose mill scale, loose rust, dust, bituminous material or any other material or substance that will destroy or reduce the bond.

16 SWG (1.6 mm) approved soft annealed steel wire shall be used for binding the reinforcement bars.

Reinforcements in piles shall be High Yield Strength deformed TMT Bars conforming to IS: 1786

3.6 Jointing/Sealing Materials All joint fillers, sealing materials etc. used for joints in concrete shall be from approved standard manufacturer and shall conform to relevant IS codes. The extent, type, method of use and control shall be as per manufacturer's recommendation, subject to approval of the MMCI/BPCL Engineer-in-charge.

3.7 Admixtures Admixtures shall be used strictly in accordance with the manufacturer's instructions and shall conform to the relevant IS codes (for eg. IS: 9103). Vendor's instruction shall be successfully incorporated in the trial mix. The extent, type, method of use and control shall be subject to approval of the MMCI/BPCL Engineer-in-charge in all cases.

Integral water proofing compound shall conform to IS: 2645.





4 Storage of Materials 4.1 Cement

Cement shall be stored in a damp-proof hopper or in sealed bags in a weather proof shed, on a floor above ground and shall be used in the order of its delivery. Different types or brands of cement shall be stored separately. Not more than 12 bags shall be stacked in any tier.

4.2 Aggregates Aggregates of different sizes shall be kept separately. Aggregates of similar grading but from different sources or different types shall not be stored together unless approved. All aggregates shall be stored in such a way that they are free from contact of deleterious matter.

4.3 Reinforcing Steel Reinforcing steel members and wire mesh which are stored at the project site shall be above ground on platforms, skids or other supports.

Steel shall be protected from rain, moisture and kept free from dirt, oil or contaminant injuries. 4.4 Miscellaneous

All other materials shall be stored in a weather tight and dry place and be protected from open flame or sparks.

All packed materials shall be stored in their original unbroken package or container.

5 Grades of Concrete Unless otherwise noted on the drawings, or called for in the schedule of rates, the grades of concrete shall generally be as per Table-1.

TABLE - 1

GRADES OF CONCRETE

Grade Designation Specified Characteristic Compressive Strength of 150 mm cube at 28 days (N/mm2)

M 7.5 7.5

M 10 10

M 15 15

M 20 20

M 25 25

M 30 30

M 35 35





M 40 40

M 45 45

M 50 50

M 55 55

Note for Table - 1 : The characteristic strength is defined as the strength of material below which not more than five (5) percent of the test results are expected to fall.

In the designation of concrete mix the letter M refers to the mix and the number to the specified characteristic compressive strength of 15 cm cube at 28 days expressed in N/sq. mm.

6 Type of Concrete Mix 6.1 General

Unless otherwise noted on drawings, all lean/plain and reinforced concrete shall be nominal mix and design mix types, respectively.

6.2 Nominal Mix Concrete This concrete shall be made (without preliminary tests) by adopting nominal concrete mix with proportions of materials as specified in Table-1 A

TABLE - 1A PROPORTIONS FOR NOMTNAT. MIX CONCRETE

Nominal mix of concrete (by mass) Quantity of water per 50 kg of cement (max) Litres 1:5:10 60 1:3:6 34 1:4:8 45 M 15(1:2:4) 32 20(l:1l/2:3) M 34

Note: 1. The proportions of the fine to coarse aggregates should be adjusted from upper 1. The proportions of the fine to coarse aggregates should be adjusted from upper limit to

lower limit progressively as the grading of the fine aggregates becomes finer and the maximum size of coarse aggregates becomes larger. Graded coarse aggregates shall be used.

2. The cement content of the mix shall be proportionately increased if the quantity of water in a mix has to be increased to overcome the difficulties of placement and compaction, so that the water-cement ratio, as specified, is not exceeded.





6.3 Design Mix Concrete The mix shall be designed to produce the grade of concrete having the required workability and characteristic strength not less than appropriate values given in Table-1. The target mean strength of concrete mix shall be equal to the characteristic strength plus 1.65 times the standard deviation.

As long as the quality of materials does not change, a mix design done earlier may be considered adequate for later work. However, in case the quality of materials changes or there is a break in the continuity of construction and the same work is allocated to a new contractor, the MMCI/BPCL Engineer-in-Charge shall ask for a new design mix.

Irrespective of the grade of concrete required to be produced as per characteristic.

The strength criteria, the minimum cement content and maximum free water cement ratio in the design concrete shall be strictly maintained as stipulated in Table 2A for the corresponding grade of concrete.

The contractor at his own cost; grade the aggregates and control the water/cement ratio, design & conduct the different trial mixes to required strength and workability & obtain MMCI/BPCL Engineer-in charges approval for the same. Duly approved mixes in accordance with IS: 456 shall be used for construction.

All concrete shall be machine mixed and no hand mixing shall be permitted. The concrete shall continuously agitate from mixing to pouring. The use of non agitating equipment in transporting ready mixed concrete or the use of partially hardened concrete is not allowed.

Where reinforcement is too closely spaced for the maximum size of aggregate in a range, the largest suitable range will be used with the approval of the MMCI/BPCL Engineer-in-charge.

7 Concrete Mix Proportioning Proportioning, as used in this specification, shall mean the process of determining the proportions of the various ingredients to be used to produce concrete of the required workability when fresh/green and strength, durability and surface finish, when hardened. The following information shall be collected prior to design of the concrete mix.

a) Grade designation b) Type of cement c) Maximum nominal size of aggregate d) Minimum cement content e) Maximum free water cement ratio f) Workability requirements.

The MMCI/BPCL Engineer-in-Charge shall verify the strength of the concrete mix, before giving his sanction of its use. However, this does not absolve the Contractor of his responsibility as regards achieving the prescribed strength as per Para 6.3. If during the execution of the work,





cube tests show lower strengths than required, the MMCI/BPCL Engineer-in-Charge shall order fresh trial mixes to be made by the Contractor. No claim to alter the rates of concrete work shall be entertained due to such changes in mix variations. Any variation in cement consumption shall be taken into consideration for material reconciliation. Preliminary mix designs shall be established well ahead of start of work.

7.1 Free Water Cement Ratio Once a mix, including its free water cement ratio, has been determined and approved for use by the MMCI/BPCL Engineer-in- Charge, that free water cement ratio shall be maintained. The Contractor shall determine the water content of the aggregates frequently as the work progresses, and the amount of mixing water shall be adjusted so as to maintain the approved free water cement ratio.

7.2 Consistency The concrete shall have a consistency such that it shall be workable in the required position and when properly vibrated it flows around reinforcing steel, all embedded fixtures, etc. The consistency of concrete shall have to be controlled as per IS: 456 and the slump tests shall be carried out by the contractor in accordance with IS: 1199.

7.3 Workability 7.4.1 The concrete mix proportion shall be such that the concrete is of adequate workability for the

placing condition and can be properly compacted with the means available. Use of additives of approved make shall be taken recourse to where required for attaining proper workability as specified under Cl. 7.4.2.

7.4.2 The suggested ranges of values of workability of concrete measured in accordance with IS:1199 are indicated in Table-2 below. However, the actual values to be followed shall be established depending on aggregate sizing, mix proportions, placing conditions, etc and shall be got approved by the MMCI/BPCL Engineer-in-Charge. At least one slump test shall be carried out per every compressive test performed. More frequent tests shall be made if there is a distinct change in work conditions, if required by MMCI/BPCL Engineer-in-charge.

TABLE - 2 Values of Workability

Placing conditions Degree of workability Slump (mm)

Lightly reinforced sections in slabs, beams, walls, columns, footings and pavements

Low 25-75

Heavily reinforced sections in slabs, beams, walls, columns, slip- form work and pumped concrete.

Medium 50-100





In-situ piling High 100-150

Tremie concrete Very High 150-200

7.4 Durability For achieving sufficiently durable concrete, strong, dense aggregates, low water-cement ratio and adequate cement content shall always be used. Workability of concrete shall be such that concrete can be completely compacted with the means available. Leak-proof formwork shall be used so as to ensure no loss of cement-slurry during pouring and compaction. Cover to reinforcement shall be uniform and as shown on drawings. Concrete mix design shall always take into account the type of cement, minimum cement content irrespective of the type of cement and maximum free water cement ratio and minimum grade of concrete conforming to the exposure conditions as given in Table-2A.

TABLE -2A Minimum Cement Content, Maximum Free Water Cement Ratio and

Minimum Grade of Concrete for Different Exposure Conditions

Plain Concrete Reinforced Concrete

Exposure Minimum Cement Content (kg/m3)

Maximum Free

Water Cement Ratio

Minimum Grade of Concrete

Minimum Cement Content (kg/m3)

Maximum Free Water

Cement Ratio

Minimum Grade of Concrete

Mild 240 0.6 M 15 330 0.55 M 20 Moderate 265 0.6 M 15 330 0.50 M 25

Severe 275 0.5 M 20 350 0.45 M 30 Very Severe 280 0.45 M 20 375 0.45 M 35

Extreme 310 0.4 M 20 400 0.4 M 40

Generally, the following types of cement shall be used for Plain and Reinforced concrete works:

a) 33 Grade Ordinary Portland Cement conforming to IS: 269. b) 43 Grade Ordinary Portland Cement conforming to IS: 8112. c) Portland Slag Cement conforming to IS:455. d) Portland Pozzolana Cement conforming to IS: 1489. e) Sulphate Resisting Portland Cement conforming to IS: 12330

Sulphate Resisting Portland Cement shall be used only for specific requirements depending on environmental and process exposure conditions to which the structures may be subjected to like high sulphate concentrations, processes involving sulphur handling etc.





The minimum cement content as mentioned in Table-2A shall be adjusted for aggregates other than 20mm nominal maximum size. The minimum cement content in the concrete mix shall be increased by 40kg/m3 and decreased by 30 kg/m3 for 10mm and 40mm nominal maximum size aggregates respectively.

8 Batching 8.1 No substitutions in materials used on the work or alterations in the established proportions,

except as permitted in 6.4 shall be made without additional tests to show that the quality and strength of concrete are satisfactory. In case the Contractor proposes any change in the already approved mix design, fresh mix design with supportive laboratory tests shall be submitted to the MMCI/BPCL Engineer-in-Charge and his approval has to be obtained prior to using the revised mix proportion in the works. However, such proposals for revision shall only be entertained in case of successive failure of test cubes to achieve the required strength.

9 Concrete Mixing 9.1 General

The mixing of concrete shall be strictly carried out in an approved type of mechanical concrete mixer. The mixer shall be fitted with water measuring devices. The mixing shall be continued until there is a uniform distribution of the material and the mass is uniform in colour and consistency. If there is segregation after unloading from the mixer, the concrete shall be remixed.

Use of Ready Mixed Concrete supplied by Ready Mixed Concrete Plants or from on/off-site batching plants (IS: 4926) shall be preferred for structural concrete.

All records and charts for the batching and mixing operations shall be prepared and maintained by the contractor as per the instructions of MMCI/BPCL Engineer-in-Charge.

Hand mixing of concrete shall not be permitted. However, for non-critical applications namely foundations for crossovers, isolated operating platforms etc. using concrete of maximum grade M20 and located at far away isolated places, this may be permitted by the MMCI/BPCL Engineer-in-charge as a special case.

10 Transportation, Placing and Compaction 10.1 General

The entire concrete placing programme including transportation arrangements, deployment of equipment, layout, proposed procedures and methods, shall be submitted to the MMCI/BPCL Engineer-in-Charge 24 hours prior to concreting for approval. No concreting shall be placed until his approval has been received. Approval of the MMCI/BPCL Engineer-in-Charge for pouring concrete shall be taken as 'conveyed', when the concrete pour card is signed by him.





10.1.1 Vibrators 10.1.1.1 In placing concrete in layers which are advancing horizontally as the work progresses, great care

shall be exercised to ensure adequate vibration, bonding and moulding of the concrete between the succeeding batches.

10.1.1.2 The vibrator shall penetrate the layer being placed and also penetrate the layer below while the under layer is still plastic to ensure good bond and homogeneity between the two layers and prevent the formation of cold joints.

10.1.1.3 Care shall be taken to prevent contact of vibrators against all embedded reinforcing steel or inserts. Vibrators shall not be allowed to come in contact with forms.

10.1.2 Transportation 10.1.2.1 All concrete shall be conveyed from the mixer to the place of final deposit such as formwork as

early as possible using suitable buckets, dumpers, pumps, transit mixers containers or conveyors which shall be mortar leak tight. Care shall be taken to prevent the segregation or loss of the ingredients and maintaining the required workability. For structural concrete produced from Ready Mixed Concrete Plants as per Cl. 9.1, concrete shall be transported from the plants to the sites only by transit mixers.

10.1.3 Placing and Compaction 10.1.3.1 Before placing concrete, all soil surfaces upon which or against which concrete is to be placed

shall be well compacted and free from standing water, mud or debris. Soft or yielding soil shall be removed and replaced, with lean concrete or with selected soils/sand and compacted to the density as directed by MMCI/BPCL Engineer-in-Charge. The surface of absorptive soil (against which concrete is to be placed) shall be moistened thoroughly so that moisture is not drawn from the freshly placed concrete. Similarly, for concrete to be placed on formworks, all chippings, shavings and sawdust etc. shall be removed from the interior of the forms before the concrete is placed.

Concrete shall be placed within a maximum period of 25 minutes of its removal from mixture.

10.1.3.2 Concrete shall not be placed until the formwork, the placement of reinforcing steel, embedded parts, pockets etc. have been inspected and approved by the MMCI/BPCL Engineer- in-Charge. Any accumulated water on the surface of the bedding layer shall be removed by suitable means before start of placement. No concrete shall be placed on a water covered surface.

10.1.4 Items Embedded in Concrete 10.1.4.1 Concreting shall not be started unless the electrical conduits, pipes, fixtures etc., wherever

required, are laid by the concerned agency. The Contractor shall afford all the facilities and maintain co-ordination of work with other agencies engaged in electrical and such other works as directed by the MMCI/BPCL Engineer-in-Charge.

10.1.4.2 Anchor bolts shall be set to template and firmly tied/fixed in vertical & horizontal line at all required positions.





10.1.4.3 All embedment, inserts etc. shall be fully held and secured in their respective positions by the concerned agencies to the entire satisfaction of MMCI/BPCL Engineer-in-Charge so as to avoid any dislocation or displacement during the concreting operations. The Contractor shall take all possible care during concreting to maintain these embedment/inserts in their exact locations.

11 Construction Joints 11.1 Construction joints shall be provided in position as shown or described on the drawings or as

directed by the MMCI/BPCL Engineer-in-Charge. Such joints shall be kept to the minimum. These shall be straight and at right angles to the direction of main reinforcement and shall be placed at accessible locations to permit cleaning out of laitance, cement slurry and unsound concrete.

12 Expansion Joints / Isolation Joint 12.1 Expansion/ Isolation joints in structures shall be formed in the positions and to the shapes shown

in the relevant drawings. Joints shall be filled with joint filling material as stipulated in the drawings/schedule of rates. Isolation joints shall be provided around all equipment foundations, columns, pedestals, trenches etc. on grade.

13 Protection of Freshly Laid Concrete 13.1 Newly placed concrete shall be protected, by approved means, from rain, sun and wind.

Concrete placed below the ground level shall be protected from falling earth during and after placing. Surface shall be kept free from contact with such ground or with water draining from such ground during placing of concrete for a period of at least 3 days, unless otherwise directed by the MMCI/BPCL Engineer-in-Charge. The ground water around newly poured concrete shall be kept to an approved level by pumping or other approved means of drainage and adequate steps shall be taken to prevent floatation and flooding. Steps shall be taken to protect immature concrete from damage by debris, loading, vibration, abrasion, mixing with deleterious materials that may, in the opinion of the MMCI/BPCL Engineer-in-Charge, impair the strength and/or durability of the concrete.

14 Curing 14.1 Concrete shall be cured by keeping it continuously moist wet for the specified period of time to

ensure complete hydration of cement and its hardening. Curing shall be started after 8 hours of placement of concrete in normal weather, and in hot weather after 4 hours. The water used for curing shall be of the same quality as that used for making of concrete. Curing shall be assured by use of an ample water supply under pressure in pipes, with all necessary appliances such as hose, sprinklers etc. A layer of sacking, canvas, hessian, or other approved material, which will hold moisture for long periods and prevent loss of moisture from the concrete, shall be used as covering. Type of covering which would stain, disfigure or damage the concrete, during and after the curing period, shall not be used. Only approved covering shall be used for curing. Exposed surfaces of concrete shall be maintained continuously in a damp or wet condition for at least the first 7 days after placing of concrete.





14.2 For concretes containing Portland pozzolana cement or Portland slag cement, the curing period as given in 14.1 shall be doubled. Curing by ponding shall, however, commence after the first 24 hours of concreting.

15 Field Tests 15.1 Workability 15.2.1 The concrete mix proportion so chosen, shall be such that the concrete is of adequate workability

for the placing condition and can be property compacted with the means available.

15.2.2 The suggested ranges of values of workability of concrete measured in accordance with IS: 1199 are indicated in Table-5.

TABLE -5

Placing Conditions Degree of Workability Value of Workability

Concreting of shallow section with vibration Very Low

20-10 seconds, Vee Bee time or 0.75 - 0.80, Compacting factor

Concreting of lightly reinforced sections with vibration

Low 10-5 seconds, Vee Bee time or 0.8 - 0.85, Compacting factor

Concreting of lightly reinforced sections without vibration, or Heavily reinforced sections with vibrations

Medium

5-2 seconds, Vee Bee time or 0.85 - 0.92, Compacting factor or 25-75 mm, slump for 20 mm aggregate

Concreting of heavily reinforced sections without vibrations

High

above 0.92, Compacting factor or 75-125 mm, slump for 20 mm* aggregate

* For smaller aggregate the values will be lower.

15.2 Work Tests 15.2.1 Over the full period of construction, the contractor shall carry out work tests of concrete at his

own cost. Sampling from fresh concrete shall be taken as per IS: 1199 and cubes shall be made, cured and tested in accordance with IS: 516. The number of specimen to be tested and their criteria for acceptance shall be according to IS: 456. Frequency of work tests shall be as indicated below:





15.2.2 Frequency of Tests

15.2.2.1 Unless otherwise specified, for each grade of concrete, sets of test cube, each set consisting of three (3) twin specimens (i.e. total 6 Nos.) shall be taken. Number of sets shall generally be calculated based on the types and corresponding volumes of work as indicated hereunder unless otherwise directed by the MMCI/BPCL Engineer-in-charge

Mass Concrete Foundations

: For every 100 Cu. M of concrete placed, one set but not less than one set for each pouring of concrete

Equipment and building Column foundations :

: For every 50 Cu. m of concrete placed one set but not less than one set for each pouring of concrete

Frame & thin walled Structural components Columns, beams, slabs etc.

: For every 30 Cu. m of concrete placed one set but not less than one set for each pouring of concrete

15.2.2.2 The test cubes shall be sampled in presence of the MMCI/BPCL Engineer-in-charge, who will also sign the record of testing in an agreed format.

15.2.2.3 For testing the cube specimen contractor shall establish his own construction laboratory at site and the cost of testing of cubes shall be borne by him.

15.2.2.4 Supply of all required consumables, construction and erection materials including but not limited to gauges, welding, brazing, gasses and rods, electrodes, oxygen, acetylene, fuel, bolts, nuts and temporary support etc. shall be by contractor at no extra cost.

15.3 Standard Deviation Standard deviation shall be calculated as given in IS: 456.

15.4 Acceptance Criteria 15.4.1 The concrete shall deemed to be accepted if it fulfils the requirements laid down in IS: 456.

15.4.2 lf the concrete does not comply with IS: 456, the structural adequacy of the parts affected shall be investigated and any consequential action as needed shall be taken up by the contractor at his own cost. Concrete of each grade shall be assessed separately. Concrete shall be assessed daily for compliance. Concrete is liable to be rejected if it is porous or honey-combed; its placing has been interrupted without providing a proper construction joint; the reinforcement has been displaced beyond the tolerances specified; or construction tolerances have not been met. However, the hardened concrete may be accepted after carrying out suitable remedial measures to the satisfaction of the MMCI/BPCL Engineer-in-charge.





16 Finishing of Concrete 16.1 General On striking the formwork, all surface defects such as bulges, ridges and honey-combing etc.

observed shall be brought to the notice of the MMCI/BPCL Engineer-in-Charge. The MMCI/BPCL Engineer-in-Charge may, at his discretion allow rectification by necessary chipping and packing or grouting with concrete or cement mortar. However, if honey-combing or sagging are of such extent as being undesirable, the MMCI/BPCL Engineer-in-Charge may reject the work totally and his decision shall be binding. No extra payment shall be made for rectifying these defects, demolishing and reconstructing the structure. However, quantity of cement actually used for this purpose may be considered for reconciliation of materials. All burrs and uneven faces shall be rubbed smooth with the help of carborundum stone.

The surface of non-shuttered faces shall be smoothened with a wooden float to give a finish similar to that of the rubbed down shuttered faces. Concealed concrete faces shall be left as from the formwork except that honey-combed surface shall be made good as specified above. The top faces of slabs not intended to be covered shall be levelled and floated to a smooth finish to the rises or falls shown on the drawings or as directed. The floating shall not be executed to the extent of bringing excess fine materials to the surface. The top faces of slabs intended to be covered with screed, granolithic or similar finishes, shall be left with a rough finish.

17 Form Work 17.1 General 17.1.1 Forms for concrete shall be of plywood conforming to IS: 6461 or steel or as directed by the

MMCI/BPCL Engineer-in-Charge and shall give smooth and even surface after removal thereof.

17.1.2 If it is desired by the MMCI/BPCL Engineer-in-Charge, the Contractor shall prepare, before commencement of actual work, design and drawings for formwork and get them approved by the MMCI/BPCL Engineer-in-Charge. For details regarding design, detailing etc., reference may be made to IS: 14687.

17.2 Cleaning and Treatment of Formwork The surfaces of forms that would come in contact with concrete shall be well treated with approved non- staining form release agents such as soft soap, oil, emulsions etc. Release agents shall be, applied so as to provide a thin uniform coating to the forms without contaminating the reinforcement.

17.3 Chamfers and Fillets All corners and angles shall be formed with 45 degree mouldings to form chamfers or fillets on the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise detailed or specified shall be 25x25mm. For heavier work chamfers or fillets shall be 50x50mm. Care shall be exercised to ensure accurate mouldings. The diagonal face of the moulding shall be planed or surfaced to the same texture as the forms to which it is attached.





17.4 Reuse of forms Before reuse, all forms shall be thoroughly scrapped, cleaned, examined and when necessary, repaired and retreated, before resetting. Formwork shall not be reused, if declared unfit or un-serviceable by the MMCI/BPCL Engineer-in-Charge.

17.5 Removal of Forms/Stripping Time In the determination of time for removal of forms, consideration shall be given to the location and character of the structures, the weather and other conditions including the setting and curing of the concrete and material used in the mix.

Forms and their supports shall not be removed without the approval of the MMCI/BPCL Engineer-in-Charge. Forms shall not be released until the concrete has achieved a strength of at least twice the stress to which the concrete may be subjected at the time of removal. The formwork shall be removed without shock and methods of form removal likely to cause over stressing' or damage to the concrete, shall not be adopted. Supports shall be removed in such a manner as to permit the concrete to uniformly and gradually take the stresses due to its own weight.

In normal circumstances when average air temperature exceeds 15 degree Celsius during the period under consideration after pouring of concrete and where ordinary Portland cement is used, forms may generally be removed after expiry of following periods.

(a) Walls, columns and vertical faces of all 16 to 24 hours as may be decided by structural members the MMCI/BPCL Engineer-in-Charge.

(b) Slabs (props left under) 3 days

(c) Beam Soffits (props left under) 7 days

(d) Removal of props under slabs:

Spanning upto 4.5m. 7 days

Spanning over 4.5m 14 days

(e) Removal of props under beams and arches:

Spanning upto 6m 14 days

Spanning over 6m 21 days

(f) Cantilever Construction Formwork shall remain till structures for counter acting or bearing down have been erected and have attained sufficient strength (minimum 14 days).

Notes:





1. For other cements, the stripping time recommended for ordinary Portland cement shall be suitably modified as per the instructions of the MMCI/BPCL Engineer- in-Charge.

2. The number of props left under, their sizes, supporting arrangement, and disposition shall be such as to be able to safely carry the full dead load of the slab, beam or arch as the case may be together with any live load likely to occur during curing or further construction.

3. Where the shape of the element is such that the formwork has re-entrant angles, the form work shall be removed as soon as possible after the concrete has set, to avoid shrinkage cracking occurring due to the restraint imposed.

4. For rapid hardening cement, 3/7 of the above mentioned periods shall be considered subject to a minimum of 16 hours.

18 Exposed / Architectural Concrete Work 18.1 Form Work

Other things remaining same as per clause 20.0, formwork shall be of high quality. Care shall be taken to arrange the forms so that the joints between forms correspond with the patter

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