Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Hindustan Organic Chemicals Ltd. Harchandrai House 81, Maharshi Karve Road Mumbai-400 002
Instrumentation Tender No.: Tender/229718/Inst-1
September 2007
VOLUME – I TECHNICAL BID
Mott MacDonald 44, Dr. R.G. Thadani Marg, Worli, Mumbai – 400 018 Tel.: (91-22) 3981 0100 Fax: 2495 0539 Email:
[email protected]
229718/P1/10 August 2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJE p\Dept\PROJECT\Inst-1.doc/pp CT\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Instrumentation Tender No.: Tender/229718/Inst-1
Issue and Revision Record Description
Rev
Date
Originator
Checker
Approver
P1
10-08-2007
PP
ADD
KB
Issued for Approval
0
01-09-2007
PP
ADD
KB
Issued for Bidding
This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project without an independent check being carried out as to its suitability and prior written authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility responsibi lity or liability for the consequence of this document being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement to indemnify Mott MacDonald for all loss or damage resulting therefrom. Mott MacDonald accepts no responsibility responsibil ity or liability for this document to any party other than the person by whom it was commissioned. To the extent that this report is based on information supplied by other parties, Mott MacDonald accepts no liability for any loss or damage suffered by the client, whether contractual or tortuous, stemming from any conclusions based on data supplied by parties other than Mott MacDonald and used by Mott MacDonald in preparing this report.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
List of Contents
Page
Chapters and Appendices 1
2
3
Letter Inviting Tender
1
1.1
Technical Bid
2
1.2
1.3
Tender Collection and Submission
Price Bid 2
Instructions to the Tenderer with Definitions and Formats 2.1
Filling of tender documents
2.2
Special Notes Regarding Submission of Tender
2.3
Important Guidelines to Tenderer
2.4
2.5
4 4 4 4
Information / Documents to be submitted along with the Tender
5 Definitions
2.6
Formats
8
2.7
Validity of Offer
8
Conditions of Contract 3.1
18
General
3.2 3.2.1 3.2.2
18 Information
Location of Site Site Particulars
18 18
3.3
Technical Specification
19
3.4
Time for Completion
19
3.5
3.6
Earnest Money Deposit
3.7
Non-Bifurcation of Tender
3.8
Sufficiency of Tender
3.9
Employment of Local Labour
3.10
Compliance of Laws
20
3.11
Completion Certificate
25
3.12
3.13
3.14
Penalty for Late Execution of Work
20
20
Setting-out of the Works Scrap, Excess Materials & Material Reconciliation (As Applicable) Measurement of Work (As Applicable) i
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25 26
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
3.15
Fabrication of Specials
27
3.16
Fabrication of Short Supports
27
3.17 Terms of Payment 3.17.1 Running Payment for Fabrication, installation, Testing, Commissioning & other related works. 3.17.2 Running Payment for Supply of Items 3.17.3 Final Payment 3.17.4 Security Deposit 3.18
3.19
3.21
3.22 3.22.1 3.22.2 3.22.3 3.22.4 3.22.5 3.22.6 3.22.7 3.22.8 3.22.9 3.23 3.23.1 3.23.2 3.23.3 3.23.4 3.23.5 3.23.6 4
Service Tax & VAT etc.
29 Extra Items
Additional Requirements
Definition of ‘Market Rate’ Discrepancies & Adjustment of Errors Rates for Similar Items Suspension of Work Uncovering & Re-making Good Changes in Constitution Underpayment/Over payment Conflict in Interpretation of Conditions Guarantee
30 30 30 30 31 31 31 31 32
Safety & Security
Personal Protection General Safety Rules For All Contractors Welding & Gas Cutting Tools and Equipments Structural Erection Rigging
4.2 4.2.1 4.2.2 4.2.3 4.2.4 5
29
32 32 33 35 35 36
Scope of Enquiry 4.1
27 27 28 28
Schedule of Rates Taxes
3.20
27
37 Scope of Work
Scope of Supply and Services (Refer Volume – II, Price Bid) Material to be supplied by Owner Material to be supplied by Contractor Utilities to be Supplied Free of Cost by the Owner Tools, Tackles and Consumable by Contractor.
37 37 38 38 38
Technical Specification 5.1
5.2
5.3
Contractor's Visit to Site
39 Standards
Approved Makes for Supply of Material by Contractor 41 ii
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39
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
5.4 SPECIFICATION FOR MATERIAL, INSTALLATION, TESTING AND COMMISSIONING 5.4.1 Lying & Termination of Power, Control and Foundation Fieldbus (FF) Cables. 5.4.2 Cable Handling, Dressing 5.4.3 Installation of Trays 5.4.8 General Requirement 6
7
Specification for Inspection and Field Tests of Instrumentation Facilities
52
6.1
6.2
General Requirements
52
6.3
Test Procedures
53
Scope
Safety Rules and Regulations 7.1
7.3 7.3.1 7.4
54
Objective
7.2 7.2.1 7.2.2 7.2.3
54
Health Safety Environment at Site Safety - A Line Function Safety Training First Aid
7.6
7.7
54
54 54 54 Responsibility
Responsibility of the Contractor
7.5 7.5.1 7.5.2 7.5.3 7.5.4
55 House Keeping
Personal Protective Equipment Head Protection Hand Protection Foot Protection Eye Protection
57 57 57 57
Plant, Tools and Equipment
58
Safety In Instrumentation
7.8 Safety Working Practice for Mechanical Job - Fabrication and Welding 7.8.1 Gas Cutting and Welding 7.8.2 Electric Arc 7.8.3 Standard Practices 7.8.4 Working Platform 7.8.5 Ladders 8
41 41 43 43 48
List of Tender Drawings & Documents
61 61 62 62 62 63 64
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
1
Mott MacDonald Hindustan Organic Chemicals Ltd.
Letter Inviting Tender
Ref: IMM/HOCL/TENDER/I IMM/HOCL/TENDER/INST. NST. - 1
Date: 07/09/2007
To:
Subject: Scope of this tender cover for: •
•
•
•
Design, Engineering, Manufacture, Test, FAT (Factory Acceptance Test), Supply & Delivery at site, Installation, Testing, Commissioning and SAT (Site Acceptance Test) of DCS system. Design, Engineering, Manufacture, Test, FAT (Factory Acceptance Test), Supply & Delivery at site, Installation, Testing, Commissioning and SAT (Site Acceptance Test) of PLC system. Manufacture, Test, Calibration, Inspection, Supply & Delivery at site, Installation, Testing and Commissioning of field instruments. Procurement, Test, Supply & Delivery at site and installation of hardwares in the field like cables, Glands, Cable Trays (GI &MS), Tray Supports, Paints, FF junction boxes, Air headers, Copper/SS tubes, impulse line connectors etc.
The scope also includes the replacement of existing control system, panels and furniture from control room, testing of existing control cables (digital signal cable), removing and rerouting of the same, removing of existing analogue signal cable and laying of new foundation field bus signal cable, testing of instruments, control junction boxes which shall be reused from existing plant and Transporting the instruments, machinery to & fro storage area within the job site. Please note that, “Removed & not to be reused” material to be delivered in the HOCL’s central stores. (E.g. DCS Panles, unused cables, Trays, etc.). The detailed quantum of work is given in the prise schedule. The job is to be carried out for revival of Caustic Soda Manufacturing Plant at Rasayani410207, District Raigad (Maharashtra) for Hindustan Organic Chemicals Ltd.
Dear Sirs, We are pleased to invite you to submit your offer for the above-referred work. The tender documents consist of the following: 1 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
1.1
Technical Bid
• • • • • • •
1.2
Mott MacDonald Hindustan Organic Chemicals Ltd.
Letter inviting Tender. Instructions to Tenderer – with Definitions. Conditions of Contract. Scope of Enquiry Technical Specifications Specification for Inspection & Field Test of Inst. Facilities. Safety Rules and Regulations.
Price Bid • •
Pricing pre-ambles. Schedule of price
The tender document comprises of two volumes shall be submitted as below: Volume I – Technical Bid Volume II – Price Bid The Technical Bid duly filled in with the information to be furnished along with the tender drawings and an un-priced copy of Price Bid (price deleted) in a sealed envelope. The Price Bid duly filled in with the rates offered in a sealed envelope. These envelopes will be superscripted with A-Technical Bid/B-Price Bid respectively and the name of work viz.: “Tender/229718/Inst-1 “Tender/229718/Inst-1 for for M/s. Hindustan Hindustan Organic Organic Chemicals Ltd. Ltd. - Due date: _______”
Both the envelopes i.e. A– Technical Bid and B- Price Bid should be enclosed in a third envelope. 1.3
Tender Collection and Submission
The Tender documents may be collected from HOCL, Mumbai office or Rasayani office by depositing D.D. for Rs.5,000/Rs.5,000/- payable to Hindustan Organic Chemicals Limited, at Mumbai. The offer shall be submitted to M/s. Hindustan Organic Chemicals Ltd. office on or before 25/09/07 3 pm. to: Hindustan Organic Chemicals Ltd. (HOCL) Harchandrai House, 81, Maharshi Karve Road, Mumbai-400 002 Tel: 022-22014269/71/72 022-22014269/71/72 Attn.: Mr. S. B. Bhide, Bhide, Chief Engineer – Mechanical. 2 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Tender sales commences on
:
10/09/2007
Tender sales closes on
:
24/09/2007
Last date of Tender submission
:
25/09/2007 up to 3 pm.
Tender opening on
:
26/09/2007
The tender document addressed to Hindustan Organic Chemicals Ltd. shall be accompanied with a crossed demand draft for Rs. 2,31,000/- as per clause no. 3.6 drawn on any Nationalised Bank payable at Mumbai towards interest free Earnest Money Deposit (EMD). The Earnest Money Deposit will be returned to the unsuccessful Tenderer along with a regret letter subject to the condition that all enclosures are returned. The Earnest Money Deposit, in case of successful Tenderer shall be retained and adjusted against the retention amount and it shall not carry any interest. The Earnest Money Deposit shall be forfeited in case the selected Tenderer does not start the work within the time limit specified. The work is to be commenced within one week and shall be completed as per clause no. 3.4, Time of Completion. These works shall be executed as per the latest applicable standards and codes as well as the tender specifications and the conditions of contract. You are requested to scrutinise the Tender Documents and visit the site of work at your cost to study the conditions at site, prior to the submission of tender / Offer. A confirmation regarding site visit shall be submitted along with Technical Bid.
The deciding Authority / Company do not bind themselves to accept the lowest or any tender or to give any reason thereof. The company reserves the right to release work order in part/full within validity. For any information / clarifications, the Tenderer can contact HOCL at the below address: Hindustan Organic Chemicals Ltd. (HOCL) at Rasayani Attn.: Mr. S. B. Bhide / Chief Engineer – Mechanical Tel. : 02192-250041-45 (Extn. 2613) Direct Phone No. : 02192-250916 E-mail :
[email protected]
Mr. C.M. Deshpande D.G.M. - Instrumentation Instrumentation (Extn. 2503) 250912
[email protected]
Thanking you, Yours Sincerely, For and on behalf of M/s. Hindustan Organic Chemicals Ltd.
S B Bhide Chief Engineer – Mechanical 3 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
2
Instructions to the Tenderer with Definitions and Formats
2.1
Filling of tender documents
2.2
1.
The Tenderer shall quote quote the unit rates for for all items in the tender schedule. All the rates given in the tender schedule shall be expressed in figures.
2.
If all the unit rates are not quoted, the tender may be treated as invalid and may be liable for rejection.
3.
All entries in the tender documents documents shall be in ink / typed. All corrections shall shall be attested by full signature of the Tenderer. Corrections wherever necessary, shall be made by scoring out the figures by drawing a line across them and attesting with the signature. Corrections shall not be erased or overwritten.
4.
Every page of the tender documents shall be signed by the tenderer at the end of last entry thereon. All drawings attached with the tender tender shall be signed with date and returned by the Tenderer along with the Tender Documents at the time of submission.
5.
Tenderer must understand that they are strictly required to conform to the conditions of this contract as contained in each of its clauses. The plea of of “custom prevails” shall not be admitted on any account as an excuse on the Tenderer’s part for infringement of any of the conditions.
Special Notes Regarding Submission of Tender
Tender Envelope/s has to be sealed with red lac (wax) and submitted super scribed with Tender No., Due Date and Time. i)
The above instructions shall be read in conjunction with: a) b) c)
ii)
2.3
Letter Inviting Tender Instructions to the Tenderer – with definitions of the terms used. Conditions of Contract
Tenderer who are unable to quote, are required to submit letter of regret showing reason for not quoting or return covering letter attached to this tender, stating as “Regretted” duly signed with stamp and dated. Please note that failure to do so may lead to deletion of your firm’s name from our list of tenderer.
Important Guidelines to Tenderer
a)
Non-submission of all documents or incomplete submission of any document may result in rejection of the Bid. It is, therefore necessary to submit all the documents in full, duly filled, signed and dated. 4
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
2.4
Mott MacDonald Hindustan Organic Chemicals Ltd.
b.
Documents indicated in this tender are to be submitted in the technical bid only. Any additional documents, if required to be submitted by the tenderer, shall be submitted along with the technical bid only.
c.
It must be clearly understood that the contract is an ITEM RATE contract & quantity indicated are are only tentative in nature. These are likely to vary vary ± 25%.
d.
The prices shall be quoted for all items and shall be firm. The amount shall include all machinery, labour, materials, all temporary works, supervision, every incidental and contingent cost and charges whatsoever required to complete the item of work in all respects conforming to related specifications, drawings etc.
e.
The tenderer shall be deemed to have been allowed in his rates and prices for the provision, maintenance and final removal of all temporary works of whatsoever nature. No specific item of any or particular temporary shed/work will be measured and paid separately.
f.
It may be carefully noted that the price bid shall be submitted in separate envelope and shall not be incorporated / submitted with any documents/counter condition(s) etc.
g.
An unpriced copy of Price Bid (Price deleted) shall be enclosed along with Technical Bid, clearly indicating the Tax structure. Any difference in tax structure mentioned in Price Bid and Unpriced Bid may lead to disqualification of the bid.
Information / Documents to be submitted along with the Tender
Tenderer shall submit following information/documents along with ‘Technical Bid’: a)
Details of works done in the last 3 years and certificate of completion from Clients.
b)
Details of present commitments giving contract values, details of work, details of commitment of work, percentage completion and scheduled date of completion.
c)
List of equipment to be deployed for this work
d)
Details of site organisation proposed to be set up by the tenderer for the work including bio-data of the proposed Site-in-Charge and the key personnel.
e)
Power of Attorney in the name of person who has signed the documents.
f)
Latest bank solvency certificate for a minimum amount of Rs. 4.62 crores.
g)
Copy of Income Tax Return for last 3 years.
h)
Company’s Organisational Chart.
i)
Execution Plan and Bar Chart Schedule indicating the mobilisation period.
j)
EMD as stated in Condition of Contract – Clause No.3.6. 5
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
2.5
Mott MacDonald Hindustan Organic Chemicals Ltd.
Definitions
The following expressions hereunder and elsewhere in the contract documents used shall be deemed to have the following meanings hereunder respectively assigned to them, namely: 1)
The “Owner” shall mean M/s. Hindustan Organic Chemicals Ltd. Harchandrai House, 81, Maharshi Karve Road, Mumbai – 400 002 and shall include its successors & assignees. Wherever words or phrases like “prior approval of the Owner” or “prior written consent of the Owner” appear, it shall mean prior approval/consent of The Project Manager / The Head, Projects & Technology of the Owner in writing.
ii)
The “Engineer-in-Charge” shall mean Mott MacDonald, Mumbai, who shall on behalf of the Owner perform all the functions connected with engineering work.
iii)
The “Contractor” shall mean the tenderer selected by the Owner for the performance of the work and shall include the successors and permitted assigns of the Contractor.
iv)
The “Project” shall mean Revamping of Caustic Soda Manufacturing Plant of M/s. Hindustan Organic Chemicals Ltd. At Rasayani-410 207, District Raigad (Maharashtra). The Project Manager shall mean the officer nominated by the Owner to coordinate / supervise all the activities connected with the implementation of project on their behalf. The Project may at his discretion depute Owner’s officers to coordinate/ supervise the work of Engineer-in-charge / Contractor at site.
v)
The “Job Site” shall mean Caustic Soda Manufacturing Plant of M/s. Hindustan Organic Chemicals Ltd. At Rasayani-410 207, District Raigad (Maharashtra) or any site at which the work is to be performed by the Contractor.
vi)
The “Work” and “Scope of Work” shall mean mean the totality of of the work by expression or implication envisaged in the contract and shall include all material / equipment and labour required for or relative or incidental to or in connection with the commencement, performance or completion of any work and/or for incorporation in the works.
vii)
The “Contract” shall mean the totality of the agreements between the parties as derived from the Contract Document.
viii)
The “Specification(s)” shall mean the various specifications as set out and form part of the tender documents and as referred to and derived from the contract and any order(s) or instruction(s) there under. In the absence of any specifications as aforesaid, covering any particular work or part or portion thereof, shall mean the relevant Bureau of Indian Standards Specifications for or relative work or part or portion thereof, or specifications of any other country applied in India, as a matter of standard engineering practice and approved in writing by the Engineerin-Charge with or without modifications.
ix)
“Order” and “Instruction” shall mean any written order or instruction given by the Engineer-in-Charge / Owner within provisions of Contract. 6
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
x)
“Plans” and “Drawings” shall mean any maps, plans, drawings, sketches, tracings and prints forming part of the tender documents and any details of working drawings, amendments and/or modifications thereof approved in writing by the Engineer-in-Charge to the Contractor for the purpose and shall include any other drawings or plans in connection with the work as may from time to time be furnished by or approved in writing by the Engineer-in-Charge in connection with the work.
xi)
“Final Test Certificate” shall mean the Final Test Certificate as issued by the Engineer-in-Charge and accepted by the Owner.
xii)
“Completion Certificate” shall mean the completion certificate issued by the Engineer-in-Charge within the provisions of contract and accepted by the Owner.
xiii)
“Final Certificate” shall mean the final certificate issued by the Engineer-inCharge within the provisions of Contract.
xiv)
“Acceptance of Tender” shall mean the acceptance of tender issued by the Owner to the Contractor.
xv)
The “Total Contract Value” shall mean up to calculation of the entire remuneration due to the contractor in terms of the contract, on successful completion of the works. works. As specified in acceptance of Tender and on successful completion of the works and shall mean the totality of such remuneration.
xvi)
“Progress Schedule” shall mean the time schedule of progress of work and shall in the event of separate job sites and/or groups of job sites or separate work, and/or groups of work, include each ea ch of such progress schedules.
xvii)
“Running Account Bill” shall mean a Bill for the payment of “On Account” moneys to the Contractor.
xviii)
“Security Deposit” shall mean the Security Deposits as specified in the contract and associated clauses there under.
xix)
“Schedule of Rates” shall mean the Schedule of Rates annexed to the Acceptance of Tender and shall include any remuneration payable to the Contractor for any work, determined in accordance with the conditions herein.
xx)
“Tender Documents” shall mean the Tender Documents specified in the General Instructions to Tenderer.
xxi)
“Defect Liability Period” shall mean the defect liability period as specified in the Contract.
xxii)
The “Sub-contractor” means any person or firm of company (other than the Contractor) to whom any part of the work has been entrusted by the Contractor, with the written consent of the Owner.
xxiii)
The “Permanent Work” means and includes works, which will be incorporated, and form a part of the work to be handed over to the Owner by the Contractor on completion of the Contract.
xxiv)
The “Construction Equipment” means all appliances and equipment of whatsoever nature for the use in or for the execution, completion and operation and maintenance of work unless intended to form part of the permanent work.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
xxv)
The “Variation in Order” means an order given in writing by the Owner to effect variation in the works.
xxvi)
All headings of the Clauses in these Conditions of Contract or otherwise in any contract document are intended solely for the purpose of giving a broad indication of the content of the Clause and not as a summary of the contents thereof.
xxvii) “Approved” means approval by the Engineer-in-Charge a nd Owner. xxviii) “Notice in Writing” means a notice in written, typed, printed characters, sent (unless delivered personally) by registered post to the last known private or business address or registered office of the addressee and shall be deemed to have been received when in the ordinary course of post, it would have reached the addressee.
2.6
xxix)
“Act of Insolvency” means an act of insolvency as defined by the Presidency Towns Insolvency Act, or the Provincial Towns Insolvency Act or any statutory modification or re-enactment thereof for the time being in force.
xxx)
“Variation” means substitution.
xxxi)
“Risks” means Force Force Measure Conditions and shall mean all risks due to fire, riots, war, invasion, act of foreign enemies, hostilities, civil war, rebellion, revolution, damage from aircraft, acts of Nature, such as earthquake, lightning, floods, and other acts over which the Contractor has no control.
amendment,
alterations,
additions,
omission
and/or
Formats
Following formats shall be used for giving details while submitting the documents along with Technical bid: i) ii) iii) iv) v) vi) vii) viii) ix)
List of Technical Staff Details of Plant and Equipment immediately available with the Bidder for use on this work. Experience Questionnaire Details of Present Commitments by the Tenderer Time Schedule Site Visit Confirmation Report Particulars of EMD Solvency Certificate Performa of Bank Guarantee for Defect Liability Period
It is mandatory to fill up all the documents, as set out in the Tender Documents. Failure to do so, shall lead to disqualification of the Bid. 2.7
Validity of Offer
The offer shall be kept valid for 3 months from the date of submission.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 1 List of Technical Staff
Sr. No.
Name & Designation
Age
Qualification
No. Yrs. Experience
Nature of work Experience
We agree that the staff mentioned herein above will be deputed full time on the project.
Company Stamp / Seal
Note:
Signature by Tenderer
The Tenderer has to enclose an organization chart indicating the proposed site team to execute the job.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 2 Details of Plant and Equipment Equipment immediately available with the Tenderer for use on this work Sr. No.
Description of Machinery in Hand
Description of Machinery the tenderer proposes to purchase for this work
Company Stamp / Seal
Signature by Tenderer
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 3 Experience Questionnaire
The Tenderer has completed the following major similar construction projects:
Owner’s name & name of place where project has been executed (1)
Brief description of the nature of job done
Value of the work
Duration of the work
Year of completi on
Whether the work has been done in partnership or independently
(2)
(3)
(4)
(5)
(6)
Company Stamp / Seal
Signature by Tenderer
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 4 Details of Present Commitments of the Tenderer
Full particulars of the works under execution
(1)
Value of Date of contract commence ment of contract (2)
Completion time as stated in tender (months)
% Complet ed as on date
(4)
(5)
(3)
Company Stamp / Seal
Date & complete postal address of client (6)
Signature by Tenderer
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Remarks
(7)
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 5 Time Schedule
•
•
•
•
Name of Work
Time of Completion
Design, Engineering, Manufacture, Test, FAT (Factory Acceptance Test), Supply & Delivery at site, Installation, Testing, Commissioning and SAT (Site Acceptance Test) of DCS system.
14 weeks
Design, Engineering, Manufacture, Test, FAT (Factory Acceptance Test), Supply & Delivery at site, Installation, Testing, Commissioning and SAT (Site Acceptance Test) of PLC system. Manufacture, Test, Calibration, Inspection, Supply & Delivery at site, Installation, Testing and Commissioning of field instruments. Procurement, Test, Supply & Delivery at site and installation of hardwares in the field like cables, Glands, Cable Trays (GI &MS), Tray Supports, Paints, FF junction boxes, Air headers, Copper/SS tubes, impulse line connectors etc.
The scope also includes the replacement of existing control system, panels and furniture from control room, testing of existing control cables (digital signal cable), removing and rerouting of the same, removing of existing analogue signal cable and laying of new foundation field bus signal cable, testing of instruments, control junction boxes which shall be reused from existing plant and Transporting the instruments, machinery to & fro storage area within the job site. Please note that, “Removed & not to be reused” material to be delivered in the HOCL’s central stores. (E.g. DCS Panles, unused cables, Trays, Etc.). The detailed quantum of work is given in the prise schedule. Notes: 1)
The time indicated above is for completing all the work in all respects as per the Tender specifications and instructions of the Engineer in-Charge.
2)
The tenderer may indicate if the time schedule mentioned above can be improved upon by him.
3)
The time shall be reckoned from the date of award of contract or the date of letter of intent / work order whichever is issued earlier.
Company Stamp / Seal
Signature by Tenderer 13
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 6 Site Visit Confirmation Report
This is to certify that we have visited the job site and have understood the scope of work with respect to job site and this tender requirement. We have also familiarised with the site conditions and location of storage areas for scraped and usable material.
Company Stamp / Seal
Signature by Tenderer
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 7 Particulars of EMD
(Draft to be enclosed)
EMD: Rs. ________ Rs. ________
(Rupees only)
EMD paid vide:
Demand Draft No.
:
………………………………
Date
:
………………………………
Bank
:
………………………………
Amount : Rs.
:
……………………………….
Notes:
1)
Demand Draft shall be enclosed in original inside the tender cover along with Tender document.
2)
The tender shall be rejected if the EMD is not furnished along with the Tender document.
Company Stamp / Seal
Signature by Tenderer
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 8 Solvency Certificate
(Certificate copy to be enclosed)
1
Solvency Certificate obtained from [ Name of Bank ]
………………………….
2
Amount
Rs. ……………………
3
Date of Certificate
……………………….
Company Stamp / Seal
Signature by Tenderer
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Format – 9 Proforma of Bank Guarantee for Defect Liability Period
To, The Hindustan Organic Chemicals Ltd. P.O. Rasayani, District. Raigad, Maharashtra State.
WHEREAS you have placed an Order No…………………………………………………….. Dated ……………… for the supply of ………………….………………………………………………..on M/s. ………………………………..………………….. a company incorporated in India under the Companies Act, 1956 and having its Registered Office at ………………………………………………………. Hereinafter referred to as the SUPPLIER and WHEREAS the SUPPLIER has accepted the said Order and WHEREAS you require the SUPPLIER to furnish the bank guarantee from a Nationalised Bank for ……………………of the said order against defective materials/equipments and workmanship for a period of ………….. months from the date of…………..or ……………. Months from the date of commissioning whichever is earlier and WHEREAS the SUPPLIER has approached us to furnish such bank guarantee which, we………. Have agreed to do at the request of the SUPPLIER and is consideration of premises, Now in consideration of your having placed the said order and of the premises we do hereby guarantee that the material/equipment supplied by the SUPPLIER to you shall STRICTLY CONFORM TO THE specifications mentioned in your Purchase Order………. Dated………….. placed by you and which has been accepted by the SUPPLIER. We further agree to pay you on demand and and without demur a sum of Rs…………… or such portion thereof not exceeding Rs………… as you may demand if the said materials/ equipment do not conform to the specifications as aforesaid and/or fail to satisfy the guarantee given in the said order. You will be at liberty to make and effect any changes in the said order without our consent provided such changes do not have the effect of increasing our burden, or liability under this agreement and if they do have such effect, our prior consent shall be obtained. Your rights to recover the the said sum of Rs………………(Rupees………………………………………..) from us in the manner aforesaid will not be affected or suspended by reasons of the fact that any dispute or disputes have been raised by the SUPPLIER and / or that any dispute/s are pending before any office, tribunal or court. The guarantee herein contained shall not be affected by the liquidation or winding up, dissolution, changes of constitution or insolvency of the SUPPLIER but shall in all respects and for all purposes be binding and operative until payment of all money due to you in respect of such liability or liabilities. (Notwithstanding anything stated above, our liability under this guarantee shall expire on………………………Unless demand or a claim under this guarantee is made on us within 90 days from that date, i.e. ……………… (mention date) all the rights of the Company under the said guarantee shall be forfeited and we shall be relieved and discharged from all liabilities hereunder. (Signature of the Guarantor)
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
3
Conditions of Contract
3.1
General
Mott MacDonald Hindustan Organic Chemicals Ltd.
Conditions of Contract Contract shall be read in conjunction conjunction with the Letter Inviting Tender, Instructions to the Tenderer, Job Specifications, Drawings and other documents forming part of this Contract wherever the context so requires. Notwithstanding the sub-division of the documents into these separate sections and volumes every part of each shall be deemed to be supplementary to and complementary of every other part and shall be read with and into the context in so far as it may be practicable to do so. Wherever it is mentioned in the Specifications that the Contractor shall perform certain works or provide certain facilities, it is understood that the Contractor shall do so at his cost, being deemed to be part of the relevant item in the Schedule of Rates whether expressly stated or not. The materials, design and workmanship shall satisfy the relevant standards, the specifications contained herein and codes referred to. Where the specifications specifications stipulate requirements in addition to those contained in the standard codes and specifications, these additional requirements shall also be satisfied. In the absence of any standard/specification/code of practice or detailed specifications covering any part of work covered, in this tender the instruction/directions of Engineer-in-Charge will be binding on the Contractor.
3.2
Information
3.2.1
Location of Site
The project site is Hindustan Organic Chemicals Ltd. at Rasayani - 410 207, District Raigad (Maharashtra). 3.2.2
Site Particulars
The intending tenderer shall be deemed to have visited the site and familiarised themselves thoroughly thoroughly with the site conditions conditions before submitting the the tender. Nonfamiliarity with the site conditions will not be considered a reason either for extra claims or for not carrying out the work in strict conformity with the drawings and specifications. For site visit, the intending tenderer may contact HOCL / IMM.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
3.3
Mott MacDonald Hindustan Organic Chemicals Ltd.
Technical Specification
Technical specification enclosed with this document should be studied carefully. For any information / clarifications vendor can visit with prior appointment Engineer inCharge’s Office at Worli, Mumbai or Owners Site at Rasayani or office at Mumbai on all working days from Monday to Friday between 9 A.M. and 4 P.M. in order to form an idea about the nature and extent of works involved.
3.4
Time for Completion
This is being a contract for dismantling, supply and erection activities, Contractor may be required to demobilize the site after completion of dismantling work to complete civil activities to be carried by other Contractor. If contractor prefers not to demobilize the site, it may do so without any commercial obligation to HOCL. After completion of civil activities, HOCL shall instruct the Contractor in writing to remobilise the site. Contractor shall remobilise the site within seven days from the date of instruction. For execution purpose, total activities are divided into two groups as under: (1)
Dismantling existing panels, DCS and PLC system, furniture from control room, removing analog and digital signal cables and junction boxes, air headers, indicating field instruments, transmitters and control valves etc. as required.
(2)
Supply, installation, testing and commissioning, SAT of new new DCS and PLC system, supply and installation of furniture in control room, laying of existing control cable and new foundation fieldbus cable. Supply, installation, testing and commissioning of field instruments, FF junction boxes and air headers. Testing and installation of existing control junction boxes, instruments.
Time for completion for all the works shall be Fourteen weeks from the date of purchase order / L. O. I.
The work shall be executed strictly as per the Time Schedule. The period of construction given includes the time required for mobilisation, fabrication, erection, inspection, testing, rectification, if any, re-inspection and completion in all respects to the entire satisfaction on the Engineer in-Charge / OWNER. The time for completion is a time for overall completion of all works. The whole whole work may be awarded to single tenderer, hence the contractor shall plan and make schedule accordingly so that all the works can be completed within stipulated time limit and will constantly keep the Engineer-in-Charge / OWNER aware of the work schedule. Monthly and weekly programs of work will be drawn up by the Contractor in consultation with the Engineer in-Charge. The Contractor shall scrupulously adhere to these schedules by deploying adequate personnel and construction tools and tackles. In all matters concerning the extent of targets set out for the weekly and monthly monthly programs and degree of achievements, the decision of Engineer-in-Charge shall be final and binding. 19 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
The time for completion mentioned above shall be inclusive of any monsoon following within the aforesaid time for completion. In addition to the provisions of clauses of the Conditions of Contract and the associated clauses there under, the Contractor shall be prepared to execute the works in two shifts and on Sundays, Sundays, and holidays, if so directed by the Engineer-in-Charge. No claim for any compensation or extra payment whatsoever on this account will be entertained. The Contractor shall give every day category-wise labour and equipment report along with progress of work done, on previous day in the Performa prescribed by the t he Engineerin-Charge.
3.5
Penalty for Late Execution of Work
The entire job shall be completed within stipulated period, failing which penalty shall be levied @ 0.5% per week for every week of delay or part of thereof over the stipulated period for balance activities, subject to maximum of 5% of contract value.
3.6
Earnest Money Deposit
The Contractor shall deposit the Earnest Money Deposit of Rs. 2,31,000/- (Rupees Two lacs Thirty one thousand only) in the form of Demand Draft payable to M/s. Hindustan Organic Chemicals Ltd., Mumbai.
3.7
Non-Bifurcation of Tender
The Tenderer are required to quote for the complete tender. Bifurcation within a section of tender is not permitted. Tenders not in conformity with this requirement are liable to be rejected.
3.8
Sufficiency of Tender
The Contractor shall be deemed to have satisfied himself before tendering as to the correctness and sufficiency in the Schedule of Rates, which shall cover all obligations under the contract and all matters and things necessary for proper completion of the works. 3.9
Employment of Local Labour
The contractor shall put their sincere effort to extent possible to employ local labour, skilled as well as unskilled available from local resources. 3.10
Compliance of Laws
The contractor shall, at his own expense, comply the various provisions of Contract Labour (Regulation & Abolition) Act, 1970 and various labour laws and keep the 20 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Company indemnified indemnified in respect thereof. The Contractor shall, at his own expense, comply with all labour and industrial laws and such other Acts and statutes as may be applicable to the contractor in respect of their employees employed by them in connection with the work of the company. The company shall be entitled to deduct directly from the bills to be paid to the contractor, any sum or sums the company is required to pay as a Principal Employer on account of default of the contractor in respect of any liability. The wages of every labourer employed by the contractor under this Contract, shall be paid by him before the expiry of 7th day after the last day of the month in respect of which the wages are payable i.e. wages of a month have to be paid by the contractor in the first week of the next month. The minimum basic wages rates, as specified by the Company/all other labour/industrial laws and such other Acts/statutes as may be applicable to the contractor and/or the subcontractor, will have to be paid in the presence of company’s representative at site office for contract labour, during the working working hours. The contractor shall pay pay not less than what is provided under under various labour laws and/or the minimum wages as fixed by the company. Any default will result in cancellation of the contract forthwith or also the contractor shall be punishable to the extent of fine of Rs.100/- for each day. As per the provisions of the Factories Act, where a contract labour works in a factory for more than 9 hours hours in any day day or more than 48 hrs. hrs. in any week, he shall, in respect of overtime work, be entitled, to wages at twice his ordinary rate of of wages and he will have to be paid accordingly. As per the provisions provisions of Factories Rules, Rules, the contractor is required to ensure that the total number of hours of overtime work shall not exceed 50 hrs. in any quarter of of 3 month. The contractor shall give his Telephone No. and address to the company so that in case of labour trouble etc., he can be contacted immediately. The contractor shall arrange to have his office outside the factory premises and keep himself present through out the working hours. The contractor is required to maintain the register of establishment labour license, register of contractor, register of wages-slip, register for deduction for damage/loss, register of fines, register of advance, register of overtime, register of compensatory holidays, register of leave with wages, leave card, accident Form No. 21 etc. These registers are required to be maintained up to date and will have to be submitted to Personnel Office for verification and inspection of records. Moreover, the contractor shall ensure up to date records and registers easily available for inspection and a responsible supervisor shall be available when the inspection is carried out by the responsible authorities. The contractor shall not employ a person below the age of 18 years for work in the factory. The contractor shall maintain a valid labour license under the contract labour (R&A) Act for employing necessary manpower to be supplied to the company as and when required. It is the responsibility responsibility of of the contractor to renew the license before the expiry expiry date. In absence of such license, the contract shall be liable to be terminated without assigning any reasons thereof.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
The contractor, shall at his own expense, comply with all labour laws and keep the company indemnified in respect thereof. Some of the major liabilities under various labour and industrial laws, which he shall comply, are as under: a)
The contractor shall make necessary deduction from the wages payable to the contract labour towards Provident Fund & Family Pension at the rate of 12 % or as may be applicable from time to time and submit a Challan of such deductions on or before 15 th of each quarter to the Personnel Office for contract labour. Copy of such Challan shall be attached with the monthly running bills.
b)
The contractor shall give prior intimation to the Owner about the date of payment of wages and such disbursement should be invariably made in the presence of authorised representative of the company at site and shall send the copy of such notice to Government Labour Officer, before the date of payment.
c)
The contractor shall pay the deposit in respect of each contract labour at the rate fixed by the Office of of the Commissioner of Labour (R&A) Act and License fee under the said Act and Rules framed there under, depending upon the number of workmen employed by him. It is the responsibility of the contractor to ensure that the employment of contract labour should not exceed the number of contract labour mentioned in the labour license. Any default on the part of the contractor, the contractor shall be held responsible for the violation of provisions of the Act.
d)
The contractor shall give paid leave to the contract labour employed by him and/or his sub-contractors under this contract as per the provision of Factories Act, i.e. one day for every 20 days working. The amount so paid for the leave shall not be reimbursed to the contractor by the company.
e)
For the purpose of compensation due to an accident, arising out of and in the course of employment, the provisions of Workmen Compensation Act, 1923 shall be made applicable. The contractor is required to produce the document of having insured the contract labourers and no premium shall be reimbursed by the company.
f)
The contractor shall pay bonus to his contract labour on the basis of the calculation of wages as per the provisions provisions of payment of bonus act. No amount of bonus so paid to his contract labourers, shall be reimbursed by the company.
g)
The provisions with regard to retrenchment as contained in the Industrial Dispute Act 1947, shall be applicable to the contractor for the contract labourers engaged by him and/or his subcontractors and he shall pay such compensation, as may be required under Act.
h)
The contractor is required to issue identity cards to his contract labourers as prescribed under the Factories Act with photo affixed thereto for identification. The cost of the photograph will have to be paid to the contract labourers by the contractors.
i)
All workers employed by Contractor shall be insured till the completion of contract. 22
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
In case of any breach of any of the terms and conditions under this contract the company may at its discretion, withdraw the work entrusted to the contractor and/or his subcontractors and in such an event, he shall be liable to pay to the company all the expenses incurred by it for getting the unfinished work completed by other contractor / sub-contractor. The contractor shall finalise and settle, at the cost and risk any dispute, between he/his firm and his contract labour/contract labour employed through his sub-contractors regarding the question of payment due to non-compliance of any of the terms and conditions of this contract. However if for these reasons, the company is required to make some payment or incur some expenses as a principal employer, the same shall have to be reimbursed by by the contractor to the company. company. The contractor shall, therefore ensure that all his liabilities mentioned herein above are fully, properly and promptly discharged to the satisfaction of the company. The contractor shall also comply with all the provisions provisions regarding licensing, welfare health, penalties and procedures, maintenance of the various records & registers etc., as provided under the contract labour (R&A) Act, 1970 and any rules framed there under by Maharashtra/Gujarat or any other State, at his own cost. In addition, the contractor shall also comply with all other labour and industrial laws and such other Acts and Statutes as may be applicable to the contractor and/or sub-contractor and his contract labour at his own cost. As per the provisions of Maharashtra Labour Welfare Fund Act. 1973 the contractor is required to deduct Rs.3/- per workman as workman’s contribution in the month of December and June and to pay contractor’s contribution of Rs.9/- per workman engaged by him him and deposit the amount amount to M.L.W.B. Within a week’s time of next month. The contractor’s contribution shall have to be borne by the contractor, if applicable and as per the current rates as per statutory requirements. Contractor shall be required to issue issue an employment card in form No. XIV to each worker within 3 days of the employment of the worker and the card is required to be maintained up to date and any change in the particulars shall have to be entered therein. The contractor is required to send half-yearly return in form No. XXIV in duplicate, so as to reach the Assistant Commissioner of Labour not later than 30 days from the close of the Half-year. The contractor is required to obtain a license under the Inter-State Migrant Workman (Regulation of Employment & Conditions of Service) Act, 1979 if he employs 5 or more inter-state migrant workmen, whether or not, in addition to other workmen, on any day of the preceding 12 months and have to maintain the various registers under the Act. The contractor is required to sign all the registers every month and the record of contractor’s supervisors is also required to be maintained on the above guidelines. The contractor is also required to issue identity cards and leave cards to each contract labourers.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
The contractor shall be solely responsible and liable in his own behalf and on behalf of his staff, contract labour, agents and sub-contractors to indemnify the company from any loss and/or damage to any of the company’s employees, company’s property, including equipment etc. supplied by the company, other agents, contractors, sub-contractors or any other person, who may be on the premises of the company on official business, which may occur or happen to be caused or be suffered either voluntarily or involuntarily, knowingly or unknowingly at any time during the period of his contract against all actions, proceedings, claims, demand, costs & other expenses which may be made against the company for or in respect of of or arising out of failure in performance of or non-compliance non-compliance of any of the obligations under under contract. The contractor shall ensure strict compliance of company’s rules, regulations safety procedure, orders, restrictions and ground rules as in force from time to time by his staff, contract labour, agents and sub-contractors. He shall, therefore make himself fully conversant with all such rules, regulations etc. Breach of or failure in compliance of these rules regulations etc. shall make him answerable and liable to the company and or to the Government as the case may be and in such an event, the company may at its discretion, take such action against him, his staff or contract labour, agents and subcontractors, as it may deem proper. In case of failure on the part of the penalty penalty as per the various Acts and or provisions of the contract. The contractor shall shall be responsible responsible for his own conduct, behaviour etc. and that of his staff, contract labour agents and sub-contractors while working at out sites. The contractor shall further see to it that his staff, contract labour, agents and subcontractors fully co-operate and co-ordinate their work etc. with company’s Personnel, other contractors, sub-contractors or any other persons who is so authorised by the company. The company will be entitled to deduct directly from the bills, to be paid to the contractor any sum / sums payable by him and which sum/sums the company is required to pay as a principal employer on account of his default in respect of all liabilities referred to in above clauses. The contractor shall be required to comply with the provisions of Minimum Wages Act and as and when Government effects changes in wage / special allowance, and corresponding rise in overtime rate per hour and the same shall have to be borne by the concerned contractor. The company may supply to the contractor necessary tools, normal safety equipments and any other equipments, equipments, which which may be required to carry out the contract job, but it is the responsibility of the contractor to ensure that their employees work with Safety appliances. In case of any default on the part of the contractor, the contractor shall be held responsible re sponsible for the violation of provisions of the Factories Act whatever fine is imposed by the Government authorities, will have to be borne by the contractor himself. In case of any dispute resulting into litigation by either of the parties hereof, the Courts of Law in the City of Mumbai only, shall have the jurisdiction and both the parties hereunder expressly and of their own free will agree to sub-decision of these courts of law at Mumbai. 24 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
3.11
Mott MacDonald Hindustan Organic Chemicals Ltd.
Completion Certificate
In additions to the stipulations of clause of the General Conditions of Contract, the Contractor shall submit to the Engineer-in-Charge the following additional documents in the manner prescribed by Engineer-in-Charge in this behalf :-
3.12
1)
Manufacturer’s certificates and Test Certificates for the materials/equipments to be supplied by the Contractor.
2)
Certificate of completion by Engineer-in-Charge for all jobs.
Setting-out of the Works
The Contractor shall install necessary facilities, at his cost, for carrying out day-to-day fabrication, erection, testing and other equipment required for all such works. The Contractor shall be responsible for the true and proper setting-out of the works and for the correctness of the position, levels, dimensions and alignments of all parts of the works and for the provisions of all necessary instructions, appliances and labour in connection therewith. The checking of the setting-out or of any line or level by the Engineer in-Charge shall not in any way relieve the Contractor of his responsibility for the correctness thereof and the Contractor shall carefully protect and preserve all bench marks, site rails, pegs and other things used in setting-out the works.
3.13
Scrap, Excess Materials & Material Reconciliation (As Applicable)
On completion of the work, the Contractor shall submit “Material Appropriation Statement” for all materials. Every month, the contractor shall submit an account for all the materials supplied by the contractor and their consumption in the pro-forma prescribed by the Engineer-in-Charge. The following scrap allowance by weight are permissible. The percentage allowance shall be accounted on the basis of erected weights as per approved for construction / fabrication drawings and as mentioned below: Sr. No. 1 2
Material
Salvageable 1.5% 3.0%
Structural steel Cable trays
Unaccountable 0. 5 % 0. 5 %
All the materials issued by Owner shall be accounted for size wise and category wise. All serviceable material and salvageable scrap material shall be returned by the contractor to owner’s storage points and weighing arrangements for scrap shall be arranged by the contractor. 25 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Cable trays of length 2 M and above and in undamaged condition will be accepted by owner at his stores as serviceable material and given full credit by the owner. Cable trays of lengths less than 2 M and damaged pipes of all lengths will be considered as salvageable scrap. Scraps of any kind including unaccountable, excess steel (though the cost recovered at penal rates) shall not be be considered as the the property of the Contractor. He shall return complete scrap/unserviceable materials to the Owner at the place indicated by him. All scrap and serviceable material shall be segregated as per quality and specification and returned to owner separately with proper identification.
3.14
Measurement of Work (As Applicable)
All the measurements shall be taken jointly by the Engineer-in-charge and his representative on the one hand and the contractor or his representative on the other hand and the contractor shall be bound to present himself or his authorized representative whenever so required for the joint measurements. Measurements of weights shall be in MT corrected to the nearest kg and shall be based on final execution of work. In case weights are not provided on on the execution drawings, then weights shall be calculated on the basis of engineering calculations if possible for fabricated equipments. Payments shall be made on the final weights indicated indicated on the execution drawings. The weld metal weight shall not be taken into consideration for measurement. Linear measurements shall be in Metric system corrected to the nearest cm. If physical measurement is not practicable, dimensions as given in the approved execution drawings may be adopted. In case of gratings and chequered plates, payment shall be certified on the basis of calculated weight as determined from the dimensions given in the drawings / bill of material. Full deductions shall be made for openings above 300 mm size. The contractor has to arrange all his tools and tackles, scaffoldings, temporary supports etc. for enabling to do his work in best engineering practice and also do the work in safe conditions. The Owner/Engineer in-charge has also the right to stop stop the work if unsafe unsafe methods are adopted or the work is not as per norms of engineering practices without without assigning any reason. Payment shall be based on linear measurement as per execution of work. Structural Steel work shall be measured as per IS: 1200, Part-8. Installation work shall be measured as per IS: 14164-1994.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
3.15
Mott MacDonald Hindustan Organic Chemicals Ltd.
Fabrication of Specials
Mitre bends and reducers shall be fabricated from the cable trays to be supplied by the Owner as needed needed or as directed by Owner/ Owner/ Engineer in-charge. The erection of mitre bends and reducers shall be part of cable tray erection. 3.16
Fabrication of Short Supports
Fabrication of all types of cable tray support, provided as per drawings and instructions of the Engineer-in-charge, shall be paid on weight basis or as per schedule of rates as applicable. While fabricating the supporting elements, the Contractor shall ensure that the dimensions shown shown in the drawings match with site conditions. No payment shall be made for rectification arising out of discrepancies in dimensions of the fabricated items of supporting elements due to site conditions. Additional supports as necessary with the site condition shall be fabricated and erected in accordance with the standard engineering practices and instructions of Engineer-incharge. 3.17
Terms of Payment
The terms of payment for fabrication, erection of panels, supply, installation, testing & commissioning of equipments / items as stated in the Price Schedule are as given below. Mobilisation Advance: No mobilisation advance shall be paid. Progress / Running payments shall be made based on actual work executed and measured. Once the said measurement and bill is accepted by Owner/Engineer incharge, progress / running payments shall be made only on a monthly basis. 3.17.1
i) ii) iii)
Running Payment for Fabrication, installation, Testing, Commissioning & other related works.
70% as against monthly progress bills after the materials are installed at site. 10% on completion of commissioning and handing over of the systems. 10% within 15 days after handing over.
7.5% of work order value shall be retained from Bills towards security deposit. 3.17.2
i) ii) iii)
Running Payment for Supply of Items
70 % against monthly progress bills. 10 % after completion of the erection on materials installed, minus the cost of excess material, if contractor to take back. 10 % on completion of commissioning, handing over of the systems. 27
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
7.5% of work order value shall be retained from Bills towards security deposit. Contractor shall raise bill once in a month and not exceeding four (4). Payment shall be made 15 days after submission of bill. 3.17.3
Final Payment
The balance payment 10 % of the contract value shall be released after all the jobs have been completed and following requirements are met: Completion certificate from Engineer / Owner on satisfactory commissioning of plant/load trials have been conducted satisfactorily. Certified material reconciliation statement by Engineer-In-Charge. Performance bank guarantee for 10% value of total work done to cover the guaranteed maintenance period of 12 months with effect from actual date of completion from nationalized bank as per Performa enclosed in tender. Any outstanding dues of contractors on whatsoever account will be deducted from this payment and also the amount of liquidated damages, if any, shall also be deducted from this payment. Release of Earnest Money: The Earnest Money will be released at the time of final payment. 3.17.4
3.18
Security Deposit
a)
Bank Guarantee towards Security Deposit @7.5 % of work order value, in case work order value exceeds 5 lacs shall be furnished by contractor. Or 7.5% of work order value shall be retained from Bills towards security deposit.
b)
Security deposit shall be released at the end of defect liability period or on completion of works against Bank Guarantee valid for defect liability period.
Schedule of Rates
The Schedule of Rates is to be read with all the other sections of this tender document. The quantities shown against various items are ar e only approximate. All works item-wise shall be measured upon completion and paid for at the rates quoted and accepted in the Schedule of Rates.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
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All items in the Schedule of Rates shall be carried out as per the specifications, drawings and instructions of the Engineer-in-Charge and rates shall provide for supply of required materials, consumables, skilled and unskilled labour, provision of tools and tackles, etc. called for in the detailed specifications and conditions of the Contract. The Owner reserves the right to delete/curtail any item or group of work or split the work between two or more more contractors at his discretion. Such step shall not not constitute a breach of the Contract nor shall it form basis for alteration of the prices. No variation in the rates till completion of the contract will be acceptable, irrespective of reduction or increase in the quantities stated in the tender. Owner reserves the right to interpolate or extrapolate the rates for such items of work falling between similar items of lower and higher magnitude. The schedule of rate includes the fabrication and erection of tag plates of material CS/SS/ Al./plastic with suitable punching/engraving for field/panel instruments, cabling etc. This is an item rate contract and payment will be made according to actual work carried out by the contractor and certified by the consultant at the rates quoted by the contractor and accepted by the Owner. The tenderer shall quote rates of additional items or jobs as per Performa. These rates are for future use. The points mentioned above shall prevail for additional items also. These rates shall be applicable, if required at site. The tenderer shall quote labour rates as per Performa given. 3.19
Taxes
Income Tax deductions will be made from all payments made to the Contractor as per rules and regulations in force in accordance with the Income Tax Act prevailing from time to time.
3.20
Service Tax & VAT etc.
Rates shall be exclusive of Service Tax, VAT and any other taxes as applicable. The same should be mentioned separately in price Bid. Please note that, the Items coated under this Contract should be MODVAT-able.
3.21
Extra Items
Should it be found after completion of the works from measurements taken that any of the quantities of amounts or works thus ascertained are less or greater than the quantities or amounts specified in the priced schedule of quantities and /or tender for the works and/or that any variation is made, the valuation of such quantities, amounts or variations, unless previously or otherwise agreed upon, shall be made in accordance with the following rules: 29 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
3.22
Mott MacDonald Hindustan Organic Chemicals Ltd.
1)
The net rates or prices in the original tender shall determine the value of the extra work where such extra work is of a similar character and has been executed under similar conditions as the work priced therein.
2)
In case the rate cannot be derived from similar items rate, the same shall be derived on the basis of reasonable cost of materials (original purchase company’s voucher to be presented for calculating the analysis of rates) + labour + 15% of the value of all materials and labour towards the Contractor’s over-heads charges and profit, excluding the cost of materials provided by the owner.
Additional Requirements
3.22.1
Definition of ‘Market Rate’
‘Market Rate’ shall be the rate as decided by the Engineer-in-Charge on the basis of the cost of materials inclusive of any taxes, octroi or such statutory statutory imposition at the time of the work. 3.22.2
Discrepancies & Adjustment of Errors
In the event of a discrepancy between description in words and figures, the rates quoted by the Contractor in ‘WORDS’ ‘WORDS’ shall be taken as correct. 3.22.3
Rates for Similar Items
In the case of composite tender, where two or more schedule of quantities may form part of the Contract, the rates for similar/same items if quoted different, the lowest quoted rate would be applicable. 3.22.4
Suspension of Work
The Contractor shall on receipt of the order in writing of the Engineer-in-Charge suspend the progress of the works or any part thereof for such time in such manner or the Engineer-in-Charge may consider necessary for any of the following reasons: i)
ii)
On account of any default on part of the Contractor, or; For proper execution of the works or part thereof for reasons other than the default of the Contractor, or; For safety of the works or part thereof;
The Contractor shall during such suspensions properly protect and secure the works to the extent necessary and carry out the instructions given in that behalf by the Engineerin-Charge/Owner.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
3.22.5
Mott MacDonald Hindustan Organic Chemicals Ltd.
Uncovering & Re-making Good
The Engineer-in-Charge may from time to time direct for his verification to uncover any part of the works or make openings in or through the same, the Contractor should reinstate and make good such part to the satisfaction of the Engineer-in-Charge at his cost. 3.22.6
Changes in Constitution
Before any change is made in the constitution of the firm, the prior approval is to be obtained by the Contractor in writing of the Accepting Authority. Authority. If the Contractor Contractor is an individual or a proprietary concern and the individual or the proprietor dies and if the Contractor is a partnership concern and one of the partners dies, then the Accepting Authority reserves the right to cancel the contract, if the Accepting Authority is not satisfied that the legal representatives of the individual firm or the proprietor of the proprietary concern and in the case of partnership, the surviving partners are capable of carrying out and completing the contract. 3.22.7
Underpayment/Over Underpayment/Over payment
The Owner reserves the right to carry out past payments, audit and technical examinations of the trial bill including all supporting vouchers, abstracts, etc. If as a result of such audit and technical examination any overpayment is discovered, it shall be recovered from any other sum due to the Contractor, which may be available with the Owner or from his security deposit or he shall pay the claim on demand. Any amount due to the Contractor under this Contract for underpayment may be adjusted against any amount then due or which may at any time thereafter become due before payment is made to the Contractor. 3.22.8
a)
Conflict in Interpretation of Conditions
If there is any conflict or difference in the interpretation of conditions stipulated in various sections of this tender document the reading and interpretation of the conditions stated shall prevail in the following order of priority: i) ii) iii)
b)
Scope of work and technical requirements Special conditions of contract General Directions and conditions of contract.
In case of any discrepancy between the description of items in schedule of quantities, specifications, drawings and other tender documents, the decision of the Engineer-in-charge, in writing, shall be final binding and conclusive conclusive for the purpose of this contract. The contractor in any case shall not delay or stop the work for the questions or disputes being referred to Arbitration, but shall proceed with the works with all due diligence and shall until the decision of the 31
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
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Arbitrator, abide by the decision of the Engineer-in-Charge and no award of the Arbitrator shall relieve the Contractor of his obligation to adhere strictly to the Engineer-in-Charge’s instruction with regard to the actual carrying out of the Works.
3.22.9
Guarantee
The contractor shall guarantee the workmanship for a period of 12 (twelve) months from the date of issue of completion certificate. In case of any defects noticed and established due to bad workmanship or use of improper material by the contractor during the abovementioned period, the contractor shall have to arrange immediate rectification of bad workmanship with proper material at his own cost to the entire satisfaction of Owner. 3.23
Safety & Security
The Contractor shall take all precautions necessary and shall abide by the relevant rules of safety. The contractor shall also take such other additional precautions and resort to such other additional safety measures as may be directed from time to time by the Engineer-in-Charge. The Contractor shall be responsible to ensure in his work force strict discipline and safety consciousness required to be observed and shall ensure that the work is carried out under constant supervision by competent supervisors who are adequately informed and experience for handling the work in such environment. 3.23.1
Personal Protection
The contractor must ensure that all his employees are provided with necessary protection appliances and that they use them while at work. These include to protection required for doing a job and other personal protective appliances required to cover hazard inherent in the job he is required to carry out. Any personal protective appliances required for protecting employees from hazards specific to the plant where the contractor’s employee is working will be provided by the concerned plant. No contractor shall start work inside factory premises without a valid safety certificate. 3.23.2
General Safety Rules For All Contractors
General: a)
It is the responsibility of the departmental head to ensure that contractor working under his control is aware of the Safety Rules.
b)
An injury sustained in the plant, must be reported to the concerned in-charge no matter how slight it is. 32
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c)
Smoking and carrying of matches and lighters except at Canteen and Rest Rooms is prohibited.
d)
Any person found under the influence of alcohol or any intoxicating drug while on duty is to be removed from the premises of the factory.
e)
Keep work surroundings clean, free from oil, greases and other obstructions or fallen objects like nuts, bolts, etc.
f)
After a job is completed, all leftover junk and other scrap materials should be cleared from the area immediately.
g)
Do not attempt to remove any foreign body from the eye of another employee. He should report the incident to his Foreman, who should immediately direct him to the dispensary.
h)
Do not use compressed air for removing dust from your clothes. Do not blow compressed air against any one as it may injure or even kill him.
i)
In case of acid or alkali burn, wash the affected part of body with water immediately and go to factory dispensary for further treatment.
j)
Do not tamper any pipeline or use it as a support without permission in writing from concerned department. It is dangerous.
k)
In case of fire or any other unusual occurrence inform any Owner/Owner’s Supervisor immediately.
l)
Do not carry matchboxes, tobacco, and Panmasala to the work place.
3.23.3
Welding & Gas Cutting
a)
Oxygen cylinders must not be stored near other cylinders, oil, grease or other combustible materials.
b)
While the cylinder is in use, the cylinder valve key must be placed on the valve spindle.
c)
Before a cylinder is moved, the cylinder valve must be closed.
d)
Gas cutting torches must be lighted by means of friction flames or similar other methods and not with matches.
e)
When torch is being changed or welding stopped for short time, all cylinder valves must be closed.
f)
The colored lenses used for welding or gas cutting must be of proper tint.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
g)
Before any heavy structured member is gas cut, make sure that it is cleared and supported by ropes, cables, chains or any other means to prevent its dropping or swinging.
h)
Screen must be used near the welding operations whenever there is a possibility of a spark falling on other workmen engaged in work close-by.
i)
All air/gas pipelines and air/gas hoses must be frequently inspected. Air/gas hoses shall not be used for dusting or for cooling purposes.
j)
Gas cylinders should not be stored near furnaces, cupolas, stove or any other source of heat.
k)
All dissolved acetylene cylinders should be kept in upright position whenever in use or while storing. Oxygen cylinders should, however, will be kept flat on the ground only when in use.
l)
Gas Cylinders should be placed in locations where sparks or flames from welding or cutting work cannot contact them.
m)
The unloading and loading of gas cylinders must be carried out with utmost care noted as below: •
•
Cylinders should not be allowed to drop or come into violent contact with one another. Additional arrangement should be made made to prevent cylinders falling from the vehicles. They should should not not be loaded loosely to avoid coming in violent contact when the vehicle moves. Avoid rolling gas cylinders. Transport them by proper trolleys.
n)
Oxygen and acetylene cylinders should not be stored together.
o)
Application of oil, greases or any other lubricating materials to regulators, valves or fittings of gas cylinders in STRICTLY PROHIBITED. Cylinders and fitting should be kept away from oil or grease to avoid ignition and explosion.
p)
In case of leakage from regulators, valves or other fittings of the gas cylinders, remove the cylinders immediately and send them for necessary repair.
q)
Wear proper protective clothing and equipments such as goggles, face shield, leather gloves, leather apron etc. as protection against radiating heat and spark.
r)
Do not watch on arc-welding operation with naked eyes.
s)
When arc-welding operations are performed in an area, not enclosed or isolated, workers or other persons connected with the arc-welding job should wear colored goggles.
t)
It is preferable to provide portable shields in the area where Arc-welding is carried out. 34
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
u)
Suitable fire extinguishers in working conditions should be kept close to all welding and gas cutting operations.
v)
When welding or gas cutting is performed in a confined space, the cylinders should be left outside.
w)
In confined spaces, where the means of exit is a manhole or other small opening, means should be provided, such as life belt and lifeline for quickly removing in case of an emergency. An attendant should be stationed outside the exit at all times while the work is in progress.
3.23.4
Tools and Equipments
a)
Keep all your hand tools such as chisels, hammers, files, punches, and spanners, wrenches etc. in good condition at all time.
b)
Never use defective tools or tools having mushroomed heads or tools having cracked or broken handles handles or improper fitting etc. Replace them at once. Keep wrenches, spanners securely so that they will not slip.
c)
Do not use tools for purpose other than for which they were designed.
d)
Tools and materials shall not be left in elevated positions if there is possibility of their falling or being knocked off.
e)
Do not drop or throw any tool or equipment from one level to another.
f)
All portable power tools such as drills, grinders etc., which are operated electrically should be thoroughly inspected before making use of them.
g)
Check that ground wire is provided to the electric tools.
h)
Insulation of the cables and the cords must be intact. There should not be any joint and exposed live parts on the cables, cords or on the tools.
3.23.5
Structural Erection
a)
No person shall stand, walk or work beneath any suspended load.
b)
Guide rope must be used for guiding while lifting loads.
c)
When guiding a beam or fabricated structure for erection it shall be so held that the employee’s hands do not get jammed against other objects. Safety belts equipped with suitable life lines must be used by persons working at heights and standing standing on structural members. Lifeline must be tied to an independent support support only. ISI marked safety belts should be used.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
3.23.6
Mott MacDonald Hindustan Organic Chemicals Ltd.
Rigging
a)
Check thoroughly all lifting tools, tackles, slings and ropes before putting them to use.
b)
Defective or worn out tools, tackles, ropes or slings should never be used even if the load appears small.
c)
While hooking, slinging or unhooking any load, hand should be kept out of the pinch point.
d)
Before lifting the load, ensure that the crane-hook is properly entered and the load is balanced so as to avoid undue tilting or disconnecting of the load while lifting.
e)
Slings should never be overloaded. For this is most important to have a correct assessment of the load being lifted. If in doubt, shift-in-charge/supervisor must always be contacted.
f)
While using double-legged slings, the angle made by the legs with the horizontal should always be kept above 45 Deg so as to prevent any over-loading of the sling. This is best achieved by using sufficiently long slings with the legs moderately spaced.
g)
No person should walk or stand below any swinging load.
h)
Slings should be released only after ensuring that they are completely free from load.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
4
Scope of Enquiry
4.1
Scope of Work
Mott MacDonald Hindustan Organic Chemicals Ltd.
Scope of this tender covers revamping of the instrumentation installation for caustic soda plant of M/s HOCL at Rasayani. •
•
•
•
Design, Engineering, Manufacture, Test, FAT (Factory Acceptance Test), Supply & Delivery at site, Installation, Testing, Commissioning and SAT (Site Acceptance Test) of DCS system. Design, Engineering, Manufacture, Test, FAT (Factory Acceptance Test), Supply & Delivery at site, Installation, Testing, Commissioning and SAT (Site Acceptance Test) of PLC system. Manufacture, Test, Calibration, Inspection, Supply & Delivery at site, Installation, Testing and Commissioning of field instruments. Procurement, Test, Supply & Delivery at site and installation of hardwares in the field like cables, Glands, Cable Trays (GI &MS), Tray Supports, Paints, FF junction boxes, Air headers, Copper/SS tubes, impulse line connectors etc.
The scope also includes the replacement of existing control system, panels and furniture from control room, testing of existing control cables (digital signal cable), removing and rerouting of the same, removing of existing analogue signal cable and laying of new foundation field bus signal cable, testing of instruments, control junction boxes which shall be reused from existing plant and Transporting the instruments, machinery to & fro storage area within the job site. Please note that, “Removed & not to be reused” material to be delivered in the HOCL’s central stores. (E.g. DCS Panles, unused cables, Trays, Etc.). The detailed quantum of work is given in the prise schedule. The job is to be carried out for revival of Caustic Soda Manufacturing Plant at Rasayani-410207, District Raigad (Maharashtra) for Hindustan Organic Chemicals Ltd.
4.2
Scope of Supply and Services
(Refer Volume – II, Price Bid)
4.2.1
Material to be supplied by Owner
Owner shall generally supply the following items from the existing plant, which shall be installed by the contractor: a)
Control cable (digital signal cable).
b)
Digital junction boxes.
c)
UPS and battery.
d)
Air header tubing. 37
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
4.2.2
Mott MacDonald Hindustan Organic Chemicals Ltd.
Material to be supplied by Contractor
The following Items shall be generally supplied, fabricated and installed by the contractor: a)
Perforated Cable Trays.
b)
M.S. sections such as angles, channels, beam, chequered and plain plates for supporting cable tray and other instruments supports.
c)
Testing and calibration kits for the instruments as per requirement.
d)
Accessories & hardware for the revamping of Inst. Installation.
Any other material though not specified in owners scope but required for completion of work as per specification and instructions
4.2.3
Utilities to be Supplied Free of Cost by the Owner
The Owner shall supply following items free of cost to the Contractor:
4.2.4
a)
Providing temporary open space for opening of Contractor’s site office.
b)
Constructed, finished suitable space for installation of mechanical systems / equipment.
c)
Electrical power, compressed air and water at one point. However further distribution shall be done by the contractor at his cost with provision to meet with the requirements of safety and statutory requirements as well as rules and regulations of supply authorities.
Tools, Tackles and Consumable by Contractor.
The procurement and supply of necessary materials and consumables except as listed above shall be entirely the Contractor’s Contractor’s responsibility. The scope of supply supply shall include but not limited to the followings: a)
Required consumables such as oxygen, acetylene, inert gases, electrodes, filler wire, flux, etc.
b)
Necessary tools & tackles required for carrying out the Inst. Work.
c)
Necessary testing equipment / instruments. i nstruments.
d)
Shims, wedges and packing plates.
e)
Required protecting materials for protecting equipment supplied by the owner.
f)
Any other material though not specified but required for completion of work as per specification and instructions.
g)
Safety equipment like helmet, safety goggles, shoes, gloves, belts etc. 38
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
5
Technical Specification
5.1
Standards
Mott MacDonald Hindustan Organic Chemicals Ltd.
a)
Material and equipment to be supplied by the Contractor for this work shall be in accordance with relevant Indian Standard Specifications. In case of any contradiction, Engineer’s decision shall be final.
b)
Erection of materials and equipment whether supplied by the Owner or by the Contractor shall be in accordance with the best engineering practice, conforming to respective provisions of Indian Standards.
c)
Site testing shall conform to relevant Indian Standards and Contractor shall furnish valid calibration certificates for all instruments used for recording “Test Readings”.
d)
In addition, the work shall conform to the following: 1) 2) 3) 4) 5) 6)
Indian Electricity rule and Acts. Fire Insurance Regulations. Requirements of Factory Inspector. Requirements of States Pollution Control Authority. Requirements of Central/State/Local Authorities. Requirements of Explosives Department.
All these requirements shall always mean the latest requirements during the execution of the contract. All safety standard set out in “IMM Safety Handbook” shall be followed (copy available for inspection at office). 5.2
Approved Makes for Supply of Material by Contractor
The contractor shall supply the materials of the following make and shall give his rates for the same. Make of some of the equipments/items are noted noted in the price schedule, schedule, which shall be followed strictly. MATERIALS
APPROVED MAKES
1.
DCS & PLC Control System
By reputed DCS Manufacturer having proven track record.
2.
Pressure Gauges,
General instruments, WIKA, Pyro-Electric.
3.
Pressure Switch
General instruments, Indfoss (I) Ltd. 39
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Switzer
Instru.,
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
4.
Temp. Temp. gauge
General Instruments, WIKA, Pyro-Electric Instruments.
5.
RTD with thermowell
General Instruments, Temptech, Pyrotech, Detrive Instruments
6.
Transmitters (DPT, PT, LT, FT, TT)
Emerson, Honeywell,Yokagawa, Invensys, ABB
7.
FF junction box, FF Power Supply, Mother Board, Etc.
P & F , MTL
8.
On-Off Valve
Rotex, Virgo, Audco.
9.
Cable (FF & Digital)
AFW Cables, Lapp Cables, General Instruments.
10.
PH Meter
Yokogawa, Grate Lake, Emerson, ABB, E&H.
11.
Rotameter (Glass Tube)
Eureka, TRAC, I/L (Hyderabad)
12.
Rotameter (Metal Tube)
Yokogawa, Forbes Marshal, Tokyo, Keiso, Fisher
13.
Mag. Flow Transmitter
Forbes E&H.
14.
Valve Positioner
Fisher, Samson, Flow Serve, Dragger, ABB.
15.
Chlorine Gas Detector
Draegar, Siegar (Honeywell)
16.
Weighing System
Avery
17.
Density Transmitter
E&H, Smar, Yokogawa, Emersion.
18.
Electrode-less Conductivity Transmitter
Gratelakes, Potence, Envitech, E&H.
19.
ORP Meter
Yokogawa, Grate Lake, Emerson, ABB, E&H.
20.
Capacitance Level Switch
Drexelbrook, E&H, Greatlakes.
21.
Temp. Input Device
Emerson, P&F.
22.
Cable Trays
Indiyana, Profab, Superfab
23.
Instruments Fittings
Wesmech, Fisto, Champ, Astec. 40
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Marshal,
Emerson,
Yokogawa,
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
5.3
Mott MacDonald Hindustan Organic Chemicals Ltd.
Contractor's Visit to Site
Once the Contractor gives the offer, it shall be deemed that he has thoroughly understood the requirements and site conditions for the Project Instrumentation. Instrumentation. Hence, the Contractor is advised to visit the site before giving the offer. 5.4
SPECIFICATION FOR MATERIAL, INSTALLATION, TESTING AND COMMISSIONING
Materials supplied and workmanship shall be of the highest quality available and all work shall be carried out to meet the requirements of IS codes of Practice, I.E. Rules and to the approval of the Engineer and Local Authorities. The following specifications give guidelines, but not limited to the quality and scope of work expected.
5.4.1 Lying & Termination Termination of Power, Control Control and Foundation Fieldbus (FF) Cables. Cables.
(i)
Scope
This specification provides for laying, termination, testing and commissioning of Power, Control & FF Cables. (ii)
Laying of Cables
The Contractor will unpack the drum if required and then transport it to a convenient spot near the overhead tray so that lying of cable becomes easy. Most important thing to bear in mind while laying cables is that there should not be any twisting while unwinding it from the drum, since this is likely to damage the insulation. Any repairing/replacement arising out of this negligence will be to the contractor's account. Power, FF & Control Cables shall be laid between various equipment as per cable schedule (which will be given to the successful contractor). Tentative routes of these cables have been shown on the drawings. Adequate length of cables shall be pulled inside DCS panels, Control and FF junction boxes, terminal boxes, etc. so as to permit neat termination of each core. While laying cables parallel to buildings or utility pipelines, drainage, electrical cable tray etc. minimum clearance shall not be less than 500 mm.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
The contractor shall quote for laying of cables on 'per meter' basis which should include following parameters: a)
Laying of cables in cable trays/ on walls.
b)
Supplying and providing of cable ties clamps of required sizes to hold the cable firmly to structure/tray.
Before the cable is cut, exact route length shall shall be measured at site. Then allowing extra length of about 1.5m, or as directed by the Engineer, the cable is cut. Rollers and pulling pulling socks shall shall be used while pulling the cable into the trays. This will be strictly enforced for larger size of cables and for long routes without which installation will not be permitted. Bending radius of cable shall be minimum. The cables shall be tested for insulation resistance with 1000 V megger, before laying. Cutting schedule for each drum to be prepared by contractor & approved by the Engineer prior to cutting. Cables shall be neatly laid, with no crossing over of cables. Cable ends after cutting shall be protected from dirt and moisture by wrapping with PVC tapes/caps. Any civil work or plastering work required as a part of cable laying work shall be done by the Contractor within the quoted rates. The quality of finish should be that of the other works or the same will be redone by the Civil Contractor and the amount deducted from the Inst. Contractor's bill. Any re-laying of cable required to be done due to wrong method of laying (for which Contractor is responsible) shall be without any extra cost to the Owner. Engraved labels of SS 316 strip to match cable Tag no. of cable numbers shall be provided near the terminal block in control room & cable identification tag number punched on SS 316. strip shall be provided on both ends near nea r equipment. The Contractor shall supply and install coloured ferrules for multicore cable connections. The ferrule markings shall be identical to the tag numbers. Cable Tag carrying the cable number number shall be at intervals of 30 mtrs. for aboveground cables and at all bends and routes changes changes of the cable run. Material of tag shall be SS 316 for above ground cables and of lead for buried cables (included in rate).
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Cable Tray as supports: (i)
The trays shall be supported as per installation drawings. If necessary, additional supports shall be provided. The supporting arrangement shall be approved by site engineer.
(ii)
Supports shall have same treatment as per trays.
(iii)
Supply & Installation rates for supports shall not be included in the rates for cable trays but paid separately under rates for supply and fabrication of structural steel.
5.4.2
Cable Handling, Dressing
Presently the existing cables have been laid on trays, which are corroded and need replacement. The cables shall be properly handled while dismantling of the cable trays/supports. Also the cables shall be placed in the newly installed cable trays. The cables shall be properly tied and dressed as per the standard practised. Also the segregation segregation shall be done between power power and low voltage instrument cables to the satisfaction of the HOCL.
5.4.3 Installation of Trays Prior to installation / fabrication, contractor to study each area and prepare “Method Statement” and “Working sketches” for review and a nd approval by HOCL.
5.4.4
Erection material supply •
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The Sub-contractor shall ensure and supply all erection hardware required for installation of all instrumentation, which form a part of the package unit. This includes items like cables, cable glands, junction boxes, instrument valves, mounting accessories, impulse piping/tubing, pipe/tube fitting, pneumatic signal tubes, air line pipes, filter regulators, steam/electrical tracing, insulation materials, cable trays, conduits, identification tags, structural material required for instrument supports and trays etc. The above broadly covers the items required for any typical plant, however the sub-contractor shall supply all necessary items to make the erection and commissioning work complete in all respects, irrespective of whether erection and commissioning is included in his scope or not. The following are the minimum acceptable salient features of some of the erection materials.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Analog signal cables •
For FF connection special cables to be used for all analog signals, as per NSD-17 specification to be supplied and erected.
Digital signal cables •
Existing cables and cable routes will be used by erection contractor.
Ac 110Vac supply cables •
Existing cables and cable routes will be used by erection contractor.
Cable Glands •
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Sub-contractor shall supply all cable glands required for glanding the above mentioned cables both at field instruments and at control room (local & main) / control room devices/junction boxes. All cables glands shall be of nickel-plated brass and they shall be double compression type suitable for armoured cables.
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Flame proof glands wherever required shall be supplied.
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For quantity of cable glands, refer in price schedule ‘D’.
Junction Boxes •
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HOCL will supply junction boxes for digital inputs and outputs as required. Contractor to supply and install 1000 nos of 2.5 sq. mm Din rail mounting type Clipon / Phonix make terminals to be fixed into existing digital junction boxes. (Existing digital junction boxes to be used for digital inputs and outputs). Contractor to supply Foundation Fieldbus junction boxes.
Instrument support/structural steel •
Sub-contractor shall supply instrument stand (stanchions and other structural steel material required for supporting the cable trays, impulse lines and instruments).
5.4.5 Installation •
Sub-contractor shall be completely responsible for installation of all instruments within his battery limit, as per the Hook up Diagrams furnished along with this specification.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718 •
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Mott MacDonald Hindustan Organic Chemicals Ltd.
All direct mounted instruments like level switch, RTD, thermowell, temperature gauge, flow switch, pressure gauge, pressure switch etc. shall be installed in such a way that they have better readability and accessibility. All capillary type instruments shall have the capillary tube supported properly and shall have protection of capillary tube against mechanical damage. All pressure, differential pressure instruments shall be provided with by-pass, drain/vent valves etc. as per the installation sketches, and shall have accessibility. All primary piping/tubing (impulse lines) shall have a slope of 1/10 on the horizontal run. All welding shall be carried out as per the relevant code with proper electrodes. Any testing (non destructive) like DP test on root weld and final weld shall be carried out as applicable. All consumable like paint, ferrules, lugs shall be part of sub-contractor’s scope of supply. Any pre/post weld treatment as required by the codes shall be carried out.
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All threaded joints shall be jointed by Teflon tapes only.
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All impulse lines shall be supported at regular intervals.
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Instrument drain/vent connections shall be piped to safe area or above pipe racks to avoid accumulation of hazardous fluid in the plant atmosphere. All tubes/cables shall be properly laid on cable trays, which shall be supported at regular intervals with identification tags. Separate routing or physical separation minimum 300mm shall be maintained between signal cables and shut down/power cables. Wherever intrinsic circuit system cabling is employed the minimum separation of 150mm. shall be adhered to between IS and non IS signal cables. The cases of instruments shall be earthed by earthing wire to the nearest earth bus bar provided by others, for safety reasons. In case the cables are to be buried or laid in concrete trench the same shall be carried out by sub-contractor with prior intimation to client. Painting of angle trays, instrument supports & all structural supports shall be as under: The surface to be painted shall be thoroughly cleaned with brush/sand paper to remove all scales. After cleaning, one coat of zinc chromate primer shall be given conforming to IS-2074 and allowed to dry. One coat of final when paint shall be applied. The paint selected shall be epoxy type : 45
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
5.4.6 Testing and Calibration •
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All impulse lines shall be properly flushed after isolating both the instrument and the vessel/piping. All impulse lines shall be tested hydraulically at 1.5 times the maximum operating pressure. Ensure that instrument and vessel/piping is isolated during this test. In case of special conditions where hydrotesting is not permitted due to service conditions, the impulse lines testing shall be carried out by using air or nitrogen. All external cage type level instruments shall be tested up to 1.5 times operating pressure by using nitrogen only. After pressure testing all these impulse lines shall be drained and dried with dry air to remove any moisture. Instrument airlines will be service tested only for any leak after pressurising and isolating the main root valve, val ve, by soap solution. Pneumatic signal tubes shall be flushed and tested with instrument air for any leak at a pressure cut off and rate of fall in pressure shall be less than 1 psi for each 100 feet for a period of 3 minutes. All instrument cables shall be tested for continuity and insulation. While megger is used for insulation testing, ensure that all instruments zener barrier are isolated at both ends. All instruments supplied by the sub-contractor shall be calibrated using proper test equipment.
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All instruments shall be calibrated for 0, 25, 50, 75 and 100 % and vice versa.
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All temperature gauges shall be calibrated using temperature baths.
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All thermocouple-activated instruments shall be calibrated by generating millivolts by a potentiometer. All transmitters shall be calibrated as per instrument ranges. All alarm and trip switches shall be calibrated over the entire range and finally set and checked for alarm/trip points and reset points as per the alarm/trip set point schedule. After setting these shall be sealed. All control valves prior to stroke checking shall be externally cleaned thoroughly. The stroke of valves shall be checked for opening and closing. Any adjustments required for obtaining full stroke and reducing. Hysterics shall be carried out. 46
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
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Mott MacDonald Hindustan Organic Chemicals Ltd.
Bubble tight shut-off control valves and shut down valves shall be checked for seat leak test and gland leak test. Solenoid valves of Actuated on / off valves shall be checked functionally for its operation. The open / close limit switch operation shall also be checked simultaneously. Safety valves and relief valves shall be set/tested by using dry air/nitrogen. Leakage if any shall be removed by proper lapping of seat and disc. All electronic/pneumatic receiver instruments shall be calibrated as per the manufacture’s instruction. Controllers shall be aligned properly. All special instruments like analyser shall be checked and calibrated as per manufacturer’s instruction. Prior to testing, all analyser sample lines shall be thoroughly cleaned by carbon tetra chloride or any other cleaning liquid. After cleaning, these lines shall be thoroughly purged with dry nitrogen. No oil should be used on oxygen service lines. The accuracy of overall loop shall be within ± 0.5 % for electronic & ± 1% for pneumatic loops. After performing the calibration of all instruments, the entire loop shall be checked for proper operation. The entire shutdown scheme shall be simulated from the process trip switches and the scheme shall be tested for its proper operation, prior to start up of the unit. If no instrument air is available sub-contractor shall provide necessary N 2 cylinders to carry out the above activity.
5.4.7 Commissioning •
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This activity shall be carried out in a systematic manner so as to avoid any accident to plant and operating personnel. During the plant start up all the instruments calibration, controller alignment, trip point settings shall be trimmed so as to meet the operation requirement. Prior to guarantee run of any package unit the vital instrument as required by subcontractor have to be recalibrated and the results recorded. Contractor has to provide Walkie – Talkie at the time of Loop checking for better communication.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
5.4.8
General Requirement
(i)
Site Staff of the Contractor
Mott MacDonald Hindustan Organic Chemicals Ltd.
The entire work shall be executed by Instrumentation Contractor under the direct supervision of competent and qualified men, who are regularly engaged in the installation and commissioning of instruments. The instrumentation contractor contractor shall have in charge of the work work at all times during construction, a thoroughly competent licensed Supervisor, qualified and experienced Instrumentation Engineer, who shall be responsible for keeping liaison and co-ordination between client’s site staff and his own staff staff at site. He shall also submit submit Progress Reports after every fifteen days. Anyone found to be incapable shall be replaced immediately as soon soon as requested by client. Instrumentation Contractor shall keep following full time technical staff at site to carry out the installation work with best best workmanship and to the satisfaction satisfaction of the Client’s Engineer. Engineer. The list only suggests the requirements and contractor will increase the staff whenever asked for by Consultant’s/client’s Engineer. S.No.
Description
i) ii) iii) iv) v)
Senior Instrumentation Engineer Junior Instrumentation Engineer Testing Engineer & Team Welders Fitters
Quantity
: : : : :
One One 1 Gang Two One
However, this shall be reviewed with Site Engineer depending on workload. The staff shall be well behaved. The plant falls under Hazardous area where smoking is strictly prohibited.
(ii)
Tools and Tackles
The work shall be done by using Tools and Tackles designed and approved for the purpose. Following tools are recommended to carry out Instrumentation Installation work. In addition, the Contractor shall bring all such tools/tackles as applicable, which are necessary to carry out/complete the work, if asked for by Consultants/Client’s Engineer. -
Welding Sets Cutting Tools Derricks, if required Jacks Electric Blower Drilling Machines (different sizes) Grinding Machine Cable Crimping Tool Digital Multimeter Pipe bending machines 48
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
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(iii)
Mott MacDonald Hindustan Organic Chemicals Ltd.
Portable test lamps with prongs Fitters tools Vices Ladders (Different sizes) Cable laying tools
Material and Equipment
The material and equipment to be installed is specified on the instrumentation drawings, materials and equipment specifications shall conform to the applicable codes and specifications. The materials and equipments supplied by others shall be installed by the Contractor as recommended and specified specified by the manufacturer manufacturer of that equipment. equipment. The person drawing drawing the materials from Client’s store shall satisfy himself that the materials supplied are in accordance with the material specification and is in a usable condition. Care shall be taken in handling the material properly from damage during transport and installation. All materials shall be new, unless specified, otherwise in writing by Client’s Engineer. The Contractor shall obtain the approval of Client for all the materials to be used by him prior to installing the same. Equipment damaged in the course of of handling, installation or testing shall be replaced/repaired by the Contractor as approved by Client and without any extra charges to client.
(iv)
Codes and Specifications
All materials and equipments shall be installed in accordance with the latest versions of Code of Practice and latest Indian Standards, including such British codes as are applicable and all state and city codes that may may apply. Installation shall be approved by Fire Insurance Association. Association.
(v)
Cutting, Patching and Excavation
The Instrumentation Contractor shall do all necessary excavation and cutting required for completion of the installation installation work. He shall be responsible responsible for any damage damage caused to the installation/equipments by his workmen. Under such circumstances, he shall shall repair/replace the damaged portion at his own own cost to the satisfaction satisfaction of the Client. He shall to the extent possible, possible, keep excavation, cutting and patching to a minimum. minimum. If the instrumentation contractor fails to perform his work in the proper manner or at the proper time so that additional excavation, cutting and patching is required, he shall bear all expenses and shall pay for the required additional cutting and patching to the concerned agency without any extra cost to the client.
(vi)
System of Working
Work shall be carried out in a systematic and sequential manner as per the priorities of work fixed by Consultant/Client. All these priorities shall be strictly adhered to. Until the particular part of the work is approved or certified as completed by the Consultant/Client, the Contractor shall not proceed with the subsequent work connected with uncertified part of the work. 49 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
(vii)
Mott MacDonald Hindustan Organic Chemicals Ltd.
Safety
The Contractor shall take all safety measures such as providing barricades, etc. for preventing the accidents. He shall provide provide and maintain any other necessary constructions required to secure safety of life or property arising out of his work. work. Whenever and wherever required, the Contractor shall obtain PERMIT TO WORK while working in or near the live parts. Contractor should provide hard helmet, safety shoes and electrical insulated hand gloves to his men.
(viii)
Accidents
The Instrumentation Contractor shall report the incident of accident pertaining to his work to the factory Inspector and MGL as per per the requirements. Any financial compensation arising out of this accident shall be borne by the Contractor and at no extra cost to the Client. Any modification or changes in the equipment or installations that may be demanded by the factory Inspector, Owner’s/Consultant’s Engineer shall be carried out at no additional cost to the Client. In accordance with the specific installation instructions as per the manufacturer drawings or as directed by the Owner, the instrumentation instrumentation Contractor shall shall unload, erect, assemble, install wire, test and commission all equipments included in this contract. Equipments shall shall be installed in a neat manner. All the necessary Erection materials, tools, testing instruments or any other machinery of any nature shall not be supplied by the the Owner. The instrumentation Contractor shall shall arrange for the same in a timely manner and he shall not be allowed to claim for any delay or extra cost of any nature. Consumable materials of any nature required for the erection job shall also have to be arranged by the instrumentation Contractor. Clearing the site after completion of erection as well as regular clearance of unwanted materials from site, returning all packing material and excess material supplied by Owner back to the Owner’s stores shall also be covered under the scope of work of instrumentation contractor. All equipments and instruments of indoor and outdoor shall be inscribed with tag number, make, model number other instructions. The Instrumentation Contractor shall touch up the surface for all equipments, which are scratched and/or damaged during transportation and erection. The paint used shall match exactly the surface being touched up. Major Civil Engineering works pertaining to instruments like foundations and plate inserts, etc. if excluded from the scope of work, the instrumentation contractor shall check their correctness as per latest drawings of the respective manufacturer and carry out minor in civil jobs, such as, but not limited to grouting of base plates, channels, supports and foundation bolts, cutting holes in walls and ceiling, chipping of floor and ceiling, chipping the foundation for outdoor equipments, sealing of cable entries and making good the same after installation of the 50 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
equipment, levelling and any other minor civil works advised by the Owner, has to be carried out without any extra charge. The instrumentation Contractor shall set up his own workshop and other facilities at site at allocated place to undertake fabrication jobs, pipe bending, threading etc. The instrumentation Contractor shall be responsible for recording of all readings and observations during erection, testing and commissioning, in registers or on prescribed Performa. These shall be carried out in the presence of `Owner’s representative. All such test data and records shall be duly signed by the instrumentation contractor’s Engineer/Owner’s representative and shall be submitted to the Owner in triplicate. The Instrumentation Contractor shall carry out all a ll tests at site for f or outdoor and indoor instruments and commission the installation in the presence of Owner’s representative. The Instrumentation Contractor shall be responsible for final adjustment of instruments, tubes and fittings, cables, etc. of instruments which they installed. The contractor who will install and commission the panel shall be responsible for final adjustment. As Built Drawings: Contractor to submit red mark as built drawings for approval of client. Contractor shall submit submit soft copies of drawings after incorporation of the red mark to the client.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
6
Mott MacDonald Hindustan Organic Chemicals Ltd.
Specification for Inspection and Field Tests of Instrumentation Facilities (Wherever applicable)
6.1
Scope
The work to be performed vide this specifications covers the inspection, pre-commissioning testing of all instruments and installation.
6.2
General Requirements
The instrumentation contractor shall arrange for necessary testing meters, instruments, temporary wiring and labour to perform all the required tests, adjustments and wiring of equipment installed and/or connected under this contract including equipment supplied by other agency. Inspection and testing shall be carried out to ensure that the material and equipment has been installed as required and/or recommended by the equipment manufacturers and as per the latest relevant Indian Standards Specifications, codes, Fire Insurance, and any other authorities having jurisdiction. The installation must pass all inspection and will be subject to the approval of the Client’s Engineer. Before the instrumentation facilities are brought in operation, the contractor shall make suitable tests to establish, to the satisfaction of the Client’s Engineer that all equipments, devices and wiring have been correctly installed, are in a satisfactory working conditions and will operate an intended and as recommended by the equipment manufacturers and as per installation standards issued. All the tests shall be performed by or under the direct supervision of competent men from original Equipment Manufacturer. The Client’s Engineer reserves the right to witness all tests and he shall be given two weeks notice before tests are to take place. Client’s Engineer reserves the right to approval/reject any test results before circuits or equipment equipment are energised for the first time. All Test Certificates should be submitted to the client. All the test results shall be recorded on test data sheets. All tests described herein which are marked with an asterisk (*) shall be recorded on forms provided or agreed upon by Client’s Engineer. The test report shall include for each test, the date of performance and name of the period in charge of the test.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Before starting the testing of installation, a visual inspection of the material and equipment shall to be made to determine that all components are installed as per drawing and in a neat, safe and workman like manner and that in general, the equipment is ready for testing. 6.3
Test Procedures
All the test results for various tests conducted on various equipments shall be properly recorded. The calibration / test certificates issued by the manufacturer of transmitters, control valves, onoff valves etc. should be submitted to the client. relay settings record.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
7
Safety Rules and Regulations
7.1
Objective
Mott MacDonald Hindustan Organic Chemicals Ltd.
1.1
The objective of the document is to provide and establish a construction Site safety Management System.
1.2
This “Summarised safety Requirement” shall be employed on the Site and shall be obligatory on the Contractor.
1.3
The Contractor shall familiarise himself with all the Health, Safety & Environment manuals available at the Owner’s as well as the Contractor’s office.
7.2
Health Safety Environment at Site
7.2.1
Safety - A Line Function
The Health Safety & Environment at site is a line function and hence it is the responsibility of the concerned Contractor to ensure that any and all activities at all times shall be carried out as per the Safety norms. 7.2.2
Safety Training
Intimation training shall be given to all the Contractor’s personnel who enter the site for the first time to carry out a particular work. This intimation training shall be given by Contractor at his own cost. Safety training on specialised subjects/area shall be provided to the Contractor’s personnel by the Contractor if required. 7.2.3
First Aid
First aid is defined as the prompt prompt treatment of injuries such as cuts or bruises. bruises. More serious injuries involving fractures or breakage to limps, head injuries or other severe wound should be treated by qualified and experienced medical personnel. In the absence of any permanent medical facility at Site the Contractor shall be responsible for establishing first aid facilities at Site and arranging emergency transports. The Contractors shall establish their own first aid facilities at the Site and arrange emergency transports, when required. The Contractor shall provide first aid boxes or similar containers like bags or cupboards that are designed to protect the contents from damp and dust. The boxes and containers should be clearly identified as first aid 54 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
containers and kept in easily accessible places, which should be made known to every employee of that location. Sufficient quantities of each medicine medicine should always be replaced as necessary. Contents should be checked regularly for expiring dates. The contractor shall train personnel to take or deploy personnel who is able to take the first aid treatment for: 7.3
Heat exhaustion Burns Wound and bleeding Bone fracture (who is capable to do) Artificial respiration Oxygen feeding Responsibility
7.3.1
Responsibility of the Contractor
The contractor is responsible for the Safety of his employees and those of his subcontractors and for the implementation of the Safety requirements in the execution of the Contract. -
Smoking limitations General hygiene and Sanitation codes to be followed at site. Traffic and parking regulations Restrictions to the use of drugs and alcohol Housekeeping Standards Prohibition of the use of solvents, chemicals and oil products for any purpose unless specifically authorised. Dangers and handling procedures for any noxious or hazardous substances. Hazards of excavation operation e.g. damaging underground cabling or piling. Use of Safety equipment such as personal protective equipment, fire extinguishers and life-saving devices. Meaning of and required action upon fire and gas alarms. Action in the event of discovering fire or loss of Containment. Action in the event of an accident.
The Contractor shall be responsible for the medical welfare of its own and sub-contractor personnel and shall provide for: -
Facilities for administering first aid Periodic medical examinations Arrangements for professional medical treatment Hospitalisation
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
The Contractor shall ensure that all its personnel are medically fit to perform their work. If requested by HOCL, the Contractor shall provide health certificates for its own and sub-contractor’s personnel. The Contractor shall ensure that all his tools, tackles and equipment are inspected. The contractor shall in the execution of the work be fully responsible for compliance with: a) b) c) d)
Relevant local national and international laws and regulations. The Company’s regulations Local, national standards or codes of practice, whichever are more stringent unless specified otherwise. International standards or codes of practice whichever is the more stringent unless otherwise specified.
The Contractor shall appoint one of his personnel on the work Site as safety advisor/officer and shall seek the Owner’s approval for the individual so appointed. The Contractor’s Site-in-charge, shall be responsible for co-ordinating the with the worker’s safety activities. The Contractor shall at its own expense ensure that all its personnel and sub-contractor’s personnel have been given the necessary safety, survival and job related training required by law. 7.4
House Keeping
The Site shall be kept clean and tidy at all times to prevent hazards and improve general working conditions. Rags, paper, wood shavings and other flammable materials shall not be scattered over and shall be collected and disposed of in sufficient frequency. Temporary electrical cables shall be installed as not to cause a tripping hazard to personnel, nor be liable to mechanical damage by equipment. Cables joined by tapes are not permitted for power tools and welding sets. All electrical tools shall be grounded. grounded. Elevated cables shall be installed at such a height as to allow unrestricted movement of construction equipment and vehicles. The area where piling is going on should be kept clean to avoid accidents due to slippery ground. Equipment or materials stored at the Site shall not obstruct access to essential facilities and/or equipment, such as fire extinguishers, fire hydrants valve, gauges, emergency exists, etc.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
7.5
Mott MacDonald Hindustan Organic Chemicals Ltd.
Personal Protective Equipment
7.5.1
Head Protection
All personnel shall be issued with safety helmets, which shall be used at all times that personnel are on the site. Safety helmets shall be checked periodically for signs of wear, and in particular for cracks in the shell, and damage to the hammock. hammock. Any evidence of such such wear shall result in the helmet being discarded, and a replacement issued. 7.5.2
Hand Protection
Gloves shall be used by personnel involved in works, for possibility of the following hazards: -
Risk of abrasion Risk of cutting Risk of tearing Risk of chemical, or other, burn Risk of infection
The wearing of gloves should be avoided if possible, when works are being carried out on, or immediately next to rotating or moving equipment. 7.5.3
Foot Protection
Suitable safety footwear shall be worn by personnel, considering the nature of works and such hazards as: 7.5.4
Risk of crushing by heavy objects Penetration by sharp objects Penetration by chemicals or harmful liquids Weld spatter Eye Protection
All personnel shall be provided with suitable eye protection wherever there is a risk from -
Flying particles High speed flying particles Dust ingress Chemical splash Radiation glare Hot sparks or metal spatter Harmful vapours 57
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
The correct selection of eye protection shall depend on the assessment of the risk, or combination of risks, based on the site situation. Eye protection with scratched or ‘fogged’ lenses shall be discarded, and replacements issued. 7.6
Plant, Tools and Equipment
The following four basic principles shall be applied to and govern the safe use of hand and power tools and which principles are: -
To choose the right tool for the job To use only tools in good condition To use the tools correctly, and only for the purpose intended To maintain and store tools properly
Hoses supplying air to pneumatic tools shall be inspected for signs of wear or damage, and connecting clamps proved secure. High speed rotating equipment, such as grinders, shall be fitted with protective guards. Grinding discs are rated by the speed at which the disc rotates, and this must be compatible with the rotational speed of the grinder itself. Power tools shall never be left operating unattended. The Contractor shall carry out periodical inspection of plant, tools and equipment. Loads must always be slung with the center of gravity directly beneath the crane hook, to prevent uneven tensions being applied to the sling legs. The angle between sling legs shall not, under any circumstances exceed (100 deg), as this doubles the tension on each leg, thereby reducing the lifting capacity of the sling by 50%. One (1) person only, usually the Supervising Rigger, shall give instructions to the crane operator. For wheeled cranes, outriggers shall be used for each lift, regardless of the size, and shall always be fully extended. A ‘trial’ lift shall be carried out, raising the load a short distance above its pick-up point, to check the stability of the crane, and the efficiency of the brakes. The load shall, at all times, be kept as close to the ground as possible.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Whenever possible, and after lifting the load from its pick-up point, the radius of the lift should be shortened to increase the crane’s lifting capacity and stability. Wire slings and chains under direct tension during the lift shall not be extended artificially, not be knotted. Wire slings which show signs of excessive wear, kinking or broken wires shall be discarded and not used further. Shackles shall be complete with the original pin, and under no circumstances shall a substitute bolt be fitted. At no time whilst the crane’s machinery is running, shall the operator leave the cab. At no time whilst a load is suspended shall the crane’s engine (s) be intentionally turned off. At no time whilst a load is suspended, shall personnel perform any works directly beneath. Particular consideration to the presence of low-level structures such as pipe bridges shall be given where crane is to move about the SITE. Consideration shall be given to prevailing weather conditions, and where a greater than normal risk exists, the lift shall be postponed until more favourable condition is developed. 7.7
Safety In Instrumentation
Only authorised persons shall carry out operations and maintenance of instruments and control system. Ensure isolation of the instruments instruments before taking up the work. Display “Look Out” Board. Use proper protective equipment. Check for defective cables, cracked or perished insulation, loose joints in conduits, damaged fuse boxes terminal boxes, junction boxes, loose pins, faulty sockets and defective earth wire. Do not overload instruments. instruments. If the fuse blows, report report it. Do not fit fuse wire without ensuring safe condition. Avoid kinking or twisting, binding or crushing of ca bles. Do not use portable tools near inflammable vapour or gases.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Ensure that all the equipment are suitably earthed. Use right type of tools for the jobs. Do not let cables trial across the floor. To disconnect equipment do not pull pull the cables. Pull the plug After maintenance of flameproof fittings, ensure that the fittings meet requirements of flame fittings. Arrange all machinery such as welding machine, generators, cutting machine etc. in such a way that special fire risk equipment are segregated and protected. Check the machines at periodic intervals. Never over heat the machines Do not accumulate unwanted material near the machines, which may cause fire hazards. DCP type fire extinguisher must be kept. No smoking board should be displayed at various points. Do not store wet or oily materials and materials like coir, jute, cotton gunny bags etc., they can ignite spontaneously. Store chemical and other such such goods in stable racks properly labelled. Mutually reactive chemicals should be kept away from each other. Hot goods must be arranged so as to allow safe cooling and should not come in contact with combustible material. Tools which are returned back after use must be kept at a earlier marked place so that it can be traceable immediately and proper stock can be kept. Storage place should have proper ventilation Electrical, welding, cables should be stored properly and secured from theft. ‘No smoking’ boards should be displayed in store. Instruments should be properly secured. No other work such as repair of machinery, testing of grinding machine or whatsoever should be done in a small workshop shed, which is temporarily constructed at site. Electrical tools shall be checked to ensure the supplied voltage is comparable to the machine’s design. 60 229718/0/Sept.,2007 D:\Documents and Settings\Administrator\Deskto Settings\Administrator\Desktop\Dept\PROJEC p\Dept\PROJECT\Inst-1.doc/pp T\Inst-1.doc/pp
Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Electrical leads and connections shall be inspected for signs of damage or wear, and repaired or replaced accordingly. At no time shall two (2) or more power tools be connected to a single power plug. Wherever required, electrical tools shall be properly earthed. Fuses means as a source of protection and safety can become hazardous if not selected and maintained carefully. Ensure all fuses are of good quality quality and conform to correct ratings. MCBS are better than ordinary fuses. Instrument maintenance workman working around a wet area near a fuse box must use wooden platform, insulated tools or rubber boots. Always replace a fuse with the same type and size as the original, for e.g. a copper wire or other conductor must never be used as substitute.
7.8
Safety Working Practice for Mechanical Job - Fabrication and Welding
7.8.1
Gas Cutting and Welding
Gas cylinders used in cutting and welding shall: •
• • • •
Be stored separately, depending on the type of gas contained, and whether empty or full. be stored upright, and shielded from direct sunlight or other heat source be stored in a well ventilated area be fitted with safety caps when not in use be properly secured during transportation
When handling cylinders, ensure hands, clothes, gloves, etc. are free from oil, dirt, grit and grease. Under no circumstances shall oil be allowed to contaminate a cylinder containing oxygen. All gas and oxygen regulators shall be fitted with Flashback Arrestors, being non-return valves designed to prevent an explosive mix developing developing in either cylinder. Such explosive mixes can occur due to loose connections, leaking hoses, etc. Prior to use, all equipment shall be thoroughly checked to ensure that: -
all connections are ‘right’ all fittings such as gauges, flashback arrestors, etc. are functioning correctly hoses are in good condition, and free from signs of cracking or perishing checking for leaks shall be by means of soapy liquid applied to each joint.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
Under no circumstances shall a naked flame be applied to any part of the Cylinder or Hose arrangement to detect leaks. The cutting and welding of certain metals, or metal coatings such as zinc galvanized surfaces give off harmful fumes and such works must, where possible be carried out in a well ventilated area. When working at height, do not place cylinders directly beneath the work area, as molten metal may fall onto hoses, causing leaks, and possibly lighting the gases. 7.8.2
Electric Arc
During the electric arc welding process, very high ultraviolet radiation is generated. Suitable eye protection must be worn by the welder, and any other persons working in a close proximity to the welding works, in order to prevent permanent damage to the eyes. When not in use, the current to the holder and electrode must be turned off. All equipment must be properly earthed and cables securely connected. All equipment must be thoroughly inspected prior to use, and cable connections shall be completely insulated to prevent injury from electric shock. 7.8.3
Standard Practices
Ensure the work area beneath or adjacent to fabrication or welding works is free from combustible materials, and cordoned-off to prevent personnel being injured by weld spatter or molten metal. Retain a dry chemical fire extinguisher at the location of fabrication or welding works at all times. 7.8.4
Working Platform
Wherever possible, all works to be carried out over water or at a height greater than (2.0) above the ground level must be performed from a properly constructed and maintained working platform. The working platform shall be: -
closely boarded
-
at least (0.7 m) wide if used only as a footing
-
if used to store materials in addition, at least the width of the materials plus (0.7 m)
-
provided with toe-boards of minimum (0.15 m) in height 62
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
Mott MacDonald Hindustan Organic Chemicals Ltd.
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provided with handrails not greater than (9.05 m) above the toe-board
-
constructed as close to the structure or building as possible
-
Boards to be used on the platform shall be of a suitable thickness, in due consideration of the spacing of supports beneath
-
supported by at least (three (3)) transom, (or cross-supports)
-
Not project beyond the last support by more than twice their thickness
-
be adequately fastened to prevent slippage or movement during use
-
Wherever possible, not overlap another board
-
be free from cracks, twists, holes or other defects which may affect the load bearing strength
-
protected from weathering by means of a clear preservative. Boards shall never be painted as this disguises defects Scaffolding shall be properly designed and erected with its intended use in mind where additional, anticipated loads are to be applied; the structure shall be redesigned and modified accordingly.
Mobile tower scaffolding shall be fitted with lockable wheels of a minimum (0.12 m) in diameter. The height of the working platform not greater than (3 times) the shorter base dimension. All working platforms shall be kept clean and free from grease, oil, rubble, debris or rubbish to ensure safe movement for personnel performing the works.
7.8.5
Ladders
Wooden ladders shall be checked such as splits in the rungs or stiles, unduly worn rungs, loose wedges or tie rods, and split or frayed feet. Wooden ladders shall be protected from ‘weathering’ by means of a clear preservative. Wooden ladders shall not be painted as this disguises defects. Metal ladders shall not be used where overhead electric cables are present. Ladders to scaffolding shall be clamped at a minimum of (three (3)) points and shall extend a minimum of (1.0 m) above the level of the platform it accesses. In other situations, ladders shall be clamped near the top to a convenient point, and sloped with proper angle, (base : height ratio 1:4)), to the horizontal, to limit the risk of slippage. If the nature of the works is such that both hands are required to perform those works, a safety belt, secured to the ladder must be worn at all times.
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Instrumentation Instrumentat ion Tender No.: Tender/229718/Ins t-1 Project No. 229718
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Mott MacDonald Hindustan Organic Chemicals Ltd.
List of Tender Drawings & Documents
Sr. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Drawing/ Document Description Specification for Distributed Control system (DCS) Specification for Programmable Logic Controller (PLC) Specification for Pressure Transmitter Specification for Pressure Switch Specification for Pressure Gauge (With Syphon) Specification for Pressure Gauge (Chemical Seal) Specification for Temp. Element & Transmitter Specification for Temp. Gauge Specification for Temp. Coupler Specification for DPT type Level Transmitter Specification for PH Meter Specification for Rotameter Specification for DPT type flow Transmitter Specification for Mag. Flow Transmitter Specification for Valve Positioner Specification for Control Valve Specification for CL2 Gas Detector Specification for Weighing System Specification for Density & Conductivity Transmitter Specification for ORP Meter Specification for Capacitance type Level Switch Specification for Cable Specification for Impulse Tube & Fittings. Specification for Cable Tray & Supports FFJB & Inst. Location Layout for Caustic Soda Plant
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Drawing / Document No
Rev. No.
229718-NSD-01
0
229718-NSD-02
0
229718-NSD-03 229718-NSD-04
0 0
229718-NSD-05
0
229718-NSD-06
0
229718-NSD-07A & B 229718-NSD-08 229718-NSD-09 229718-NSD-10 229718-NSD-11 229718-NSD-12 229718-NSD-13 229718-NSD-14 229718-NSD-15 229718-NSD-16 229718-NSD-17 229718-NSD-18
0 0 0 0 0 0 0 0 0 0 0 0
229718-NSD-19A & B
0
229718-NSD-20
0
229718-NSD-21
0
229718-NSD-22 229718-NSD-23 229718-NSD-24
0 0 0
229718-NLE-01
0
