Bid Book

NOTICE INVITING TENDER
TENDER SPECIFICATION
BHEL: PSSR: SCT: 1518 FOR Handling at site stores / storage yard, Transportation to site of work, Preassembly, Erection, Testing and Commissioning of Power Cycle Piping and Application of Refractory & Insulation works for Boiler, ESP, Power cycle Piping and Supply & Application of Final Painting for Power Cycle piping & Insulation for Unit-2 of 1x600 MW set
at KAKATIYA THERMAL POWER PROJECT, CHELPUR VILLAGE, WARANGAL DISTRICT, AP
VOLUME I BOOK - I
TECHNOCOMMERCIAL BID (Book I & II) Book-I consists of o Notice Inviting Tender, o Volume-IA : Technical Conditions of Contract Book-II consists of o Volume-IB : Special conditions of Contract, o Volume-IC : General conditions of Contract o Volume-ID : Forms & Procedures
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking) Power Sector Southern Region 690, Anna Salai, Nandanam, Chennai 600 035.

BHARAT HEAVY ELECTRICALS LIMITED (A Government of India Undertaking) Power Sector, Southern Region 690, Anna Salai, Nandanam, Chennai 35
Tender Specification No. BHEL: PSSR: SCT: 1518 for Handling at site stores / storage yard, Transportation to site of work, Pre-assembly, Erection, Testing and Commissioning of Power Cycle Piping and Application of Refractory & Insulation works for Boiler, ESP, Power cycle Piping and Supply & Application of Final Painting for Power Cycle piping & Insulation for Unit-2 of 1x600 MW set at Kakatiya Thermal Power Project, Chelpur Village, Warangal District, AP. One set of Tender documents consisting of 1) TECHNOCOMMERCIAL BID 2) RATE SCHEDULE Book Sl no . Issued to M/s
- 2 copies - 2 copies
Refer NIT for Last date of submission Please note this tender document is not transferable For and on behalf of BHARAT HEAVY ELECTRICALS LIMITED
ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35 Date:

Tender Specification BHEL PSSR SCT 1518
Rev 01 1st Jun 2012
Bharat Heavy Electricals Limited

NIT Ref: BHEL PSSR SCT 1518, (advertised in the Newspapers on) Date: 07/12/2012
NOTICE INVITING TENDER (NIT)

NOTE: BIDDER MAY DOWNLOAD FROM WEB SITES OR PURCHASE TENDERS FROM THIS OFFICE ALSO
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To
Dear Sir/Madam
Sub : NOTICE INVITING TENDER
Sealed offers in two part bid system are invited from reputed & experienced bidders (meeting PRE QUALIFICATION CRITERIA as mentioned in Annexure-I) for the subject job by the undersigned on the behalf of BHARAT HEAVY ELECTRICALS LIMITED as per the tender document. Following points relevant to the tender may please be noted and complied with. 1.0
Sl. No
Salient Features of NIT ISSUE TENDER NUMBER Broad Scope of job BHEL PSSR SCT 1518
DESCRIPTION
i ii
iii a b c d e iv
Handling at site stores / storage yard, Transportation to site of work, Pre-assembly, Erection, Testing and Commissioning of Power Cycle Piping and Application of Refractory & Insulation works for Boiler, ESP, Power cycle Piping and Supply & Application of Final Painting for Power Cycle piping & Insulation for Unit-2 of 1x600 MW set at Kakatiya Thermal Power Project, Chelpur Village, Warangal District, AP DETAILS OF TENDER DOCUMENT Volume-IA Technical Conditions of Contract (TCC) consisting of Scope of work, Technical Specification, Drawings, Applicable Procedures, Bill of Quantities, Terms of payment, etc Volume-IB Special Conditions of Contract (SCC) Applicable Volume-IC General Conditions of Contract (GCC) Applicable Volume-ID Forms and Procedures Applicable Volume-II Price Schedule (Absolute value). Applicable Issue of 1. Sale from BHEL PSSR Regional office at Tender :Chennai Applicable

Start : Dec 07, 2012 Closes: Dec 26, 2012 , Time :15.00 Hrs 2. From BHEL website (www.bhel.com) Tender documents can however be downloaded from website till due date of submission DUE DATE & Date : Dec 27, 2012, Time :15.00Hrs Applicable TIME OF Place : BHEL PSSR :Chennai-address as below OFFER Tenders can be submitted through representative / in SUBMISSION person/post at Office of the AGM/SCT Dept, 7th floor, A wing, BHEL PSSR, EVR Periyar Building, 690, Annasalai, Nandanam, Chennai-600035. OPENING OF Date : Dec 27, 2012, Time :15.30Hrs Applicable TENDER Notes: (1) In case the due date of opening of tender becomes a non-working day, tenders shall be opened on next working day at the same time. (2) Bidder may depute representative to witness the opening of tender EMD Applicable Rs 2,00,000/- (Rupees Two Lakhs Only) AMOUNT COST OF Rs 2000/-. Applicable TENDER LAST DATE At least 7 days before the due date of offer submission FOR or two days before the scheduled date of pre-bid Applicable SEEKING meeting whichever is earlier CLARIFICATI Along with soft version also, addressing to undersigned ON & to others as per contact address given below SCHEDULE Date: Dec 20, 2012. Time 11.00AM OF Pre Bid at BHEL:PSSR:Chennai-35 Applicable Discussion (PBD) INTEGRITY Bidders shall enter into an Integrity Pact (IP) with Applicable PACT & BHEL as per format given at Volume 1D Formats of DETAILS OF this tender. The bidders are required to return this INDEPENDEN Integrity Pact (IP) along with Techno Commercial Bid T EXTERNAL duly signed and stamped by the authorized signatory MONITOR who signs the bid. It may be noted that only those (IEM) bidders who have entered into such an IP with BHEL would be competent to participate against this tender .i.e. entering into this pact is a preliminary qualifications for the bidders. The Independent External Monitor against this NIT shall be Shri Kanwarjit Singh, IRS (Rtd.) D-6/12, Ground Floor,
Documents
vi
vii viii ix
xi

Vasant Vihar, New Delhi - 110 057 Latest updates on the important dates, Amendments, Correspondences, Corrigenda, Clarifications, Changes, Errata, Modifications, Revisions, etc to Tender Specifications will be hosted in BHEL webpage only (www.bhel.com Tender Notifications View Corrigendum) and not in the newspapers. Bidders to keep themselves updated with all such information. This also form part of tender hence the same shall be enclosed with their offer.
xii Latest updates
2.0
The offer shall be submitted as per the instructions of tender document and as detailed in this NIT. Bidders to note specifically that all pages of tender document, including these NIT pages of this particular tender together with subsequent correspondences shall be submitted by them, duly signed & stamped on each page, as part of offer. Rates / Price including discounts / rebates, if any, mentioned anywhere/in any form in the techno-commercial offer other than the Price Bid, shall not be entertained. Unless specifically stated otherwise, bidder shall remit cost of tender and courier charges if applicable, in the form of Demand Draft drawn in favour of Bharat Heavy Electricals Ltd, payable at Power Sector Regional HQ at Chennai issuing the Tender, along with techno-commercial offer. Bidder may also choose to deposit the Tender document cost by cash at the Cash Office as stated above against sl no iv of 1, on any working day; and in such case copy of Cash receipt is to be enclosed with the Techno Commercial offer. Sale of tender Documents shall not take place on National Holidays, holidays declared by Central or State Governments and BHEL PS HQ at Chennai, Sundays and second/ last Saturdays Unless specifically stated otherwise, bidder shall deposit EMD through Demand Draft/Pay Order in favour of Bharat Heavy Electricals Ltd, payable at Chennai. For other details and for One Time EMD please refer General Conditions of Contract. Procedure for Submission of Tenders: The Tenderers must submit their Tenders to Officer inviting Tender, as detailed below: PART-I consisting of PART-I A (Techno Commercial Bid) & PART-I B (EMD/COST of TENDER) in two separate sealed and superscribed envelopes (ENVELOPE-I & ENVELOPE-II) PART-II(Price Bids) in sealed and superscribed envelope (ENVELOPE-III) One set of each document shall be retained by the bidder for their reference. The contents for ENVELOPES and the superscription for each sealed cover / Envelope are as given below. (All pages to be signed and stamped)
3.0
4.0
5.0
6.0

Sl no Description Part-I A ENVELOPE I superscribed as : PART-I (TECHNO COMMERCIAL BID) TENDER NO : NAME OF WORK : PROJECT: DUE DATE OF SUBMISSION: CONTAINING THE FOLLOWING:i. Covering letter/Offer forwarding letter of Tenderer. ii. Duly filled-in `No Deviation Certificate' as per prescribed format to be placed after document under sl no (i) above. Note: a. In case of any deviation, the same should be submitted separately for technical & commercial parts, indicating respective clauses of tender against which deviation is taken by bidder. The list of such deviation shall be placed after document under sl no (i) above. It shall be specifically noted that deviation recorded elsewhere shall not be entertained. BHEL reserves the right to accept/reject the deviations without assigning any reasons, and BHEL decision is final and binding. (i) In case of acceptance of the deviations, appropriate loading shall be done by BHEL (ii) In case of unacceptable deviations, BHEL reserves the right to reject the tender. iii. Supporting documents / annexure / schedules / drawing etc as required in line with Pre-Qualification criteria. It shall be specifically noted that all documents as per above shall be indexed properly and credential certificates issued by clients shall distinctly bear the name of organization, contact ph no, FAX no, etc. iv. All Amendments / Correspondences / Corrigenda / Clarifications / Changes / Errata etc pertinent to this NIT. v. Integrity Pact Agreement (Duly signed by the authorized signatory) If appli cable vi. Duly filled-in annexures, formats etc as required under this Tender Specification / NIT vii. Notice inviting Tender (NIT) viii. Volume I A : Technical Conditions of Contract (TCC) consisting of Scope of work, Technical Specification, Drawings, Procedures, Bill of Quantities, Terms of payment, etc b. Remarks

Volume I B : Special Conditions of Contract (SCC) Volume I C : General Conditions of Contract (GCC) Volume I D : Forms & Procedures Volume II (UNPRICED without disclosing rates/price, but mentioning only QUOTED or UNQUOTED against each item xiii. Any other details preferred by bidder with proper indexing. PART-I B ENVELOPE II superscribed as: PART-I (EMD/COST of TENDER) TENDER NO : NAME OF WORK : PROJECT: DUE DATE OF SUBMISSION: CONTAINING THE FOLLOWING:i. 1. Earnest Money Deposit (EMD) in the form as indicated in this Tender OR Documentary evidence for One Time EMD with BHEL PSSR Chennai 2. Cost of Tender (Demand Draft or copy of Cash Receipt as the case may be) PART-II PRICE BID consisting of the following shall be enclosed ENVELOPE-III superscribed as: PART-II (PRICE BID)TENDER NO : NAME OF WORK : PROJECT: DUE DATE OF SUBMISSION: i ii CONTAINING THE FOLLOWING Covering letter/Offer forwarding letter of Tenderer enclosed in Part-I Volume II PRICE BID ( Duly Filled in Schedule of Rates rate / price to be entered in words as well as figures) OUTER COVER ENVELOPE-IV (MAIN ENVELOPE / OUTER ENVELOPE) superscribed as: TECHNO-COMMERCIAL BID, PRICE BID & EMD TENDER NO: NAME OF WORK: Refer NIT CL 1.0 (v) for place ix. x. xi. xii.

PROJECT: DUE DATE OF SUBMISSION: CONTAINING THE FOLLOWING: i of tender submi ssion
o Envelopes I o Envelopes II o Envelopes III SPECIAL NOTE: All documents / annexures submitted with the offer shall be properly annexed and placed in respective places of the offer as per enclosure list mentioned in the covering letter. BHEL shall not be responsible for any missing documents. Deviation with respect to tender clauses and additional clauses/ suggestions/ in Techno-commercial bid/ Price bid shall NOT be considered by BHEL. Bidders are requested to positively comply with the same. BHEL reserves the right to accept or reject any or all Offers without assigning any reasons thereof. BHEL also reserves the right to cancel the Tender wholly or partly without assigning any reason thereof. Also BHEL shall not entertain any correspondence from bidders in this matter (except for the refund of EMD). Assessment of Capacity of Bidders: Bidders capacity for executing the job under tender shall be assessed LOAD wise and PERFORMANCE wise as per the following: I. LOAD: Load takes into consideration ALL the contracts of the Bidder under execution with BHEL Regions, irrespective of whether they are similar to the tendered scope or not. The Load is the sum of the unit wise identified packages (refer Table-1) for contracts with BHEL Regions. The cut off month for reckoning Load shall be the month, two (2) months preceding the month corresponding to the latest date of bid submission, in the following manner: (Note: For example if latest bid submission is in Aug 2011, then the load shall be calculated upto and inclusive of June 2011) i). Total number of Packages Total number of Packages in hand = P Where P is the sum of all unit wise identified packages under execution with BHEL Regions as of the cut off month defined above, including packages yet to be commenced. Weightage A assigned to bidders based on Total number of Packages P: a) If P = 0-9, : A will be equal to 4
7.0
8.0
9.0
ii)

b) c) d) e) II. If P = 10-18, If P = 19-36, If P = 37-60, If P is above 60 : : : : A will be equal to 3 A will be equal to 2 A will be equal to 1 A will be equal to 0
PERFORMANCE: Here Monthly Performance of the bidder for all the packages (under execution/ executed during the Period of Assessment in all the Power Sector Regions of BHEL) SIMILAR to the packages covered under the tendered scope, excepting packages not commenced shall be taken into consideration. The Period of Assessment shall be 6 months preceding the cut off month. The cut off month for reckoning Period of Assessment shall be the month two (2) months preceding the month corresponding to the latest date of bid submission, in the following manner: (Note: For example if latest date of bid submission is in Aug 2011, then the performance shall be assessed for a 6 month period upto and inclusive of June 2011, for all the unit wise identified packages (refer Table I) i). Calculation of Overall Performance Rating for similar Package/Packages for the tendered scope under execution at Power Sector Regions: This shall be obtained by summing up the Monthly Performance Evaluation scores obtained by the bidder in all Regions for all the similar Package/packages, divided by the total number of Package months for which evaluation should have been done, as per procedure below: a) P1, P2, P3 , P4 , P5 , . PN etc be the packages (under execution/ executed during the Period of Assessment in all Regions) SIMILAR to the packages covered under the tendered scope, excepting packages not commenced. Total number of similar packages for all Regions = PT ( ie PT = P1 +P2 + P3 +P4 + .. PN ) b) Number of Months T1 for which Monthly Performance Evaluation as per relevant formats, should have been done in the Period of Assessment for the corresponding similar package P1. Similarly T2 for package P2, T3 for package P3, etc for the tendered scope. Now calculate cumulative total months TT for total similar Packages PT for all Regions ( i.e TT = T1 + T2 + T3 +T4 + .. TN ) c) Sum S1 of Monthly Performance Evaluation Scores (S1-1, S1-2, S1-3, S14, S1-5,. S1-N ) for similar package P1, for the period of assessment T1 (i.e S1 = S1-1+ S1-2+ S1-3+ S1-4+ S1-5+S1-N). Similarly S2 for package P2 for period T2, S3 for package P3 for period T3, etc for the tendered

scope for all Regions. Now calculate cumulative sum ST of Monthly Performance Evaluation Scores for total similar Packages PT for all Regions (i.e ST = S1+ S2+ S3+ S4+ S5+. SN.) d) Overall Performance Rating RBEHL for the similar Package/Packages (under execution/ executed during the Period of Assessment) in all the Power Sector Regions of BHEL): Aggregate of Performance scores for all similar packages in all the Regions = ------------------------------------------------------------------------------------------Aggregate of months for each of the similar package for which performance should have been evaluated in all the Regions = ST ------TT
e) Bidders to note that the risk of non-evaluation or non-availability of the Monthly Performance Evaluation reports as per relevant formats is to be borne by the Bidder f) Table showing methodology for calculating a, b and c above Sl no Item Description Details for all Regions Total (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) 1 Similar Packages for P1 P2 P3 P4 P5 PN Total No of all Regions similar packages for all Regions = PT ie Sum () of columns (iii) to (ix) 2 Number of Months T1 T2 T3 T4 T5 TN Sum () of for which Monthly columns Performance (iii) to (ix) Evaluation as per relevant formats = TT should have been done in the period of assessment for corresponding similar Package ( as in row

1) Monthly performance scores for the corresponding period (as in Row 2)
S1-1, S1-2, S1-3, S1-4, S1-T1 Sum of Monthly S1 Performance scores of the corresponding Package for the corresponding period (as in row-3) ii)
S2-1, S2-2, S2-3, S2-4, S2-T2 S2
S3-1, S3-2, S3-3, S3-4, S3-T3 S3
S4-1, S4-2, S4-3, S4-4, S4-T4 S4
S5-1, S5-2, S5-3, S5-4, S5-T5 S5
..
SN-1, SN-2, --------SN-3, SN-4, SN-TN SN Sum () of columns (iii) to (ix) = ST
Weightage B assigned to bidders based on Overall Performance Rating (RBHEL) at Power Sector Regions, for the respective Package: a) If RBHEL is 80%, B will be equal to 6 b) If RBHEL is 75% < 80%, B will be equal to 5 c) If RBHEL is 70% < 75%, B will be equal to 4 d) If RBHEL is 65% < 70%, B will be equal to 3 e) If RBHEL is 60% < 65%, B will be equal to 2 f) If RBHEL is < 60%, B will be equal to 0 Assessment of Capacity of Bidder to be Qualified for the tender: Shall be based on the sum of the weightages obtained in LOAD (A) and PERFORMANCE (B) as below: a) If the sum (A+B) is 6 or above for each of the applicable Package, then the Bidder is considered Qualified for the tender b) If the sum (A+B) is less than 6 for any of the applicable Package, then the Bidder is considered NOT Qualified for the tender Explanatory note: a) Similar package means Boiler or ESP or Piping or Turbine or Civil or Structure or Electrical or CI, etc at the individual level irrespective of rating of Plant, and irrespective of whether the subject tender is a single package or as part of combined/composite packages. Normally Boiler, ESP, Piping, Turbine, Electrical, CI, Civil, Structure, etc is considered individual level of package. For example in case the tendered scope is a Boiler Vertical Package comprising of Boiler, ESP and Power Cycle Piping (i.e the identified packages as per TabIe-1 below), the PERFORMANCE part against sl no II above, needs to be evaluated considering all the identified packages (ie Boiler, ESP and Power Cycle
III.
IV.

Piping) and finally the Bidders capacity to execute the tendered scope is assessed in line with III above b) Identified Packages (Unit wise) Table-1 Civil Electrical & CI Mechanical i). Enabling works i). Electrical i). Boiler & Aux (All types ii). Pile and Pile ii). CI including CW Piping if Caps iii). Others (Elec applicable) iii). Civil Works & CI) ii). Power Cycle including Piping/Critical Piping foundations iii). LP Piping iv). Structural Steel iv). ESP Fabrication & v). Steam Turbine Erection Generator set & Aux v). Chimney vi). Gas Turbine vi). Cooling Tower Generator set & Aux vii). Others (Civil) vii). Hydro Turbine Generator set & Aux viii). Turbo Blower (including Steam Turbine) ix). Material Handling x). Material Management xi). Material Handling & Material Management xii). Others (Mechanical) c) Vendors who are first timers to any BHEL Region, may be considered subject to satisfying other tender conditions. Eligibility of the party for the next tender of any package in that Region, shall be subject to the bidder satisfying the Assessment of Capacity of Bidder for a period of first nine months after commencement of work or contract duration whatever is lesser. In case the first timer is executing any other packages in any BHEL Region, then the performance evaluation will be based on the data available for the other packages though not similar, for the Period of assessment, for the purpose of Assessment of Capacity of Bidder d) Vendors who are not first timers and who have not been executing any package or packages similar to the packages under the tender in the

Period of assessment, shall be considered qualified subject to them satisfying all other tender conditions. e) In the unlikely event of all bidders shortlisted against Technical and Financial Qualification criteria not meeting the criteria on Assessment of Capacity of Bidders detailed above, OR leads to a single tender response on applying the criteria of Assessment of Capacity of Bidders, then BHEL at its discretion, reserves the right to consider the further processing of the Tender based on the Overall Performance Rating RBHEL only. f) Under execution shall mean works in progress as per the following: i. upto Boiler Steam Blowing in case of Steam Generator and Auxilliaries ii. upto Synchronisation in case of all other works excepting sl no (i) and (iii) iii. upto execution of at least 75% of anticipated contract value (unit wise), in case of Enabling works or Civil & Structures. Note : BHEL at its discretion can extend (or reduce in exceptional cases in line with Contract conditions) the period defined against (i), (ii) and (iii) above, depending upon the balance scope of work to be completed. g) Performance evaluation in CL 9 above is applicable to Prime bidder and consortium partner (or Technical tie up partner) for their respective scope of work. 10.0 Since the job shall be executed at site, bidders must visit site/ work area and study the job content, facilities available, availability of materials, prevailing site conditions including law & order situation ,applicable wage structure, wage rules, etc before quoting for this tender. They may also consult this office before submitting their offers, for any clarifications regarding scope of work, facilities available at sites or on terms and conditions. 11.0 For any clarification on the tender document, the bidder may seek the same in writing or through e-mail, as per specified format, within the scheduled date for seeking clarification, from the office of the undersigned. BHEL shall not be responsible for receipt of queries after due date of seeking clarification due to postal delay or any other delays. Any clarification / query received after last date

for seeking clarification may not be normally entertained by BHEL and no time extension will be given. 12.0 BHEL may decide holding pre-bid discussion [PBD] with all intending bidders as per date indicated in the NIT. The bidder shall ensure participation for the same at the appointed time, date and place as may be decided by BHEL. Bidders shall plan their visit accordingly. The outcome of pre-bid discussion (PBD) shall also form part of tender. 13.0 In the event of any conflict between requirement of any clause of this specification / documents / drawings / data sheets etc or requirements of different codes / standards specified, the same to be brought to the knowledge of BHEL in writing for clarification before due date of seeking clarification (whichever is applicable), otherwise, interpretation by BHEL shall prevail. Any typing error/missing pages / other clerical errors in the tender documents, noticed must be pointed out before pre-bid meeting / submission of offer, else BHELs interpretation shall prevail. 14.0 Unless specifically mentioned otherwise, bidders quoted price shall deemed to be in compliance with tender including PBD. 15.0 Bidders shall submit Integrity Pact Agreement (Duly signed by authorized signatory who signs in the offer), if applicable, along with techno-commercial bid. This pact shall be considered as a preliminary qualification for further participation. The names and other details of Independent External Monitor (IEM) for the subject tender is as given at point (1) above. 16.0 The Bidder has to satisfy the Pre-Qualifying Requirements stipulated for this Tender in order to be qualified. The Price Bids of only those bidders will be opened who will be qualified for the subject job on the basis of satisfying the prequalification criteria specified in this NIT as per Annexure--1(as applicable) past performance etc. and date of opening of price bids shall be intimated to only such bidders. BHEL reserves the right NOT to consider offers of parties under HOLD. 17.0 In case BHEL decides on a `Public Opening', the date & time of opening of the sealed PRICE BID shall be intimated to the qualified bidders and in such a case, bidder may depute one authorised representative to witness the price bid opening. BHEL reserves the right to open in-camera the PRICE BID of any or all Unsuccessful/Disqualified bidders under intimation to the respective bidders. 18.0 Validity of the offer shall be for six months from the latest due date of offer submission (including extension, if any) unless specified otherwise. 19.0 BHEL reserves the right to decide the successful bidder on the basis of Reverse Auction process. In such case all qualified bidders will be intimated regarding procedure/ modality for Reverse Auction process prior to Reverse Auction and price will be decided as per the rules for Reverse Auction. . However, if reverse auction process is unsuccessful as defined in the RA

rules/procedures, or for whatsoever reason, then the sealed PRICE BIDs will be opened for deciding the successful bidder. BHELs decision in this regard will be final and binding on bidder. 20.0 Consideration 20.1 On submission of offer, further consideration will be subject to compliance to tender & qualifying requirement and customers acceptance, as applicable. 20.2 The offers of the bidders who are on the banned list as also the offer of the bidders, who engage the services of the banned firms, shall be rejected. The list of banned firms is available on BHEL web site. 21.0 In case the bidder is an Indian Agent of Foreign Principals, Agency agreement has to be submitted along with Bid, detailing the role of the agent along with the terms of payment for agency commission in INR, along with supporting documents. The bidders shall not enter into any undisclosed M.O.U. or any understanding amongst themselves with respect to tender. Consortium Bidding (or Technical Tie up) shall be allowed only if specified in Pre- Qualifying Requirement (PQR) criteria, and in such a case the following shall be complied with: Prime Bidder and Consortium Partner or partners are required to enter into a consortium agreement with a validity period of six months initially. In case the consortium is awarded the contract, then the Consortium Agreement between the Prime Bidder and Consortium Partner or partners shall be extended till contractual completion period including extension periods if any applicable. Standalone bidder cannot become a Prime Bidder or a Consortium bidder or Technical Tie up bidder in a consortium (or Technical Tie up) bidding. Prime bidder shall neither be a consortium partner to other prime bidder nor take any other consortium partners. However, consortium partner may enter into consortium agreement with other prime bidders. In case of noncompliance, consortium bids of such Prime bidders will be rejected. Number of partners for a consortium Bidding (or Technical Tie up) shall be as specified in the PQR Prime Bidder shall be as specified in the Pre-Qualification Requirement, else the bidder who has the major share of work In order to be qualified for the tender, Prime Bidder and Consortium partner or partners shall satisfy (i) the Technical Pre Qualifying Requirements specified
22.0 23.0
23.1
23.2
23.3 23.4 23.5

for the respective package, (ii) Assessment of Capacity of Bidder as specified in clause 9.0 23.6 23.7 23.8 Prime Bidder shall comply with additional Technical criteria of PQR as defined in Explanatory Notes for the PQR Prime Bidder shall comply with all other Pre Qualifying criteria for the Tender unless otherwise specified In case customer approval is required, then Prime Bidder and Consortium Partner or partners shall have to be individually approved by Customer for being considered for the tender. Prime Bidder shall be responsible for the overall execution of the contract In case of award of job, Performance shall be evaluated for Prime Bidder and Consortium Partner or partners for their respective scope of work(s) as per prescribed formats In case the Consortium partner or partners back out, their SDs shall be encashed by BHEL. In such a case, other consortium partner or partners meeting the PQR have to be engaged by the Prime Bidder, and if not, the respective work will be withdrawn and executed on risk and cost basis of the Prime Bidder. The new consortium partner or partners shall submit fresh SDs as applicable. In case the prime Bidder withdraws, the whole contract shall be considered cancelled and short closed. After execution of work, the work experience shall be assigned to the Prime Bidder and the consortium partner or partners for their respective scope of work. After successful execution of two similar works with the same consortium partner or partners under direct orders of BHEL, the Prime Bidder shall be eligible for becoming a standalone bidder for similar works, subject to certification from BHEL about the active involvement of the Prime Bidder for satisfactory execution of the works. The consortium partner shall submit SD equivalent to 2% of the total contract value in addition to the SD to be submitted by the prime Bidder for the total contract value. In case there are two consortium partners, then each partner shall submit SD equivalent to 1% of the total contract value in addition to the SD to be submitted by the prime Bidder for the total contract value.
23.9 23.10
23.11
23.12 23.13
23.14

23.15 24.0 In case of a Technical Tie up, all the clauses applicable for the Consortium partner shall be applicable for the Technical Tie up partner also The bidder shall submit documents in support of possession of Qualifying Requirements duly self-certified and stamped by the authorized signatory, indexed and properly linked in the format for PQR. In case BHEL requires any other documents/proofs, these shall be submitted immediately. The bidder may have to produce original document for verification if so decided by BHEL.
25.0
26.0 Order of Precedence In the event of any ambiguity or conflict between the Tender Documents, the order of precedence shall be in the order below: a. Amendments/Clarifications/Corrigenda/Errata etc issued in respect of the tender documents by BHEL b. Notice Inviting Tender (NIT) c. Price Bid d. Technical Conditions of Contract (TCC)Volume-1A e. Special Conditions of Contract (SCC) Volume-1B f. General Conditions of Contract (GCC) Volume-1C g. Forms and Procedures Volume-1D For BHARAT HEAVY ELECTRICALS LTD Enclosure 01. Annexure-1: Pre Qualifying criteria. 02. Annexure-2: Check List. 03 Other Tender documents as per this NIT. AGM /SCT

ANNEXURE - 1
PRE QUALIFYING CRITERIA
JOB
TENDER NO SL NO
Handling at site stores / storage yard, Transportation to site of work, Preassembly, Erection, Testing and Commissioning of Power Cycle Piping and Application of Refractory & Insulation works for Boiler, ESP, Power cycle Piping and Supply & Application of Final Painting for Power Cycle piping & Insulation for Unit-2 of 1x600 MW set at Kakatiya Thermal Power Project, Chelpur Village, Warangal District, AP BHEL PSSR SCT 1518 Bidders claim in respect of fulfilling the PQR Criteria Name and Description Page no of of qualifying criteria supporting document. Bidder must fill up this column as per applicability
PRE QUALIFICATION CRITERIA
B C: C-1
C-2
Submission of Integrity Pact duly signed (if applicable) Applicable (Note: To be submitted by Prime Bidder & Consortium/Technical Tie up partner jointly in case Consortium bidding is permitted, otherwise by the sole bidder) Technical Applicable Refer Annexure-3 Financial Applicable TURNOVER Bidders must have achieved an average annual financial turnover (Audited) of Rs 550 Lakhs or more over last three Financial Years ending on 31.3.2012 (FY) i.e 2009-2010, 2010-2011,20112012 NETWORTH (only in case of Companies) Net worth of the Bidder based on the latest Audited Accounts as furnished for C-1 above should be positive PROFIT Bidder must have earned cash profit in
Fill the details in Annexure-4 Fill the details in Annexure-4
Fill the details in Annexure-4
C-3
Fill the details in Annexure-4

any one of the three Financial Years as applicable in the last three Financial Years defined in C-1 above based on latest Audited Accounts. D E Assessment of Capacity of Bidder to Applicable execute the work as per sl no 9 of NIT (if applicable) Approval of Customer (if applicable) Not Applicable Note: Names of bidders (including consortium/Technical Tie up partners in case consortium bidding is permitted) who stand qualified after compliance of criteria A to D shall be forwarded to customer for their approval. Price Bid Opening Applicable Note: Price Bids of only those bidders shall be opened who stand qualified after compliance of criteria A to E Consortium/Tie-up criteria (if Applicable applicable) By BHEL BY BHEL
BY BHEL
Explanatory Notes for the PQR (unless otherwise specified in the PQR): 1. Bidder to submit Audited Balance Sheet and Profit and Loss Account for the respective years as indicated against C-1 above along with all annexures 2. In case audited Financial statements have not been submitted for all the three years as indicated against C-1 above, then the applicable audited statements submitted by the bidders against the requisite three years, will be averaged for three years i.e total divided by three. 3. C-2:-NETWORTH: Shall be calculated based on the latest Audited Accounts as furnished for C-1 above. Net worth = Paid up share capital + Reserves. (Net worth is required to be evaluated in case of companies) 4. C-3:- PROFIT : shall be NET profit (PAT + Non cash expenditure viz depreciation) earned during any one of the three financial years as in C-1 above 5. Additional Criteria in respect of Technical criteria of PQR (as in B above) for Civil, Electrical, CI, unless otherwise specified : 1. Bidder should have executed similar work of any one of the following: a. One (1) work of value not less than Rs XXX OR b. Two (2) works of not less than Rs YYY OR c. Three (3) works of not less than Rs ZZZ

(Value XXX, YYY, ZZZ shall be as indicated by BHEL Similar work for criteria 5 above means a. Civil or Structures or Civil & Structures or Chimney respectively as applicable to the tendered scope in respect of CIVIL Works b. Electrical works in respect of ELECTRICAL c. CI works in respect of CI Works d. Material Handling and/or Management works in respect of MM works
2.
6. Time period for achievement of the Technical criteria of PQR (as in B above) will be the last 7 years ending on the latest date of Bid submission 7. EXECUTED means the Vendor should have achieved the criteria specified in the Technical criteria of PQR (as in B above) even if the Contract has not been completed or closed 8. Unless otherwise specified, for the purpose of Technical criteria of PQR ( as in B above), the word EXECUTED means: 1. BOILER LIGHT UP in respect of Boiler & Aux and ESP 2. SYNCHRONISATION in respect of STG/GTG and SPINNING in case of HTG 3. STEAM BLOWING COMPLETION in respect of at least Main Steam Line of Power Cycle Piping 4. HYDRAULIC TEST of the system in respect of Structures, Pressure parts/IBR Piping 5. CHARGING in respect of power Transformers, Bus ducts, HT/LT switchgears 6. Completion of RCC Shell and liner (steel or brick as per tendered scope) up to the HEIGHT specified using slip form in case of RCC Chimney. 7. Achievement of physical Quantities as per respective PQRs in respect of Civil & Structures and Piling Works 8. Readiness for coal Filling in respect of Bunker Structure Work. 9. Boiler means HRSG or WHRB or any other types of Steam Generator 10. Critical/Power Cycle piping means Main Steam, Hot Reheat, Cold Reheat, HP Bypass, LP Bypass lines 11. For the purpose of evaluation of the PQR, one MW shall be considered equivalent to 3.5TPH where ever rating of HRSG/BOILER is mentioned in MW. Similarly, where ever rating of Gas Turbine is mentioned in terms of Frame size, ISO rating in terms of MW shall be considered for evaluation. 12. In case the experience/PO/WO certificate enclosed by bidders do not have separate break up prices for the E&C portion of Electrical and CI Works, (i.e. the certificates enclosed are for composite order for supply and erection of Electrical & CI and other works if any), then value of Erection and Commissioning for the Electrical & CI portion shall be considered as 15% of the supply & erection of Electrical & CI, unless otherwise specifically indicated in the PQR. 13. Scope for capital overhaul of STG shall cover Bearing Inspection work and

overhauling of all cylinders of the Turbine unless otherwise specifically indicated in the PQR. 14. In case the tendered scope is not a Pulverised Fuel Boiler, experience of Oil/Gas Fired Boilers also can be considered unless otherwise specifically indicated in the PQR. BIDDER SHALL SUBMIT ABOVE PRE-QUALIFICATION CRITERIA FORMAT, DULY FILLED-IN, SPECIFYING RESPECTIVE ANNEXURE NUMBER AGAINST EACH CRITERIA AND FURNISH RELEVANT DOCUMENT INCLUSIVE OF WORK OREDER AND WORK COMPLETION CERTIFICATE ETC IN THE RESPECTIVE ANNEXURES IN THEIR OFFER.

ANNEXURE - 2 CHECK LIST NOTE: - Tenderers are required to either fill in or submit separately the following details. 1 Name and Address of the Tenderer 2 Details about type of the Firm / Company Details of Contact person for this Tender: Name : Mr / Ms Designation: 3a Telephone No: Mobile No: Fax No: E-mail ID: Details of alternate Contact person for this Tender: Name : Mr / Ms Designation: 3b Telephone No: Mobile No: Fax No: E-mail ID: EMD DETAILS 4 DD No: Date : Bank : Amount: Please tick ( ) whichever applicable:ONE TIME EMD / ONLY FOR THIS TENDER To be valid for six months from due date APPLICABILITY ENCLOSED (by BHEL) BY BIDDER Whether the format for compliance with PRE QUALIFICATION CRITERIA is understood and 6 Applicable filled with proper supporting documents referenced in the specified format 7a Audited profit and Loss Account for the last three years submitted Applicable YES / NO
5 Validity of offer
YES/NO

7b Audited profit and Loss Account of Tie-up guarantor Applicable for the last three years submitted Applicable YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO
8 Copy of PAN Card submitted
Whether all pages of the Tender documents 9 including annexures, appendices etc are read Applicable understood and signed 10 Integrity Pact 11 Declaration by Authorised Signatory 12 No Deviation Certificate 13 Declaration confirming knowledge about Site Conditions Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable
14 Declaration for relation in BHEL 15 Non-Disclosure Certificate 16 Bank Account Details for E-Payment 16 Capacity Evaluation of Bidder for current Tender 17 18 Tie Ups / Consortium Agreement are submitted as per format Power of Attorney for Submission of Tender / Signing Contract Agreement
19 Analysis of Unit rates 20 Unquoted price bid submitted or not NOTE: STRIKE OFF YES OR NO, AS APPLICABLE
Date:
AUTHORISED SIGNATORY (With Name, Designation and Company seal)

ANNEXURE 3 Qualification Criteria A. Bidder should have executed Erection and commissioning of one Boiler or Power Cycle Piping of a unit rating 190MW or above capacity in a Power plant in the last seven years preceding the latest due date of bid submission. OR Bidder should have executed Erection and commissioning of One STG of minimum 630MW rating under direct order from BHEL in a power plant subject to having a tie-up with an associate who has executed either Boiler pressure parts of 190MW rating or above capacity with his own T&P and consumables (OR) IBR/ power cycle piping of 190MW rating or above capacity with his own T&P and consumables in the last seven years preceding the latest due date of bid submission, provided the bidder and associate, together, satisfies the conditions stipulated in the Annexure-A. Note: 1. The term executed in the above QR means Completion of Steam Blowing. 2. Incase of tie-up, the associate shall submit SD equivalent to 2% of the total contract value (quoted value) in addition to the SD submitted by the prime bidder for the total contract value. The validity of BG shall be six months initially while submitted along with offer and on successful the same shall be extended up to the contract period.

ANNEXURE-4 Name of the Bidder: M/s...
Additional Format to be submitted by Bidders in an additional separate cover superscribed as"Annexure to Pre-Qualifying Criteria" Sl.No. PQR Ref PQR Qualifying Work Experience order Ref with page no in Offer for supporting documents Completion certificate ref for the referred Work with page no in Offer for supporting documents Details Remarks of work with Project, Unit , Qty & Period
1 A: Technical 1.1.1
Bidder should have executed Erection and commissioning of one Boiler or Power Cycle Piping of a unit rating 190MW or above capacity in a Power plant in the last seven years preceding the latest due date of bid submission. (OR)
2 1.1.2
Bidder should have executed Erection and commissioning of One STG of minimum 630MW rating under direct order from BHEL in a power plant subject to having a tie-up with an associate who has executed either Boiler pressure parts of 190MW rating or above capacity with his own T&P and consumables (OR) IBR/ power cycle piping of 190MW rating or above capacity with his own T&P and consumables in the last seven years preceding the latest due date of bid

submission, provided the bidder and associate, together, satisfies the conditions stipulated in the Annexure-A 3 C:Financial Criteria 4 C1 Financial TURNOVER Bidders must have achieved an average annual financial turnover (Audited) of Rs 550 Lakhs or more over last three Financial Years ending on 31.3.2012 (FY) i.e, 2009-2010, 2010-2011,2011-2012 NETWORTH (only in case of Companies) Net worth of the Bidder based on the latest Audited Accounts as furnished for C-1 above should be positive PROFIT Bidder must have earned cash profit in any one of the three Financial Years as applicable in the last three Financial Years defined in C-1 above based on latest Audited Accounts. Non submission of this additional format (Annexure-4) will make the bid liable for rejection.
5 C2
6 C3

Anneure-5
Tender Schedule
Description Technical Bid Opening Communication from BHEL for Clarifications, if any, required by BHEL Last date for Bidders to submit the clarifications / documents required If Reverse Auction is applicable, then the tentative date for conducting Reverse Auction Schedule As mentioned in Notice Inviting Tender. On or before fifth day from the tender opening day On or before tenth day from the tender opening day Twenty first day from the tender opening day Remarks
Bidders to note that their competent representative to be readily available in this week for offering clarifications / submitting the further documents, if any, required. Exact date of reverse auction shall be informed to the bidders through BHELs reverse auction agency. Bidders to note that their competent representative to be readily available at one day notice for Reverse Auction.
Note: 1. Bidders to note that the above schedule should be adhered to and no further extension will be given. To adhere to the schedule indicated below, Bidders should ensure the adequacy of the documents submitted in their offer, with proper validation. 2. Bidders who have not been working with Power Sector Regions of BHEL in the last twelve months should enclose the duly filled in certificates for performance as per the format provided in Notice Inviting Tender in Annexure-6

Annexure-6 Performance certificate Performance certificate to be submitted by bidders who have not been working with any of the four BHEL Regions in the last 12 months previous to the latest date of bid submission. Performance of the Agency XXXXXXXXXXXXXXX in Project XXXXXXXX Name of the Agency : Address of the agency : Work Order issued : Erection and Commissioning works in Project XXXXX under work order dated xx.xx.xxxx under reference number / LoI number XXXXXXXXXXX for the scope of XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX. (Copy of work order issued enclosed) Duration of work as per contract without extended periods : XX months Time taken for actual completion of works : XX months (Actual completion of works will mean the completion of contracted works enabling the intended purpose of contract, and not necessarily the closure of contract) Delays in execution of works attributable to contractor : XX months Performance of the Contractor in the referred works : Sl.No. Description of Parameter Max. Please Remarks, Marks enter your if any score here 01 Performance Technical performance with 45 respect to plan, progress achieved and organization of works at site and HQ 02 Resources Capacity to plan, organize and utilize 20 the resources like skilled manpower, T & P, Consumables 03 Management of Finance for the project 7 04 Compliance with Safety requirements 10 05 Compliance with Quality requirements 10 06 Site infrastructure and services 8 Total 100 X Total score of the Agency XXXXXXXXXXXXXXX in work above is (in words)________________________________________ Signature Name and Seal of the issuing Authority

Note: The average marks scored by the bidder in the qualifying works should be above 60% for qualifying the bidder against tendered work. For Ex: A1.1.1 or A1.1.2: there is one projects with score say x1, or x2 The score= x1 (or) x2 >60 is considered as qualified Further to this BHEL reserves the right to obtain feedback from customer directly and any adverse report from respective customers on the performance of the bidder will render the bidder liable for rejection.
Annexure-A Associate MUST 1. The associate must have executed the respective area of work in the last seven years preceding the scheduled date of bid submission can provide tie-up. 2. The associate must also satisfy the assessment of capacity of Bidders indicated for the Bidder in NIT and his performance in this project will also be assessed for loading purpose. 3. The associate must also attend the monthly reviews and be a joint signatory to monthly evaluation of progress. 4. The associate must function with the spirit of ensuring the performance of the bidder for successful completion of the scope of the works tendered. 5. The tie-up shall be technically specific to the project. The bidder will be individually and severally responsible for the execution of the contract. 6. In the event of failure of bidder in the execution of the contract, the associate shall ensure the smooth execution of the part of the contract. 7. In the event of breach by the associate necessitating replacement and deploying a new Associate should satisfy the technical criteria as stipulated and the bidder shall ensure the smooth execution of the contract. 8. In so far as BHEL is concerned, the bidder and / or associates shall be jointly and severally responsible and liable to BHEL in execution of the contract. 9. The overall responsibility of execution of contract rests with the bidder 10. On Completion of works, the experience certificate of subject work execution will be assigned to the bidder on whom the award has been placed with a mentioning that The bidder executed the subject work ___________in association with M/s __________.

Tie-up Agreement (To be executed on Rs.100/- nonjudicial stamp paper) THIS AGREEMENT is made and executed on this _______ day of _______, between (1) M/s _____________________(the First Party, i.e, the Bidder) a company incorporated under the Company's Act 1956, having its registered office at ________________________(hereinafter called the "Bidder", which expression shall include its successors, administrators, executors and permitted assigns) and (2) M/s ________________________, (the Second Party, i.e, the Associate), a company incorporated under the Company's Act 1956, having its registered office at ________________________ (hereinafter called the Associate", which expression shall include its successors, administrators, executors and permitted assigns). WHEAEAS the owner, M/s.Bharat Heavy Electricals Ltd, a Government of India undertaking, proposes to issue / issued an NIT (hereinafter referred to as the said NIT) inviting bids from the individual bidders for undertaking the work of ____________________________________________________________, at _____________________________ (hereinafter referred to as the said works). WHEREAS the said NIT enables submission of a bid with an Associate Tie-up Agreement subject to fulfillment of the Qualification criteria and other tender conditions specified in the said NIT. AND WHEREAS M/s _____________________________ (The First Party, i.e, the Bidder) will submit its proposal in response to the aforesaid invitation to bid by the Owner for ______________________________________________ (as detailed in the Bid doc. no. < TENDER REF--------> ) AND WHEREAS M/s _______________________ (The First Party, i.e the Bidder) itself is meeting the qualifying requirements in PQR _________________and financial criteria ____________________________________________ (as detailed in the NIT) and in order to fully meet the qualifying requirements of _____________________ in NIT, this tie-up agreement is being entered into with M/s __________________________ (The Second Party, the Associate) , who fully meets the balance part of the said works (_____________________________). WHEREAS the First Party and the Second Party are contractors engaged in the business of carrying out similar/various items of works. WHEREAS the two parties have agreed to constitute themselves into an Associate Tie-up agreement for the purpose of carrying out the said works, and that the agreement will be continued till the completion of the works in all respects. The associate will undertake and

complete the work in case the bidder fails to execute the subject work with the same terms and conditions of the subject tender. WHEREAS the parties have agreed to certain terms and conditions in this regard: NOW THEREFORE THIS AGREEMENT WITNESSETH AS FOLLOWS: 1. First and Second parties hereby constitute themselves into a Associate tieup Agreement for the purpose of bidding and undertaking the said works pursuant to the said NIT as hereinafter stated. 2. The First Party will be the Lead bidder and will be responsible for the execution of entire works. ASSOCIATE TIE-UP AGREEMENT 3. The First Party shall undertake the following part(s) of work detailed in the NIT namely ____________________________________________ __________________________________________________________ The Second Party shall undertake to ensure smooth & proper completion of the work for the said NIT by providing the below services to the bidder in addition to whatever stated elsewhere for the scope of work. a) Technical Supervision and Guidance to the bidder b) Preparation of Monthly plan for submission to BHEL through the bidder c) Participating in the regular monthly performance review meeting d) Executing the total/balance works incase the bidders performance is not satisfactory 5. The parties hereby declare and confirm that each of them will fulfill the required minimum qualifying requirements as prescribed in the said NIT for the works agreed to be undertaken by them as stated here-in-above. It is also agreed between the parties hereto that all of them shall be severally and jointly responsible for the completion of the said works as per the schedule. Further, if the Employer/Owner sustains any loss or damage on account of any breach of the contract(s), we(First party & associate), severally and jointly undertake to promptly indemnify and pay such losses / damages caused to the Employer/Owner on their written demand without any demur, reservation, contest or protest in any manner whatsoever.
4.
6.

7. The parties hereby agree and undertake that they shall provide adequate finances, suitable tools, plants, tractors, trailers, other transportation equipment, other tools & plants, measuring & monitoring equipments (MMEs), men and machinery etc. for the proper and effective execution of the works to be undertaken by them as specified here-in-above. It is agreed between the parties hereto that all the consequences, liabilities etc., arising out of any default in the due execution of the said works shall be borne by both the parties for the portion of work the default has occurred, provided however, so far as M/s Bharat Heavy Electricals Limited is concerned, all the parties shall be liable severally and jointly. The associate hereby ensures that they have submitted a BG equivalent to 2% of the bid amount in the prescribed format, valid for the duration of the tendered works in a SEALED cover super scribed as BG from associate along with Rate Schedule/price bid (Volume II). A declaration certificate in his letter head to this effect is submitted by him to BHEL, duly signed along with the Techno Commercial bid.
8.
9.
IN WITNESS HEREOF the parties above named have signed this agreement on the day month and year first above written at __________ (Place).
WITNESS
For
1. NAME (FIRST PARTY) 2. OFFICIAL ADDRESS
WITNESS
For
1. NAME (SECOND PARTY) 2. OFFICIAL ADDRESS
[The bidder shall have to execute the "ASSOCIATE TIEUP AGREMENT in the format to be made available to BHEL at the time of submission of tender].
ASSOCIATE TIEU-UP DECLARATION (THIS DECLARATION CERTIFICATE IN HIS LETTER HEAD WITH DULY SIGNED AND ENCLOSED IN THE BIDDERS TECHNICAL OFFER).
I/WE_____________________ (ASSOCIATE) DECLARES THAT A BANK GUARANTEE BEARING NO:_______________________________,DT:__________ FOR ________% OF THE BID AMOUNT TOWARDS______________________________VALID UPTO______________FROM_______________(BANK) IS ENCLOSED WITH PRICE BID (VOLUME II).
FOR AND BEHALF OF M/S___________
(SIGNATURE WITH OFFICIAL SEAL) Note: The tender will be liable to be rejected if the requisite BG is found to be not enclosed in the Price bid by the bidder.

BIDDERS DECLARATION (THIS DECLARATION CERTIFICATE IN HIS LETTER HEAD WITH DULY SIGNED AND ENCLOSED IN THE BIDDERS TECHNICAL OFFER).
I/WE ___________________________________________________________ DECLARE THAT WE GONE THROUGH THE TENDER CONDITIONS AND ACCORDINGLY WE SELECTED THE ASSOCIATE M/S___________________________________________________________________ FOR TIEUP WHO IS FULFILLING THE STIPULATED QUALIFICATION REQUIREMENT IN THE TENDER AND WHOSE QUALIFYING EXPERIENCE DOCUMENTS ARE ENCLOSED IN OUR OFFER.
FOR AND BEHALF OF M/S___________
(SIGNATURE WITH OFFICIAL SEAL) Note: The tender will be liable to be disqualified if the required documents of the associate are found to be not enclosed in the offer.

Rev 01 1st June 2012
VOLUME IA Part I & II TECHNICAL CONDITIONS OF CONTRACT (TCC)
TECHNICAL CONDITIONS OF CONTRACT (TCC)

CONTENTS Sl No VolumeIA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 DESCRIPTION Part-I: Contract specific details Project Information Scope of Works Chapter-I Chapter-II 2 1 8 1 2 2 6 2 7 3 2 1 11 2 7 6 3 3 2 61 Chapter No. OF PAGES
Facilities in the scope of Contractor/BHEL (Scope Chapter-III Matrix) T&Ps and MMEs to be deployed by Contractor T&Ps and MMEs to be deployed by BHEL on sharing basis Time Schedule Terms of Payment Taxes and other Duties Weight schedules/BOQ General Foundation & Grouting Handling of Material/Storage Erection Progress Work Welding Testing & Commissioning Painting Construction Power Supply Painting Scheme Welding Schedule
Chapter-IV Chapter-V Chapter-VI Chapter-VII Chapter-VIII Chapter-IX Chapter-X Chapter-XI Chapter-XII Chapter-XIII Chapter-IVX Chapter-XV Chapter-XVI Chapter-XVII Chapter-XVIII Chapter-XIXI Chapter-XX

21 22 Guidelines for welding&P91 welding procedure Guide lines for insulation Chapter-XXI Chapter-XXII 93 56

Volume 1A Part-1 Chapter -I PROJECT INFORMATION KAKATIYA THERMAL POWER PROJECT
1 2 3 4 5 6 7 8 9 10 11 12 13 Name of the Project Station Capacity Owner Consultant Site Location Latitude Longitude MSL Nearest Highway Nearest Town / City Nearest Railway Station Nearest Air port Metrological Data A) Temperature i. Average Max Temperature ii. Average Min Temperature iii. Highest Max Temperature iv. Lowest Minimum Temperature v. Temperature to be considered for design of Electrical Equipments / Devices B) Relative Humidity average C) Rainfall ( Average Annual ) D) Wind Data / Basic Speed E) Seismic Data 14 Languages spoken in the Kakatiya Thermal Power Project 1 x 600 MW ( Coal based ) Andhra Pradesh Power Generation Corporation Limited ( APGENCO ) M/s DESEIN Chelpur Village, Ghanur Mandal, Warangal District ( Km from State High way ) and 10 Km from Bhoopalapally 18 23 N 79 51E 180 M SH-7 ( Connecting Parkal with Mahadevpur ) Warangal 65 Kms South East 1. Uppal Railway station on SCR & 45 Kms from site 2. Warangal Railway station of SCR 65 Kms from Site 240 Kms ( Hyderabad)
34.5 Deg C 22.3 Deg C 45.7 Deg C 9.0 Deg C 50 Deg C 55% 1005 mm 47 M / Sec Zone II English, Telugu

15 region Language for communication with SubContractor / Vendors Tropicalisation Supply Voltage English All Equipments supplied against this specification shall be given tropical and fungicidal treatment in view of climatic conditions prevailing at site 240 V AC for Lighting
16 17

Volume 1A Part-1 Chapter -II Scope of Works 1.2.0 SCOPE OF WORK The scope of the work will comprise of but not limited to the following: 1.2.1 Handling at site stores / storage yard, Transportation to site of work, Pre-assembly, Erection, Testing and Commissioning of Power Cycle Piping and Application of Refractory & Insulation works for Boiler, ESP, Power cycle Piping and Supply & Application of Final Painting for Power Cycle piping & Insulation for Unit-2 of 1x600 MW set at Kakatiya Thermal Power Project, Chelpur Village, Warangal District, AP 1.2.2 CONTRACTOR SCOPE OF WORKS ALSO INCLUDES THE FOLLOWING 1.2.2.1 The contractors scope of work includes but not limited to: Handling at site stores / storage yard, transporting to site, inspection, pre-assembly, erection, alignment, welding, NDT, fixing of hangers & supports, chemical cleaning / pickling, oil flushing, water flushing, hydro testing & steam blowing, surface finish, supply & application of primer & finish paints and application of refractory& insulation as per requirement / as given in the drawings including labeling & flow direction on the piping / over insulation & hangers and supports, pre-commissioning, commissioning, trial operation & handing over to customer and Supply & Application of Final Painting for Power Cycle piping & Insulation of Unit-2 of 1x600 MW set at Kakatiya Thermal Power Project, Chelpur Village, Warangal District, AP. 1.2.2.2 Welding, NDT, SR of IP Turbine inlet assembly (Turbine package no: 75906) is in the scope of this contract.

Sl.No 1.3.1 1.3.1.1 a b c d e f g 1.3.1.2 a b 1.3.2.0 1.3.2.1 a b c 1.3.2.2 a Volume 1A Part-1 Chapter- III Facilities in the scope of Contractor/BHEL Scope / to be Description taken care by Remarks PART I BHEL Bidder ESTABLISHMENT FOR CONSTRUCTION PURPOSE: Open space for office (as per Yes availability) Open space for storage (as per Yes availability) Construction of bidders office, canteen and storage building including supply Yes of materials and other services Bidders all office equipments, office / Yes store / canteen consumables Canteen facilities for the bidders staff, Yes supervisors and engineers etc Firefighting equipments like buckets, Yes extinguishers etc Fencing of storage area, office, canteen etc of the bidder FOR LIVING PURPOSES OF THE BIDDER Open space for labour colony (as per availability) Labour Colony with internal roads, sanitation, complying with statutory requirements ELECTRICITY Electricity For construction purposes of Voltage 415/440 V Single point source Further distribution including all materials, Energy Meter, Protection devices and its service Duties and deposits including statutory clearances if applicable Electricity for the office, stores, canteen etc of the bidder Single point source Yes
Yes Yes Free of charges yes Yes Yes Yes
Yes

Sl.No b c 1.3.2.3 a b c 1.3.3.0 1.3.3.1 a b 1.3.3.2 a b 1.3.3.3 a b 1.3.4.0 Description PART I Further distribution including all materials, Energy Meter, Protection devices and its service Duties and deposits including statutory clearances if applicable Electricity for living accommodation of the bidders staff, engineers, supervisors etc Single point source Further distribution including all materials, Energy Meter, Protection devices and its service Duties and deposits including statutory clearances if applicable WATER SUPPLY For construction purposes Making the water available at single point Further distribution as per the requirement of work including supply of materials and execution Water supply for bidders office, stores, canteen etc Making the water available at single point Further distribution as per the requirement of work including supply of materials and execution Water supply for Living Purpose Making the water available at single point Further distribution as per the requirement of work including supply of materials and execution LIGHTING For construction work (supply of all the necessary materials) 1. At office/storage area 2. At the preassembly area 3. At the construction site /area Scope / to be taken care by Remarks BHEL Bidder Yes Yes
Yes Yes Yes yes Yes Yes Free of charges
Yes Yes
Yes Yes
Yes

Sl.No Description PART I For construction work (execution of the lighting work/ arrangements ) 1. At office/storage area 2. At the preassembly area 3 At the construction site /area Providing the necessary consumables like bulbs, switches, etc during the course of project work Lighting for the living purposes of the bidder at the colony / quarters COMMUNICATION FACILITIES FOR SITE OPERATIONS OF THE BIDDER Telephone, fax, internet, intranet, email etc COMPRESSED AIR wherever required for the work Demobilization of all the above facilities TRANSPORTATION For site personnel of the bidder For bidders equipments and consumables (T&P, Consumables etc) Scope / to be taken care by Remarks BHEL Bidder Yes
c d 1.3.5.0 a 1.3.6.0 1.3.7.0 1.3.8.0 a b
Yes Yes
Yes Yes Yes Yes Yes
Description Sl.No 1.3.9.1 a b PART II 1.3.9.0 ERECTION FACILITIES Engineering works for construction: Providing the erection drawings for all the equipments covered under this scope Drawings for construction methods
Scope / to be taken care by BHEL Bidder
Remarks
Yes Yes Yes In consultation with BHEL

Description Sl.No PART II 1.3.9.0 ERECTION FACILITIES As-built drawings whereever deviations observed and executed and also based on the decisions taken at site- example routing of small bore pipes Shipping lists etc for reference and planning the activities Preparation of site erection schedules and other input requirements Review of performance and revision of site erection schedules in order to achieve the end dates and other commitments Weekly erection schedules based on Sl No. e Daily erection / work plan based on Sl No. g Periodic visit of the senior official of the bidder to site to review the progress so that works are completed as per schedule. It is suggested this review by the senior official of the bidder should be done once in every two months. Preparation of preassembly bay Laying of racks for gantry crane if provided by BHEL or brought by the contractor/bidder himself Arranging the materials required for preassembly Scope / to be taken care by BHEL Bidder Remarks
YES
d e f g h
Yes Yes Yes yes yes Yes Yes Yes
Yes
j k L
Yes NA YES

1.3.10 SPACE FOR SITE OFFICE
1.3.10.1 To establish a temporary site office and storage area at the site of erection, open space will be provided free of charges. Contractor has to make his own arrangements for labour colony. 1.3.10.2 BHEL will not provide the contractor any residential accommodation to any of his staff and the contractor has to make his own arrangements. 1.3.10.3 Contractor has to furnish along with their offer, the details of requirements of area of space for his temporary site office, stores / storage shed. 1.3.10.4 Location and area requirement for office / storage sheds / pre assy yard shall be discussed and mutually agreed to. 1.3.11 CONSTRUCTION WATER 1.3.11.1 Water shall be provided by BHEL free of charges at one point. However bidder shall arrange for further distribution at their cost. 1.3.11.2 No separate payment shall be made for any contingency arrangement made by contractor, due to delay / failure of water supply. 1.3.12 CONSTRUCTION POWER 1.3.12.1 Electricity will be provided at one single point free of charges and further distribution shall be arranged by the contractor at his cost. Construction power shall be provided from the nearest Substation / tapping point. 1.3.12.2 Any duty, deposit involved in getting the Electricity shall be borne by the bidder if applicable. As regards contractors office shed also all such expenditure shall be borne by the contractor. 1.3.12.3 Provision of distribution of electrical power from the given single central common point to the required places with proper distribution boards, approved cables and cable laying including supply of all materials like cables, switch boards, pipes etc., observing the safety rules laid down by electrical authority of the State / BHEL / their customer with appropriate statutory requirements shall be the responsibility of the tenderer / contractor. 1.3.12.4 BHEL is not responsible for any loss or damage to the contractors equipment as a result of variations in voltage / frequency or interruptions in power supply. 1.3.12.5 As there are bound to be interruptions in regular power supply, power cut / load shedding in any construction sites, suitable extension of time, if found necessary only be given and contractor is not entitled for any compensation. Contractor shall make his own arrangement for alternative source of power supply through deployment of adequate number of DG sets with consumables at their cost during the power breakdown / failure to get urgent and important work to go on without interruptions. No separate payment shall be made for this contingency.

1.3.12.6 If required, necessary Capacitor Banks to improve the Power factor (0.8) as stipulated by customer shall be provided by the contractor at his cost as per customer requirement. Penalty if any levied by customer on this account will be recovered from contractors bills. 1.3.13 CONSUMABLES: Any special electrodes / consumables supplied by the manufacturing units for the respective packages will be issued free of cost. All other consumables, filler wires, electrodes, gas, paint etc. are to be arranged by the contractor at his cost. WATER DISTRIBUTION: Distribution of water for construction purpose and as well as drinking purpose to various work-fronts shall be contractors responsibility at his cost. 1.3.15 ELECTRICITY DISTRIBUTION: Provision of distribution of electrical power from the given single central point to the required places with proper distribution boards, cables etc., observing the safety rules laid down by electrical authority of the State / BHEL / their customer with appropriate statutory requirements shall be the responsibility of the tenderer / contractor. Necessary Capacitor Banks to improve the Power factor (.8) as stipulated by customer shall be provided by the contractor at his cost as per customer requirement. Penalty if any levied by customer on this account will be recovered from contractors bills. 1.3.16 POSSESSION OF GENERATORS As there are bound to be interruptions in regular power supply, power cut/ load shedding in any construction sites, suitable extension of time, if found necessary only be given and contractor is not entitled for any compensation. It shall be the responsibility of the tenderer / contractor to provide, and maintain the complete installation on the load side of the supply with due regard to safety requirements at site. It shall be responsibility of the contractor to have at least (2 to 4) diesel operated welding generator sets to get urgent and important work to go on without interruptions. The consumables required to operate the generators are to be provided by tenderers. This may also be noted while quoting. LIGHTING FACILITY: Adequate lighting facilities such as flood lamps, hand lamps and area lighting shall be arranged by the contractor at the site of construction, pre assembly yard and contractors material storage area etc. at his cost. 1.3.18 POWER REQUIREMENT: For the purpose of planning, contractor shall furnish along with tender the estimated requirement of power (month wise) for execution of work in terms of maximum KW demand.
1.3.14
1.3.17

1.3.19 CONTRACTOR'S OBLIGATION ON COMPLETION: On completion of work, all the temporary buildings, structures, pipe lines, cables etc. shall be dismantled and leveled and debris shall be removed as per instructions of BHEL by the contractor at his cost. In the event of his failure to do so, the expenditure towards clearance of the same will be recovered from the contractor. The decision of BHEL Engineer in this regard is final. 1.3.20 GASES: 1.3.20.1 All the required gases like Oxygen / Acetylene / argon / Nitrogen required for construction work shall be supplied by the Contractor at his cost. It shall be the responsibility of the contractor to plan the activities and store sufficient quantity of these gases. Non-availability of gases cannot be considered as reason for not attaining the required progress. 1.3.20.2 BHEL reserves the right to reject the use of any gas in case required purity is not maintained. 1.3.20.3 The contractor shall submit weekly statement report regarding consumption cost analysis purposes. / fortnightly / monthly of all consumables for
1.3.20.4
The contractor shall ensure safe keeping of the inflammable cylinder at a separate place away from normal habit with proper security etc. All the integral lube and control oil pipelines required TIG welding operations are to be purged with Nitrogen Gas / Argon Gas for the purpose of creating inert atmosphere in the pipelines during the process of TIG welding. Nitrogen, Argon gas required for this purpose shall have to be arranged by the contractor at his cost. ELECTRODES SUPPLY AND STORAGE
1.3.20.5
1.3.21
1.3.21.1 It shall be the responsibility of the contractor to obtain prior approval of BHEL, before procurement regarding, suppliers, type of electrodes etc. On receipt of the electrodes at site, it shall be subject to inspection and approval by BHEL. The contractor shall inform BHEL details regarding type of electrodes, batch number and date of expiry etc. 1.3.21.2 Shortage of any of the electrodes or the equivalent suggested by BHEL shall not be quoted as reason for deficiency in progress or for additional rate. 1.3.21.3 Storage of electrodes shall be done in an air conditioned / controlled humidity room as per requirement, at his own cost by the contractor. 1.3.21.4 All low hydrogen electrodes shall be baked / dried in the electrode drying oven (range 375 deg. C - 425 deg. C) to the temperature and

period specified by the BHEL Engineer before they are used in erection work and each welder should be provided with one portable electrode drying oven at the work spot. Electrode drying oven and portable drying ovens shall be provided by contractor at his cost. 1.3.21.5 Incase of improper arrangement of procurement of above electrodes BHEL reserves the right to procure the same from any source and recover the cost from the contractor's first subsequent bills at market value plus departmental charges of BHEL communicated from time to time. Postponement of such recovery is not permitted. 1.3.21.6 BHEL reserves the right to reject stage, if found defective because date expiry, unapproved type of responsibility of the contractor to of time. the use of any electrodes at any of bad quality, improper storage, electrodes etc. It shall be the replace at his cost without loss

VOLUME-IA PART I CHAPTER IV
T&Ps and MMEs TO BE DEPLOYED BY CONTRACTOR 1. All the T&Ps and MMEs required for this scope of work, except the T&Ps provided by BHEL are to be arranged by the contractor within the quoted rates.

T&Ps TO BE PROVIDED BY BHEL ON SHARING BASIS
1.5.1 List of T&Ps to be made available by BHEL to contractor free of hire charges on sharable basis.
VOLUME-IA PART I CHAPTER - V
S.No Description 01 EOT Cranes at TG Hall without operator 02 03 04 05 06 07 08 Induction Heating machine with complete accessories Spot welding Machine Chemical Cleaning Pumps with accessories Diesel Generator 250/500 KVA will be provided as standby arrangement for P91 welding. Required fuel and operator to be arranged by the contractor Hydro Test pump (400-600kg/cm2) Sky climber (for inside furnace work) Digital Temperature indicator
Qty 1No As required 1No As required 1No 1No 1No As required
BHEL will not provide crane operators for EOT cranes. Trained operators for EOT crane to be arranged by the contractor at his cost. Note 1. All the above T&Ps shall be given to the contractor on sharable basis and the allotment is made by BHEL/Site-in charge on need basis and to be shared with other contractors. 2. For handling at store and transportation, contractor shall make his own arrangement 3. Diesel Generator will be provided as standby arrangement for P91 welding and the required fuel and operator to be arranged by the contractor 4. EOT Crane Allotment will be made only on need basis. Trained operators are to be arranged by the contractor within the quoted rates. Contractor has to plan

the activities on item wise where the EOT crane is required to be used and submit to BHEL site for approval. In case the erection can be carried out by using other T&Ps, contractor shall make his own arrangement. The decision of BHEL Site I/c on this will be final and binding. 6. Fill pump shall be arranged by the contractor, wherever required. For testing LP lines necessary Hydraulic Test pumps/ Hand pumps are to be arranged by the contractor 7. Any Loss/Damage of tools by the contractor, the same shall have to be replaced by the contractor or otherwise cost thereof shall be recovered from the contractor. 8. Apart from the above mentioned tools, any other tools and plants required for satisfactory completion of the work has to be arranged by the contractor. 9. In case of non-availability of the above, due to any unavoidable reason, like breakdown, overhaul etc., contractor shall make arrangement at his own cost to meet the erection schedules. No extra claim will be admitted due to the nonavailability of any of the above equipment. No delay in execution of work shall be accepted on this account. 10. Providing manpower assistance required for free movement of trailing cable of EOT Crane is included in the scope of this contract.
VOLUME-IA PART I CHAPTER-VI TIME SCHEDULE

1.6.1 TIME SCHEDULE 1.6.1.1 The entire work of erection testing and commissioning of Power Cycle Piping and Application of insulation including supply & application of Final Painting, as detailed in the Tender Specification shall be completed within 15 (Fifteen) months from the date of commencement of work at site. 1.6.1.2 During the total period of contract, the contractor has to carry out the activities in a phased manner as required by BHEL and the program of milestone events. 1.6.1.3 The erection work shall be commenced on the mutually agreed date between the bidder and BHEL engineer and shall be deemed as completed in all respect only when the unit is in operation. The decision of BHEL in this regard shall be final and binding of the contractor. The scope of work under this contract is deemed to be completed only when so certified by the site Engineer. 1.6.1.4 The contractor is required to refer Form F15 in Volume 1 Book -2 for all the instructions to be taken immediately after receipt of fax LOI. 1.6.2 COMMENCEMENT OF CONTRACT PERIOD The date of commencement of contract period shall be the mutually agreed date between the bidder and BHEL engineer to start the work. In case of discrepancy the decision of BHEL engineer is final. 1.6.3 MOBILISATION FOR ERECTION, TESTING, ASSISTANCE FOR COMMISSIOING ETC., The activities for erection, testing etc shall be started as per directions of Construction manager of BHEL. The contractor has to augment his resources in such a manner that following major milestones of erection & commission are achieved on specified schedules: Major Milestones:Sl.No. 01 02 03 Mile stone Steam Blowing Synchronisation Trail Operation & Handing over Completion from date of Start of Piping erection 11th month 12th month 15th month

1.6.4 In order to meet above schedule in general, and any other intermediate targets set, to meet customer / project schedule requirements, contractor shall arrange & augment all necessary resources from time to time on the instructions of BHEL. CONTRACT PERIOD The contract period for completion of entire work under scope shall be 15 (Fifteen) months from the COMMENCEMENT OF CONTRACT PERIOD as specified earlier for completion of the entire work. GUARANTEE PERIOD The guarantee period of twelve months shall commence from the date of handing over of the Unit to Customer or six months from the date of first synchronisation of the set, whichever is earlier (Provided all erection, testing, and commissioning works are completed in all respects).
1.6.5
1.6.6

VOLUME-IA PART I CHAPTER-VII TERMS OF PAYMENT
1.7.0 Terms of payment : The progressive payment for erection, testing and commissioning on accepted rate / price of contract value will be released as mentioned below in Clause 1.7.1 & 1.7.2. 1.7.1 Progressive Payment against monthly running bills will be made upto 85 % of the value of the erected items Pro rata as per clause 1.7.1 1 to 1.7.1.14 below. 1.7.2 Further 15 % payment on pro-rata basis common to all PG shall be released on achievement of the following stage / milestones events for the erected items as mentioned in Clause no 1.7.2 .1 to 1.7.2.15 of the following table.
PIPING 1) P91 2) HP 3) LP 4) SS 1) Temp piping 1)Hangers Steam & Supports blowing/che 2)Other mical structures cleaning
INSULATION 2) Wool mattresses / Calcium silicate 2) Aluminium sheeting(cladding) 3)Iron components
CL NO 1.7.1. 1.7.1.1
1.7.1.2 1.7.1.3 1.7.1.4 1.7.1.5
Rate schedule Identification----> PRO RATA PAYMENTS (85%) ON PRE-ASSEMBLY WHEREVER APPLICABLE ( If not applicable this portion shall be clubbed with placement in position) PLACEMENT IN POSITION ALIGNMENT WELDING/BOLTING/FI XING COMPLETION OF NON DESTRUCTIVE EXAMINATION & STRESS RELIEVING/ HEAT TREATMENT (if not applicable, then this portion to be paid along with welding)
20 20 10 15
15 25 15 30
-50 15 20
--
--

1.7.1.6 Installation of Temp piping 1.7.1.7 Dismantling of Temp piping, Edge preparation and return to BHEL stores, area cleaning. 1.7.1.8 HANGERS & SUPPORTS ETC WHEREVER NECESSARY AS PER DRG 1.7.1.9 HYDRAULIC TEST OR PNEUMATIC TEST 1.7.1.10 FLOATING OF LINES, FINAL ADJUSTMENT OF SUPPORTS FOR COLD AND HOT VALUES (if not applicable, this portion to be clubbed along with hydraulic test/pneumatic test) 1.7.1.11 TANKS & VENT SILENCERS 1.7.1.12 ERECTION OF TANKS & VENT SILENCERS 1.7.1.13 ALIGNMENT OF TANKS & VENT SILENCERS AND THEIR ASSOCIATED APPROACH PLATFORM WITH LADDERS ETC. 1.7.1.14 TESTING & COMMISSIONING OF TANKS & VENT SILENCERS TOTAL FOR PRO RATA PAYMENTS (TOTAL 85%) 60 25
10 3
---
---
--
--
--
--
--
--
--
--
-85
-85
-85

1.7.2 1.7.2.1 1.7.2.2 1.7.2.3 1.7.2.4 1.7.2.5 1.7.2.6 1.7.2.7 1.7.2.8 1.7.2.9 STAGE/MILESTONE PAYMENTS (15%) Boiler Light Up ABO/chemical cleaning Steam Blowing SVF Rolling and Synchronisation Coal Firing Full Load Trial Operation of Unit Completion of all drains and vents to respective locations and placement of instrument sensors after steam blowing Painting Area cleaning, temporary structures cutting/removal and return of scrap Punch List points/pending points liquidation Submission of 'As Built Drawings' Material Reconciliation Completion of Contractual Obligation TOTAL FOR STAGE / MILESTONE PAYMENTS (15%) TOTAL I + II
-2 1
2 1
2 1
1.7.2.10 1.7.2.11
2 2
2 2
--
1 1 2 1 1 15 100
2 1 1 1 1 15 100 15 100 15
3 2 -3 2 15 100
1.7.2.12 1.7.2.13 1.7.2.14 1.7.2.15
Note: 1. Recovery of Retention amount as per Cl. 2.22 of GCC (Volume IC). 2. Payment for the first running bill will be released only on production of the following. i. PF Regn. No. ii. Labour License No.

iii. iv. v. vi. Workmen Insurance Policy No. Unqualified Acceptance for Detailed L.O.I. Security Deposit as per GCC Rs 100 /- Stamp Paper for Preparation of Contract SUBMITTED AT PSSR HQ
agreement. TO BE
1.7.3 PROVIDENT FUND & MINIMUM WAGES 1.7.3.1 The contractor is required to extent the benefit of Provident Fund to the labour employed by you in connection with this contract as per the Employees Provident Fund and Miscellaneous Provisions Act 1952. For due implementation of the same, you are hereby required to get yourself registered with the Provident Fund authorities for the purpose of reconciliation of PF dues and furnish to us the code number allotted to you by the Provident Fund authorities within one month from the date of issue of this letter of intent. Incase you are exempted from such remittance an attested copy of authority for such exemption is to be furnished. Please note that in the event of your failure to comply with the provisions of said Act, if recoveries therefore are enforced from payments due to us by the customer or paid to statutory authorities by us, such amount will be recovered from payments due to you. 1.7.3.2 The contractor shall ensure the payments of minimum labour wages to the workmen under him as per the rules applicable from time to time in the state. 1.7.3.3 The final bill amount would be released only on production of clearance certificate from PF/ESI and labour authorities as applicable. 1.7.4 OTHER STATUTORY REQUIREMENTS 1) The Contractor shall submit a copy of Labour License obtained from the Licensing Officer (Form VI) u/r25 read with u/s 12 of Contract Labour (R&A) Act 1970 & rules and Valid WC Insurance copy or ESI Code (if applicable) and PF code no alongwith the first running bill. 2) The contactor shall submit monthly running bills along with the copies of monthly wages (of the preceding month) u/r78(1)(a)(1) of Contract Labour Rules, copies of monthly return of PF contribution with remittance Challans under Employees Provident Fund Act 1952 and copy of renewed WC Insurance policy or copies of monthly return of ESI contribution with Challans under ESI Act 1948 (if applicable) in respect of the workmen engaged by them. 3) The Contractor should ensure compliance of Sec 21 of Contract Labour

(R&A) Act 1970 regarding responsibility for payment of Wages. Incase of Non-compliance of Sec 21 or non-payment of wages to the workmen before the expiry of wage period by the contactor, BHEL will reserve its right to pay the workmen under the orders of Appropriate authority at the risk and cost of the Contractor. 4) The Contractor shall submit copies of Final Settlement statement of disbursal of retrenchment benefits on retrenchment of each workmen under I D Act 1948, copies of Form 6-A (Annual Return of PF Contribution) along with Copies of PF Contribution Card of each member under PF Act and copies of monthly return on ESI Contribution Form 6 under ESI Act1948 (If applicable) to BHEL along with the Final Bill. 5) In case of any dispute pending before the appropriate authority under I D act 1948, WC Act 1923 or ESI Act 1948 and PF Act 1952, BHEL reserve the right to hold such amounts from the final bills of the Contractor which will be released on submission of proof of settlement of issues from the appropriate authority under the act. 6) In case of any dispute prolonged/pending before the authority for the reasons not attributable to the contractor, BHEL reserves the right to release the final bill of the contractor on submission of Indemnity bond by the contractor indemnifying BHEL against any claims that may arise at a later date without prejudice to the rights of BHEL. 7) In addition to the clause 2.8 of General Conditions of Contract (Vol-1C of Book II) the contractor shall comply with the following. 7.1 The Contractor should Register their Establishment under BOCW Act 1996 read with rules 1998 by submitting Form I ( Application for Registration of Establishment) and Form IV ( Notice Of Commencement /Completion of Building other Construction Work) to the respective Labour Authorities i.e., a) Assistant Labour Commissioner (Central) in respect of the project premises which is under the purview of Central Govt. NTPC, NTPL etc b) Inspector of Factories in respect of the project premises which is under the purview of State Govt. 7.2 The Contractor should comply with the provisions of BOCW Welfare Cess Act 1996 in respect of the work awarded to them by BHEL

7.3 The contractor should ensure compliance regarding Registration of Building Workers as Beneficiaries, Hours of work, welfare measures and other conditions of service with particular reference to Safety and Health measures like Safety Officers, safety committee, issue of Personal protective equipments, canteen, rest room, drinking water, Toilets, ambulance, first aid centre etc 7.4 The contractor irrespective of their nature of work and manpower (Civil, Mechanical, Electrical works etc) should register their establishment under BOCW Act 1996 and comply with BOCW Welfare Cess Act 1996.
1.8.0 TAXES
VOLUME-IA PART I CHAPTER VIII TAXES AND OTHER DUTIES
1.8.1 Value Added Tax (VAT) for the works 1.8.1.1 Price quoted shall be inclusive of VAT except service tax. 1.8.1.2 Notwithstanding the fact that this is only an erection service contract not involving any transfer of materials whatsoever and not attracting VAT liability, being labour oriented job work, for the purpose of VAT the contractor has to maintain the complete data relating to the expenditure incurred towards wages etc. in respect of the staff/workers employed for this work as also details of purchase of materials like consumables, spares etc., inter alia indicating the name of the supplier, address and VAT Registration No. and VAT paid for the purchases, etc 1.8.1.3 The bidder shall get registered with State VAT authorities and the registration certificate shall be forwarded to BHEL immediately after commencement of work. In case the bidder had already registered under respective State VAT, they must quote their registration Number and forward copy of Registration Certificate while submitting this tender. 1.8.1.4 The monthly/quarterly VAT return, duly incorporating the erection income from BHEL as turnover, should be submitted to BHEL at regular intervals with all annexure and details of payment of VAT (WCT). 1.8.1.5 You have to obtain VAT Clearance Certificate from the on concerned authorities as per the provisions of local VAT act, on completion of the project and submit along with the final bill. 1.8.1.6 The bidder shall quote very competitive price after taking into consideration of above points. 1.8.2 Service Tax 1.8.2.1. Price quoted shall be exclusive of Service Tax. The service tax as statutorily leviable and payable by the bidder under the provisions of service tax Law / Act shall be paid by BHEL as per bidder claim through various running bills. The bidder shall furnish proof of service tax registration with Central Excise Department specifying the name of services covered under this contract. Registration Certificate should also bear the endorsement for the premises from where the billing shall be done by the bidder on BHEL for this project. The bidder shall obtain prior consent of BHEL before billing the service tax amount.

1.8.3.0 Other Taxes & Levies 1.8.3.1 Any other taxes and duties (except VAT & Service Tax) if any, as applicable, viz. Entry Tax, Octroi, Licenses, Deposits, Royalty, Stamp Duty, other charges / levies, etc. prevailing / applicable on the date of opening of technical bids and any variation thereof during the tenure of the contract are in the scope of bidder. In case BHEL is forced to pay any such taxes, BHEL shall have the right to recover the same from the bidder either from running bills or otherwise as deemed fit. 1.8.4.0 New Levies / Taxes 1.8.4.1 In case Government imposes any new levy / tax after award of the work during the tenure of the contract, BHEL shall reimburse the same at actual on submission of documentary proof of payment subject to the satisfaction of BHEL that such new levy / tax is applicable to this contract.. 1.8.5.0 Statutory variations
1.8.5.1 Statutory variations are applicable only in the cases of Value Added Tax and Service Tax. The changes implemented by the Central / State Government in the VAT Act / Service Tax during the tenure of the contract viz. increase / decrease in the rate of taxes, applicability, etc. and its impact on upward revision / downward revision are to be suitably paid/ adjusted from the date of respective variation. The bidder shall give the benefit of downward revision in favour of BHEL. No other variations shall be allowed during the tenure of the contract. 1.8.6.0 Direct Tax 1.8.6.1 BHEL shall not be liable towards Income Tax of whatever nature including variations thereof arising out of this contract as well as tax liability of the bidder and their personnel. Deduction of tax at source at the prevailing rates shall be effected by BHEL before release of payment as a statutory obligation, unless exemption certificate is produced by the bidder. TDS certificate will be issued by BHEL as per the provisions of Income Tax Act.

WEIGHT SCHEDULE OF PCP&INSULATION
VOLUME-IA PART I CHAPTER - IX
FOR UNIT-2 OF KAKATIYA TPP, 1 X 600 MW 1.9.1 WEIGHT SCHEDULE SUMMARY:Power Cycle Piping Weight Schedule- Summary
Sl.N o 1 2 3 4 5 6 7 Description Weight approx( MT) 528 1053 594 5 583 113 136 3012 Rate schedule ID 1A 1B 1C 1D 1E 2 3
Piping-P91 HP Piping LP Piping SS piping Hangers & Supports including tanks, Vessels, Pumps etc Temporary piping- Chemical cleaning Temporary piping- Steam blowing Total
Insulation-Weight schedule summary Sl.No Description 1 2 3 4 Castable ,Pourable,Fire bricks, Sealing compound & Calcium silicate Mineral wool mattresses for thermal & Acoustic insulation Iron components for fixing insulation including structural materials for enclosure(Fixing components) Outer casing/Claddding, Aluminum sheet TOTAL Weight in MT 600 1151 285 274 2310 Rate Schedule ID 4 5 6 7
DETAILED WEIGHT SCHEDULE

KAKATIYA 1X600MW -STAGE -II - Piping Weight Schedule
PG MA PGMA Description Weight in Kg(Approx )
45916 133843 31822 221464
Category
Rate schd ID 1A 1A 1A 1A 1A 1A 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B
80 300 MS FROM SUPERHEATER TO BOILER STOPVALVE 80 301 MS FROM BOILER STOPVALVE TO ESV 80 304 MS HEADER TO HPBP VALVE 80 310 HRH FROM REHEATER TO INTERCEPTOR VALVE 80 311 HRH FROM INTERCEPTOR VALVE TO TURBINE 80 312 LPBP VALVE UPSTREAM & DOWN STREAM 80 303 MS HEADER TO AUX PRDS 80 307 HP AND LP BYPASS WARMUP 80 320 CRH FROM TURBINE TO REHEATER 80 321 HPBP VALVE TO CRH PIPING 80 322 CRH PIPING TO DEAERATING HEATER 80 323 STEAM TO BFP DRIVE TURBINE 80 324 CRH HEADER TO AUX.PRDS 80 325 SMALL BORE FITTINGS 80 329 EXTRACTION STEAM TO BFP DRIVE TURBINE 80 331 EXTRACTION STEAM TO LP HEATER -2 80 332 EXTRACTION STEAM TO LP HEATER -3 80 335 EXTRACTION STEAM TO DEAERATING HEATER 80 336 EXTRACTION STEAM TO HP HEATER-1 80 337 EXTRACTION STEAM TO HP HEATER-2 80 338 EXTRACTION STEAM TO HP HEATER-3 80 339 AUX STEAM TO BFD TURBINE 80 340 AUX STEAM HEADER 80 341 AUX STEAM HEADER INTERCONNECTION BETWEEN UNITS 80 342 AUX STEAM TO SCAPH 80 343 AUX STEAM TO AH SOOT BLOWERS 80 344 AUX STEAM TO FO SYSTEM TP 80 345 AUX STEAM TO DEAERATING HEATER 80 349 AUX STEAM TO GLAND SEALS-TG SCOPE
P91 P91 P91 P91 P91

16742
P91
78332 8334 1900 168526 17642 19604 2449 756 6819 12904 8697 11873 14318 7350 3809 5300 2139 4645 34000 6822 2307 24674 3742 1185
HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP

80 351 AUX STEAM TO UNLISTED USERS-SG SCOPE 80 355 STEAM TRACING PIPING 80 364 CBD TANK VENT TO SYSTEM 80 395 AUX STEAM TO FUEL OIL ATOMISING 80 418 ERECTION MATERIALS FOR INSTRUMENTS 80 420 BOILER FEED PUMP SUCTION 80 421 BOILER FEED PUMP RECIRCUALTION 80 423 BOILER FEED PUMP TO HPH INCLUDING BYPASS 80 424 BFD BETWEEN HTRS AND GROUP PROTECTION VALVE 80 425 BFD FROM FINAL HPH TO SG TP 80 430 SPRAY WATER TO HPBP 80 431 SPRAY WATER TO AUX PRDS 80 432 SPRAY WATER TO BOILER DESH UP TO SG TP 80 433 SPRAY WATER FROM BFP INTERSTAGE 80 450 CBD AND EMERGENCY DRUM DRAIN 80 451 BOILER INTEGRAL PIPING DRAINS 80 452 HP PIPING DRAINS - SG SCOPE 80 454 SCAPH DRAINS 80 901 SUB DELIVERY VALVES 81 415 TEST THERMOWELLS 81 416 PERFORMANCE GUARANTE 80 992 IMPORTED ELECTRODES PCP VALVES(TRY & PEM) QCNRV PEM SUPPLY VALVES 80 363 EXHAUST STEAM FROM PRIME MOVERS TG SCOPE 80 365 CBD TANK VENT/SV EXHAUST TO ATMOSPHERE 80 366 IBD TANK VENT TO ATMOSPHERE 80 371 DRAIN FLASH TANK VENT TO CONDENSER 80 373 AUX STEAM HEADER SV EXHAUST 80 375 UNLISTED SV EXHAUSTS-TG SCOPE 80 379 HPH SV EXHAUST TO FLASH TANK 80 381 HP HEATER VENTS - TG SCOPE 80 382 LP HEATER VENTS 80 385 VENT FROM UNLISTED PPG/EQPT TO CONDENSER 80 388 CONDENSER AIR EVACUATIONPIPING 80 400 CONDENSATE SUCTION HP
10517 6480 2625 60 224 28457 36633 139270
1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1B 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C
HP HP HP HP HP HP HP HP
28500 78028 8167 2600 10974 5600 2123 29190 13100 2616 15000 752 1558 4746
HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP HP LP LP
206094 5200 44660

25852 693 13764 1804 8555 156 4400 3200 1897 3458 5134 9752
LP LP LP LP LP LP LP LP LP LP

80 401 CD FROM PUMP TO LPH1/DC INLET TEE & RECIRCULATION 80 402 CD FROM LPH1/DC INLET TEE TO TG TP 80 403 CD FROM TG TP TO DEAERATING HEATER 80 407 CONDENSATE FOR SEALING OF VACUUM 80 408 CONDENSATE DUMP FROM HEADER 80 419 DEAERATOR SAFETY VALVE EXHAUST TO ATMOSPHERE 80 436 SPRAY WATER TO LPBP DESH 80 439 TURBINE FLASH TANK DRAIN TO CONDENSER 80 442 GLAND STEAM COOLER DRAINS 80 443 LP HEATER-1 TO CONDENSER 80 444 LP HEATER-2/3/4/5 DRAINS & DRIP PUMP INCL 80 446 DEAERATING HEATER OVERFLOW AND DRAIN 80 447 HP HEATER DRAINS 80 448 DRAIN FROM UNLISTED EQPT/VESSEL -TG SCOPE 80 449 TG CYCLE PIPING DRAINS & VENTS 80 453 LP PIPING DRAINS - SG SCOPE 80 455 DRAIN FROM UNLISTED EQPT/VESSEL -SG SCOPE 80 457 MANIFOLDS FOR HP FLASH BOX & CONDENSER 80 459 HP FLASH TANK DRAIN TO CONDENSER 80 460 SG AUX COOLING WATER UNIT SYSTEM 80 463 TG AUX COOLING WATER 80 471 BOILER WATER WASH TO & FROM UNIT 80 480 FIRE WATER-OTHER AREAS 80 493 HP FLASH TANK VENT TO CONDENSER 80 494 LP FLASH TANK VENT TO CONDENSER 80 495 LP FLASH TANK DRAIN TO COND 80 610 SERVICE AIR-COMP SUC & DIS TO RECEIVER 80 612 SERVICE AIR FOR INDIVIDUAL UNITS 80 614 INST AIR COMP SUC & DIS TO RECEIVER 80 616 INSTRUMENT AIR FOR INDIVIDUAL UNIT 80 650 FUEL OIL SUPPLY AND RETURN PIPING 80 673 LUBE OIL PIPING SYSTEM MISC ITEMS- ME BELLOWS,ETC 80 412 CONDENSATE TRANSFER 80 473 DEMINERALISED WATER SYSTEM 80 600 HIGH PRESSURE DOSING PIPING LP
32731 7174 11180 437 1364 4576 2688 1040 513 8266 6639
1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1C 1D 1D 1D
LP LP LP LP LP LP LP LP LP LP LP
5003 22225 918 10600 2748 4149
LP LP LP LP LP LP
894 3076 43601 153926 13225 11472 6898 1768 2328 13308 10264 13252 12381 58988 7029 40915 1806 1200 658
LP LP LP LP LP LP LP LP LP LP LP LP LP LP LP SS SS SS

80 601 LOW PRESSURE DOSING PIPING 80 830 H AND S FOR CRITICAL PIPING- STEAM LINES 80 840 AUX STR FOR MAIN STEAM FOR SB 80 920 H AND S FOR HYDRO TEST
10000 1312 175000 154258
80 921 H AND S FOR LIGHT UP

7765
80 928 H&S for BFD

150000
80 930 H AND S FOR SYNCHRONISATION

30000
80 933 H AND S FOR LP PIPING

27000
80 993 MISC ERECTION MATLS

1000
81 003 CONTINUOUS BLOW DOWN EXPANDER

4304
81 009 INTERMITTENT BLOW DOWN EXPANDER

6794
81 036 CW STORAGE TANK

8200
81 110 COOLING WATER PUMP

400
81 128 HIGH PRESSURE DOSING SYSTEM

3500
81 412 DIRECT GAUGES FOR NO

794
80 80 80 80
399 927 816 604
LP DOSING SYSTEM(HYDRAZINE,NAOH & AMMONIA) STEAM BLOWING PIPING H AND S FOR TEMPORAR H AND S OF ACID CLEA ACID CLEANING PIPING TOTAL
4000
126538 9000 23961 88874
SS H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els H&S/TANKS/Vess els
1D 1E 1E 1E 1E 1E 1E 1E 1E 1E 1E 1E 1E 1E 1E 1E 3 3 2 2
3011693
Insulation -Weight schedule -Details

Sl.No PG MA
1 2 3 4 33 33 33 33 201 212 230 975
Description
Main Boiler Formed Refractory Main Boiler Castable Refractory Main Boiler Pourable Insulation Misc Equipments Sealing Compound Tender Specification BHEL PSSR SCT 1518
Weight in Rate Kg Schedule (Approx) ID

804 175000 360000 200 4 4 4 4

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 81 341 PEM PEM 33 021 33 121 33 126 33 321 33 421 33 521 33 721 33 924 55 911 55 931 79 167 81 325 PEM PEM 32 10 32 110 32 120 32 310 32 410 32 510 32 710 33 970 33 971 55 911 55 931 79 168 81 318 PEM 37 010 37 810 81 350 PEM PEM PEM 79 168 55 911 55 931 32 010 32 110 32 120 32 310 32 410 Sealing Compoundas External piping Sealing Compound Pipe sections (Calcium silicate) Boiler Pr.Parts Mineral wool Boiler mountings mineral wool SB pipes Mineral wool Air Ducts Mineral wool Air heater & Gas ducts mineral wool ID Ducts mineral wool Oil system Mineral wool Misc Equipments asbestas Insulation wool for FD Fan Insulation wool for PA Fan Insulation wool for ESP Mineral wool- External piping Ceramic mill board Mineral wool Fixing components for boiler Fixing components for boiler Fixing components for SB pipes insulation Fixing components for Air Ducts insulation Fixing components for AH & Gas ducst insulation Fixing components for ID Ducts insulation Fixing components for Oil system insulation Misc equipments expanded metal Woven wire cloth & Fasteners Fixing components for FD Fan Fixing components for PA Fan Fixing components for ESP Fixing components for insulation of Misc piping Anciliary materials Boiler Outer casing components Boiler outer casing Aluminium sheet -External piping Anodised Aluminium bands Seals for Aluminium bands Aluminium sheet Aluminium sheet Aluminium sheet Aluminium sheet Aluminium sheet Aluminium sheet Aluminium sheet Aluminium sheet Aluminium sheet Tender Specification BHEL PSSR SCT 1518 600 600 62782 217120 6930 2310 240570 65095 57128 4620 166 11424 9240 164920 50000 600 320700 4275 1338 64 16909 5176 39666 232 3417 1007 725 561 50689 10500 74470 37861 38484 27000 4300 400 59300 66215 2604 2113 3477 2668 892 47888 12783 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 7 7 7

50 51 32 32 510 Aluminium sheet 710 Aluminium sheet 42405 1776 7 7
TOTAL
2310004
Note: 1. The above detailed weight schedule is furnished for reference 2. The weight indicated above is approximate and liable to vary. However the payment will be made to the contractor for the tonnage actually erected at the respective category as per the quoted/accepted tonnage rate. 3 There may be variation or addition of PGMAs, description, weights etc., and any additional scope of work supplied under the above package shall be erected by the contractor and payment will be made as per the quoted/accepted rate in the respective category.

PART I CHAPTER -X GENERAL
The scope of the work will comprise of but not limited to the following: 1.10.1 All the works such as cleaning, leveling, aligning, trial assembly, dismantling of certain components for checking and cleaning, surface preparation, fabrication of sheets, tubes and pipes as per general engineering practice and as per BHEL Engineers instructions at site, cutting, weld depositing, grinding, straightening, chamfering, filing, chipping, drilling, reaming, scrapping, lapping, fitting-up etc., as may be applicable in such erection works and are necessary to complete the work satisfactorily, shall be carried out by the contractor as part of the work within the quoted rate. Major machining work, which is only to be carried out in workshops, will be arranged by BHEL. 1.10.2 The work shall conform to dimensions and tolerances given in various drawings and quality manuals provided by BHEL. If any portion of work is found to be defective in workmanship not conforming to drawings or other stipulations, the contractor shall dismantle and redo the work duly replacing the defective materials at his cost, failing which the job will be carried out by BHEL by engaging other agencies and recoveries will be effected from contractors bill towards expenditure incurred including BHELs overhead charges. 1.10.3 Contractor shall execute the work as per sequence and procedure prescribed by BHEL at site. The applicable erection manuals which are available with BHEL site office are to be referred for compliance and guidance before taking up the work. Any rework on this failure to comply with will be to account contractor only. BHEL engineer, depending upon the availability of materials, fronts etc, will decide the sequence of erection and methodology. No claims for extra payment from the contractor will be entertained on the grounds of deviation from the method of erection adopted in erection of similar jobs or for any reason whatsoever. 1.10.4 Contractor has to work in close co-ordination with other erection agency at site. BHEL engineer will co-ordinate area clearance. In a project of such magnitude, it is possible that the area clearance may be less/more at a particular given time. Activities and erection program have to be planned in such a way that the milestones are achieved as per schedule/ plans. Contractor shall arrange & augment the resources accordingly. 1.10.5 The contractor is strictly prohibited from using BHELs regular components like angles, channels, beams, plates, pipe/tubes, and handrails etc for any temporary supporting or scaffolding works. Contractor shall arrange himself all such materials. In case of such misuse of BHEL materials, a sum as determined by BHEL engineer

will be recovered from the contractors bill. The decision of BHEL engineer is final and binding on the contractor. 1.10.6 The contractor will be responsible for the safe custody and proper accounting of all materials in connection with the work. If the contractor has drawn materials in excess of design requirements, recoveries will be effected for such excess drawls at the rate prescribed by manufacturing units. 1.10.7 No member of the already erected structure/ platform, pipes, grills, platform, other component and auxiliaries should be cut without specific approval of BHEL engineer. 1.10.8 Contractors shall ensure that all their Staff/Employees are exposed to periodical training programme conducted by qualified agencies/ personnel on ISO 9001 2000 Standards. 1.10.9 For other agencies, such as TG, Electrical, cabling, instrumentation, insulation etc., to commence their work from/on the equipments coming under this scope, Contractor has to clear the front, expeditiously and promptly as instructed by BHEL Engineer. Some time it may be required to re-schedule the activities to enable other agencies to commence/continue the work so as to keep the overall project schedule. 1.10.10 The terminal points decided by BHEL are final and binding on the contractor for deciding the scope of work and effecting the payment for the work done up to the terminals. 1.10.11 For the purpose of planning, contractor shall furnish the estimated requirement of power (month wise) for execution of work in terms of maximum KW demand. 1.10.12 On Completion of work, all the temporary buildings, structures, pipe lines, cable etc. shall be dismantled, leveled and debris shall be removed as per instruction of BHEL by the contractor at his cost. In the event of his failure to do so, the expenditure towards clearance of the same will be recovered from the contractor. The decision of BHEL Engineer in this regard is final. 1.10.13 All the necessary certificates and licenses required to carry out this scope of work are to be arranged by the contractor then and there at no extra cost. 1.10.14 For the movement of cranes it may become necessary to lay sleeper bed for obtaining safe approach for usage of equipment. It shall be the contractors responsibility to lay necessary sleepers. Necessary sleepers shall be arranged by the contractor at his cost.

1.10.15 The contractor must obtain the signature and permission of the security personnel of the customer for bringing any of their materials inside the site premises. Without the Entry Gate Pass these materials will not be allowed to be taken outside. SITE INSPECTION The owner/employer or his authorized agents may inspect various stages of work during the currency of the contract awarded to him. The contractor shall make necessary arrangements for such inspection and carry out the rectification pointed out by the owner/employer without any extra cost to the owner / employer. No cost whatsoever such duplication of inspection of work be entertained.
1.10.16

PART I CHAPTER -X I FOUNDATIONS AND GROUTING
The scope of the work will comprise of but not limited to the following: 1.11.1 Foundation for the equipments to be erected shall be provided by BHEL/ clients of BHEL. The dimension of the foundation and anchor bolt pits shall be checked by the contractor for their correctness as per drawings. Further, top elevation of foundations shall be checked with respect to bench mark etc. All adjustments of foundations surfaces, enlarging the pockets in foundations etc. as may be required for the erection of equipments plants shall be carried out by the contractor. Cleaning of foundation surfaces, pocket holes and anchor bolt pits etc., dewatering, making them free of oil, grease, sand and other foreign materials by soda wash, water wash, compressed air or any other approved methods etc., form/shuttering work are within the scope this work. It shall be contractors responsibility to check the various equipment foundations for their correctness with respect to level, orientation, dimensions etc., and ascertained dimensions shall be measured and submitted to BHEL for approval before erection. Also minor chipping, dressing of foundations up to 30 mm for obtaining proper face for packer plates/shims, and may be required for the erection of the equipment/plants will have to be carried out by the contractor without extra cost. The surface of foundations shall be dressed to bring the surface of the foundations to the required level and smoothness prior to placement of equipments Foundation pockets are to be cleaned thoroughly before placing the columns / equipments. Verticality of foundation bolts to be checked along with correctness of the threads and freeness of the nuts movement. If required, cleaning of the threads to be done with proper dies. The concrete foundation, surfaces shall be properly prepared by chipping, as required to bring the top of such foundation to the required level to provide the necessary roughness for bondage and to ensure enough bearing strength. All laitance and surface film shall be removed and cleaned and the packers placed with suitable mortar prior to erection of the equipment. Packer plates should not only be blue matched with foundation but also inter-packer contact surfaces between the packers and foundation frame etc., shall also be blue matched by Prussian Blue match checks and required percentage contact shall be achieved by chipping and scrapping as per BHEL Engineers instructions.
1.11.2
1.11.3
1.11.4 1.11.5
1.11.6

1.11.7 The certificate of the grout is to be submitted to BHEL. If necessary test cubes are to be made and tested at site to ensure the quality of the grout as per relevant IS standards. In case grouting with Portland cement is approved, necessary cement, sand etc to be arranged by the contractor including the fine aggregates. All the materials required for grouting including free flow special cements like Conbextra GPI,GP2, ACC- Shrinkkomb-N20, Sika Anckor, NSG/ NSG -1, CICO Excem GP, or its equivalent as approved by BHEL and other materials like Portland cement, sand etc., are to be arranged by the contractor at his cost. It shall be the responsibility of the contractor to obtain prior approval of BHEL, regarding suppliers, type of grouting cements before procurement of grouting cements. Certain packer plates and shims over and above the quantity received as part of supplies from manufacturing units of BHEL will have to be cut out from steel plates/sheets at site by the contractor to meet site requirement. However machining of the packers, wherever necessary, will be arranged by BHEL at free of cost.
1.11.8
1.11.9
1.11.10 PROCEDURE FOR GROUTING : Contractor has to carry out the grouting as per the work instructions for grouting available at site.

PART I CHAPTER -XII MATERIAL HANDLING AND SITE STORAGE
The scope of the work will comprise of but not limited to the following: 1.12.1 Loading at BHEL/Customer stores and storage yard, transport to site, unloading at site/working area of equipment placement on respective foundation/location, fabrication yard, pre-assembly bay or at working area are in the scope of work. The scope includes taking materials / Equipments from customer stores / storage yard also. Contractors Quoted / Accepted rate shall be inclusive of the same. Required cranes, tractors, trailer or trucks / slings / tools and tackles / labour including operators Fuel lubricants etc for loading & unloading of materials will be in the scope of contractor. The equipments / materials from the storage yard shall be moved in sequence to the actual site of erection /location at the appropriate time as per the direction of BHEL Engineer so as to avoid damage/loss of such equipment at site. Sometimes it may become necessary for the contractor to handle certain unrequired components in order to take out the required materials. The contractor has to take this contingency also into account. No extra payment is payable for such contingencies. Materials shall be stacked neatly, preserved and stored in the contractors shed/work area in an orderly manner. In case it is necessary to shift and re-stack the materials kept at work area/site to enable other agencies to carry out their work, same shall be done by the contractor at no extra cost. All pipe and tube ends shall be covered with plastic caps or will be closed with wooden plugs as the case may be. The contractor shall provide any fixtures, concrete blocks & wooden sleepers, which are required for temporary supporting of the components at site. Contractor has to arrange required fire proof tarpaulins to protect the machined components / assembled parts drawn from BHEL before and after erection at their cost.
1.12.2
1.12.3
1.12.4
1.12.5 1.12.6 1.12.7

PART I CHAPTER- XIII ERECTION
The scope of the work will comprise of but not limited to the following: ERECTION 1.13.1 The contractor should erect and assemble the components as per the drawings issued and the number of components supplied to him will be on the basis of shipping list / completion schedules. Complete pre assembling of components are in the scope of the contractor. 1.13.2 Any fixtures, concrete block supports, steel structures required for temporary supporting for pre-assembly or checking and welding for lifting and handling during pre-assembly and erection shall be arranged by the contractor. 1.13.3 The scope of equipments to be erected under this contract is detailed in other chapter elsewhere in Tender Specification. The schedule of weights given is approximate and is meant only to give a general idea to the tenderer about the magnitude of the work involved. 1.13.4 List of PGMA to be erected by the contractor & approximate weight of individual PGMAs and number of weld joints are given in the tender are meant for giving general idea to the tender only about magnitude of the work involved. The piping components are sent in parts for convenient transportation / layout requirements. They are to be cleaned, pre-assembled in stage by stage, welded, erected and aligned as per the drawing dimensions / tolerance and instructions of BHEL Engineers. Welding NDT, SR for IP Turbine inlet assembly (Turbine
Package No 75906) is included in the scope of contract. The same to be executed within the quoted rates without any additional payment. However the scope of transportation from BHEL stores & erection of the same is excluded.
1.13.5 The work on piping systems (air, water, oil, steam, gas etc.,) will include laying, edge preparation, fixing and welding of the elbows / fittings / valves etc., welded on the lines, NDT fixing and adjustment of supports / hangers / shock absorbers and carrying out all other activities / works to complete the erection and also carrying out all pre-commissioning / commissioning operations mentioned in the specification as per BHEL Engineer's instructions and/or as per approved drawings / documents. 1.13.6 For erection & welding of SA335P91 material please refer the ERECTION & WELDING PROCEDURE FOR SA335 P91 MATERIALS.

1.13.7 Welding, non-destructive testing and heat-treatment as prescribed in BHEL Welding / Heat treatment manual is to be carried out by the contractor. The contractor shall conduct non - destructive tests like radiography, ultrasonic test for weld defects etc., ultrasonic test for finding thickness, dye penetrant tests, magnetic particle test etc. on weld joints, castings, valve bodies and other equipments etc. as per BHEL Engineers instructions within the quoted rate. 1.13.8 Contractor should obtain the formal clearance from Director of Boilers to carry out erection & Welding of piping under IBR. Arrangement for the visit of Boiler inspector for field inspection etc. is in the scope of contractor, and necessary drawing / details only will be given by BHEL. Inspection fee, if any shall be paid by BHEL. 1.13.9 Contractor shall arrange the necessary clearance from other statutory authorities as required for installation of the plant and equipment and render all assistance, service required in this regard. 1.13.10 Carrying out piping as per the specification between equipments constituting terminal points, whether the terminal equipments fall within the scope of work/specification, contractor shall carry out the terminal joints at either end. Also where the piping connection to the terminal points involve flanged joints, matching of flanges, fixing gaskets, bolting and tightening as per BHEL Engineers instructions is in the scope of work. In case piping connected to equipment, matching of flanges for achieving the parallelism and alignment at the equipment end, by suitably resorting to heat correction or other method as instructed by BHEL Engineer, within the quoted rate. 1.13.11 All the works such as cleaning, inspection, edge preparation if required, cutting, weld depositing, grinding, straightening, chamfering, filing, chipping, drilling, reaming, scrapping, lapping, fitting-up etc., as may be applicable in such erection works and are necessary to complete the work within the quoted rate. Major machining work, which is only to be carried out in workshops, will be arranged by BHEL. 1.13.12 Normally weld neck valves will have prepared edges for welding. It may be occasionally necessary to prepare new edges, re-prepare the edges to suit site conditions, which shall be done by the contractor at no extra cost. All fittings like elbows, tees, reducers, flanges, inserts etc., shall be matched with pipes for welding which may require re-edge preparation, grinding etc., 1.13.13 The valves will have to be checked, lapped or overhauled in full or in parts before erection / after chemical cleaning / during commissioning. The contractor, at his own cost, shall arrange experienced technicians for the above work, including required consumables.

1.13.14 All the bearings, gearboxes etc., of the equipment/actuators and electrical motors to be erected are provided with protective greases only. Contractor shall arrange as and when required by the engineer for cleaning the bearing/ gear boxes etc., with kerosene or some other agent if necessary by dismantling some of the parts of the equipment during erection and shall arrange for re-greasing / lubricating them with recommended lubricants and assembling back. Lubricants will however be supplied by BHEL at free of cost. 1.13.15 The contractor shall take necessary measures to see that all the machined surfaces preserved and covered. 1.13.16 Certain instruments like pressure switches, gauges, air sets, regulators, filters, junction boxes, power cylinders, dial gauges, thermometers, flow meters, valve actuators, flow indicators etc., are received in assembled conditions as integral part of equipments. Contractor shall dismount such instruments and re-erect whenever required prior to commissioning. Sometime this may have to be handed over to store or instrumentation contractor. 1.13.17 During connection & floating of any decks, Condenser etc., before and after pipe connections, adding tentative loads, readjusting of spring to the required level is covered in this scope of work. 1.13.18 For other agencies, such as TG erection, cabling, instrumentation etc., to commence their work from / on the equipments coming under this scope, Contractor has to clear the front, expeditiously and promptly as instructed by BHEL Engineer. Some time it may be required to re-schedule the activities to enable other agencies to commence / continue the work so as to keep the overall project schedule. 1.13.19 All dimensions / elevations refers to centerline of pipe unless otherwise specified, the pipe routing shall be carried out as per the drawing. Wherever the dimensions are not specified / shown as approximate the same may be routed as per site requirement / convenience as per site engineers advice. 1.13.20 For pipes nominal size 2 and below routing shall not be shown in piping layouts or in isometrics and the same to be routed / connected as shown in schematics. For the above sizes if the routing is shown in layouts it is only for guidance and the same shall be routed and supported as per site requirement/ convenience as per site engineers advice. Piping below size 2, valves, flanges, fittings etc. shall be supplied as commercially available. Hence fit-ups, edge preparation including welding of stubs, shall be included in the contractors scope. 1.13.21 Contractor should fabricate bends of </=2 diameter size from running meters of pipe.

1.13.22 Slope of 1:500 shall be maintained towards drain point unless otherwise specified. 1.13.23 All site-fabricated pipes will be issued in running meters as straight length. These are to be cut and edge prepared at site to required length to suit layout as given in the erection drawing. In some cases attachments like lugs, stoppers, cleats etc., will be supplied as loose items and to be cut and welded to the pipes at site as per erection drawing necessary drilling of holes on main pipe for welding stubs shall also be done at site by the contractor. 1.13.24 Fittings like bends, tees, elbow/bends, reducers, flanges etc., will be supplied as loose items. 1.13.25 Certain adjustments in length may be necessary while erecting pipelines and the contractor should remove the extra lengths / add extra lengths / to suit the final layout after preparing edges afresh and adopting specified heat treatment procedure, are in the scope of work. 1.13.26 Minor adjustment like removal of ovalities in pipes and opening or closing of the fabricated bends by process of heat correction or any other method approved by BHEL Engineer to suit the layout, with specified heat treatment procedure within the quoted rate. 1.13.27 Pipes above 2 diameter have to be cleaned by means of wire brush as per the instruction of BHEL Engineer and subsequently flushed with air before lifting them into position. For pipes below 2 diameter, shall be cleaned by sponge with air flushing. 1.13.28 Contractor shall arrange all equipments, alignment bolts, tools, consumables like welding electrodes (all type) in their scope, and argon gas cylinders etc. for welding of pipes at his cost. Consumables like jute, cotton waste, hacksaw blades, petrol, Kerosene oil etc. are in contractors scope. 1.13.29 Contractor shall use only bolted clamps for achieving alignment of piping, wherever L shaped stoppers and wedges are to be used for aligning piping and equipments, the same shall be subjected to the approval of BHEL Engineer. Contractor shall remove the bridge, stopper etc., and not by hammer. Any burrs left on the equipments / piping, after welding, shall be ground off or any scar or cavity made good by welding and grinding. NDT tests shall be carried out if necessary to detect surface and sub-surface cracks in these ground areas. 1.13.30 All the weld joints on equipments and piping shall be ground or filled on completion of welding and before radiography as per instructions of BHEL Engineer so as to achieve smooth surface to avoid of ripples, undulations etc.,

1.13.31 Pipelines shall be cleaned off welding slag and burrs by hand files, wire brushes and flexible grinders wherever required and using cloth. 1.13.32 Flame cutting of piping shall be strictly done as per BHEL Engineers instructions and in his presence only. 1.13.33 Wherever elbows of 45 deg or any other angle (>2 dia pipe) are required, the same shall be cut from 90 deg. Elbow supplied and used. No extra cost shall be paid. 1.13.34 Flow nozzles, orifice, spray nozzles etc shall be mounted / erected after chemical cleaning / flushing / or steam blowing at site. 1.13.35 Erection of Flow nozzles, flow orifice, flow switches, flow meters, flow indicators, spray nozzles, steam traps, filters, suction strainers other metering elements, control valves, NRVs, servomotors etc forming part of the system (under this scope of work) irrespective of the suppliers is also to be carried out by the agency without any extra cost after chemical and / or steam blowing/ oil flushing at site. This will include issue and collecting the same from BHEL stores, transport to site, suitably cutting the erected piping, cleaning, erection, welding, radiography and stress relieving and commissioning. 1.13.36 The Matching Pieces / Nozzles / Reducers (including the reducers to be connected with HP heaters) supplied for connecting BFP discharge piping with the Heaters are forming part of the systems and are also in the scope of work including issue, transportation, suitably cutting the erected piping, cleaning, erection, welding, radiography and stress relieving and commissioning. 1.13.37 Cutting and removal of dummies from all the shop welded stubs (irrespective of the equipments supplier for the above) form as terminal points and preparation of edge where the piping is to be terminated is also in the scope of the contractor without any extra payment. 1.13.38 Contractor shall also weld small length of piping with root valve to the pressure, flow and level tapping points on piping or flow and level tapping points on piping or flow nozzles / orifices / metering elements fixed on piping as per the instructions of BHEL Engineer. 1.13.39 All drains / vents / relief / escape / safety valve piping to various tanks/ sewage / drain canal / flash box / flash tank / condenser / sump / atmosphere etc. from the stubs on the piping and equipments erected by the contractor is completely covered in the scope of work.

1.13.40 Contractor should fabricate bends at site from running meters of piping for the above and cut, edge prepare and lay the piping as per BHEL Engineers instructions. 1.13.41 Fixing / fitting / welding of thermo wells, stubs, tapping points, root valves etc. on different lines / equipments (Which will be supplied by BHEL) is within the scope of work. 1.13.42 Plate / Pipe shoes for piping supports shall be fabricated at site by the contractor. Other supports namely Hangers, U-Clamps etc. shall be supplied by BHEL duly bent and threaded. Assembly and necessarily cutting work shall be carried out at site by contractor within the quoted rate. 1.13.43 For Hangers and Support the instruction given in the drawing & documents must be followed for handling, erection, setting of COLD/HOT values and logging etc., 1.13.44 Wherever hanger and support materials of piping are not received from manufacturing unit in time to suit the erection schedule, contractor shall erect the piping system on temporary supports to ensure the progress of work within quoted rate. The required structural steel materials will be issued on free of charges by BHEL, either from scrap / spare materials. The same shall be removed and returned to BHEL store after erection of permanent supports. 1.13.45 All Operating / Approach platforms, cross over, canopies, ladders etc., shall have to be fabricated from raw materials supplied by BHEL and erected by the contractor as per instruction of BHEL and shall be paid as per accepted Tonnage rate for Structural Erection work. 1.13.46 Contractor shall be supplied with two blue prints of the layout & isometrics. Contractor to incorporate in one of the blue prints with red ink all the changes/ deviations / alterations etc. carried out at site due to various reasons, with site engineers endorsement. Marked up drawings shall be submitted to BHEL for approval. APPLICATION OF INSULATION 1.13.47 The scope of the work will comprise of but not limited to the following:1.13.48 The work to be carried out under the scope of these specifications is broadly as under: 1.13.49 Handling at site stores / storage yard, Transportation to site of work, Application of refractory &Insulation materials and connected works for Boiler , ESP , ducts, Power cycle Piping, Vessels, etc., and binding & cladding with sheets etc.,

using their own tools plants, tackles, all consumables, supervisor and men as enumerated in the scope of contract at Boiler, ESP and all PIPIPING under Piping scope of supply, and other equipment like VESSELS, FEED PUMPs, FLASH TANKS, HEATERS, DEAERATOR, etc. for 1 x 600 MW Kakatiya TPP, Chelpur village, Warangal DT,AP . 1.13.50 Application of insulation and removal of the same for temporary piping under scope of erection of this contract is also included in the scope of the work. However, BHEL will supply the insulation materials free of cost. 1.13.51 The work shall conform to dimensions and tolerances given in various drawings and quality manuals provided by BHEL. If any portion of work is found to be defective in workmanship not conforming to drawings or other stipulations, the contractor shall dismantle and redo the work duly replacing the defective materials at his cost, failing which the job will be carried out by BHEL by engaging other agencies / departmentally and recoveries will be effected from contractors bill towards expenditure incurred including BHELs overhead charges. 1.13.52 The contractor will have to follow the instructions provided in the technical manuals, drawings, and specifications provided by BHEL, to the contractor from time to time. In case of ambiguity or deviation the decision / clarification of BHEL Engineer will have to be followed. 1.13.53 All insulations materials including iron components and other sheets casing materials, etc., required as per drawing will be supplied by BHEL and the same have to be erected / applied as per the drawings and specifications of BHEL by the contractor. 1.13.54 Clean the Surface to be Insulated from Rust, Dust, Grease, Loose scale, Oil, Moisture, etc.. Care shall be taken that flexible insulation is not unduly compressed. After insulating the equipment the gaps / joints shall be filled with loose wool/ moulded insulation as applicable. 1.13.55 Painting of inner side of sheet metal covering over the insulation walls with two coats of anti-corrosive paint (IS-158) to be applied to the entire satisfaction of BHEL Engineer and application of bituminous sealing compound on cladding/ sheet metal joints shall also be carried out by the contractor. Retainer type A must be coated with Aluminum paint. For which the required amount of paint, thinner and other accessories for painting, cleaning the surfaces etc., shall be arranged by the contractor within the quoted rate. 1.13.56 Bituminous sealing compound will be provided by BHEL free of cost which is supplied by the respective Mfg. Units.

1.13.57 It is the responsibility of the contractor to ensure that the insulation materials and sheet metal covering issued to him for application are well protected against loss or damage or weather conditions tending to affect its quality by the provision of close / semi closed sheds at his cost. 1.13.58 All the insulation materials and sheet metal covering etc., issued to the contractor shall be properly stored and handled before application due the same. If any damage occur to the materials due to improper storage or due to any causes attributable to the contractor except for normal breakage or damaged material shall be to the cost of the contractor. 1.13.59 Contractor is liable for the exact accounting of the materials issued to him and any unaccountable losses shall be made good by him. The necessary accounting of the material issued will have to be furnished by the contractor periodically. 1.13.60 The contractor shall provide the required quantity of wire, nails and other materials for centering works at their cost. 1.13.61 Wherever iron components are to be welded on non-pressure parts, the contractor shall employ only approved structural welders. It shall also be the responsibility of the contractor to arrange for welding hooks, flats, plates, supports and other fixtures also. All consumables tools and plants etc., required for the work shall be arranged by the contractor at their cost. 1.13.62 Wool insulations are received at site as bonded and unbonded mattresses in standard sizes. These has to be dressed / cut to suit equipment / site work by the contractor. 1.13.63 Dressing of insulation to suit site conditions, sheet cladding over insulations, form the part of this work. 1.13.64 Removal type of insulation to be provided for valves fittings, expansion joints etc., as per the drawings or as directed by BHEL Engineer. 1.13.65 All piping insulations shall be carried out in such a manner as to facilitate removal of bolts nuts and washers from the flanges. 1.13.66 Fabrication of covering sheets may be necessary like preparing the sheets to the sizes and shapes specified in drawings, beading, swaging, beveling of sheets crowning of the sheets if necessary the same to supports over wool insulation with screws as specified in BHEL drawings or as instructed by BHEL engineer.

1.13.67 Fabrication, fixing or welding of hooks / supports to equipment piping and other connected equipments to support wool insulation applying of primer paint to welded portion parts welding certain supports on parts as per the drawings or as instructed by BHEL Engineer will have to be carried out by the contractor. 1.13.68 Cladding sheets shall be suitably pressed along with diagonals to form diamond shape so as to improve the strength of the sheets, to avoid humpiness and to give aesthetic look. 1.13.69 Plates ,bars, rods and other materials that are to be cut, and re-welded from the fabricated places to suit erection requirements for which no extra payment will be made to the contractor. 1.13.70 A log book shall be maintained by the contractor for the clearance of the area for application of insulation. If the contractor does the work on his own accord without prior permission the area should be redone at his cost. 1.13.71 The contractor shall draw only one weeks requirement of material for their work from BHEL stores and keep them in their semi-closed shed near to the work area. The materials required for a particular space of work only shall be taken to the work spot. At the end of the days work the leftover or unused materials shall be taken back to their semi-closed shed for keeping the materials safe. Necessary records shall have to be maintained by the contractor in respect of the above drawls / deposits, on daily basis as instructed by BHEL. Wastages allowance for the materials issued are envisaged as follows: a) Wool mattresses 2% b) Cladding sheets 5% 1.13.72 Upon completion of daily work , the contractor shall remove from the vicinity of work all scrap packing materials rubbish, unused and other materials and deposit them in places to be specified by BHEL Engineer. Also, the contractor will demolish all the hutments, sheds, offices, constructed by him and shall clean the debris after the contract is over. In the event of his failure to do so, the same will be arranged / removed by BHEL Engineer and the expenses incurred with overhead will be recovered from the contractors. 1.13.73 Welding of hooks as per pitch, applying red oxide paint to the welded portion as directed as per drawings before application of mineral wool mattresses will have to be done by the contractor.

1.13.74 Applying different layers of mineral wool as directed and as per drawings and specifications for pipelines valves and other vessels and after fixing require holdings materials, suitably if necessary, fabrication of rings etc., and fixing as directed and as per drawings and specifications shall also form part of this work. 1.13.75 If necessary the hooks may have to be made from the rods, raw materials supplied in running lengths. The contractor may have to carry out this work also and use the same hooks. 1.13.76 In-case the contractor is required to dismantle and re-erect certain area as and when required for pre-commissioning / commissioning activities the rate as indicated in the rate schedule shall be paid by BHEL for erection. However, for dismantling no extra charge will be paid under any circumstances. 1.13.77 Wherever additional / clamps, frame works, etc., are required to be fabricated and installed even though not indicated in the drawings shall be fabricated and installed at their cost. Only steel materials shall be given by BHEL free of cost , consumables like electrodes, gases etc., are to arranged by the contractor at his cost. 1.13.78 Contractor has to arrange required fire retardant covering material at their cost to protect the insulation materials drawn from BHEL before and after erection. 1.13.79 The contractor shall provide any fixtures, concrete blocks / wooden sleepers, etc., which are required for temporary supporting of the insulation materials at site. 1.13.80 In case of any class of work for which there is no such specifications as laid down in the contract, the work shall be carried out in accordance with instructions and requirements of the BHEL engineer at the quoted rates only. 1.13.81 The temporary structures / items welded to permanent members / pipes are to be cut and removed without any damage. Any damage so to permanent members / pipes to be made good by the contractor at his cost. 1.13.82 Delay in clearance of mechanical equipment and piping for insulations is unlikely to happen. However, if any delay occurs, the contractor shall not claim anything extra, like idle charges. 1.13.83 Welding of iron components directly on HP piping is not covered in the scope of this contract since these welding are to be carried out by certified IBR high pressure welders. This is included in the scope of erectors of respective equipment / components.

Field Quality Assurance Formats:1.13.84 It is the responsibility of the contractor to collect and fill up the relevant FQA log sheets of BHEL and present the same to BHEL after carrying out the necessary checks as per the log sheets and obtaining the signature of BHEL and customer as token of their acceptance. Payment to the contractor will be linked with the submission of these FQA log sheets.

PART I CHAPTER - XIV PROGRESS OF WORK
The scope of the work will comprise of but not limited to the following: 1.14.0 Refer forms F -14 to F-18 of volume I D of volume -I book-II. Plan and review will be done as per the formats. 1.14.1 Contractor is required to draw mutually agreed monthly erection programs in consultation with BHEL well in advance. Contractor shall ensure achievement of agreed program and shall also timely arrange additional resources considered necessary at no extra cost to BHEL. 1.14.2 Progress review meetings will be held at site during which actual progress during the week vis-a-vis scheduled program shall be discussed for actions to be taken for achieving targets. Contractor shall also present the program for subsequent week. The contractor shall constantly update / revise his work program to meet the overall requirement. All quality problems shall also be discussed during above review meetings. Necessary preventive and corrective action shall be discussed and decided upon in such review meetings and shall be implemented by the contractor in time bound manner so as to eliminate the cause of nonconformities. 1.14.3 The contractor shall submit daily, weekly and monthly progress reports, manpower reports, materials reports, consumables (gases / electrodes) report, cranes availability report and other reports as per Performa considered necessary by the Engineer as per the format enclosed with this tender document. 1.14.4 The contractor shall submit weekly / fortnightly / monthly statement report regarding consumption of all consumables for cost analysis purposes. 1.14.5 The monthly report ending on 24th of every month shall be submitted as a booklet and shall contain the following details :a) b) Colour Progress photographs to accompany the report should be submitted. Erection progress in terms of tonnage, welding joints, radiography, stress relieving, etc., completed as relevant to the respective work areas against planned. Site Organization chart of engineers & supervisors as on 24th of the month with further mobilization plan Category- wise man hours engaged during the previous month under the categories of fitters, welders, riggers, khalasis, grinder-men, gas-cutters,
c) d)

electricians, crane operations and helpers. Data will be spilt up under the work area of Boiler e) f) g) h) Consumables report giving consumption of all types of gases and electrodes during the previous month. Availability report of cranes Safety implementation report in the format Pending material and any other inputs required from BHEL for activities planned during the subsequent month.
1.14.6 The manpower reports shall clearly indicate the manpower deployed, category wise specifying also the activities in which they are engaged. 1.14.7 During the course of erection, if the progress is found unsatisfactory, or if the target dates fixed from time to time for every milestone are to be advanced, or in the opinion of BHEL, if it is found that the skilled workmen like fitters, operators, technicians employed are not sufficient BHEL will induct required additional workmen to improve the progress and recover all charges incurred on this account including all expenses together with BHEL overheads from contractors bills.

PART I CHAPTER - XV WELDING
The scope of the work will comprise of but not limited to the following: WELDING, HEAT TREATMENT, RADIOGRAPHY AND NON-DESTRUCTIVE TESTING 1.15.1 The contractor has to establish the WPS (Welding Procedure Specification) and PQR (Procedure Qualification Requirement) applicable for the scope of work for all the materials involved at his own cost. However Test Materials for the same will be given by BHEL free of cost. All necessary preheating, post heating of welds and stress relieving operation of welds are part of the erection work and shall be performed by the contractor in accordance with the relevant regulations and standards of BHEL practice and to the satisfaction of BHEL Engineer and in accordance with the drawings and specifications. Erection of equipment involves good quality of Welding, Heat treatment and Non Destructive Testing. Wherever required, 100% dye penetration tests have to be carried out as per instructions of BHEL Engineer. Contractors Engineers, Supervisors, Technicians and workers engaged should have adequate knowledge on the above works. The pressure parts pipings shall be erected in conformity with the provision of Indian Boiler Regulations and as may be directed as per any other standard/specification in practice in BHEL. The method of welding (viz.) Arc, Gas, TIG or other methods are indicated in the detailed drawings. BHEL Engineer will have the option of changing the method of welding as per site requirements. Welding of high pressure parts shall be done by certified High Pressure Welders who possess valid certificate of CIB of the State in which the equipment is erected as per provision of IBR. The high pressure welders who possess necessary certificate shall appear well in advance before the expiry of the validity of their certificate for re-qualification test as per relevant provision of IBR and keep the certificate valid till the completion of work. The services of such welders, the validity of whose certificates has expired shall have to be suspended forthwith. All welders deployed on this work shall be tested and approved by BHEL Engineer before they are actually engaged on work though they may possess the IBR certificate. BHEL reserves the right to reject any welders without assigning any reason.
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1.15.7 BHEL Engineer is entitled to stop any welder from the work, if his work is unsatisfactory for any technical reasons or there is a high percentage of rejection of joints welded by him, which in the option of the BHEL Engineer will adversely affect the quality of the welding, though the welder has earlier passed the tests prescribed by BHEL Engineer. The welders having passed qualification tests does not relieve the contractor of a contractual obligation to check on the welders performance. All charges towards testing of welders for destructive and non-destructive testing and approval of welders for engaging in the erection work shall be borne by the contractor. All radiographs shall be free from mechanical / chemical process marks to the extent they shall not confuse the radiographic image and defect finding penetrometer. As per ASME / SI shall be used for all exposures. All welded joints shall subject to acceptance by BHEL Engineer. Preheating, post weld heating and stress relieving after welding are part of erectors work and shall be performed by the contractor in accordance with the instructions of BHEL Engineer. Contractor shall arrange to supply heating equipment with automatic recording devices. Also the contractor shall have to arrange for labour, all heating elements thermocouples etc. insulating materials like mineral wool, asbestos, clothes, ceramic beads, asbestos ropes etc., required for heat treatment and stress relieving works. During the heat/stress relieving operations, the temperature required, by attaching thermocouples and recorded on a continuous printing type recorder. All the recorded graphs for the heat treatment works carried out shall be got signed by BHEL Engineer prior to the commencement of each cycle and handed over to BHEL on completion. The graphs will be the property of BHEL. The contractor has to provide (Thermo chalks) temperature recorders, thermocouple attachment units, graph sheets, etc. required for the job and maintain them in good condition. All electrodes shall be baked and dried in an electric electrode drying oven to the required temperature and for the period specified by the Engineer before they are used in production work, and all welders including high pressure welders shall have a portable electrode drying oven at the work spot. All butt Joints shall be carried out by TIG root run and subsequent runs by Arc welding. Full TIG welding, wherever necessary shall be carried out within the quoted rates. For oil system piping root run of all the butt joints shall be carried out by TIG welding only. The technical particulars, specifications and other general details of work shall be in accordance with BHEL welding, Heat treatment and NDE manuals or equivalent as decided by BHEL Engineer.
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1.15.14

1.15.15 Contractor shall carryout Radiography as per welding Manual booklet applicable as per IBR, enclosed. However percentage radiography shown in the respective drawings shall be final and binding on the contractors. The field joints are to be radiographed and preheating and post weld heat treatment to be done as per BHEL procedure and manuals. The percentage of Radiography are tentative, which may be increased depending upon the quality of joints at the discretion of BHEL. Low speed high contrast fine grain films (D7 or equivalent) in 10 cm width only should be used for weld joint radiography. Film density shall be between 1.5. to 2.00 All radiographs shall be free from mechanical, chemical or process marks to the extent they shall not confuse the radiographic image and noticed. Penetrometor as per ASME/ISO, shall be used for all exposures. The contractor shall maintain a record in the format as prescribed by BHEL of all operations carried out on each weld and maintain a record indicating the number of welds, the names of welders who welded the same, date and time of start and completion, preheat temperature, radiographic results, rejection if any, percentage of rejection etc. and submit copies of the same to the BHEL Engineer as required. Interpretation of the BHEL Engineer regarding acceptability or otherwise of the welds shall be final. All site welds shall be subject to acceptance of BHEL / Customer Engineers. The contractor shall carry out the edge preparation of weld joints at site in accordance with details acceptable to BHEL Engineer. Wherever possible machining or automatic flame cutting will be allowed only for edge preparation. Some extra lengths in various fabricated pipes given as erection allowance shall have to be cut and edges prepared to suit the site conditions at no extra cost. Lead numbers, letters (Generally of 6 mm size) are to be used for identification of radiographs. Contract number, joint identification, source used, welders identification, SFD used are to be noted down on the paper cover of radiograph. Lead intensifying screens for front and back of the film shall be used as per the instruction of BHEL Engineer. The weld joint is to be marked with permanent mark A, B, C, etc to identify the segments. For this a low stress stamp shall be used to stamp the pipe on the downstream side of the weld. For multiple exposures on pipes an overlap of about 25 mm of film shall be provided. The contractor shall be fully equipped with radiography equipments,, films, chemicals and other dark room facilities. There must be a number of radiographic personnel with sufficient experience and certified by BARC for field radiographic inspection. Further, the contractor must follow strictly the safety rules laid down by
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1.15.25

BARC, from time to time, contractors radiographers shall also be registered with BARC for film badge service. 1.15.26 Contractor shall provide all skilled, unskilled work men required for the job, which will include Engineers, supervisors, operators, as required for timely and satisfactory execution of radiography work. If the contractor does not carry out radiography work in time due to non-availability of film, chemical etc. BHEL shall get the work done through some other agency at the risk and cost of the contractor. All the radiographs shall be properly preserved in air-conditioned rooms and shall become the property of BHEL. Radiography of joints shall be so planned after welding that the same is done either on the same day or next day of the welding to assess the performance of high pressure welders. If the performance of the welder is unsatisfactory, he shall be replaced immediately. The defects as pointed out by the Engineer shall be rectified immediately to the satisfaction of Engineer and Re-radiographed. The decision of Engineer regarding acceptance or otherwise of the joint shall be final and binding on the contractor. The contractor shall also be equipped for carrying out other NDT like liquid penetrant inspection, magnetic particle inspection, etc as and when required in the interest of work within the quoted rates. For carrying out ultrasonic testing of welded joints of large size tubes and pipes, it will be necessary to prepare the surface by grinding to a smooth finish and contour as desired by BHEL Engineer. The contractors scope of work include such preparation and no extra charges are payable for this. The contractor has to make his own arrangements for air-conditioned dark room to process the radiographs. It may also become necessary to adopt inter layer radiography / MPT / UT depending upon the site/technical requirement necessitating interruptions in continuity of the work and making necessary arrangements for carrying out the above work. The contractor shall take all this into account and quote the price inclusive of all such work and radiography. The welded surface irrespective of place of welding shall be cleaned of slag and painted at the center with primer paint to prevent corrosion at no extra cost towards this. FACILITY TO BE PROVIDED BY BHEL FOR P91 Welding. 1. Induction Heating M/C with accessories as indicated in the T&P chapter in TCC. 2. The following consumables
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2.1 2.2 Annealing cables Compensating Cables
3. Welding Electrodes for P91 welding in PG 80 4. Spot Welding M/C for fixing thermocouple as indicated in the T&P chapter in TCC 5. DG set as indicated in the T&P chapter in TCC. The contractor shall provide necessary cables & switches, fuel and operator. The induction heating equipments and other equipments shall be drawn from BHEL stores, transported and installed & commissioned wherever required. For routine maintenance & attending all type of brake-down maintenance, contractor shall deploy sufficient manpower, tools and plant within the quoted rate. The contractor shall provide electrical cables & Switches required. All the equipments shall be protected by providing covers or sheds at site by the contractor with in the quoted rate. 1.15.37 FACILITY TO BE PROVIDED BY THE CONTRACTOR FOR P91 WELDING 1. Required no of operators/ Technicians/ Electrician for installation, commissioning & operating continuously 2. Gas Burners arrangement with required gas for maintaining temperature in the event of power failure 3. Ultrasonic Flaw detector with recording device & complete accessories (Digital Type Krautkramer Model USN 50 or equivalent) capable of storing calibration data. All recordable indications will be stored in memory of digital flaw detector and in PC (to be provided by the contractor) for review at later period. 4. EQUOTIP or MICRODUR make or equivalent portable hardness tester. 5. MPI/LPI Kits with required consumables 6. Consumables 1. Glass fibre cloth 1mm x 1000mm Temp rating 12600 C 2. Glass fibre cord Dia 3mm (twisted) Temp rating 12600 C 3. Ceramic fibre Blanket RT Grade, density 96Kg/M3 - Temp rating 12600 C

4. Ceramic fibre rope Fibre Glass braided, Dia 12mm - Temp rating 12600 C 5. K Type Thermocouple 0.5mm Dia Single Strand individual fibre glass insulated 6. heavy duty TC connectors for - K Type Thermocouple 0.5mm Dia Single Strand individual fibre glass insulated 7. All other consumables/ equipments required to carry out the work 1.15.38 Heat treatment may be required to be carried out at any time (day and night) to ensure the continuity of the progress. The contractor shall make all arrangements including labour required for the work as per directions of BHEL. All the data such as heating temperatures, heating rate, soaking time, maximum temperature reached during heat treatment shall be properly recorded and documented which will be property of BHEL. Oxy-acetylene flame heating or exothermic chemical heating for stress relieving is not permitted. Heating shall be by means of Electric Induction coil or Electric resistance coil. Potentiometric type recorders shall only be used for temperature recording purposes. Radiography work of the welds connected with this contract shall be arranged by the contractor including provisions of services of technicians and necessary equipment and consumables like Isotope camera, Radiography films, chemicals and other dark room facilities etc. Also contractor has to provide necessary labour required such as Riggers, Helpers etc. to assist the technicians for carrying the above radiography work and making other arrangements. Such as providing scaffolding, approaches, platform lighting arrangements at his cost as per the instructions of BHEL. It may please be noted that invariably the radiography will be carried out after the normal working hours only. Radiography inspection of welds shall be performed in accordance with the requirements and recommendation of BHEL Engineer. The Minimum extent of radiographic inspection shall be as per BHEL Drgs / provision of IBR Regulations. They may however be increased depending upon the performance of the individual welder at the discretion of BHEL Engineer/Boiler inspection authority. If the contractor does not carry out radiography work in time due to non-availability of film, chemicals etc. BHEL shall get the work done departmentally or through some other agency at the risk and cost of the contractor. Wherever radiographs are not accepted on account of exposure, joints shall be reradiographed and new films submitted for evaluation. Radiographs shall be taken again on joints after carrying out repairs. However, if the defects persist after first repair as per radiograph, carrying out radiography shall be repeated till the joint is made acceptable. In case the joint is not repairable the same shall be cut, rewelded and re-radiographed at contractors cost.
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1.15.45 1.15.46 1.15.47 Contractor has to make his own arrangements for air conditioned dark room to process the radiographs. Quantum of radiography (percentage of joints) shall be enforced as per specifications and as per the drawings. BHEL Engineer reserves the right to alter the quantum of radiography of joints. The decision of the BHEL Engineer in this regard is fixed and final and binding on the contractor. Any defects as pointed out by BHEL Engineer shall have to be rectified by the contractor at his cost. All radiogrpy films of joints radiographed at site in connection with work shall be properly preserved in air-conditioned rooms and shall become the property of BHEL. All field joints shall be subjected to dye penetrant examination as specified in the respective drawings and shall have to be accepted by BHEL Engineer. Any rectifications required shall have to be done by the contractor at his cost. For carrying out ultrasonic testing of welds including large size tubes and pipes it will be necessary to prepare the surface by grinding to a smooth finish and contour as desired by BHEL Engineer. The contractors scope of work includes such preparation and no extra charges are payable to this. It may also become necessary to adopt inter layer Radiography / MPT/ UT depending upon the site / technical / requirement necessitating interruptions in continuity of the work and making necessary arrangements for carrying out the above work. The tenderers shall take all this into account and quote the price inclusive of all such work and radiography. The welded surface irrespective of place of welding shall be cleaned of slag and painted with primer paint to prevent corrosion at no extra cost towards this. The contractor shall have to do root run by TIG process, wherever required as per the instruction of BHEL Engineer. Welding of Hangers, supports, stubs and impulse piping to be carried out by the contractor as per drawing specification and as per BHEL Engineers instructions. According to drawing specifications and as per BHEL Engineers instructions preheating, post-heating, stress relieving, etc. have to be carried out by the contractor wherever necessary.
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PART - I CHAPTER- XVI TESTING AND COMMISSIONING
The scope of the work will comprise of but not limited to the following: 1.16 TESTING, PRE COMMISSIONING & COMMISSIONING AND POST COMMISSIONING (All the works mentioned hereunder shall be carried out within the quoted and accepted rate) 1.16.1 Contractor to provide necessary commissioning assistance from pre-commissioning state onwards and up to continuous operation of the unit and handing over to customer. 1.16.2 Hydraulic testing pump for HP lines shall be provided by BHEL free of hire charges. The servicing, installation, electrical connection, erection, testing and dismantling and returning to BHEL Stores, etc., shall be carried out by the contractor as part of this work without any extra charges. For LP lines contractor has to arrange Hydraulic Test pump / Hand Pump for HT at his cost. 1.16.3 All pressure parts and some of the Low Pressure parts shall be subjected to hydraulic test as per the Standard / statutory requirements. The contractor shall supply necessary labour and other services and make necessary arrangements including erection of temporary pipe lines to carry out the required tests as per the instructions and directions of the BHEL Engineers. 1.16.4 Contractor at his cost shall lay all necessary temporary piping, install the pumps, blanks, valves required for the test, pressure gauges etc. Required pipes, valves, plates etc., will be given by BHEL. Temporary piping, pumps, valves, flanges, blanks etc shall be removed by him and returned to BHEL. 1.16.5 All the above tests shall be repeated till all the equipment satisfy the requirement of BHEL to their customer. As far as the hydraulic pressure test is concerned and same shall be conducted to the satisfaction of Boiler Inspector wherever applicable. Any rectifications required shall have to be done / redone by the contractor at his cost. 1.16.6 The contractor shall carry out all the required tests and pre-commissioning and commissioning activities required for successful and reliable operation. These would include hydraulic test of piping, pre-boiler system detergent flushing/chemical cleaning , steam blowing, water washing etc. as instructed by BHEL 1.16.7 Contractor shall lay the temporary pipelines with fittings, accessories and erection & commission of pumps, tanks and other installations as instructed by BHEL Engineer for the purpose of chemical cleaning/alkali flushing/steam blowing/ steam washing/

steam flushing/water flushing/ water washing/oil flushing etc., of piping and other equipments are within the scope of work. Necessary materials for this will be provided by BHEL. Overhauling / cleaning / revisioning /servicing of valves, fittings in temporary system and acid cleaning tanks for re-commissioning activities / operation like water flushing / steam blowing / washing / flushing / passivation / chemical cleaning etc. and also over hauling / revisioning of the pumps & equipments and also to carry out the repairs to attend leaks etc. in the temporary piping & equipments, prior & while carrying out the above operations/activities. All the above works are within the scope of work. All the chemicals will be supplied by BHEL free of cost. 1.16.8 Chemical cleaning (Acid cleaning of piping/alkali flushing) will involve the installation of temporary piping, valves, cutting of some of the existing valves, placing the rubber, wedges in the valves, gagging of valves, and installation of temporary tanks for chemical and for mixing. Necessary temporary access platforms to mixing tank are to be made by the contractor. The dissolving tank, neutralizing tank etc. required for acid pickling will have to be carried out by the contractor. Required materials will be provided by BHEL free of cost. Chemicals for chemical Cleaning will be provided by BHEL. All other consumable are to be provided by the contractor. 1.16.9 Contractor shall lay all necessary electric cables, switches, etc. required for the hydraulic tests and other tests, flushing etc., and maintain the system till the tests are completed satisfactorily. 1.16.10 Steam blowing of system piping if required will involve laying of temporary pipe lines, valves, etc and dismantling & restoration of piping. The required steam shall be provided at a central point by BHEL. 1.16.11 During the initial stages of work, trenches for draining water may not be available after Leak test, Hydro test, Flushing or mass flushing. For discharging/ emptying the equipment, system and piping, necessary low point drains and temporary piping upto safe location are be erected by the contractor at his cost. The materials will be provided by BHEL. 1.16.12 After the chemical cleaning has been successfully completed, removing all temporary piping, fittings of tanks etc. Checking all the valves for any accumulation of foreign materials, welding the valves & pipes which were cut and cleaning & re-fixing as per BHEL Engineers instructions is within the scope of work/ specification. 1.16.13 Raw materials for all temporary piping necessary for conducting Hydraulic test, Chemical cleaning, Steam blowing, Flushing, effluent disposal, etc. will be provided by BHEL free of cost. However, fabrication, servicing, erection and dismantling the same and return of the temporary piping, flanges, valves etc. to BHEL stores is the responsibility of the contractor without any extra charges.

1.16.14 The contractor shall carryout the required tests on the equipments & pipelines, such as gas tightness test/air tightness test, kerosene test, hydrostatic test and rectify all the defects caused due to contractor's fault at his own cost. Contractor may have to replace old/damaged gaskets / packing etc. of equipments and the same shall be carried out by contractor as per requirement. Compressed air for pneumatic testing is to be arranged by contractor. The contractor shall carry out the trial run of motors including checking the direction of rotation in the uncoupled condition, checking, aligning and coupling the motor to the respective driven equipment. Before starting the motor IR values of insulation shall be recorded and if found necessary dry out to be done by the contractor to improve the IR value at no extra cost. 1.16.15 In case any erection defect is detected during various tests / operations, trial runs as detailed above, such as loose components, undue noises, vibration, strain on connected equipment, steam/oil/water leakage, etc. the contractor shall immediately attend these defects and take necessary corrective measures. If any readjustment and realignments are necessary the same shall be done as per BHEL Engineer's instructions. If any part needs repairs rectification and replacement the same shall be done by the contractor at no extra cost. The parts to be replaced shall be provided by BHEL free of cost. If insulation is to be removed to attend any of the defects the cost of removal and reapplication of insulation should be borne by the contractor. 1.16.16 Welding and stress relieving of temporary blanks or suitably fixing temporary blank flanges with gaskets and fasteners and welding and providing suitable de-aeration / venting / draining points with valves as per BHEL Engineers instructions, for performing hydro-test of piping and other equipments is within the scope of work. Gaskets, valves, fasteners will be provided free of cost by BHEL. Contractor shall cut steel blanks from steel provided without charging extra. After completion of hydraulic test, welded blanks shall be cut and removed and weld burrs ground finished and cavities/scars of cutting weld filled and ground as per BHEL Engineers instructions. 1.16.17 Necessary scaffolding and approaches for conducting the above shall also be within the scope of the contract. 1.16.18 Main Steam Line Strainers bodies are erected first before steam blowing of the lines. After Hydraulic Test, the strainer elements are fixed. During trial operation, if required the strainers are removed for inspection of derbies & cleaning. Contractor has to carry out the work as part of his work without any extra cost. 1.16.19 For conducting Hydro test / steam blowing of MSL,CRH&HRH internals of valves and NRVs (LP BP, ESV, IV & LP BP Valves & NRVs) are to be removed, Hydro Test devices are to be fixed and after Hydro Test the internals are to be re-assembled by the contractor as instructed by BHEL without any additional cost.

1.16.20 Temporary blinds/lugs/caps of piping and associated equipments like tanks, pumps etc required for oil flushing / alkali cleaning / acid cleaning of piping & other equipments during erection & pre-commissioning shall be erected by contractor within the quoted rate. 1.16.21 In case any malfunctioning and/or defect is found during tests/trials runs such as loose components, undue noise or vibrations, strains etc. on equipment, the contractor shall immediately attend to these defects/malfunctioning and take necessary corrective measures. If any readjustment and re-alignment are necessary the same shall be done as per BHEL Engineer's instructions as part of work at no extra cost. 1.16.22 During this period, though BHEL's and customer's staff also be associated in the work, it is the contractor's responsibility to make available the resources in his scope till such time the commissioned units are taken over by the customer/BHEL. 1.16.23 During Commissioning, opening / closing of valves, changing of gaskets, attending to leakage and adjustments of erected equipment may arise. The finally accepted price /rates shall also include all such work. 1.16.24 Replacing / cleaning of filters of the erected equipments and piping system etc. during pre-commissioning / commissioning stage is within the scope of work. 1.16.25 During steam blowing operations the required manpower for fixing the target plates shall be arranged by the contractor as per the instructions of BHEL Engineer within the quoted rates. The manpower for the above operation may be required round the clock if necessary. The contractor shall carry out the above operation as per the instructions of BHEL Engineer within the quoted rates. 1.16.26 Contractor may have to replace old/damaged gaskets / packing etc. for equipments and the same shall be carried out by contractor as per requirement. 1.16.27 Main Steam Line & Hot Reheat Line Strainers bodies are erected first by other agency and the lines will be erected by piping contractor. After Hydraulic Test, the strainer elements are to be fixed, by other agency. During trial operation, if required, the strainers are to be removed for inspection of debris & cleaning. During all these operation piping contractor shall extend all assistance by providing necessary man power, T & P and required materials. 1.16.28 The contractor shall carryout any other test as desired by BHEL Engineer on erected equipment covered under the scope of this contract during testing, pre-commissioning, commissioning, and operation, to demonstrate the completion of any part or whole work performed by the contractor.

1.16.29 It shall be the responsibility of the contractor to provide Various categories of workers in sufficient numbers along with Supervisors during pre-commissioning, commissioning and post commissioning of equipment, transporting & adding of chemicals/consumables and attending any problem in the equipment erected by the contractor till handing over. The contractor will provide necessary consumables in his scope, T&Ps, IMTEs etc., and any other assistance required during this period. Association of BHELs / Client's staff during above period will not absolve contractor from above responsibilities. 1.16.30 Contractor shall cut open the works if needed, as per BHEL Engineer's instructions during commissioning for inspection, checking and make good the works after inspection is over. This contingency shall be included within the quoted value. During commissioning, opening of valves, changing of gaskets, attending to leakages, minor modification/ rectification works may arise. The contractor has to carry out these works at his cost by providing required manpower in all the three shifts. In case any rework is required because of contractors faulty erection and which is noticed during commissioning the same has to be rectified by the contractor at his cost. 1.16.31 After synchronisatin, the commissioning activities and trial operations will continue upto handing over. It shall be the responsibility of the contractor to provide various categories of workers in sufficient numbers as per the work requirement along with supervisors including necessary consumables, tools, etc. during this period. The rate quoted shall include all these contingencies also. The various categories of workers required for pre-commissioning, commissioning and postcommissioning activities are as follows. a. Pipe fitters b. Mill Wright Fitters c. HP / Structural welders d. Riggers e. Unskilled workers f. Supervisors g. Electricians h. Any other category of workers as may be required Further in addition to the above, contractor has to arrange the following manpower exclusively for assisting BHEL commissioning engineers during stabilization and trial operation period. This manpower will be directly controlled by BHEL commissioning engineers only. 1. One supervisor per shift for three shifts 2. Two fitters per shift for three shifts 3. Two helpers per shift for three shifts.

It shall be specifically noted that the contractor may have to work round the clock during the pre-commissioning, commissioning and post-commissioning period along with BHEL Engineers and hence considerable overtime payment is involved. The contractor's quoted rates shall be inclusive of all these factors. 1.16.32 During commissioning any improvement / repair / rework / rectification / fabrication / modification due to design improvement / requirement is involved, the same shall be carried out by the contractor promptly and expeditiously. 1.16.33 It is the responsibility of the contractor to provide necessary manpower, tools, tackles and consumable till the completion of work under these specifications including for trial operation, commissioning of piping and the other equipments, even though the delay reasons are not attributable to the contractor. 1.16.34 Hanger adjustment / re adjustment during erection, before and after Hydraulic Test, before and after steam blowing, during and after full load operation, are to be carried out by the contractor within Quoted Rate.

PART- I CHAPTER-XVII PAINTING
The scope of the work will comprise of but not limited to the following: 1.17.0 FINAL PAINTING 1.17.1 The scope of work shall also include supply and application of final painting of all the erected equipments as required and specified for the components of PCP & Insulation. 1.17.2 In the case of steel fabricated items, raw steel after fabrication has to be cleaned and subsequent painting to be carried out. 1.17.3 All the exposed metal parts of the equipments including piping, structures, hangers etc., wherever applicable after installation unless otherwise specified the surface protected, are to be first painted with at least one coat of suitable primer and required number of finish coats as indicated in the Painting Specification in TCC which matches the shop primer paint used, after thoroughly cleaning the dust, rust, scales, grease oil, and other foreign materials by wire brushing scrapping and chemical cleaning and the same being inspected and approved by BHEL engineers for painting. Afterwards the above parts shall be finished with as per the instructions of BHEL/Customer official. 1.17.4 Paint shall be applied by brushing or by spray painting as per the instruction of BHEL Engineer. Spray painting gun and compressed air arrangement has to be made by the contractor himself. It shall be ensured that brush marks are minimum. 1.17.5 Before applying the subsequent coats the thickness of each coat shall be measured and recorded with BHEL / Customer. 1.17.6 Paint used shall be stirred frequently to keep the pigment in suspension. Paint shall be of the ready mix type in original sealed containers as packed by the paint manufacturer. No thinners shall be permitted. Paint manufacturers instructions shall be followed in method of application, handling, drying time etc., 1.17.7 The scope of painting includes application of colour bands, lettering the names of the systems equipments; tag Nos of valves, marking the directions of flow and other data required by BHEL within the quoted rate. 1.17.8 All surfaces shall be thoroughly cleaned, free from scales, dirt and other foreign matter. Each coat shall be applied in an even & uniform film free from lumps, streaks, runs, sags and uncoated spots. Each coat (Primer, intermediate, finish) shall have a minimum thickness of dry film thickness (DFT) in microns and the DFT

of finish paint shall not be less than the specified. Necessary instrument for measuring the thickness of paint applied is to be arranged by the contractor. 1.17.9 Finish coat paint, No of coat and DFT shall be as indicated in the painting specification enclosed in this tender / relevant BHEL document/ customers approved specifications. The painting specification which is forming part of this tender as in TCC shall be used as guidelines to be followed. 1.17.10 The actual colour to be applied shall be approved by the customer before starting of actual painting work. 1.17.11 Primer & finish paint shall be of reputed paint supplier approved by BHEL / Customer. Contractor has to procure paints from the BHEL / Customer approved agencies only, and the paints should be as per the customer painting specification. The quality of the finish paint shall be as per the standards of IS or equivalent as approved by BHEL / Customer. Before procurement of paint the contractor has to obtain the clearance from BHEL authorities. 1.17.12 No paint shall be applied when the surface temp is above 55 deg. Centigrade or below 10 deg. Centigrade, and when the humidity is greater than 90% to cause condensation on the surface or frost / foggy weather. 1.17.13 If needed and insisted either by BHEL / Customer in certain cases, spray painting has to be carried out within the Quoted rates. 1.17.14 Before commencement of final painting, contractor has to obtain written clearance from BHEL / Customer for effective completion of surface preparation. 1.17.15 Before applying the subsequent coats, the thickness of each coat shall be measured and recorded with BHEL/ Customer. 1.17.16 PRESERVATION / TOUCH UP PAINTING 1.17.16.1 Contractor shall carryout cleaning and preservation / touch up painting for the materials / equipments under this tender specification right from preassembly stage to till the equipment is cleared for final painting. 1.17.16.2 The contractor shall effectively protect the finished work from action of weather and from damage or defacement and shall cover the finished parts, then and there, for their protection. 1.17.16.3 Any equipment which has been given the shop coat of primer shall be carefully examined after its erection in the field and shall be treated with touch up coat of red oxide primer wherever the shop coat has been abraded, removed or damaged during transit / erection, or defaced during welding.

1.17.16.4 Mostly the equipment / items/ components will be supplied with one coat of primer paint and one coat of finish paint. However during storage and handling, the same may get peeled off / deteriorate. All such surfaces are to be thoroughly cleaned and to be touch up painted with suitable approved primer and finish paint matching with shop paint / approved final colour.

Volume 1A PART I CHAPTER 18
CONSTRUCTION POWER SUPPLY CLEARENCE/ PERIODIC INSPECTION CHECK LIST SL.NO 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 CHECKS TO BE CARRIED OUT Whether switch fuse isolators and other accessories are of suitable rating to match the connected load Whether suitable earthing is provided Whether double earthing is provided for DB,Motor, Motorstarter, welding machine etc. Whether surrounding area of the installation is clear and easily accessible Whether the installation is covered properly with a shed or canopy IR value of cable Operation of ELCB Operation of Isolators Whether any live part is exposed Whether all cable entry holes/openings are plugged Whether Neutral link is provided Whether industrial plug and sockets are used wherever applicable Whether the cable is of proper size and without any cuts in insulations Whether the proper cable termination is done using suitable lugs. Whether the cable termination is done using suitable lugs. Is Earth resistance of the earth pit is within permissible limit Whether danger tag is provided Whether HRC fuses are provided Whether ELCBs of suitable ratings are provided in outgoing feeders. OBSERVATIONS YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO SATIFACTORY/ UNSATISFACTORY SATIFACTORY/ UNSATISFACTORY SATIFACTORY/ UNSATISFACTORY YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO YES/ NO

CONSTRUCTION POWER SUPPLY SYSTEM DOS AND DONTS DOs i. Use Personal Protective equipments like Helmet, Safety Belt, hand gloves, Rubber boots etc. while working on electrical installation. Check yourself that the installation on which you are going to work is electrically isolated. Use proper tools for carrying out the work. Ensure that the tools and measuring equipments are of good quality. Check the healthiness of T & P and test equipments regularly. Use protective devices like fuse, MCB, ELCB of proper rating. Use 24 v supply for carrying out work in enclosed area. Use 3-pin plug and socket for power hand tool. Ensure double earthing of all the installations. Cover the installation properly to avoid ingress of water. Identify the source of supply clearly. Use appropriate starters for starting and stopping motors. Insulate joints properly with good quality insulation tapes. Allow only qualified electrician to carry out maintenance work. Educate the people about the electrical hazards. Use only insulated cables for supply extension. Use only wooden bullies for fixing the light fixtures. Electrically operated mixture machine to be earthed locally by driving earthing spikes.
ii.
iii.
iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii.

xviii. Cables shall be either buried or supported on bullies/other suitable structures above ground. Only industrial type plug top and socket shall be used in the system. DONTS xx. xxi. xxii. xxiii. xxiv. No cable should be laid on the surface. Dont use wires for extension of supply. Do not keep live wires/ joints open. Do not use copper wires as fuse wires. Dont fix any light fixture on scaffolding pipe / reinforcement rod.
xix.
Volume 1A PART I CHAPTER 19 PAINTING SCHEME
Volume 1A PART I WELDING SCHEDULES

CHAPTER 20
Material Spec 1
Material Spec 2 OD OD Thick Thick Type of WPS (Minim (Maxi ness (Maxi Weld No. um) mum) (Mini mum) mum) SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr C SA106 Gr C SA106 Gr C SA106 Gr C SA335P11 SA335 P22 SA106 Gr C SA106 Gr C SA106 Gr C SA106 Gr C SA335 P11 SA335 P22 SA335P11 SA335P11 SA335P22 SA335 P22 SA335 P22 SA335 P22 SA335 P22 SA335 P91 SA335 P22 SA335 P91 SA335 P22 SA335 P22 SA335 P22 SA335 P22 SA312 SA106 SA106 SA106 SA106 SA335 TP 304H Gr B Gr B Gr C Gr C P22 Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl >127 Unl Unl Unl Unl Unl Unl Unl Unl 110 88.9 110 110 Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl Unl 127 Unl Unl Unl Unl Unl Unl Unl Unl Unl 1.6 20 26 75 1.6 20 26 75 4.8 5 1.6 20 26 75 4.8 5 1.6 14 1.6 9 1.6 9 14 20 20 20 >30 7 >30 >30 1.6 4.8 26 4.8 26 5 1.6 4.8 26 14 Unl 50 25 40 25 40 40 9 25 38 19 19 8 19 8 8 Unl 13 Unl 10 19 25 74 200 19 25 74 200 200 46 19 25 74 200 50 46 13 200 8 200 8 13 200 200 200 200 G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G F F F F F F F F F 1003 1004 1004 1004 1003 1004 1004 1004 1033 1041 1003 1005 1005 1005 1018 1041 1009 1010 1011 1012 1013 1014 1014 1034 1035 1034 MSW 72 / 97 MSW 75 / 97 MSW 74 / 97 MSW 83 / 97 1032 1025 1025 1025 1025 1024 1001 1213 1213 1021 1021 1108 1021 1108 1108 1023 1020 1029
Pre heat PWHT Holding Deg. C Temp. time per Deg. C mm thick (minutes) NIL NIL 100 150 NIL NIL 100 150 150 150 NIL NIL 100 150 150 150 125 150 150 150 150 NIL 150 220 220 220 NIL 610+15 610+15 610+15 NIL 610+15 610+15 610+15 655+15 695+15 NIL 635+15 635+15 635+15 665+15 695+15 NIL 655+15 NIL 700+20 NIL 725+25 725+25 760+10 745+15 760+10 NIL 2.5 2.5 2.5 NIL 2.5 2.5 2.5 2.5mts 2.5 NIL 2.5 2.5 2.5 2.5 2.5 NIL 2.5mts NIL 2.5 2.5 2.5 2.5 2.5 2.5
Holding time minimum (minutes) NIL 30 30 30 NIL 30 30 30 120 30 NIL 30 30 30 30 NIL 30 NIL 60 60 60 120 60 120 240 15 240 240
SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr C SA106 Gr C SA106 Gr C SA106 Gr C SA106 Gr C SA106 Gr C SA335 P11 SA335 P11 SA335 P11 SA335 P11 SA335 P22 SA335 P22 SA335 P22 SA335 P91 SA335 P91 GX 12Cr Mo W V Nb N 10-1-1 GS 17 CrMoV 511 GS 22 Mo 4 G17 CrMo 9 10 21 Cr Mo Ni V47 SA312 TP 304H AISI 321 AISI 321 AISI 321 AISI 321 AISI 321 IS 1239 IS 3589 IS 3589 SA106 Gr B SA106 Gr B SA106 Gr B SA106 Gr C SA106 Gr C SA335 P11 SA335 P22 SA335 P22 SA312 TP 304H
300 TO 690+10 350 (Note3) 200 610+10 2.5 300 TO 350 300 TO 350 NIL NIL 150 NIL 150 150 on AS side NIL NIL 150 NIL NIL 150 NIL 150 150 150 150 NIL 690+10 (Note3) 690+10 (Note3) NIL 610+15 610+15 610+15 610+15 700+20 NIL NIL NIL
2.5 2.5 2.5 2.5 2.5 NIL
30 30 30 30 60 NIL
IS 1239 IS 3589 IS 3589 SA106 SA106 SA335 SA106 SA335 SA335 SA335 SA335 SA182 Gr B Gr C P22 Gr C P22 P22 P22 P22 F 304H
NIL NIL NIL NIL NIL NIL 725+25 2.5 NIL NIL
60
1 2 3 4 5 6
Notes:Material specification for pipes is indicated. However, the requirements are applicable to other specification of same P group. (eg.) SA 335 P 91 is to be applied for SA 182 F 91, SA 234 WP 91. For SA 335 P91, PWHT shall be done immediately after welding. Rate of heating 50 Deg. C per hour; Rate of cooling 30 Deg. C per hour. This is as per BHEL HEEP - Hardwar recommendation. OD - "Unl" means unlimited. Type of weld: G = Groove ( Butt); F = Fillet. Groove ( Butt) welding WPS may be used for Fillet welding of higher thickness.
Sl. Material no Specification (Note 1) 1 SA 335 P 91 (Note 2) SA 335 P 22/ P11 / P12
Nb/ Temp.> 4000 C or IBR Class I thickness Press > 71 bar Piping (other mm than than $$) $$ @@ All 100 % UT 100 % UT 100 % MT 100 % MT 100 % Hardness 100% Hardness Nb > 50 100 % RT 3% Hardness Nb < 50 100 % RT (Note 7) Thickness 100 % RT > 19 mm Thickness 100 % RT < 19 mm (Note 7) All 100 % RT All All Not applicable Not applicable 100 % RT 3% Hardness 100 % RT (Note 7) 100 % RT 10 % RT 100 % RT Not applicable Not applicable
IBR Class II piping ##
Piping other than $$, @@, ##
100 % UT 100 % UT 100 % MT 100 % MT 100 % Hardness 100 % Hardness 100 % RT 3% Hardness 100 % RT (Note 7) 100 % RT 10 % RT 10 % RT 100 % LPT Not applicable Not applicable 10 % RT 3% Hardness 10 % RT (Note 7) 10 % RT 10 % RT 10 % RT 100 % LPT 10 % RT 10 % RT
SA 106 Gr C/ Gr. B
4 5 6
SA 312 TP 304 H IS 3589 IS 1239
Notes :1 Material specification for pipes is indicated. However, the requirements are applicable to other specification of same P group. (eg.) SA 335 P 91 is to be applied for SA 182 F 91, SA 234 WP 91. 2 For SA335 P 91, NDE (UT,MT) shall be done after PWHT. 3 Additional 100% MT / PT has to be done - when hydrotest could not be carried out for a part of piping (eg. Main steam from ESV to turbine, Lines connected to condenser...). 4 Thermowell joints for all systems : 100% RT is applicable. 5 MT / PT is applicable for fillet welds and socket welds. Quantum shall be as per RT / UT. 6 IBR class I: Temperature > 218 deg C or steam pressure >17.6 kg/sq.cm or Feed Water pressure >24.6 kg/sq.cm. IBR class II: Not exceeding above values. 7 Drains & vents piping: 100% RT upto the last root valve. Beyond the last root vlave, 10% RT is applicable.
Volume 1A PART I GUIDELINES FOR WELDING AND P91 WELDING

CHAPTER 21
GUIDELINES FOR
WELDING, NDE AND HEAT TREATMENT
THIS BOOKLET IS GIVEN AS A GENERAL GUIDELINE TO THE TENDERERS ABOUT WELDING, NDE & HT FOR THE PIPING SYSTEMS, HOWEVER INSTRUCTIONS GIVEN IN THE DRAWINGS & WELDING SCHEDULE ISSUED DURING EXECUTION OF THE WORK SHALL BE FINAL AND BINDING OF THE CONTRACTOR.
BHEL PSSR SCT :

BOOK NO :

(A Government of India Undertaking) Power Sector Southern Region 690, Anna Salai, Nandanam, Chennai 600 035.
BASE MATERIALS
1.0 1.1 Scope: This chapter contains tabulations of chemical compositions & mechanical properties of various materials generally used in BHEL sites. Contents: Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 3.0 4.0 Pipes (ASME) Tubes (ASME) Forgings (ASME) Castings (ASME) Plates / Sheets (ASME) Pipes (Other specifications) Tubes (Other specifications) Forgings (Other specifications) Barstock
2.0
The data are for general information purposes. The corresponding P Numbers are also indicated. For materials not covered in this chapter, the supplier shall be contacted.
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES

Table - 1 Pipes
Sl. No P.NO / Group No. Material Specification (ASME) SA 106 Gr.B 1 P 1/1 (Remarks: Carbon restricted to 0.25% Max.) SA 672 Gr.B, Cl.22 Max SA 106 Gr.C SA 335 P 11 SA 335 P 12 SA 335 P 22 SA 376 TP 321H (Titanium Stabilised) SA 376 TP 304H SA 376 TP 316H SA 376 TP 347H (Cb+Ta Stabilised) 0.30 Max. 0.291.06 0.048 Max. 0.058 Max. 0.10 Max 0.24 Max. 0.35 Max. 0.15 Max. 0.15 Max. 0.15 Max. 0.040.10 0.040.10 0.040.10 0.040.10 0.9 Max. 0.291.06 0.30.6 0.30.60 0.30.61 2.0 Max 2.0 Max 2.0 Max 2.0 Max 0.035 Max. 0.048 Max. 0.03 Max. 0.045 Max. 0.03 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.058 Max. 0.03 Max. 0.045 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.150.30 0.10 Max 0.5 Max. 0.5 Max. 0.5 Max. 0.75 Max. 0.75 Max. 0.75 Max. 0.75 Max. 9.013.0 8.011.0 11.014.0 9.013.0 1.01.5 0.81.25 1.92.6 17.020.0 18.020.0 16.018.0 17.020.0 N 0.009 Max. 0.440.65 0.440.65 0.871.13 42.250.6 49 42 42 42 53 53 53 53 22.5 28 21 21 21 21 21 21 21 25 30 30 30 30 35 35 35 35 42 25 30 Chemical Composition (%) C Mn P S Si Ni Cr Mo Mech. Properties (Min.) T.S. kg/mm2 Y.S. kg/mm2 %E Min
2 3 4 5 6 7 8 9 10
P 1/1 P 1/ 2 P 4/1 P 4/1 P 5/1 P 8/1 P 8/1 P 8/1 P 8/1
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 2 Tubes

Sl. No P.NO / Group No. P 1/1 P 1/1 P 1/1 P 1/ 2 P 1/ 2 P 3/1 P 3/1 P 3/1 P 4/1 P 4/1 Material Specification (ASME) SA 192 SA 210 Gr A1 SA 179 SA 210 Gr. C SA 556 Gr C2 SA 209 T1 SA 209 T1a SA 209 T1b SA 213 T11 SA 213 T12 Chemical Composition (%) C 0.060.18 0.27 0.18 0.062Max. 0.35 Max. 0.3 Max. 0.10 0.20 0.05 0.25 0.14 Max. 0.15 Max. 0.15 Max. Mn 0.270.63 0.93 Max 0.270.63 0.291.06 0.29 Max. 0.30.8 0.30.8 0.30.8 0.300.60 0.300.61 P 0.048 Max. 0.048 Max. 0.048 Max. 0.048 Max. 0.048 Max. 0.045 Max. 0.045 Max. 0.045 Max. 0.03 Max. 0.045 Max. S 0.053 Max. 0.058 Max. 0.058 Max. 0.058 Max. 0.048 Max. 0.045 Max. 0.045 Max. 0.045 Max. 0.03 Max. 0.045 Max. Si 0.25 Max. 0.10 Max. 0.10 Max 0.10 Max 0.100.50 0.100.50 0.100.50 0.51.0 0.5 Max. Ni 1.01.5 0.81.25 Cr 0.440.65 0.440.65 0.440.65 0.440.65 0.440.65 Mo Mech. Properties (Min.) T.S. kg/mm2 33 42 49 49 39 42 37 42 42 Y.S. kg/mm2 18 26 28 28 21 22.4 20 21 21 %E Min 35 30 30 25 30 30 30 30 30
1 2 3 4 5 6 7 8 9 10
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 2 Tubes (Contd..)
Sl. No
P.NO / Group No. P 5/1 P 5/1 P 5/2 P 8/1 P 8/1 P 8/1 P 8/1 P 8/1 P 8/1 P 8/1
Material Specification (ASME) SA 213 T22 SA 213 T5 SA 213 T9 SA 213 TP 321H (Ti Stabilised) SA 213 TP 304 H SA 213 TP 304 SA 249 TP 304 SA 688 TP 304 SA 213 TP 316 H SA 213 TP 347 H (Cb+Ta Stabilised)
Chemical Composition (%) C 0.15 Max. 0.15 Max. 0.15 Max. 0.040.10 0.040.10 0.08 Max. 0.08 Max. 0.08 Max. 0.040.10 0.040.10 Mn 0.300.60 0.300.60 0.300.60 2.0 Max. 2.0 Max. 2.0 Max. 2.0 Max. 2.0 Max. 2.0 Max. 2.0 Max. P 0.03 Max. 0.030 Max. 0.03 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. S 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. Si 0.50 Max. 0.50 Max. 0.251.00 0.75 Max. 0.75 Max. 0.75 Max. 0.75 Max. 0.75 Max. 0.75 Max. 0.75 Max. 9.013.0 8.011.0 8.011.0 8.011.0 8.011.0 11.014.0 9.013.0 Ni Cr 1.92.60 4.06.0 8.010.0 17.020.0 18.020.0 18.020.0 18.020.0 18.020.0 16.018.0 17.020.0 Mo 0.871.13 0.450.65 0.91.10 2.03.0 -
Mech. Properties (Min.) T.S. kg/mm2 42 42 42 53 53 53 53 53 53 53 Y.S. kg/mm2 21 21 21 21 21 21 21 21 21 21 %E Min 30 30 30 35 35 35 35 35 35 35
11 12 13 14 15 16 17 18 19 20
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 3 Forgings
Sl. No
P.NO / Group No. P 1/ 2 P 4/1 P 5/1 P 8/1 P 8/1 P 8/1 P 8/1
Material Specification (ASME) SA 105 SA 182 F12 SA 182 F22 SA 182 F321 H (Ti Stabilised) SA 182 F304 H SA 182 F316 H SA 182 F347 H (Cb+Ta Stabilised)
Chemical Composition (%) C 0.35 Max 0.100.20 0.15 Max. 0.040.10 0.040.10 0.040.10 0.040.10 Mn 0.61.05 0.30.8 0.30.6 2.0 Max. 2.0 Max. 2.0 Max. 2.0 Max. P 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. S 0.05 Max. 0.04 Max. 0.04 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. Si 0.35 Max. 0.10.6 0.5 Max. 1.00 Max. 1.00 Max 1.00 Max 1.00 Max 9.012.0 8.011.0 10.014.0 9.013.0 Ni 0.81.25 2.02.5 17.0Min 18.020.0 16.018.0 17.020.0 Cr 0.440.65 0.871.13 2.03.0 Mo
Mech. Properties (Min.) T.S. kg/mm2 49 49 52.5 52.5 52.5 52.5 52.5 Y.S. kg/mm2 25.2 28 31.5 21 21 21 21 %E Min 30 20 20 30 30 30 30
1 2 3 4 5 6 7
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 4 Castings

Sl. No P.NO / Group No. P 1/2 P 1/2 P 3/1 P 4/1 P 5/2 P 5/1 P 8/1 P 8/1 P 8/1 P 8/2 Material Specification (ASME) SA 216 WCB SA 216 WCC SA 217 WC1 SA 217 WC6 SA 217 C 5 SA 217 WC 9 SA 351 CF 8 SA 351 CF 8M SA 351 CF 8C SA 351 CH 20 Chemical Composition (%) C 0.3 Max. 0.25 Max. 0.25 Max. 0.2 Max. 0.2 Max. 0.18 Max. 0.08 Max. 0.08 Max. 0.08 Max. 0.20 Max. Mn 1.0 Max. 1.20 Max. 0.50.8 0.50.8 0.40.7 0.40.7 1.5 Max. 1.5 Max. 1.5 Max. 1.5 Max. P 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. S 0.045 Max. 0.045 Max. 0.045 Max. 0.045 Max. 0.045 Max. 0.045 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. Si 1.60 Max. 0.60 Max. 0.6 Max. 0.6 Max. 0.75 Max. 0.6 Max. 2.0 Max. 1.5 Max. 2.0 Max. 2.0 Max. Ni 0.5 Max. 0.5 Max. 8.011.0 9.012.0 9.012.0 12.015.0 Cr 0.5 Max. 0.5 Max. 1.01.5 4.06.5 2.02.75 18.021.0 18.021.0 18.021.0 22.026.0 Mo 0.20 Max. 0.20 Max. 0.450.65 0.450.65 0.450.65 0.91.20 0.5 Max. 2.03.0 0.5 Max. 0.5 Max. Mech. Properties (Min.) T.S. kg/mm2 49 49 45.5 49 63 49 49 49 49 49 Y.S. kg/mm2 25.2 28 24.5 28 42 28 21 21 21 21 %E Min 22 22 24 20 18 20 35 30 30 30
1 2 3 4 5 6 7 8 9 10
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 5 Plates / Sheets

Sl. No P.NO / Group No. P 1/1 P 1/ 2 P 1/3 P 1/ 2 P 4/1 P 5/1 P 8/1 P 8/1 P 8/1 P 8/1 Material Specification (ASME) SA 516 Gr 60 SA 516 Gr 70 SA 299 SA 515 Gr 70 SA 387 Gr 12 SA 387 Gr 22 SA 240 TYPE 321 (Ti Stabilised) SA240 TYPE 304 SA240 TYPE 316 SA240 TYPE 347 Ca+Ta Stabilised Chemical Composition (%) C 0.210.25 0.35 Max. 0.30 Max. 0.35 Max. 0.17 Max. 0.15 Max. 0.08 Max. 0.08 Max. 0.08 Max. 0.08 Max. Mn 1.851.20 0.851.20 0.84 Max. 1.3 Max. 0.350.73 0.250.66 2.0 Max. 2.0 Max. 2.0 Max. 2.0 Max. P 0.035 Max. 0.035 Max. 0.035 Max. 0.035 Max. 0.035 Max. 0.035 Max. 0.045 Max. 0.045 Max. 0.045 Max. 0.045 Max. S 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.04 Max. 0.035 Max. 0.03 Max. 0.03 Max. 0.03 Max. 0.03 Max. Si 0.150.40 0.150.40 0.130.45 0.130.45 0.130.45 0.5 Max. 1.0 Max. 1.0 Max. 1.0 Max. 1.0 Max. 9.012.0 8.010.5 10.014.0 9.013.0 Ni 0.741.21 1.882.62 17.019.0 18.020.0 16.018.0 17.019.0 Cr Mo N 0.009 N 0.009 0.400.65 0.851.1 2.03.0 Mech. Properties (Min.) T.S. kg/mm2 56 4963 52.566.5 49.263 38.556.0 4259.5 52.5 52.5 52.5 52.5 Y.S. kg/mm2 26 27 29.4 26.6 23.1 21 21 21 21 21 %E Min 25 21 19 21 22 18 40 40 40 40
1 2 3 4 5 6 7 8 9 10
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 6 Pipes (Other Specifications)

Sl. No 1 2 3 4 5 P.NO / Group No. P 1/1 P 1/ 1 P 1/1 P 1/1 P 4/1 Material Specification DIN St 35.8 DIN St 45.8 BS 3602 410 BS 3602 / 460 BS 3604 620460 HFS or CDS 620-440 6 P 5/1 BS 3604 622 HFS or CDS BS 3604 HFS 660 or CDS 660 Chemical Composition (%) C 0.17 Max. 0.21 Max. 0.21 Max. 0.22 Max. Mn 0.40.8 P 0.04 Max. S 0.04 Max. 0.04 Max. 0.045 Max. 0.045 Max. 0.04 Max. 0.04 Max. 0.04 Max. Si 0.100.35 0.100.35 0.35 Max. 0.35 Max. 0.100.35 0.100.35 0.5 Max. Ni 0.701.10 0.701.10 2.02.5 Cr 0.450.65 0.450.65 0.91.2 Mo V Mech. Properties (Min.) T.S. Y.S. %E kg/mm2 kg/mm2 Min 36.748.96 41.854.1 41.8256.1 46.961.2 46.962.22 44.960.2 48.8 26.8 17 24 26 25 28.6 18.36 29.58 25 21 22 21 22 22
0.45- 0.04 1.20 Max. 0.40- 0.045 1.20 Max. 0.80- 0.045 1.40 Max. 0.04 Max.
0.100.40 0.15 Max.
0.100.40- 0.04 0.18 0.70 Max. 0.08- 0.40- 0.04 0.15 0.70 Max.
0.15 Max.
0.40.7
0.04 Max.
0.04 Max.
0.100.35
0.250.50
0.50.7
0.220.30
47.3
30
17
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 7 Tubes (Other Specifications)

Sl. No 1 2 3 4 5 6 7 P.NO / Group No. P 1/1 P 1/ 1 P 1/1 P 1/1 P 3/1 P 4/1 P 4/1 Material Specification DIN St 35.8 DIN St 45.8 BS 3059 / 360 BS 3059 / 440 DIN 15 Mo3 DIN B Gr. Mo 4 BS 3059 / 620 Chemical Composition (%) C 0.17 Max. 0.21 Max. 0.17 Max. Mn P S 0.04 Max. 0.04 Max. 0.045 Max. 0.035 Max. 0.035 Max. 0.035 Max. 0.04 Max. Si 0.100.35 0.100.35 0.35 Max. 0.10 0.35 0.100.35 0.100.35 0.100.35 0.71.10 0.71.1 Cr 0.250.35 0.450.65 0.450.65 Mo V Mech. Properties (Min.) T.S. Y.S. %E Min kg/mm2 kg/mm2 36.7048.96 41.8054.06 36.7051.00 44.8859.2 45.961.2 44.8860.18 46.962.2 24 26 22 25 27.5 29.6 18.4 25 21 24 21 22 22 22
0.40- 0.04 0.80 Max. 0.40- 0.04 1.20 Max. 0.40.8 0.045 Max. 0.040 Max. 0.035 Max. 0.035 Max. 0.04 Max.
0.120.90.18 1.20 0.120.40 0.20 0.80 0.10- 0.40.18 0.7 0.10 0.15 0.40.7
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 7 Tubes (Contd.) (Other Specifications)
Sl. No 8 9 10 11 P.NO / Group No. P 5/1 P 5/ 1 P 5/1 Material Specification DIN 10 Cr Mo 910 BS 3059(622) 440 BS 3059(622)490 DIN 14 Mo V63 Chemical Composition (%) C 0.08 0.15 0.080.15 0.080.15 0.100.18 Mn 0.40.7 0.40.7 0.40.7 0.40.7 P 0.035 Max. 0.04 Max. 0.04 Max. 0.035 Max. S 0.035 Max. 0.04 Max. 0.04 Max. 0.035 Max. Si 0.5 Max. 0.5 Max. 0.5 Max. 0.100.35 Cr 2.02.5 2.02.5 2.02.5 0.30.6 Mo 0.91.2 0.91.20 0.91.20 0.50.7 0.220.32 V Mech. Properties (Min.) T.S. Y.S. %E Min kg/mm2 kg/mm2 45.928.6 20 61.2 44.917.85 20 60.18 49.9828.05 20 65.0 46.932.6 20 62.22
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 8 Forgings (Other Specifications)

P.NO / Group No. P 1/1 Chemical Composition (%) C Mn P S 0.05 Max. 0.05 Max. 0.04 Max. Si 0.150.35 0.150.35 0.100.35 Ni 0.25 Max. 0.40 Max. 0.3 Max. Cr 0.25 Max. 0.25 Max. Mo 0.05 Max. 0.10 Max. V 0.05 Max. Cu 0.30 Max. 0.25 Max. Mech. Properties (Min.) T.S. Y.S. %E kg/mm2 kg/mm2 Min 44 44.152 47.263 24 24
Sl. No 1
Material
Specification
IS 1875 CL II BS 1503 161 Cr 28 BS 1503 660
0.15- 0.60- 0.05 0.25 0.90 Max. 0.25 Max. 0.65- 0.05 1.20 Max.
P 1/ 1
22.1
22
0.08- 0.40- 0.04 0.15 0.70 Max.
0.25- 0.50- 0.220.50 0.70 0.32
29.9
21
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES Table 9 Bar stock (Other Specifications)
Sl. No 1 2 3 4 P.NO / Group No. P 1/1 P 1/ 1 P 1/1 Material Specification IS 1570 - 1508 IS 226 (St 42) CSN 11416.1 VX22 Cr Mo V121V Chemical Composition (%) C 0.10.2 0.23 Max. 0.2 Max. 0.180.23 Mn 0.60.9 0.65 Max. 0.30.8 P 0.055 Max. 0.055 Max. 0.045 Max. 0.035 Max. S 0.055 Max. 0.055 Max. 0.045 Max. 0.02 Max. Si 0.050.35 0.35 Max. 0.10.5 0.30 Max 0.30.5 Ni 0.30 Max. 11.511.9 Cr 0.81.2 Mo 0.250.35 V Mech. Properties (Min.) T.S. Y.S. %E kg/mm2 kg/mm2 Min 43 4254 4150 95 25 24 60 25 23 25 15
RECEIPT INSPECTION OF WELDING ELECTRODES / FILLER WIRES

1. 2. 3. 4. 5. 6. 7. All electrodes / filler wires received at site stores shall be segregated for type and size of electrode. Ensure that electrode packets received are free from physical damage. Where electrodes are damaged, the same shall be removed from use. Only electrodes identified in the Rationalized List of Electrodes are to be accepted. Where filler metals are supplied by manufacturing unit, inspect for damages, if any. Ensure availability of relevant test certificates. Refer tables of chemical compositions and mechanical properties for acceptance. Endorse acceptance / rejection on the test certificate.
STORAGE & IDENTIFICATION OF WELDING ELECTRODES / FILLER WIRES
1.0 1.1 2.0 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3
Scope This procedure is applicable for storage of welding electrodes / filler wires used at sites. Procedure: Only materials accepted (based on receipt inspection) shall be taken into account for storage. Storage Facility: The storage facility shall be identified. Access shall be restricted to authorized personnel. The storage area shall be clean and dry. Steel racks may be used for storage. Avoid storing wood inside the storage room. Maintain the temperature of the storage facility above the ambient temperature. This can be achieved by the use of appropriate heating arrangements. The electrodes / filler wire shall be segregated and identified for a. Type of electrode e.g. E7018. b. Size of electrode e.g. Dia 3.15 mm.
2.4 2.4.1
Colour coding for filler wires: On receipt of GTAW filler wires, codify the filter wires as per table I below . Both ends shall be coloured. Table - 1 Specification RT 1/ 2 Mo (ER80s-D2) Brand Name* TGSM Colour Code Green Silver grey/White Brown / Red Blue
RT 1 Cr 1 / 2 Mo (ER80S-B2) TGS 1CM RT 2 1/ 4 Cr 1 Mo (ER90S-B3) TGS 2CM RT 347 (ER 347) TGS 347
(* or other approved equivalents) 2.4.1.1 2.4.2 2.4.3 Where another set of colour code is followed, maintain a record of coding used where the filter wire is cut, apply the appropriate colour code at both ends of the piece. For other filler wires, a suitable colour distinct from table 1 shall be applied.
BAKING AND HOLDING OF WELDING ELECTRODES

1.0 1.1 Purpose: This section details activities regarding baking and holding of welding electrodes used at sites. Procedure: While handling, avoid contact of oil, grease with electrodes. Do not use oily or wet gloves. It is recommended that not more than two days requirements are baked. GTAW Filler Wires: These wires do not require any baking. Covered Electrodes: Baking and holding: Identify baking oven and holding oven. They shall have a temperature control facility upto 3500C for baking oven and 200 Deg. C for holding oven. A calibrated thermometer shall be provided for monitoring temperature. On opening a packet of electrodes, segregate and place them in the baking oven. Avoid mix up. After loading, raise the baking oven temperature to the desired range as per Table in 2.3.2.5. Note the time when the temperature reaches the desired range. Maintain this temperature for the duration required as per Table in 2.3.2.5. On completion of baking, transfer the electrodes to holding oven, maintain a minimum temperature of 1000C till issue. The electrode shall not be subjected to more than two cycles of baking.
2.0 2.1 2.1.1 2.2 2.2.1 2.3 2.3.1 2.3.1.1 2.3.1.2 2.3.1.3 2.3.2 2.3.2.1 2.3.2.2 2.3.2.3 2.3.2.4
2.3.2.5
Maintain a register containing following details : a) b) c) d) e) Brand name (e.g. Supratherme) Size (e.g Dia 4.0 mm) Quantity (e.g. 110 pieces) Time at required temperature ie. Above 2500C Time of Transfer to holding oven. Activities a,b,c to be recorded before loading into the oven. Baking and Holding Parameters AWS Classification (*) Baking Temperature C 250 300 250 300 250 300 250 300 250 300 250 300 250 300 250 - 300
0
Time (Hours) 2 2 2 2 2 2 2 1
Holding Temperature 0 C (@ ) 100 min 100 min 100 min 100 min 100 min 100 min 100 min 100 min
E7018 E7018-1 E7018-A1 E8018-B2 E9018-B3 E8018-B2L E9018-B3L E309 & E347
Note : (*) For other electodes, suppliers recommendations shall be followed. (@) Maintain the temperature in the oven till issue. 2.3.2.6 2.3.3 After issue, maintain the electrodes in a portable oven at a minimum temperature of 650C till use (not applicable for E6013, E309 & E347 electrodes). Unused, returned electrodes shall be segregated and kept in the holding oven.
SELECTION AND ISSUE OF WELDING ELECTRODES / FILLER WIRES
1.0 1.1 2.0 2.1 2.1.1
Purpose: This procedure details methods for selection and issue of welding electrodes / filler wires for site operations. Procedure: Selection: The type of filler wire / electrode for welding shall be based on the details given in the contract documents like Erection Welding Schedules, drawings, Welding Procedure Specifications as supplied by the Manufacturing Units. Where not specified by the Manufacturing Units, selection shall be based on the tables enclosed. Where electrodes / filler wire are not covered in the documents mentioned in 2.1.1, 2.1.2, refer to manufacturing Units. Issue: Issue of welding electrodes / filler wires shall be based on authorized Welding Electrodes Issue Voucher. It is recommended to restrict quantity issued to not more than 4 hours requirements. Redried low hydrogen electrodes shall be carried to the work spot in a portable oven. Maintain the temperature in the portable oven at the work spot above 65 Deg. C. Unused electrodes shall be returned and kept in the holding oven till reissue.
2.1.2 2.1.3 2.2. 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5
TABLE 1 SELECTION OF GTAW FILLER WIRE, SMAW ELECTRODE FOR BUTT WELDS IN TUBES, PIPES, HEADERS P1 GROUP 1 P1 GROUP 2 RT 1/ 2 Mo E7018 (ATT) Note 1 RT 1 / 2 Mo E7018 (ATT) RT 1 / 2 Mo E7018 (ATT) RT 1 / 2 Mo E7018 (ATT)
MATERIAL P1 Group 1 P1 Group 2 P3 Group 1 P4 Group 1 P5 Group 1 PS Cr Mo V Note- 2
WELDING PROCESS GTAW SMAW GTAW SMAW GTAW SMAW GTAW SMAW GTAW SMAW GTAW SMAW
P3 GROUP 1
P4 GROUP 1
P5 GROUP 1
P8
Cr Mov
RT 1 / 2 Mo E7018 A1 RT 1 / 2 Mo E7018 A1 RT 1 / 2 Mo E7018 A1
RT 1 Cr 1/ 2 Mo E8018- B2 RT 1 Cr 1/ 2 Mo E8018- B2 ERMiCr3 ENiCrFe2
RT 2 1/ 4 Cr 1 Mo E9018 B3 ERNiCr3 RT347 ENiCrFe2 E347 RT 2 1/ 4 Cr 1 Mo E9018-B3 RT 2 1/ 4 Cr 1 Mo E9018B3
Note 1 E7018 - A1 For P1 Gr 2 + P1 Gr 2 and Dia > 127 mm. Note 2 DIN 14MoV63 or equivalent.
TABLE 2 SELECTION OF ELECTRODES FOR WELDING ATTACHMENTS TO TUBES
TUBE MATERIAL P1 Group 1 P1 Group 2 P3 P4 Group 1 P5 Group 1 P8
ATTACHMENT MATERIAL P1 GROUP 1 P3 GROUP 1 P4 GROUP 1 PS GROUP 1 P8
E7018 E7018-A1 E8018-B2 E9018-B3
E7018 E7018-A1
E7018 E7018-A1 E8018-B2 E9018-B3 E 309 Note 1
E7018 E7018-A1 E8018-B2 E9018-B3 E 309 Note - 1
E7018-A1 E7018-A1 E7018-A1 E7018-A1 E347
Note 1 Used as circumferential attachment only.
TABLE 3 SELECTION OF ELECTRODES, PREHEAT, PWHT FOR ATTACHMENT TO ATTACHMENT WELDS (Seal bands, High crown bars, End bars, End bar lifting lugs and Collector plates etc.) MATERIAL P1 P4 P5 P8 Note : 1. 2. WELDING REQUIREMENTS Electrode Preheat PWHT Electrode Preheat PWHT Electrode Preheat PWHT Electrode Preheat PWHT P1 E7018 Nil Nil E7018 (Note-2) Nil (Note 2) Nil (Note 2) E7018 Note 1 & 2 Nil (Note-2) E309 Nil Nil P4 P5 P8 GRUP 1 P8 GROUP 2
E8018-B2 Nil Nil E8018-B2 Note-1 Nil E309 Nil Nil
E9018-B3 Note-1 Nil E309 Nil Nil
E347 Nil Nil
E309 Nil Nil
When P5 material thickness is more than 10mm, 150 Deg.C preheat is required. Electrode, Preheat and PWHT requirement for welding end bar lifting lug are as follows: END BAR LIFTING LUG P1 P1 END BAR P4 P5 ELECTRODE E8018-B2 E9018-B3 PREHEAT DEG.C 120 150 PWHT DEG.C 650 680 680-720
TABLE 4 SELECTION OF ELECTRODES FOR WELDING NOZZLE ATTACHMENTS, HANDHOLE PLATE, RG PLUG ETC TO HEADERS, PIPES
HEADER, PIPE MATERIAL P1 P4 P5 Cr Mo V Note-1
ATTACHMENT MATERIAL P1 E7018 (ATT) P3 P4 E7018 (ATT) E8018-B2 P5 E8018-B2 E9018-B3 E9018-B3 P8 ENiCrFe2 ENiCrFe2 ENiCrFe2
TABLE 5 SELECTION OF ELECTRODES FOR NON-PRESSURE PARTS (INCLUDING STRUCTURES) MATERIAL P1 + P1 ELECTRODES a. For butt welds, upto 6mm including Over 6 mm b. For fillets, upto 8 mm including Over 8 mm Carton Steel + P1 Carton + Carton Steel Steel E6013 or E7018 : E6013 : E7018 : E6013 : E7018
E8018-B2
WELDER QUALIFICATION 1.0 1.1 2.0 Scope: This chapter details the procedure for qualification of welder at site. Contents: 1. 2. 3. 4. Qualification of Welders at Site. Table-1 Welder qualification Requirements. Record of Welder Performance Qualification Tests. Figure- 1 Figure-2 Figure-3 Figure-4 Figure-5 Figure-6 Figure-7 Fillet Weld Break Specimen. Method of Rupturing. Positions. Plate Butt Weld specimen. Pipe Butt Weld Specimen. Bend Specimen. Bend Jig.
QUALIFICATION OF WELDERS AT SITES 1.0 1.1 2.0 2.1 2.2 2.3 2.4 3.0 3.1 Base Metal: For selection refer tables in chapter II. Test coupon: Depending on the range to be qualified, choose the appropriate test coupon from table-1. For plate butt welds, details of edge preparation shall be as per Figure-4. For pipe butt welds, details of edge preparation shall be as per Figure-5. For structural tack welds, refer Figure-1. Requirement of Tests: For Structural Tack Welders:
3.1.1 Break Test as per Figure-2. 3.2 For Plate Butt Welds:
3.2.1 Minimum of 2 specimens for bend test; one for root bend and other for face bend. Width of specimen shall be 38 mm for plate thickness upto 9.5 mm. For thickness greater than 9.5 mm, width of specimens shall be 10 mm and they shall be side bend tested. 3.3 For Pipe Welder:
3.3.1 The order of removal of test specimens shall be as per Figure-6.
3.3.2 For width and number of bend specimens, refer table below: TABLE OD > 101.6 50.8 101.6 < 50.8 <= 25.4 (**) (++) OD W 3.4 W 38.0 19.0 9.5 (+ +) No. of Bend Specimens Face Root 2 2 2 2 2 2 2 2 Side (**) (**) (**) -
for thickness greater than 9.5 mm, side bend test of width 9.5 mm may be substituted. Cut into 4 equal sections (with allowance for saw cuts or machine cutting); sharp corners to be rounded off. Outer diameter of pipe in mm Width of bend test specimen in mm For bend jig refer Figure-7, for thickness of bend specimen 9.5 mm; for other thicknesses (t) the dimension shall be as below: A B C D = 4t = 2t = 6t+3.2 mm = 3t + 1.6 mm
The above values are nominal. 3.5 4.0 4.1 Radiographic examination of test welds may be carried out in lieu of bend tests. Procedure and acceptance criteria are as per NDE Manual. Essential Variables: Changes to the following variables require requalification.
4.1.1 Process: Example: Change from GTAW to SMAW or vice versa. 4.1.2 Joint: A Change from one type of bevel to another.
Example: vee bevel to u bevel. 4.1.3 Base Metal: A change in thickness or pipe diameter beyond the limits prescribed in Table-1. 4.1.4 Filler Metal: A change from one F number to another F number, except as specified in table-1, 4.1.5 Positions: Note: This procedure envisages qualification of welders to perform in all positions. Deviation to this are not recommended. 4.1.6 Gas: Note: This procedure envisages test to pre-prescribed gas as for production welds. Deviation to this are not recommended. 4.1.7 Electrical Characteristics: a. AC to DC and vice versa. b. In DC, DCEN (Electrode Negative) to DCEP (Electrode Positive) and vice versa. 4.1.8 Technique: Note:- This procedure envisages only use of uphill progression technique. 5.0 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 Acceptance Criteria: Structural Tack Welding: No cracks. No lack of fusion. Undercut not exceeding 1 mm. Not more than 1 porosity (max. diameter of porosity 2 mm). Plate / pipe Welding:
5.2.1
Visual Inspection: a. No cracks. b. No lack of fusion or incomplete penetration. c. Not more than 1 porosity in a length of 100 mm of length of weld (max. porosity diameter 2 mm).
5.2.2
Bend Test results: The convex surface of the bend test specimen shall be visually examined for surface discontinuities. For acceptance, the surface shall contain no discontinuities exceeding the following dimensions. 1. 2. 3. 3 mm measured in any direction on the surface. The sum of the greatest dimensions of all discontinuities exceeding 1 mm but less than or equal to 3 mm, shall not exceed 10 mm. The maximum corner crack of 6 mm, except when that corner crack resulted from visible slag inclusion or other fusion type discontinuities, then the 3 mm maximum shall apply. Specimens with corner cracks exceeding 6 mm with no evidence of slag inclusions or other fusion type discontinuities shall be disregarded, and a replacement test specimen from the original weldment shall be tested.
6.0 6.1 7.0 7.1
Retests : A welder who fails to meet the acceptance criteria for one or more test specimens, may be retested as per this procedure after adequate practice. Validity : When a welder meets the requirements of this procedure, the validity will be for a maximum of 2 years from the date of test, limited to Validity specified by statutory authority, as applicable. The validity may be extended by one year each time, based on satisfactory performance. Requalification : Requalification is required for the following : a. Where there is a specific reason to doubt the skill of the welder. b. Due to non-engagement of the welder for a continuous period of 6 months.
7.2 8.0 8.1
9.0 9.1
Records ; The welding in charge at site shall maintain the following records. A. Record of welder performance Qualification Test (as per format). B. Register of qualified welders (employer-wise) containing the following details : 1. 2. 3. 4. 5. 6. 7. Name of welder. Age. Tested for pipe / plate / tack. Performance Test No. Validity. Welder Code. Remarks.
The above register shall be updated for deletions also. 9.2 9.3 10.0 Copies of welder identity card (including details as in 9.1 B and relevant variables qualified). Pertinent radiography reports. Enclosures : 1. Table 1 - Welder qualification Requirements. 2. 3. 4. 5. 6. 7. 8. 9. Record of Welder Performance Qualification Test. Figure-1 - Structural Tack weld specimen. Figure 2 - Break Test. Figure 3 Weld Positions. Figure 4 - Plate Butt Weld Specimen. Figure 5 - Pipe Butt Weld Specimen. Figure 6 - Order of Removal of Test Speciemen. Figure 7 - Bend Jig
S L. N O
TEST FOR
BASE METAL Note -1
TEST COUPON DIMENSION OD, t
TO BE USED Note 2.4
WELDERS QUALIFICATION REQUIREMENTS TABLE 1 ELECTRODE WELD REFEREN RANGE
POSITIONS
CE FIGURE
QUALIFIED DIA. & T
POSI TIO N QUA LIFI ED
ELECTROD E QUALIFIED Note 2,4 REMARKS
1.
Structural Tack
P1 Gr1
t=10 mm OR 12 mm
(E 6013 F2) (E 7018 ) F4 F4 F4 F4 F4 F4 F4 F4 F4 F4
3F & 4F 3F & 4F
Fig. 1 &2 -doFig . 3 -do-do-do-do-do-do-do-do-
T = Unlimited T = Unlimited T=>3.2 mm T>3.2 mm <=2t T = Unlimited OD=>600 mm T<=2t OD=>600 mm OD=> Above OD &25 mm OD>73 mm T <=2t T= Unlimited
ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL
F2, F1 F4 & Below F4 & Below F4 & Below F4 & Below F4 & Below F4 & Below F4 & Below F4 & Below F4 & Below F4 & Below
Refer Fig.1,3
2.
Plate Welder (Structural) Plate Welder (Other than Structural) Pipe Welder
t=>25 mm -dot>25 mm t=>25 mm -do-dot>25 mm OD=>25 mm OD=>25 mm & <=73 mm OD>=73 mm t<19 mm t.>=19 mm
3G & 4G 3G & 4G 2G 3G & 4G 2G 3G & 4G 6G 6G 6G 6G 6G
3.
4.
1 TACK WELDER QUALIFICATION 4
1/2
4 2
in 1/2 2
mm 13 50 100
1/2 Fig 1 Fillet Held Break specimen
FORCE
Fig 2 Method of Rupturing
RECORD OF WELDER PERFORMANCE QUALIFIACATION TEST Performance Test No., Date : Site : Welders Name & Address : Welder Code :
Material groupings permitted : Thickness Qualified : (This performance test is as per Procedure No. TEST MATERIAL Specification : Thickness (and Dia. Of Pipe) : Shielding Gas(es) PROCESS VARIABLES Position of test weld : Pre-heat temp ; Test joints Current : inter Pass Temp: Test Results Type Bend Type Bend Type Bend Type Bend Radiography Ref. & Results :
Welding Processes : Position(s) Qualified : Dia Qualified :
Filler Metal : SFA No. : AWS Classification :
Polarity : Post-heat Temp : Results Results Results Results
(Sketch ) Welders signature Agency Conducting Test We certify that the statements in this record are correct and that the test weld were prepared, welded and tested in accordance with requirements. This is valid upto ------------------------------------------Welding In-charge / BHEL.
INSPECTION OF WELDING 1.0 Purpose : This procedure provides details for performing visual inspection of weld fitups, welding in progress and completed welds. 2.0 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 4.0 4.1 4.2 Reference : Contract drawings Erection welding schedule (supplied by Units) or equivalent. Welding procedure specification, where supplied. Indian Boiler Regulations (for boilers erected in India). General Requirements : Ensure that the components to be welded are in accordance with the contract drawings, Welding Schedule and other relevant documents. The condition of welded Surfaces to be inspected must be clean and dry. There shall be sufficient lighting to allow proper interpretation of visual inspection. Weld fit-up Inspection : The surface to be welded shall be smooth and free from deep notches, irregularities, scale, rust, oil, grease and other foreign materials. Piping, tubing and headers to be jointed shall be aligned within allowable tolerances on diameters, wall thicknesses and out-of-roundness as below: Maximum Permissible out-of-alignment at bore Bore (mm) Upto 100 Over 100 to 300 Over 300 Max. Misalignment (mm) For GTAW For SMAW 1.0 1.6 1.6 1.0 1.6 2.4
4.3 4.4 4.5
When fit, components to be welded shall not show an appreciable off-set or misalignment when viewed from positions apart. The root opening of components to be joined shall be adequate to provide acceptable penetration. On fillet welds, the parts to be jointed shall be brought as close to contact as practical, although in most instances a small opening between the parts is desirable. Root gaps should be maintained at 1.6 mm 2.4 mm (refer relevant document). Weld area should be protected from drafts and wind, to maintain inert gas shield. Checks during welding operation: Ensure the required minimum preheat temperature is applied and established during welding. Ensure correct electrode / filler metal is used for welding. Tack welds are examined by the welder before they are incorporated in the final weld. Ensure proper drying / holding of electrodes prior to use. Ensure the correct interpass temperature is maintained. Ensure proper cleaning of weld between beads. Checks on the completed weld: No visible cracks, pin-holes or incomplete fusion. The weld surface must be sufficiently free of coarse ripples, grooves, overlaps, abrupt ridges and valleys, visible slag inclusions, porosity and adjacent starts and stops. Undercuts not to exceed 1 mm. Where inside surface is readily accessible, the same shall be inspected for excess penetration and root concavity. The permissible limits are given below.
4.6 4.7 5.0 5.1 5.2 5.3 5.4 5.5 5.6 6.0 6.1 6.2
6.3 6.4
Root concavity: max of 2.5 mm or 20% of thickness at weld, whichever is lesser, provided adequate reinforcement is present. Excess penetration: upto and including 3.2 mm. 6.5 6.6 For plate butt welds, the weld reinforcement should not exceed 3.2 mm. For circumferential joints in piping and tubing the maximum weld reinforcements permitted are given below: Maximum Permissible Reinforcements Thickness of of base metal Upto 3.2 Over 3.2 4. Over 4.8 12.7 Over 12.7 25.4 Over 25.4 All Dimensons in mm 6.7 There shall be no overlaps. The faces of fillet welds are not excessively convex or concave and the weld legs are of the proper length. 6.8 In case of weld joints in pressure parts and joints like ceiling girder, the weld joint must be suitably identified. For service above 400 Deg.C 1.6 1.6 2.4 3.2 4.0 Temperature upto & incl. 400 Deg.C 2.4 3.2 4.0 4.8 6.3
WELDER PERFORMANCE MONITORING 1.0 1.1 2.0 2.1 2.2. 2.3 2.4 2.5 2.5.1 2.5.1.1. 2.5.1.2 2.5.2 2.5.2.1 2.5.2.2 2.6 2.6.1 Purpose: This procedure deals with monitoring the performance of welders engaged at sites. This procedure is applicable where radiography is performed. Procedure: The welder performance shall be monitored on a calendar month basis. Extent of radiography shall be representative of weekly outputs of the welder. Quantum of radiography shall be as per contractual requirements. Evaluation of welds radiographed shall be as per NDE manual or other documents as specifically applicable. Welder performance evaluation: For welds dia 88.9 mm and below: The percentage defectives (repairable) is calculated as a percentage of number of unaccepted to those radiographed. Upto and including 5% defectives performance is satisfactory else unsatisfactory. For welds over dia 88.9 mm and plate welds: The percentage defectives is calculated as a percentage of length of defectives repairable to the length radiographed. Upto an including 2.5% defectives performance is satisfactory else unsatisfactory. When a welder gives unsatisfactory performance for a continuous period of 3 months he shall be requalified Requalification of welder shall be called for when there is a specific reason to question his ability to make acceptable welds. This shall override requirements of cl.2.6 Welds produced during any month shall be radiographed and evaluated latest by 10th of the succeeding month.
2.7
2.7.1
Under circumstances when cl.2.7 is not satisfied for any particular welder, he may be disengaged from the job till such time his performance can be evaluated for the month in study. Site in-charge may waive the restriction imposed in 2.7.1 reviewing the situations for non-compliance of cl.2.7 and may allow engagement of the welder in question for a period not exceeding one successive month to the month in study. Records: Welding in-charge shall prepare and maintain Welder Performance Records, welderwise.
2.7.2
3.0 3.1
REPAIR WELDING 1.0 1.1 2.0 2.1 2.2 2.2.1 2.2.2 2.2.2.1 2.2.2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 4.0 4.1 Purpose: This procedure details steps to be taken for weld repairs. Procedure: Unacceptable welds, based on visual inspection or NDE, shall be repaired. Removal of Defects: The identified defect area shall be marked on the part. The defects may be removed by grinding / thermal gouging. Where thermal gouging is done, adopt the requirements of preheating as detailed in Heat Treatment Manual. However, only grinding is permitted for the last 6 mm from the root. Removal of defects shall be verified by visual inspection PT, MT, RT as appropriate. The profile of ground portion shall be smooth and wide enough to permit proper fusion during repair welding. Repair welding shall be carried out as per the procedure for the initial weld. Repair weld shall undergo the same type of NDE as the initial weld. Repeat steps 2.1 to 2.6 till acceptable weld is made. Where cutting, re-edge preparation and re-welding the joint will yield better results, the same shall be followed. Where a specific repair procedure is supplied by the Manufacturing Unit, the same shall be followed. Records: Records pertaining to the repairs like Welder, NDE records shall be maintained
APPENDIX A Recommended Electrical Characteristics for Welding at Sites. Electrical Process Classification && E6013 @@ EXX18 ## EXXX GTAW SMAW SMAW SMAW Dia mm 2.5 3.15 2.5 3.15 4.0 2.5 3.15 4.0 2.5 3.15 4.0 Type DCEN DCEN DCEP DCEP DCEP DCEP DCEP DCEP DCEP DCEP DCEP Current Amp range 70-120 110-160 50-100 90-140 130-190 70-120 100-160 150-220 70-100 100-140 120-170 Voltage range 12-20 12-20 18-26 18-26 18-26 18-26 18-26 18-26 18-26 18-26 18-26
Notes: && @@ ## The current ranges are applicable for all filler materials used in GTAW process EXX18 include E7018, E7018-1, E7018-A1, E8018 B2, E9018 B3. EXXX include E309, E347 electrodes.
APPENDIX B Extract from AWS D 1.1. 1992 SAFE PRACTICES (Non-mandatory Information) (This Appendix is not a part of ANSI/AWS D1.1-92, Structural Welding CodeSteel, but is included for information purposes only) This appendix covers many of the basic elements of safety general to arc welding processes. It includes many, but not all of the safety aspects related to structural welding. The hazards that may be encountered and the practices that will minimize personal injury and property damage are reviewed here. J1 Electrical Hazards
Electric shock can kill. However, it can be avoided. Live electrical parts should not be touched. Read and understand the manufacturers instructions and recommended safe practices. Faulty installation, improper grounding, and incorrect operation and maintenance of electrical equipment are all sources of danger. All electrical equipment and the work pieces should be grounded. A separate connection is required to ground the workpiece. The work lead should not be mistaken for a ground connection. To prevent shock, the work area, equipment, and clothing should be kept dry at all times. Dry gloves and rubber soled shoes should be worn. The welder should stand on a dry board or insulated platform. Cables and connectors should be kept in good condition. Worn, damaged, or bare cables should not be used. In case of electric shock, the power should be turned off immediately. If the rescuer must resort to pulling the victim from the live contact, nonconducting materials should be used. A physician should be called and CPR continued until breathing has been restored, or until a physician has arrived. See references 8,7 and 10 J2 Fumes and Gases
Many welding, cutting and allied processes produce fumes and gases which may be harmful to ones health. Fumes and solid particles originate from welding consumables, the base metal, and any coating present on the base metal. Gases are produced during the welding process or may be produced by the effects of process radiation on the surrounding environment. Everyone associated with the welding operation should acquaint themselves with the effects of these fumes and gases.
The possible effects of over-exposure to fumes and gases range from irritation of eyes, skin and respiratory system to more severe complications. Effects may occur immediately or at some later time. Fumes can cause symptoms such as nausea, headaches, dizziness, and metal fumes fever. Sufficient ventilation, exhaust at the arc, or both, should be used to keep fumes and gases from breathing zones and the general work area. For more detailed information on fumes and gases produced by the various welding processes, see References 1,4 and 11 J3 Noise
Excessive noise is a known health hazard. Exposure to excessive noise can cause a loss of hearing. This loss of hearing can be either full or partial, and temporary or permanent. Excessive noise adversely affects hearing capability. In addition, there is evidence that excessive noise affects other bodily functions and behavior. Personal protective devices such as ear muffs or ear plugs may be employed. Generally, these devices are only accepted when engineering controls are not fully effective. See References 1,5 and 11. J4 Burn Protection
Molten metal, sparks, slag, and hot work surfaces are produced by welding, cutting and allied process. These can cause burns if precautionary measures are not used. Workers should wear protective clothing made of fire resistant material. Pant cuffs or clothing with open pockets or other places on clothing that can catch and retain molten metal or sparks should not be worn. High top shoes or leather leggings and fire resistant gloves should be worn. Pant legs should be worn over the outside of high top boots. Helmets or hand shields that provide protection for the face, neck, and ears, should be worn, as well as head covering to protect. Clothing should be kept free of grease and oil. Combustible materials should not be carried in pockets. If any combustible substance is spilled on clothing it should be replaced with fire resistant clothing before working with open arcs or flame. Appropriate eye protection should be used at all times. Goggles or equivalent also should be worn to give added eye protection. Insulated gloves protection should be worn at all times when in contact with hot items or handling electrical equipment. For more detailed information on personnel protection Reference 2,3,8 and 11 should be consulted.
J5
Fire Prevention
Molten metal, sparks, slag. and hot work surfaces are produced by welding, cutting, and allied processes. These can cause fire or explosion if precautionary measures are not used. Explosions have occurred where welding or cutting has been performed in spaces containing flammable gases, vapours, liquid, or dust. All combustible material should be removed from the work area. Where possible, move the work to a location well away from combustible materials. If neither action is possible, combustibles should be protected with a cover or fire resistant material. All combustible materials should be removed or safely protected within a radius of 35 ft. (11m) around the work area. Welding or cutting should not be done in atmospheres containing dangerously reactive or flammable gases, vapours, liquid, or dust. Heat should not be applied to a container that has held an unknown substance or a combustible material whose contents when heated can produce flammable or explosive vapours. Adequate ventilation should be provided in work areas to prevent accumulation of flammable gases, vapours or dusts. Containers should be cleaned and purged before applying heat. For more detailed information on fire hazards from welding and cutting operations, see References 6,8,9 and 11 J6 Radiation
Welding, cutting and allied operations may produce radiant energy (radiation) harmful to health. Everyone should acquaint themselves with the effects of this radiant energy. Radiant energy may be ionizing (such as X-rays) or non-ionizing (such as ultraviolet, visible light, or infrared). Radiation can produce a variety of effects such as skin burns and eye damage, if excessive exposure occurs. Some processes such as resistance welding and cold pressure welding ordinarily produce negligible quantities of radiant energy. However, most arc welding and cutting processes (except submerged arc when used properly), laser welding and torch welding, cutting, brazing, or soldering can produce quantities of non-ionizing radiation such that precautionary measures are necessary. Protection from possible harmful radiation effects include the following: 1) 2) Welding arcs should not be viewed except through welding filter plates (see Reference 2) Transparent welding curtains are-not intended as welding filter plates, but rather, are intended to protect passers by from incidental exposure.
3) 4) 5)
Exposed skin should be protected with adequate gloves and clothing as specified. See Reference 8. The casual passerby to welding operations should be protected by the use of screens, curtains, or adequate distance from aisles, walkways, etc. Safety glasses with ultraviolet protective side shields have been shown to provide some beneficial protection from ultraviolet radiation produced by welding arcs.
References Cited 1. American Conference of Governmental Industry Hygienist (ACGIH). Threshold limit values for chemical substances and physical agents in the workroom environment, Cincinnati, Ohio; American Conference of Governmental Industry Hygienists(ACGIH) American National Standards Institute. Practice for occupational and educational eye and face protection, ANSI Z87.1New York: American National Standards Institute. -----------------------.Safety-toe footwear, ANSI Z41.1 New York: National Standards Institute. American
2.
3. 4. 5. 6.
----------------------.American Welding Society. Fumes and gases in the welding environment, AWS Report. Miami, Florida: American Welding Society. -----------------------Method for sound level measurement of manual arc welding and cutting processes, ANSI / AWS F6.1. Miami, Florida. ------------------------Recommended safe practices for the preparation for welding and cutting containers that have held hazardous substances, ANSI/AWS F4.1. Miami, Florida: American Welding Society. -------------------------Safe Practices.(Reprint from Welding Handbook, Volume 1, Eight Edition) Miami, Florida: American welding Society. ----------------------- Safety in welding and cutting, ANSI/ASC Z49.1 Miami, Florida: American Welding, society. National Fire Protection Association: Cutting and welding processes NFPA Standard 51B. Quincy, Massachusetts: National Fire Protection Association ---------------------- National Electrical Code. Massachusetts National Fire Protection Association. NFPA No.70.Quincy,
7. 8. 9. 10. 11.
Occupational Safety and Health Administration. Code of Federal Regulations, Title 20 Labour, Chapter XVII, Part 1910; OSHA General Industry Standards. Washington, DC:U.S Government Printing Office.
APPENDIX A MINIMUM REQUIREMENTS OF NDE AS PER IBR (Quantum of Radiography or other approved NDE methods for Butt Welds) 1.0 Boiler and Superheater Tubes (Regulation No.151 (h): BORE, MM OVER 178 OVER 102 AND UPTO 178 INCLUDING BELOW 102 2.0 2.1 PERCENTAGE OF NDE 100% 10% (MIN. 2 WELDS PER WELDER) 5% (MIN 1 WELD PER WELDER)
Steam pipes and fittings (Regulation No.360 (d) NDE Requirements: Pipelines NDE requirement:
DESCRIPTION BORE mm PERCENTAGE OF NDE FOR EACH WELDER PERCENTAGE OF CUTOUT JOINTS FOR VISUAL AND BEND TEST FOR EACH WELDER __
CLASS I PIPELINES: A. WHERE THE COMPLETED PIPELINES ARE NOT SUBJECTED TO HYDRAULIC TEST OVER 102 100%
OVER 38 AND UPTO 102 INCLUDING BELOW 38 OVER 102
5% (MIN. 2 WELDS PER WELDER) 2% (Note.1) 10% (MIN. 2 WELDS PER WELDER) 2% (MIN 1 WELD PER WELDER) __ __
B:WHERE THE COMPLETED PIPELINES ARE SUBJECTED TO HYDRAULIC TEST
OVER 38 AND UPTO 102 INCLUDING BELOW 38 mm CLASS II PIPELINES: ALL SIZE ALL PIPES
2% (Note.1) 2% (Note 1)
Note. 1: It is suggested that in lieu of this radiography may be substituted at sites.

2.2 Retest: If any test specimen is unsatisfactory, two further weld specimen for retest shall be selected from the production welds and subjected to tests.
APPENDIX B Extract from ASME/ ANSI B 31.1/1992 MANDATORY MINIMUM NDE for pressure welds or welds to pressure retaining components.
I.
Piping service conditions temperature over 400 deg C and all pressures. Type of weld Butt welds NDE RT for over NPS 50 MT-& PT for NPS 50 And less
Fillet, Socket, attachment & seal welds MT or PT for all sizes and Thicknesses II Piping service conditions: Temperatures between 175 deg C Inclusive and 400 deg C inclusive with all pressures above 7100 kPa(gauge) Type of weld Butt welds NDE RT for over NPS 50 with Thickness over 19 mm. Visual For others.
Fillet, socket, attachment and seal weld Visual for all sizes & Thicknesses. III All others : Visual examination.
NOTES: 1) 2) 3) 4)
5)
NPS - nominal pipe size All welds must be given a visual examination in addition to the NDE specified. The thickness of buttwelds is defined as the thicker of the two abutting ends after end preparation Temperatures and pressures shown are design. Fillet welds not exceeding 6 mm throat thickness which are used for the permanent attachment of nonpressure retaining parts are exempt from the PT & MT requirements.
APPENDIX C
NDE Requirements as per ASME Sec I
Following buttwelds shall be radiographed or ultrasonically tested. A. For drums, shells excluding pipes, tubes, headers. I NPS exceeding 250 mm or wall thickness greater than 28 mm. Bring against ( B. For pipes, tubes and headers. Radiography is not mandatory for the following conditions.)
1. For parts containing steam: NPS <= 400 mm or wall thickness <= 40 mm 2. For parts containing water : NPS <=250 mm or wall thickness <= 28 mm 3. For parts in flue gas path but not subject to radiation: NPS <=150 mm or wall thickness <= 19 mm 4. For parts in flue gas path and subject to radiation: NPS <= 100 mm or wall thickness <= 12.5 mm II Where radiography is to be performed and geometric uncharpness cannot be within 1.8 mm, ultrasonic testing shall be performed. Note: NPS nominated pipe size
HEAT TREATMENT 1.0 1.1 2.0 2.1 Purpose: This procedure provides information, method and control for preheat (PH) and post weld heat treatment (PWHT) of welds at sites. Document: The following documents are referred in preparation of this procedure.
2.1.1 ASME Sec.1, II(a) 2.1.2 ANSI B 31.1
2.1.3 Indian Boiler Regulations 2.1.4 AWS D1.1/Steel 2.1.5 Welding Manual PS:CMX:001:00:93 2.2 The following are referred to as Primary Documents Erection Welding Schedules or equivalent Contract Drawings Plant Standards, where supplied Welding Procedure Specification, where supplied
2.2.1 Where parameter for Preheating (PH) and PWHT are not available in the primary documents reference may be made to this manual. 2.2.2 Where such parameters are not contained either in the primary documents or in this manual reference may be made to Manufacturing Units. 3.0 3.1 Procedure: Preheating:
3.1.1 When parts of two different thicknesses are welded together, the preheating requirements of the thicker shall rule. 3.1.2 When parts of two different P numbers are jointed together, the material requiring higher preheat shall govern (Please refer Welding Manual for P numbers)
3.1.3
Preheating shall be checked using thermal chalk (temperature indicating crayons) prior to start-up welding as well as at frequent intervals during welding. It is preferable to have a thermocouple and a temperature recorder in case of alloy steels of thickness greater than 50 mm. In case of any interruption during welding, preheating temperature shall be maintained at joint by wrapping in dry thermal insulating blankets to ensure slow and uniform cooling. Preheating Methods: Preheating shall be applied by any of the methods given below: a. Electrical Resistance Heaters b. Induction Heating c. Oxy-Acetylene or other Gas Torches
3.1.4
3.1.5 3.1.5.1
3.2 3.2.1
Post Weld Heat Treatment(PWHT): The method shall be by locally heating a circumferential band including the entire weld and adjacent area of base metal, by Induction or Electrical Resistance Heating. Heat Band for PWHT For Boilers: a. When heat treating welded joints in components in the boiler, proper width of the heated circumferential band on either side of the weld. (W) must be as, W = 3 times the width of the wides part of the weld groove but in no case, less than twice the width of weld at reinforcement. b. When used in post weld heat treatment in sections W = 3 times the plate thickness. c. For nozzle and other welded attachments W = must be wider than the nozzle or attachment or 3 times the wall thickness.
3.2.2 3.2.2.1
3.2.2.2
For Piping: W = Three times the wall thickness of thickest part, in case of nozzles and attachment welds, the width of the heat band shall extend beyond the nozzle or the attachment wall on each side by at least twice the higher thickness and shall extend completely around the header.
AMENDMENT NO : 1 3.2.2.3 Other Pressure Vessels: Heat band width, placement of thermocouple and preheat and PWHT information shall be obtained from the supplier. 3.3 3.3.1 3.4 3.4.1 3.4.2 3.4.3 3.4.4 Condition of Welded Joints: The weldment shall be free of grease, oil etc, prior to PH/PWHT. Temperature Measurement for PWHT: Post weld heat treatment temperature shall be measured and monitored by use of thermocouples with calibrated recorders. The periodicity of calibration of the equipment must be every twelve months or before use. Where the soaking temperature is found to be lesser than specified, the PWHT cycle shall be repeated. In case interruption during PWHT, the following actions are to be taken depending on the stage during which interruption occurred. a. Interruption during heating cycle: The whole operation to be repeated from the beginning
b. Interruption during soaking: The joint can be treated subsequently for the balance left over soaking period.
c. Interruption during cooling: Ensure slow cooling by covering with insulation to a minimum width of 1.5 times the outer diameter applied equally about the central line of weld, till the temperature reaches around 350 deg.C.
3.5 3.5.1 3.5.1.1 3.5.1.2 3.5.1.3 3.5.1.4 3.5.1.5 3.5.2
THERMOCOUPLE ( t / c) Fixing: Thermocouples shall be used for recording post weld Heat Treatment temperatures. Following are thermocouples. guidelines regarding number and placement of
Minimum of two thermocouples per weld. Thermocouples located 180 deg. Apart. Thermocouples located top and bottom of weld. Thermocouples located at a distance of approximately 1.5 times of the wall thickness about the centre line of weld. The following guidelines may be used for attaching thermocouples to job. a. For capacitor discharge method: Thermocouple elements should be attached within 6 mm of each other. b. For other type of t / c Insert the elements in a ss tube of internal diameter approximately 6 mm. Apply force on tube and crimp it. Place this t / c and weld the crimped button to the pipe in area of interest. Do not weld the elements. c. Insulate the t / c leads suitably and protect t / c ends from direct radiation from heating elements.
3.5.3 3.5.3.1
For Bunched Tubes: Where a bunch of closely placed tube welds (e.g Super Heater / Reheater Coils) require to be stress relieved, the same shall be grouped together as if they form a single component. In such cases attachment of a minimum of three thermocouples, two at the end tubes and one at the middle is recommended. Soaking Time Wherever not specified the soaking time shall be 2.5 minutes per mm. The minimum soaking shall be 30 minutes.
3.5.3.2 3.6 3.6.1
3.6.2
The following guidelines shall be used to determine the thickness and subsequent selection of the soaking time of PWHT. a. For butt welds, the thickness shall be the thickness of the material at the weld. For bar stock, the thickness shall be the diameter. b. For fillet welds, the thickness shall be the throat thickness. c. For partial penetration branch welds, the thickness shall be the depth of the groove prior to welding. d. For repairs, the thickness shall be the depth of the groove as prepared for repair welding. e. For combination of different welds in a component, the maximum thickness in the definitions given above shall govern.
3.6.3
Soaking time is to be reckoned from the time temperature of the joint crosses the recommended lower temperature of the cycle, to the time it comes down below the same recommended lower temperature of the cycle. Heating and Cooling rates: Whenever not specified, the heating rate above 400 deg. C and cooling rate after soaking upto 400 deg.C shall be as follows. This is applicable for all materials other than BS 3604:622 and 660 materials. Thickness of Material Maximum Heating Rate Maximum Cooling Rate Above 400 Deg.C Upto 400 Deg.C 220 Deg. C / Hour 110 Deg. C / Hour 75 Deg. C / Hour 55 Deg. C / Hour 110 Deg.C / Hour 110 Deg.C / Hour 110 Deg.C / Hour 110 Deg.C / Hour
3.7 3.7.1
Upto and including 25 mm Over 25 to 50 mm (incl) Over 50 to 75 mm (incl.) Over 75 mm
For Structural 65 deg. C / Hour (Max.) 3.7.2 For BS:3604:622 and 660 materials, for a combination of diameter below 127 mm and thickness below 12.5 mm, maximum rate of heating is 250 x 25 T or 100 deg.C / Hour, whichever is less.
Maximum rate of cooling is 50 deg C / hour. T = Thickness of material in MM. 3.8 Temperature Records:
3.8.1 All the heat treatment cycles may be controlled within a tolerance of + or - 20 deg. C around the recommended temperature. The recommended temperature for stress relieving must be selected as the midpoint of recommended range of temperature for the material. 3.9 All the heat treatment cycles may be controlled within + / - 20 deg.C around the midpoint of the recommended range of temperature for the material. SR Job Card: Prior to start of stress relieving operations, a job card may be prepared including details of weld reference, soaking time, soaking temperature, maximum rates of heating and cooling, temperature recorder details, date of PWHT as per sample format. On completion of PWHT the actuals may be recorded on the job card. A chart number shall be given to each chart. List of Tables: Table 1 PH, PWHT for GIRTH BUTT Welds in Tubes and Pipes Dia <= 76.1 mm. Table 2 PH, PWHT for Headers Table 3 PH, PWHT for Pipes Dia > 108 mm Table 4 Heat Treatment requirements for Non-Pressure Parts including Structurals.
4.0 4.1
4.2 4.3 5.0
Table 5 PH for Flame Cutting Annexure 1 Soaking Time Annexure 2 Heat Treatment of X-20 materials. 6.0 6.1 Records: Pertinent Records like Job Card, SR Charts, shall be maintained.
STRESS RELIEF (S.R) JOB CARD

Site: ------------------------------------Unit No. --------------------------------Description ----------------------------Weld Reference ---------------------Material Spec:------------------------Size: Dia--------------------------mm Thick---(t) -------------------mm Date: Package: Temp. Recorder Details 1. 2. 3. 4. Make----------------------------------Type-----------------------------------Sl.No:---------------------------------Calibration Due on:--------------------------------
NDE Cleared on:---------------------------------------
Thermocouple Locations: Minimum 2 d = 1.5 x t
Heating Band = 6 x t Insulation Band = 12 x t
Date of S.R--------------------------------Start Time:---------------------------------Chart No.:----------------------------------Rate of Heating (Max) deg C / h Soak Temperature deg C Soak Time (Minutes) Rate of Cooling(Max) deg C / h Contractor Results Accepted / Not Accepted: End Time-----------------------------Required ----------------------------------------------------Actual --------------------------------------------------------B.H.E.L Released for further processing
TABLE I
GIRTH BUTT WELDS

(Tubes and Pipes Dia < 76.1)
Applicable for Tahickness upto 19 mm for P1ABC and Thickness Upto 13 mm for other materials
MATERIAL P1 P3 Group 1 P4 Group 1 &2 (Note 1) P5 Group 1 (Note 1) P5 Group 2 P8 Group 1 & Group 2 GTAW SMAW - do -
PROCESS PH PWHT PH PWHT
P1ABC NIL NIL NIL NIL 120 NIL 200 NIL 200 680-720 NIL NIL
P3A
P4Gr.1,2
P5 Gr.1
P5 Gr.2
P8
NIL NIL 120 NIL 200 NIL 200 680-720 NIL NIL 120 NIL 200 NIL 200 680-720 120 NIL 200 NIL 200 200
- do -
PH PWHT PH
- do PWHT PH - do PWHT - do PH PWHT 680-720 680-720 150 NIL 200 680-775 NIL NIL
Note: Preheating of P4 and P5 tubes can be waived off if PWHT is envisaged at site. If Preheating is done for the above, PWHT can be waived off subject to the approval from Chief Inspector of Boilers of the respective region. PH = Preheat; PWHT = Post Weld Heat Treatment.
TABLE II PREHEAT AND PWHT TO HEADERS (Note 4) (Applicable for Welding of Header to Header Joints at Site) Header Pipe Material (Note 3) P1 Group 1 & 2 (Note 1) P4 Group 1 & Group 2 Thickness, (mm) t < 25 t 25 75 t > 75 t < 75 t > 75 Plates & Pipes P5 Group 1 Castings & forgings Preheat 0 C NIL 100 150 120 150 150 200 Post Heating (Note 2) 0 C NIL NIL NIL NIL NIL 2500 for 4 hours PWHT 0 C 600-650 600-650 600-650 650-700 650-700 700-750
Note 1:
For SA 106 Gr. C materials, a minimum preheat of 1000C is required for all thickness and a post heat of 1500C for two hours after completion of welding. All P5 headers shall be interstage heat treated at 700-7500C for 30 minutes soaking prior to any cold straightening operation. In lieu of this, the straightening can be done after final PWHT. Irrespective of the stub or attachment material, the PWHT cycles shall be governed by the header pipe material. However, the preheat for welding shall be as shown below: P1 Header to P3 stub P1 Header to P4 stub P1 Header to P5 stub 1200C (min.) 1200C (min.) 1500C (min.)
Note 2:
Note 3:
Note 4: Seal welding of hand hole plates, radiographic plugs and screws can be carried out after final PWHT, provided the preheat is carried out as per the table.
Note 5:
Soaking time for BS 622 & 660 materials shall be 180 mts. (min) irrespective of thickness. However, when diameter is less than 127 mm and thickness less than 12.5 mm, soaking time shall be 30 minutes (min). Throat shall be as specified in the drawing. Wherever flanges are welded to pipes combined throat shall be taken into consideration.
Note 6:
TABLE - IV Heat Treatment Requirements for Non Pressure Parts Including Structurals (Note 7)
Shearing Material Post Forming Heat Treatment
Gas cutting Thickness SMAW (Non-Low H2 Electrodes Nil 100 120 150
Welding SMAW (Low H2 electrodes) GMAW, SAW etc. Nil Nil 100 120 PWHT (Note 7)
Preheat
P1 A.36 Is 2062 IS 226
t < 19 Nil t < 50 Nil t > 19 600-6500C t > 50, 1000C No<- soaking <- is required. (Note 1) All sheared edges t < 25 Nil at 650 7000C for t > 25, 1200C 15 mts.
t < 19 t - 19 38 t - 38 63 t > 63
a. All butt welds when > 50 mm b. Any welds to a tension member (Note 2) SR at 600-6500C a. All butt welds tension member. b. All fabricated components when t>16 mm (Note 3) SR at 650 7000C All welds (Note 5 & 6) SR at 680-7300C in
P4
t < 75 t > 75
-----
120 150
P5
All sheared edges t < 13, 1200C at 680-7300C for 15 t 13 25, 1500C mts. t > 25, 2000C (Note 4)
All
---
150
Note 1: Clip angles above 10 mm, used for beam connections, which are sheared to length, shall required heat treatment. Note 2 : All tension members, when thickness is above 50 mm, the entire assembly shall be post weld heat treated. Note 3 : All fabricated structural components of P-4 material, with any member above 16 mm thickness, the entire assembly shall be post weld heat treated. Note 4: All gas cut edges of P-5 material shall be heat treated at 680-7300C for 15 mts. As an alternative to this heat treatment, the gas cut edges may be chipped off, ground or machined to remove the HAZ with 6 mm minimum removal.
Note 5 : All welds of P-5 material shall be post heated at 2500C for 2 hours or 1500 C for 4 hours immediately following welding. Note 6 : All fabricated structural members of P-5 material, the entire assembly shall be post weld heat treated after completion of fabrication. Note 7: For soaking time details refer Annexure I.
ERECTION WELDING PRACTICE FOR SA 335 P91 MATERIAL 1.0 1.1 2.0 SCOPE This document details salient practices to be adopted during erection of SA335 P91 material. MATERIAL Materials shall be identified as follows : 1. Colour Code: Brown & Red 2. Hard Stamping : Specification, Heat No. Size 3. Paint / Stencil: WO DU, as per the relevant drg & document. 2.1 When any defect like crack, lamination, deposit noticed during visual examination the same shall be confirmed by Liquid Penetrant inspection. If confirmed, it shall be referred to unit. 3.0 3.1 3.1.1 ERECTION Edge Preparation and fit up Cutting of P-91 material shall be done by band saw / hacksaw / machining / grinding only. Edge preparation (EP) shall be done only by machining. In extreme cases, grinding can be done with prior approval of Welding Engineer / Quality Assurance Engineer. During machining / grinding, care should be taken to avoid excessive pressure to prevent heating up of the pipe edges. 3.1.2 All Edge Preparations done at site shall be subjected to Liquid Penetrant Inspection (LPI). Weld build-up on Edge Preparation is prohibited. 3.1.3 The weld fit-up shall be carried out properly to ensure proper alignment and root gap. Neither tack welds nor bridge piece shall be used to secure alignment. Partial root weld of minimum 20 mm length by GTAW and fit-up by a clamping arrangement is recommended. Use
of site manufactured clamps for fit up is acceptable. The necessary preheat and purging shall be done as per clause 4.1 and 3.2.2. 3.1.4 The fit-up shall be as per drawing. Root gap shall be 2 to 4 mm; root mismatch shall be within 1 mm. Suitable Reference punch marks shall be made on both the pipes (at least on three axis) a) At 200 mm from the EP for UT. b) At 1000 mm from the EP for identifying weld during PWHT. 3.2.0 FIXING OF THERMOCOUPLE (T/C) AND HEATING ELEMENTS DURING PREHEATING AND PWHT 3.2.1 No Preheating is required for fixing T/C with resistance spot welding Following are the equipment / facilities for heating cycles 1. Heating methods : Induction heating 2. Thermo couples : Ni-Cr / Ni-A1 of 0.5 mm gauge size. 3. Temp. Recorders : 6 Points / 12 Points. 3.2.2 ARRANGEMENT FOR PURGING : Argon gas of 99.99% conforming to Gr 2 IS 5760 1998 shall be used for purging the root side of weld. The purging dam (blank) shall be fixed on either side of the weld bevel prior to pre-heating. The dam shall be fixed inside the pipe and it shall be located away from the heating zone. Purging is to be done for root welding (GTAW) followed by two filler passes of SMAW in case of butt welds. Purging is not required in the case of nozzle and attachment welds, when they are not full penetration joints. The Argon to be used shall be dry. The flow rate is to be maintained during purging is 10 to 26 litres / minute and for shielding during GTAW IS 8 to 14 litres / minute (A minimum flow rate as per welding Procedure specification shall be maintained).
Start purging from inside of pipe when root temperature reaches 220 deg. C. Provide continuous and adequate Argon Gas to ensure complete purging in the root area. The minimum pre-flushing time for purging before start of welding shall be 5 minutes, irrespective of the size. Wherever possible, solid purging gas chambers are to be used which can be removed after welding. If not possible, only water-soluble paper is to be used. Plastic foils that are water-soluble are NOT acceptable. 3.2.3 USING ALUMINIUM DAM ARRANGEMENT In order to retain the Argon gas at the inside of the pipe near root area of the weld joint, the purging dams made of Aluminium (or other suitable material like mild steel) and permanent gaskets may be provided during the weld fit-up work as indicated in the sketch. The Aluminium discs shall be firmly secured with a thin wire rope. After completion of the root welding followed by two filler passes, the disc may be pulled outwards softly.
CAUTION : ENSURE REMOVAL OF PURGE DAM ARRANGEMENT AFTER WELDING :
3.2.4
USING OF WATER SOLUBLE PAPER The dams can be made of water-soluble paper for creating the purging chamber. The advantage in such dam arrangement is that dissolving in water can flush the dams. The following are different methods used.
4.0
WELDING / WELDERS QUALIFICATION: Only qualified welding procedures are to be used. Welders Qualified as per ASME Sec IX and IBR on P91 material shall only be engaged. Welders log book to be maintained and welders performance to be monitored by site welding engineer / Quality assurance engineer. The applicable WPS for P91 + P91 shall be WPS No.1034.
4.1
PREHEATING Prior to start of pre heating ensure that surfaces are clean and free from grease, oil and dirt. Preheating temp shall be maintained at 220 deg C (min) by using Induction heating. The Temperature shall be ensured by using a Calibrated autographic recorder and two calibrated then no couples fixed at 0 deg and 180 deg positions on both pipes 50
mm away from the EP. The thermocouple shall be welded with the condenser discharge portable spot welding machine. The preheating arrangements shall be inspected and approved by welding engineer / Quality Assurance Engineer. (Ref Fig 1) Alternate arrangements shall be made during power failure. Two additional spare thermocouple to be fixed (as described above) for emergency use. Gas burners shall be employed to maintain the Temperature until the power resumes. 4.2 WELDING:Root Welding shall be done using GTAW process (as per WPS) five minutes after the start of argon purging. Filler wire shall be cleaned and free from rust or oil. Argon purging shall be continued minimum two filler passes of SMAW. 4.3 STORAGE OF WELDING CONSUMABLES a. Welding consumables are received with proper packing and marking which includes the relevant batch number for easy identification. b. Electrodes are stored in their original sealed containers / packages until issued and kept in dry and clean environment as per the instructions of electrode manufacturers, taking care of shelf life. c. d. Welding filler wires are received with proper packing and marking which includes the relevant batch number for easy identification. The filler wires are stored in their original packages until issue and kept in dry and clean environment. 4.3.1 The electrode GTAW wires issued to the welders should be controlled through issue slips. SMAW electrodes used must be dried in drying ovens with calibrated temperature Controller. The drying temp shall be as recommended by the electrode manufacturer. The drying Temp shall be 200 300 deg C for two hours if it is not specified by the
manufacturer. Portable flasks shall be used by the welders for carrying electrodes to the place of use. The electrodes shall be kept at minimum 100 deg C in the flask. Welding shall be carried out with short are and stringer bead technique only. 4.4 The inter-pass temperature shall not exceed 350 deg. C. After completion of Welding bring down the temp to 80 100 deg C and hold it at this temp for one hour minimum. The PWHT shall commence after completing one hour of soaking. CAUTION :- No LPI / Wet MPI shall be carried out on weld before PWHT. 5.0 POST WELD HEAT TREATMENT Arrangements :- A minimum of four thermocouples shall be placed such that at least two are no the weld and the other two on the base material on either side of the weld within the heating band at 180 degrees apart about 50mm from the weld joint. Two stand by thermocouple shall also be provided on the weld in case of any failure of the thermocouple. The width of the heated circumferential band on either side of the weld must be at lease 5 times the thickness of the weld. In case of fillet joints the heating band shall be six times the thickness of the base material. (Ref Fig 2). An insulation of about 10mm thickness shall be provided between the cable and weld joint. 5.1 Obtain the clearance for post weld heat treatment cycle from QAE / Welding Engineer. The PWHT temp for P91 material shall be 760 + 10 deg C and the soaking time shall be 2.5 minutes per mm of weld thickness, subject to a minimum of TWO Hours. All records shall be reviewed by Welding Engineer prior to PWHT clearance.
Heating shall be done by Induction heating only. The rate of heating / cooling :(above 350 deg C) Thickness up to 50 mm 110 deg C/hr.(max) Thickness 50 to 75 mm 75 deg C/hr.(max) Thickness above 75 mm 55 deg C/hr.(max) Thickness = Actual thickness as measured. 5.2 INSULATION : The width of the insulation band beyond the heating band shall be at least two times the heating band width on either side of the weldment. The recording of time & temp shall be continuously monitored with a calibrated recorder right from preheating. This will be ensured at every one hour by site authorized personnel. 5.3 PREVENTIVE MEASURES DURING POWER FAILURE AND NONFUNCTIONING OF EQUIPMENTS. No interruption is allowed during welding and PWHT. Hence all the equipment for the purpose of power supply, welding, heating etc., shall have alternative arrangements. (diesel generator for providing power to the welding and heating equipments, standby welding and heating equipments, reserve thermocouple connections, gas burner arrangement for maintaining temp etc.) Following preventive measures shall be adopted until normal power supply or backup power supply through diesel generator is restored. (a) During start of preheating : In case of any power failure / interruption during preheating, the weld fit-up shall be insulated and brought to room temperature. After the electric supply resumes the joint shall be preheated as per Clause No:4.1. (Ref : Fig 3)
(b) During GTAW / SMAW: Use gas burner arrangement to maintain the temperature at 80 deg 100 deg C up to a length of 50 mm on either side from weld center line along the complete circumference of the pipe. Root welding shall be continued after power is restored and preheating temperature is raised to 220 Deg. C. During the above period temperature shall be recorded through contact type Thermometer. (Ref: Fig 4) (c) During cooling cycle after SMAW welding to holding temperature at 80 to 100 deg C for one hour ( Ref: Fig 5) Care shall be taken to avoid faster cooling rate by adequate insulation. The required temp 80 100 deg C shall be maintained by gas burner arrangements till power resumes / start of PWHT. (d) During post weld heat treatment. The following shall be followed * 1) During heating cycle The whole operation to be repeated from the beginning (Ref : Fig 6) * 2 ) During soaking Heat treat (soak) subsequently for the entire duration. (Complete period). (Ref : Fig 7) The heating rate shall be as per the chart. 3) During cooling (above 350 deg C). Reheat to soaking temperature and cool at the required rate. (Ref: Fig 8) * Temp should not be allowed to fall below 80 100 deg C. Gas burner arrangement shall be used to maintain the temperature. 5.4 In all the above cases (a to d) the temp. Measurement on the weld joint by means of contact type calibrated temp. gauges shall be
employed to record the temperature at regular Intervals of 15 minutes in the log book by Quality Assurance Engineer / Welding Engineer. 5.5 TEMPERATURE MONITORING: The welding and heat treatment chart given in Figure 9 shall be followed for the following details. The actual PWHT chart shall be monitored for the following: a) b) c) Preheat Inter pass Temperature (GTAW SMAW) Controlled cooling and Holding at 80-100 Deg C for minimum one hour under insulation. Start PWHT after minimum one hour of soaking. d) e) f) g) 5.6 Heating to PWHT Soaking at PWHT Cooling to 350 Deg C Cooling to Room Temperature (under insulation )
CAUTION THE PWHT TEMP. SHALL NOT DEVIATE FROM THE VALUES SPECIFIED IN THE CHART RANGE SINCE ANY DEVIATIONS TO THE SPECIFIED HOLDING TEMPERATURE RANGE, WILL ADVERSLY AFFECT THE MECHANICAL PROPERTIES OF THE WELDMENT AND MAY LEAD TO REJECTION OF THE WELDMENT. THE WELD JOINTS SHOULD BE KEPT DRY. UNDER NO CIRCUMSTANCES ANY WATER / LIQUID IS ALLOWED TO COME IN CONTACT WITH WELD AS WELL AS PREHEATED PORTION OF PIPE.
5.7
CALIBRATION All equipments like recorder, thermocouple, compensating cable, oven thermostat etc. should have valid calibration carried at BHEL approved labs. The calibration reports shall be reviewed and accepted by Calibration In-Charge at site prior to use.
6.0 6.1
NONDESTRUCTIVE EXAMINATION: All NDE shall be done after PWHT only. Prior to testing all welds shall be smoothly ground. All welds (fillet & butt) shall be subjected to MPI ( MPI shall be done by YOKE type only). In addition to MPI, butt-welds and all full penetration welds shall be examined by UT. LPI procedure shall be BHE: NDT : PB : PT : 01 Rev 13 and MPI procedure shall be BHE : NDT : PB : MT : 05 Rev 02 The penetrant materials (Dye Penetrant, Solvent cleaner & Developer) and medium (dry /wet particles) used in MPI shall be of BHEL approved brands only. UT procedure shall be as per BHE:NDT:PB:UT21 Rev 04 with additional requirements as in (a) through (c) a. The calibration blocks used shall be of same material specification (P91) dia & thickness. b. The UT equipment shall be calibrated prior to use and should be of digital type Krautkramer Model USN 50 of equivalent, capable of storing calibration date as well as ultrasonic test results as per UT-21 / Rev 04. c. All recordable indications will be stored in memory of either the digital flaw detector or a PC for review at a later period. d. The equipment calibration data for specific weld as well as the hard copy of Static echo-trace pattern Showing the flaw echo amplitude with respect to DAC, flaw depth, projection surface distance (probe position) and beam path shall be attached to UT test report. This hard copy of echo-trace with equipment calibration data will form part of test documentation. e. The examination as well as evaluation will be performed by a qualified Level II personnel, and a test report will be issued. Any defect noticed during NDT shall be marked with marker.
7.0
REPAIR OF WELD JOINTS : (A) WELD REPAIR AT ROOT: On visual examination during root welding if it reveals any surface defects, the same shall be removed by grinding maintaining temperature 80 100 deg. C and rewelded with GTAW maintaining 220 deg. C before starting SMAW. (B) WELD REPAIR ON COMPLETION: Any defect observed on the weld shall be brought to the notice of Quality assurance engineer. The size and nature of defect shall be reviewed. Any repair on weld to be carried on their approval only. If any defects are noticed on the fully completed weld while performing U.T. after completion of PWHT, the same may be assessed in order to find the seriousness of the defect and to locate where exactly the defect lies from the weld outside surface. The defect area shall be marked and repaired as below: a) The weld shall be removed by grinding (gouging not permitted) such that the area for repair welding is free from sharp corners and provided with sufficient slope towards the weld face sides. Incase of cut & weld joints HAZ (=5 mm ) will have to be removed by grinding. b) Surface examination (MPI / LPI) on the ground and welded area to be performed to ensure a sound base metal before depositing weld layers using SMAW. c) The temp. of the weld is to be maintained at preheat temp. d) Carry out SMAW using the same procedure as that of welding.
e) All the specified precautions w.r.t to welding consumables, heating cycles, post weld heat treatment etc. as followed for original welding, shall be strictly adhered. f) The NDE shall be conducted for the entire weld joint. g) If any further defects are observed on the repaired weld, the same may be further reworked as mentioned above. 8.0 HARDNESS SURVEY The equipment recommended to measure the hardness are EQUOTIP or MICRODUR make or equivalent portable equipment. The equipment used for the hardness measurement shall be calibrated as recommended by the manufacturer and also on a P91 calibration block provided by PC. The surface shall be cleaned and prepared as per hardness test instrument manufacturers recommendation prior to hardness survey. Hardness survey shall be done on each joint at three locations along the circumference. At each location three readings shall be taken on weld and parent metal. The readings on the parent metal shall be taken within 15 mm from the weld fusion line. All the hardness values shall be recorded. The max allowable hardness at weld and parent metal shall be 300 HV10. Joints having hardness above 300 HV shall be reheat treated and hardness shall be checked again. If hardness is still more refer to unit.
9.0
COMBINATION WELDING For other combination of material like P22 with P91, and X22 with P91 the applicable WPS for the involving material shall be obtained from equipment supplier / WTC / PC and the same shall be used.
9.1
SOAKING TIME FOR COMBINATION WELDING
WPS No
Material P91 + P22
Temp. 745+150C
Soaking time 2.5 mts / mm minimum one hour 2.5mts / mm minimum two hour for thickness Up to50 mm and minimum four hours for thickness above 50 mm.
1035 MS W0454 P91 + X22
750 + 100C
However the precautions as required for P91 shall be fully taken care of.
10.0
DEMAGNETISATION In case magnetization is noticed on the pipes, the following procedure shall be Followed during welding. Use Residual field-indicator at one end of pipe and measure the residual field. Note reading and direction of field (+ ve or ve & No units) IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII + 10 0 - 10 Indicator may show readings greater than + or 10 Divisions. A small size electrode or gem clip will get attracted & stick to pipe. Wrap insulated welding cable 5 turns clockwise on the OD surface or pipe. Wrapped cable to be 50 to 100 mm away from joint end. One cable end connect to ve terminal of welding generator and the other to ve terminal. Complete electrical circuit & pass 400 amps current for 3 to 4 seconds. Measure residual field now at the same end of pipe. If demagnetization is effective the reading will come closer to O For eg. If it is formerly > + 10 Divisions, it may show 5 Division. The electrode or gem-clip will not stick to pipe end. If de-magnetization is NOT effective The readings will be greater in the same direction The gem clip / electrode will Still stick to pipe, Then repeat the following.
Now wrap the insulated cable (5 turns) in anti-clockwise direction pass current slightly excess of 400 Amps Reduce the current gradually to 0 amps in one minute when current is on. Check for demagnetization using gem-clip / electrode. The gemclip/electrode WILL NOT GET attracted. If the reading is shifted to opposite direction, reverse the turns. 11.0 11.1 TRAINING The personnel engaged in P91 piping fabrication shall be trained in the following areas. a. Method and Care during fit-up b. Argon gas root purging arrangement c. Fixing of thermocouple and wires. d. Arrangements for Pre/Post heating requirements and methods. e. Adjustment of heating pads / cables at the time of controlling the temperature within specified tolerance limits during welding or PWHT in case of induction heating. f. Good appreciation of the WPS requirements. g. Handling of P91 welding consumables and re-drying conditions. h. Special precautions during the power / equipment failure. i. Weld joints of dissimilar thickness / material specification. j. Weld defect control and weld repair system. 11.2 SPECIFIC TRAINING FOR WELDERS a. The qualified welders who will be engaged in P91 welding shall be given training or pipe joints simulated with P91 welding and heating cycle conditions. b. The acquaintance on welding positions, as applicable shall be given using P91 pipes and P91 welding consumables. c. Welding techniques and instructions on Dos and Do Nots of P91 welding.
d. Welders only who are qualified on P91 welding alone shall be engaged. Whenever new welders have to be engaged they shall undergo all the training as above and shall be qualified with P91 material only. 11.3 CONTROL ON WELDERS The welder during welding at site follow the following procedures. The welder shall interact with the HT operator (Induction equipment operator) to ensure that preheat and interpose temperature during welding are maintained as per requirements. The welder shall not mix the welding electrodes with that of the other welder. At the end of the shift, the unused electrodes shall be returned to the stores. 11.4 PERSONNEL / CONTRACTORS ENGAGED FOR HEATING
CYCLES (HT Operator) 11.4.1 11.4.2 The Personnel / Contactor shall have adequate heat treat experience on P91 or similar material. HT operator shall be aware of the following : a. The equipment used and its working principle and operation. b. The procedures to be followed in using heating equipments. c. Procedure to be followed in case of power failure or equipment non-functioning so that heating cycle is not disrupted. d. Calibration of equipments e. Method of fixing thermocouples and compensating cables leading to HT recorder. f. Fixing of heating pads or elements on the pipe joints and also in maintaining the temperature within the specified limits.
11.5
NDE PERSONNEL QUALIFICATIONS All NDE personnel performing NDT like UT & MPI / LPI shall be qualified in accordance with BHEL Procedure meeting the requirements of recommended practice SNT TC 1A. MPI & LPI shall be carried out by level I qualified personnel and shall be evaluated by level II qualified personnel. However UT examination and evaluation shall be done by level II qualified personnel.
11.6
LEVEL OF SUPERVISION Site in-charge Shall be responsible for the completion of all activities from weld fit-up to final clearance of weld joints after satisfactory NDE and acceptance by BHEL/Customer / IBR.
12.0 12.1
DOs and DONTs during P91 welding, heat treatment and NDE at construction site. DOs a. Cutting by Band saw / Hack saw / Machining b. Pipes Edge Preparation by machining. Machining shall be done without excessive pressure to prevent heating up of pipe. c. Grinding may be done on exceptional cases after approval and taking adequate care to prevent overheating. d. Thermocouple wire (hot/Cold junctions) shall be welded with condenser discharge portable spot-welding equipment. e. Reserve Thermocouples shall be made available, incase of failure of connected thermocouple elements. f. Ensure adequate Argon Gas for complete purging of air inside the pipe before starting GTAW root welding. g. Ensure Preheating at 220 Deg. C minimum before GTAW root welding.
h. Start preheating only after clearance from Welding engineer / Quality assurance engineer for weld fit-up and alignment of the joint as well as fixing of Thermocouple connections (for Induction heating) i. Do visual inspection on root weld maintaining weld preheating temp. j. Continue Argon purging until the GTAW root welding followed by minimum two filler passes SMAW, is completed. k. Perform partial root welding to facilitate fit-up if necessary. l. Ensure that only one layer of root welding using TGS 2 CM filler wire (2 Cr 1 Mo) is deposit (wherever specified). m. Ensure proper use of TIG wires as identified by colour coding or suitable hard punching. n. Keep the GTAW wires in absolutely clean condition and free from oil, rust, etc. o. Dry the SMAW electrodes before use. p. Ensure the interpass temperature is less than 350 Deg.C. q. Hold at 80-100 Deg. C for a period of Minimum 1 hour before the start of PWHT. r. Record entire heating cycle on Chart through recorders. s. Exercise control during grinding of weld and adjoining base metal while removing surface / sub-surface defects or during preparation for NDE. t. Ensure no contract with moisture during preheat, welding, post heat and PWHT of weld joints. u. Ensure removal of argon purging arrangements after welding. v. Use short Arc only. The maximum weaving shall be limited to 1.5 times the dia of the electrode.
13.0
DONTs a. Avoid Oxy-Acetylene flame cutting. b. Avoid Weld-build up to correct the weld end-di or to set right the lip of the weld bevel. c. Avoid Are strike on materials at the time of weld fit up or during welding. d. Do not Tack weld the thermocouple wires with Manual Are/TIG welding. e. NO GTAW root welding without thorough purging of root area. f. Do not use Oxy-acetylene flame heating for any heating requirements. g. Do not use Thermal chalks on the weld groove. h. Do not stop argon purging till completion of GTAW root welding and two layers of SMAW. i. No Tack welding or Bridge piece welding is permitted. j. Do not use unidentified TIG wires or electrodes. k. Do not exceed the maximum interpass temperature indicated in WPS l. Do not allow moisture, rain, water, cold wind, cold draft etc. to come in contact with the weld zone or heating zone during the entire cycle from preheat to PWHT. m. Do not exceed the limits of PWHT soaking temperature. n. Do not Interrupt the Welding / heating cycle except for unavoidable power failures o. Do not use uncalibrated equipment for temperature measurement during heating, welding, post weld, heat treating etc.,
14.0
NDE Consumables Technically approved Brands by BHEL HPBP. 1. Liquid Penetrant, Penetrant Remover (Solvent cleaner) and Aerosol Developer from the same manufacturer considered as a family group.
BRAND VENDOR PENNETRANT PENNETRANT REMOVER SPOT CHECK SKC-1 FLAW CHECK a. PP - 21 b. PP 120 CHECK MATE SUPER CL 96 FLAW GUIDE GP CRACK CHECK FC 911 DEVELOPER SPOT CHECK SKD-S2 FLAW CHECK a. PD 31A b. PD 131A CHECK MATE SUPER DV 98 FLAW GUIDE GP CRACK CHECK FC 911
ITW SIGNODE SPETCHECK INDIA LTD., SKL-SP P.MET CO., FLAW CHECK a. PP - 15 b. PP 110 CHECK MATE CHECK MATE CHEMICALS (P) SUPER LTD., PT 97 PRADEEP METAL FLAW GUIDE TREATMENT GP CHEMICAL (P) LTD., FERROCHEM CRACK CHECK FC 911 2. Dry Magnetic powder:
a. MAGNAFLUX PRODUCT GREY; 8A RED b. FERROCHEM PRODUCT NO : 266 c. K-ELECTRONICS PRODUCT RD 200 (SPECIAL)
3. Non-fluorescent magnetic ink: (Prepare bath as instructed by supplier) a. MAGNAFLUX Product 9C RED with MX/MG carrier II oil vehicle. b. FERROCHEM PRODUCT NO: 146 A with oil vehicle (with high flash point 920C) c. SARDA MAGNA CHECK INK with oil vehicle (with high flash point 920C) 4. Fluorescent magnetic ink: (Prepare bath as instructed by supplier) a. MAGNAFLUX Product 14A with MX/MG carrier II oil vehicle. b. MAGNA FLUX Product 14 AM Prepared bath of 14A and MG/MX carrier II ready to use without measuring and Mixing in aerosol container with MS/MG carrier II oil vehicle. 15.0 DOCUMENTATIONS The documentation shall be as per the customer approved BHEL Quality Plan.
Volume 1A PART I GUIDELINES FOR INSULATION

CHAPTER 22
GENERAL GUIDELINES FOR INSULATION WORKS
This booklet is given as a general guideline to this tenderers about insulation works, However instructions given in the drawings & other schedule issued during execution of the work shall be final and binding of the contractor.
Bharat Heavy Electricals Limited ( A Govt. Of India Undertaking) Power Sector Southern Region 690, Anna Salai , Nandanam, Chennai 600 035
GENERAL NOTES ON ERECTION OF INSULATION

1. 2. It is important that the sheet metal covering is done, by a experienced and competent tinsmith. Person, who is doing the actual job, can alter the following said methods of fixing the sheet metal, as and when necessary, only after consulting the BHEL Erection Engineer. Fixing pin of corresponding thickness of insulation shall be welded by STUD WELDING process. Circumferential and axial overlapping of outer casing should be 50 mm unless specified otherwise. FOR HORIZONTAL AND INCLINED DUCT AND PIPE: 1) 2) 3) 5A. All overlapping in axial direction should be at the bottom of the duct and pipe. Provision of beading and Sealing compound is not required. For circumferential overlapping of inclined duct and pipe, provision of beading and Sealing compound is not required. For circumferential overlapping of horizontal pipe and duct, provide beading. Apply Sealing compound if necessary.
3. 4. 5.
FOR VERTICAL DUCT AND PIPE: 1) 2) For overlapping in the axial direction provide beading. Apply Sealing compound if necessary. For circumferential overlapping provision of beading and Sealing compound is not required.
6.
The joints of wool mattresses should be staggered in both circumferential and axial direction. The Wire netting at the joints of Wool mattresses are to be sewn together by G.I. sewing wire dia 0.71 mm. In case more than one layer of Wool mattress is to be applied for pipe insulation the inner layer should be tied by two turns of G.I binding wire dia 1.22 mm at a pitch of 240 mm, and the outer layer should be tied by two turns of G.I. binding wire dia 1.22 mm at a pitch of 160 mm. The ends of the wire should be twisted and pressed in to the insulation.
7.
8. 9. 10.
All the overlapping of outer casing should be made such that no rain water enters into the insulation through the joints. Incase of insulation fixing pin welding to tubes, equal circumferential pitch is to be maintained. Use a minimum number of 4 pins, at 90 degree radial spacing. The inner side of the Aluminum / G.I sheet of outer casing should be painted with two coats of anticorrosive Paint (IS:158). Retainer Type A must be coated with Aluminum paint to avoid bi-metal corrosion or Neoprene strip must be provided between Retainer Type A and Casing support. The above mentioned paints are not in BHEL scope of supply
11.
Self tapping screws should be fixed over the circumferential overlapping. The axial joints should be on the Casing supports and outer casing should be fixed to Casing supports with Self tapping screws at a pitch of 150 mm approximately. The outer casing should be wound tightly around the insulation and then fixed with Self tapping screws when there is not any Fixing pin for insulation. Loose wool can be taken from the Wool mattresses wherever required. Clean the surface to be insulated of rust, dust, grease, loose scale, oil, moisture, etc. Care shall be taken that flexible insulation is not unduly compressed. After insulating the equipment with Calcium silicate / Mineral wool mattress, all voids in the joints shall be filled with Moldable insulation / loose mineral wool respectively. Each day application of insulation should be weather proofed overnight by either with the final protective casing or with some temporary weatherproof covering so that it does not get drenched in rain. The indicated thickness of insulation is the minimum requirement which should be provided. Any alteration in the thickness of insulation should be done only after getting the prior approval from the Design Engineer. The layers of Wool mattresses are to be taken as indicated below: THICKNESS IN mm 250 230 210 200 190 180 1st 50 50 50 50 40 60 LAYER IN mm 2nd 3rd 4th 50 50 50 60 60 60 50 50 60 50 50 50 50 50 50 60 60 5th 50
12. 13. 14. 15. 16.
17.
18.
19.
160 150 140 120 100 80 20.
50 50 40 60 50 40
50 50 50 60 50 40
60 50 50
Where junctions between two or three bodies or different dia, occur and different insulation thickness is specified the greater thickness shall be continued for a length equal to one dia of the smaller body then smoothly tapered to the required smaller thickness over a length equal to two dia of the smaller body. When there is a differential thermal expansion between these bodies, they should be insulated individually. The required fixing components and outer casing sheets have been released under PG_32. The insulation materials have been released under PG-33. STORAGE INSTRUCTIONS:
21. 22.
22a) Mineral wool mattress: These materials should be stored under fully covered sheds. Stocking must be done over planks and must be out of contact with ground. Height of stacking should not exceed 3 Meters. Once drenched in water these materials loose all the desired properties and become unsuitable for use. Drying the material does not restore the desired properties. 22b) Outer casing sheets: Outer surfaces are meant for improving the appearances also scratch marks, dents, etc, spoil the appearance. Typical insulation arrangement drawings are indicated below. 1) 2) 3) 4) 5) 6) Tees Elbows Flanges Expansion joint for pipe Expansion piece for duct Manhole door for duct 4-00-235-08546 4-00-235-08547 4-00-235-08548 4-00-235-08549 3-00-235-06258 & 3-00-235-06259 3-00-235-06260
23.
INSULATION OF DRUM END MATERIAL: 1) 2) 3) 4) 5) 6) 7) 8) APPLICATION: Install Flat 50 x 6 circumferential bands to fit snugly around the drum. Flat 50 x 6 lattice bar 8 numbers should be radially placed over the dished end and contouring the same and it is to be welded over circumferential bands. Weld the Fixing pins to the lattice bars circumferential bands. Fix the Wool mattress. Position the Retainer and tack weld to the Pin. Tie with Binding wire across the Pins. Fix the outer casing strips by Self tapping screws. FLAT 50 X 6 FIXING PIN INSLN DIA 6 RETAINER TYPE A G.L. BINDING WIRE DIA 1.22 / 0.914 WOOL MATTRESS OUTER CASING SELF TAPPING SCREW M4 X 13 G.L. SEWING WIRE DIA 0.71 / 0.914
INSULATION OF PIPES AND BUNCH OF TUBES MATERIAL: 1) 2) 3) 4) 5) WOOL MATTRESS G.L. SEWING WIRE DIA-0.71 / 0.914 G.L. BINDING WIRE DIA 1.22 / 0.914 OUTER CASING SELF TAPPING SCREW M4 x 13
APPLICATION: Fix the insulation over the bunch of tubes / pipes. Tie the insulation with G.I. binding wire circumferentially. Fix the outer casing sheet with self-tapping screws.
INSULATION OF VERTICAL PIPES (WELDING OF FIXING PINS NOT PERMITTED ON PIPES) MATERIALS: 1) 2) 3) 4) 5) 6) 7) 8) FIXING PIN INSLN DIA 6 RETAINER TYPE A CASING SUPPORT 850MM OUTER CASING WOOL MATTRESS SELF TAPPING SCREW M4X13 CLAMP SUPPORTING SHEET 9) 10) 11) 12) 13) 14) 15) 16) FLAT 50 x 6 PACKING CLOTH 3 MM TK HEX HD BOLT M8X40 HEX NUT M8 PNCHD WASHER A9 GI BINDING WIRE DIA 1.22 /0.914 GI SEWING WIRE DIA 0.71 / 0.914 SHEET 3.15x30x3000
APPLICATION: At every three meters provide the Clamps over the pipe with bolt but and washer by using packing cloth in between the pipe and clamp. Fix the sheet 3.15x30x3000 over the pipe and weld to the clamps. Weld the fixing pin over the sheet. Consult the Welding engineer before welding. Weld the Flat to the Clamps. Weld the Supporting sheets to the Flats. Fix the insulation. Position the Retainer Type A and tack weld to the Pins. Tie the insulation to the pipe with GI biding wire circumferentially. Fix the casing support to the Retainer by using two numbers of Self tapping screws, fixed diagonally for each Retainer. Fix the outer casing sheet with self tapping screws.
INSULATION OF VALVE MATERIAL: 1) SM CLAMP FOR DETACHABLE INSULATION TYPE A (To be used up to 200 mm overall dia)
1)a SM CLAMP FOR DETACHABLE INSULATION TYPE B (To be used above 200 mm overall dia) 2) 3) 4) 5) 6) 7) 8) WOOL MATTRESS OUTER CASING SELF TAPPING SCRES M4 x 13 G.I SEWING WIRE DIA 0.71 SNAP HD RIVET 3 x 8 CHS SCREW M4 x 20 HEX NUT M4
APPLICATION: The sheeting shall be made in two halves and the Sheet metal clamp mounted. Wool mattress thickness according to adjacent pipe lines shall be pressed in to two halves. The two halves shall be fitted over the valve to be insulated and locked by Sheet metal clamp. Self tapping screws shall be used for clamping the two edges of the outer sheet casing when the length of the valve is more. After assembling the Clamp put a bit of GI Binding wire as a pin through 1.6 mm hole provided.
INSULATION OF DUCT / FLAT SURFACE

MATERIALS: 1) 2) 3) 4) FIXING PIN INSLN DIA 6 WOOL MATTRESS OUTER CASING RETAINER TYPE A 5) 6) 7) 8) GI BINDING WIRE DA 1.22 / 0.914 CASING SUPPORT 650 MM SELF TAPPING SCREW M4 x 13 GI SEWING WIRE DIA 0.71 / 0.914
APPLICATION: Weld the Fixing pin over the Duct / Flat surface. Fix the insulation. Position the Retainer Type A and tack weld to the Fixing pins. The GI Binding wire dia 1.22 shall be wound across the Fixing pins diagonally underneath the Retainer Type A. Fix the Casing support 650 long to the Retainer Type A by using two numbers of Self tapping screws, fixed diagonally for. Retainer Type A. Fix the outer casing by using Self tapping screws. DUCT STIFFENERS When the stiffeners protrudes through the insulation and are exposed to atmosphere, provide an additional 40 mm insulation over the stiffener. DUCT DAMPER & GATE Insulation thickness shall be s per the adjacent duct insulation. The stuffing boxes should not be insulated. A clear gap of 50 mm (minimum) should be maintained all around the stuffing boxes. AIR HEATERS DO NOT insulate over the axial seal, adjuster seal access covers and basket removal doors insulation should be applied in a manner to permit a free circulation of ambient air around the bearing.
INSULATION OF DUCT
(CLEARING STIFFENERS) MATERIALS: 1) 2) 3) 4) 5) 6) FIXING PIN INSLN DIA 6 RETAINER TYPE A RETAINER TYPE C CASING SUPPORT 650 MM GI BINDING WIRE DIA 1.22/0.914 GI SEWING WIRE DIA 0.71 / 0.914 7) 8) 9) OUTER CASING SELF TAPPING SCREW M4X13 WOOL MATTRESS
10) WELD MESH 11) CORNER SUPPORT 12) ANGLE 40X40X5 100
APPLICATION: Weld the Fixing pin over the Duct. Position the Retainer Type C so that it will be in the same plane as that of the top surface of the stiffener. Tack weld the Retainer Type C to the Fixing pin. For the top plate of the horizontal duct, spread the Weld mesh over the Retainer Type C. This serves as the additional support where people walk over the insulation. Weld the Corner support to the bottom corners of the duct. Weld the Angle to the corner support. This arrangement will help to achieve a sharp corner for the insulation and outr casing. Fix the insulation. Position the Retainer Type A and tack weld to the Fixing pin. The Biding wire shall be wound across the pins diagonally underneath the Retainer Type A. Fix the Casing support - 650 mm long to the Retainer by using 2 numbers of Self tapping screws, fixed diagonally for each Retainer. Fix the outer casing by using Self tapping screws.
PROCEDURE FOR CURING OF CASTABLE REFRECTORY CURING OF REFRACTORY WORK Curing of refractory means retaining the moisture for a minimum period in order to ensure the proper hydration of the binder. Curing of exposed castable surfaces should start after the surface has become firm. This can be tested when a finger rubbed across the surface comes away clean or when the surface feels warm to the touch. Moisture loss for the first 24 hours, after the material has been installed shall be retarded. Initial set occurs within one or two hours. Castables should be cured for 24 hours. Moist conditions can be maintained by protection with damp sacking or plastic sheet which should not come into immediate contact with the refractory or alternatively by dry coating the castable with an impervious organic based sealing compound. In some instances, satisfactory results can be obtained by sparkling water over the surface. It should be watered for a period of 20 to 24 hours after 4 to 5 hours of construction. The rate of water applicable should be carefully controlled to prevent washing of the fines and to prevent collection of pools in low spots. Shield the surface from direct sunlight at least for about 48 hours. 8 hours after casting and pouring, remove the wooden frames which have no load bearing function in order to permit watering of the lateral parts of the structures. In case of steel frames apply water without stripping them. On completion of the curing period the application of moisture should be stopped. The exposed castable should be allowed to air dry for 24 hours. Naturally air drying of castable after curing will actually cause slight increase in strength. The castable can be all dried indefinitely without adverse effect. Optimum results cane be obtained with a drying period of 48 hours. Before lighting the boiler for drying the setting the following shall be attended. 1. 2. 3. All dirt and foreign objects sticking to tube surface are to be removed to ensure a thoroughly clean surface. Expansion joints are to be cleaned and inspected for the proper functioning of expansion during operation. Test sample of castable refractory is to be taken from entry door regions to determine the moisture content in the laboratory. Sample of castable are to be taken for the determination of moisture content before and after drying. When the moisture content drops below 0.58 the castable is considered to be dry and the boiler is ready for commissioning. All result of measurement should be duly recorded.
CARE OF THE REFRACTORY WORK The refractory work is subjected to considerable thermal stresses during boiler operation. Sudden application of heat or cooling introduces severe stresses and endangers the refractory work. Even when the boiler is operated in the recommended regime possibilities of damage occurring to the refractories (due to severed reasons such as bad workmanship, poor quality, slag deposition, corrosive atmosphere etc) must be kept in mind. The following simple rules to be observed. Avoid sudden cooling of the furnace after a shut down. A cooling rate of 20 to 30 per hour for the refractory lining in the initial period is recommended. This means that FD fans must be stopped after a shut down of the boiler. Ventilation of the furnace by natural draft is permissible only after six hours of shut down. Forced cooling can be started only after 16 hours. Avoid quick heating of the furnace. Boiler starting diagram is usually a reliable guide. Thoroughly examine the refractory work during shot downs for cracks, chipping off spelling etc. During operation also this can be checked periodically by visual examination through observation holes. Whenever defects are notice arrange for their quick alimentation, by shutting down the boiler at the earliest depending on the scarceness of the defect. (iv) Abnormal heating of outside metal sheet covering of the boiler and hot spots are usually a good indication of damaged refractory and insulation in this area. The leakage of flue gas will spoil the property of good mattresses within a short time. Deep the access door, observation doors, etc. properly shut. They are entry points for cold air and this cold air can damage the refractory work by localized cooling. Sufficient quantity of water is to be added to the castable refractory for mixing before application as per suppliers recommendations.
(i)
(ii) (iii)
(v)
(vi)
(i) (ii) (iii) (iv) (v)
METHOD OF APPLICATION AND CURING OF POURABLE INSULATION Typical application are for insulating behind buckstays and areas such as roofs having multiplicity of hangers, rods and other penetrations. The application of pourable insulation cab be pumping and gunning. Density of the pourable insulation installed and cured is around 600 to 650 Kgs/ M Pourable insulation is a hydraulic setting insulation additive or air entrainment agents shall not be used. (a) Empty the entire bag at a time and mi the while material so that segregated particles get mixed. (b) The pourable insulation should be thoroughly mixed with coal clean water to develop casing and pump consistencies. The correct quantity of water shall be placed in the mixer before adding the dry pourable insulation normally about 70 to 100 by weight. However this has to be confirmed from the supplier while purchasing this material. (d) Mixing time shall not to be less than the minutes or more than five minutes. (e) Dried out material shall not be remixed. (f) Pourable insulation once mixed must be in place within half an hour. (a) All areas where pourable insulation will be placed must be fee of scale, rust, dust or other loose materials. (b) All porous forms used such as wood etc shall be oiled before pouring. All absorbent surface such as insulation brick, concrete, shall be wet down thoroughly to prevent water absorption. (d) Waiting of wall insulation used as forms at buckstay levels is not required.
(vi)
(vii)
(a) The surface of pourable insulation once in place will become firm in approximately two hours. The surfaces should be kept damp with an occasional light spray or covering with a cloth that is kept damp for the entire 24 hours curing period. (b) For mixing and spraying the water should be clean and cold. Application of moisture after 24 hours should be stopped forms etc should be removed and the materials allowed to air dry for 24 hours. The shuttering scaffolding moulds should be removed after about 36 hours of casing.
(viii)
APPLICATION OF INSULATION FOR BOILER PIPING, PIPING AND EQUIPMENTS / VESSELS AND ACCESSORIES. Bonded mattress having standard thickness to 25, 10, 50, 60, 75 mm confirming IS 8103 having a density of 150 kg/cubic meter and light bonded mattress having a density of 150 kg/cubic meter and light bounded mattress having standard thickness of 25. 40, 50, 60, 75 mm conforming to IS 9842 having a density of 144 kg/cubic meter and pipe section in the standard thickness of 25, 40, 50, 60, 75 mm confirming IS 9842 having density of 144 kg/cubic meter will be 100 kg/cubic Mtr. The application of insulation will be done as per general notes/ drawings enclosed. The application commissioning shall be as per latest editions of IS 7413 code of practice for application and finishing of thermal insulation materials between 40 C to 700 C of Bs 5970 code for practice for thermal insulation of pipe work and equipment (in the temperature range 100 C to + 870 C). Inspection before application, during the application and after the application of insulation will be carried out by BHEL Field Quality Engineer as per BHEL Field Quality Plan. Every layer of insulation shall be got approved by BHEL Engineer / FQA Engineer. Prior to applying insulation the surfaces to be insulated shall be made clean and dry and free from dirt and grease. Where cladding is attached to carbons steel or low alloy steels the steel shall be first prime painted with zinc chromate and then painted with Aluminum paintings. Wherever required to provide aluminum foil as protective covering for bolts and other fittings shall be arranged by contactor. The prints wherever required for preservation coating shall be supplied by contractor. For insulation of piping with performed pipe sections the came shall be applied over pipe and finally be held in position with 15 mm wide aluminum band at greater than 300 mm spacing for mineral wool insulation. For insulation of piping with mattresses having backing GI wire netting, the required lengths and shapes are to be cut from the blankets and wrapped on the piping and held in position with proper support by fastening the binding to be done circumferential at not greater than 300 mm spacing. Performed insulation on vertical or near vertical piping must be supported in position by means of metal ring at interval not greater than 960 mm. The support attachment may be welded or clamped to the pipe, subject to the approval of BHEL Site Engineer Necessary fabrication of support rings to be done as per site requirement.
Piping bends shall be insulated to the same specification as adjacent straight piping and should form a smooth external surface. Where performed material is used it should be cut loster-back fashion and wired or strapped into position. Pipe insulation shall be cut to fit nearly around hangers and supports. On horizontal lines which are supported directly on pipe racks the insulation and weather proofing shall be sufficiently cut away at the support to accommodate pipe movement. Protrusions through insulations which themselves do not required insulations such as pipe clamps supports of small pipings instrument take offs etc shall be covered to the same thickness as the adjacent insulation expect for hanger rods. At outdoor location the hanger rod protraction shall be shielded with metal flashing to deflect rain and protect the insulation from moisture while permitting the movement of the hanger rod. Arrangement of securing the metal finish even the insulation shall ensure that direct metal contact between the insulated surface and outer meter cladding is avoided. 4mm thick asbestos board packing shall be used at interface to thermally isolate the metal covering from supporting arrangement. All cladding joints shall be vapours tight and shall be able to accommodate thermal movements. Paste type self setting vapours sealing compound shall be used. Metal cladding on piping shall be screwed with self tapping screws. These joints should be arranged approximately 30 below horizontal centre line so as to shed water on any horizontal pipe line. The screws shall be flat or round head types of 12mm size and overlapping of 50 mm on both longitudinal and circumferential joints. The screws shall be provided at not greater than 150 mm spacing. Insulation expansion joints shall be provided in all pipelines to allow movements and expansion of the pipe. The recommended intervals of expansion joints are. Pipe Temperature Below 200C 201 - 300C 301C - 400C Above 400C Spacing of Insulation Expansion joints 5.5 M 3.5 M 3.0 M 2.0 M
All joints in the insulation shall be staggered. For multiple layer of insulation the different layers shall be applied so that the butt joints of one layer do not coincide with those of the other layers. At the joint of each layer of insulation loose insulation shall be packed firmly.
Equipments Insulation Application Procedure For equipment and shells a matrix of insulation support shall be developed by:(a) Welding the insulation support lugs on a frame work prepared with 20 mm x 3 mm size MS Straps where direct welding of lugs to he sheet is not permitted. Welding the directly on shell after written permission by Site Engineer. The material of the support shall be similar to the material of the shell in this case.
(b)
The support shell be pitched at 300 mm for vertical and underside surfaces and 500 mm for oppressed surfaces. A support shall be located above each vessel flange at a sufficient distance above the flange bolts to allow for easy removal. The top and bottoms supports shall be slotted suitably for attachments of straps and wires. The support lugs shall be 6 mm Insulation with back up GI wire noting, shall be cut to fit the equipments and shall be wrapped on the equipment and held in position with proper support and tie wires. All joints between course shall be staggered and tightly butter and adjacent edges laced together with lacing wire. Insulation shall be fastened in place with MS Straps of 20 x 3 mm, on approx., 300 mm centers where contour of equipment permits. Straps shall be tightened with a banding machine and champed with seals. Insulation on top of horizontal heads shall be cut to fit the curvature of the head and shall be secured in place with the help of radial straps fixed in between circumferential rings. Insulation on bottom heads shall be wired to nuts welded to head. Insulation shall also be strapped to bottoms insulation support. For outdoor equipments insulation shall be arranged to be weather proof. Metal jacketing shell be applied directly over the met insulation and neatly fitted to place. All gaps shall be arranged so as to shed water. Suitable flashing and weather proofing shell be provided at all nozzles, manholes and other projections to prevent the entrance of water.
VALVES & FLANGES INSULATION APPLICATION The insulation on all valves and flanged joints shall be enclosed in a removable jacketing so that it may be removed without disturbing the concerned equipment or piping. The thickness of insulation shall be same as that of the pipe line in which these valves and fittings are located. The layout of wool mattresses to be adopted to obtain the specified insulation thickness are as per be on unless otherwise specified: Thickness of Insulation (mm) Layer I 25 40 50 60 65 75 80 100 110 125 135 150 155 160 165 25 40 50 60 40 75 40 50 60 75 75 75 75 75 75 II 25 40 50 50 50 60 75 40 60 50 III 40 25 40 IV -
The material density of boned mineral wool used for pipe having outside diameter more than 355.6 mm is 150 kg/cubic mater 13 8183. The material density of bonded mineral wool used for pipe having outside diameter less than or equal to 355.6 mm is 144 kg/cubic meter IS 9842. Cladding material used is galvanised steel sheet as per IS 277 GRADE 375. Cladding material gauge for pipe outside diameter less than or equal to 300 mm is 24 SWG. Cladding material gauge for pipe outside diameter greater than 300 is 22 SWG. For piping up to including 355.6 mm OD, first layer shall be pipe sections and subsequent layer shall be bonded. Wherever pipe sections are not supplied the first layer has to be wrapped using bonded wool material for piping 355.6 mm OD, bonded mattress shall be used or all the layers.
Description of type of insulation and the method of Application for Boiler Feed Pumps 1. Type of insulation The pumps should be insulated with 125 mm thick flexible wire backed mineral wool mattress of 150 kg/ density. 2. Method of Application The above insulation is to be applied to 2.0 mm thick flats aluminum sheeting (18 SWG) and secured by 19 mm vide aluminum retaining dips and 1/8 inch diameter aluminum pop rivets, all to be secured by 2 inch long X No.8 spacing to a 40 mm wide x 3 mm thick angle iron frame work of all welded construction bound by 40 mm PVC tape.
SECTION A
TITLE METHOD OF APPLICATION OF THERMAL INSULATION FOR PIPING AND EQUIPMENTS AND MATERIAL SPECIFICATIONS (ANNEXURE-1) THERMAL INSULATION APPLICATION DRAWINGS
NO. OF SHEETS 4
13
SECTION - A
1.0
THERMAL INSULATION FOR PIPING AND EQUIPMENTS INTRODUCTION In a thermal power station or process plant, thermal insulation or heat lagging of piping and equipments carrying hot fluids is essential for hest economy and protection of operating personnel. Any pip which is at a temperature higher than it s surroundings will loose heat and the amount of heat lost will depend upon the temperature of the fluid and the thermal conductivity of the piping material/covering. The heat lost through bare pipe increases with a) b) c) Increase in the temperature of fluid conveyed Decrease in ambient temperature and Increase in wind velocity of the surroundings.
The heat so lost hast potential for work and rapidly increasing cost of fuel in the recent past has promoted to find all possible means to conserve energy. Providing proper and adequate insulation on to the piping and equipments controls heat transfer and maintains the required services temperature. 2.0 METHOD OF APPLICATION The method of application is highly skilled job. Badly fitted/laid insulation can lead to greater hear loss, higher cold surface temperature than that estimated and frequent maintenance. Following are the important points to be considered in the application of the insulation. 2.1 Before applying insulation, it should be ensured that all instrument tappings, clamps, lugs and other connections on the surface to be insulate d have been properly installed as per relevant drawings. All surfaces to be insulated shall be cleaned of all foreign materials such as dirt, grease, loose scale, moisture etc. Welding of lugs, attachments, clips etc. on the surface to be insulated for supporting insulation shall not be carried out without the permission of the authorized person. All flanged joints shall be insulated only after final tightening and testing. The insulation shall be applied to all surfaces when they are at ambient temperature. Where more than one layer of insulation is involved, mattresses should have staggered joints (at 60 deg) and they must be held in close contact with face of
2.2 2.3
2.4 2.5 2.6
pipes/fittings by means of binding wires / Aluminum bands / seals. Circumferential joints of multilayer insulation should also be staggered by at least 150 mm. (Refer Drg. No. PE-4-999-169-01). 2.7 2.8 For the first layer of insulation and in case of multi layer of insulation, mattresses with hexagonal wire netting will be facing on outer side. Insulation mattresses shall be held in place by fastening over with binding wire. Care should be taken to see that the flexible insulation mattresses are not unduly compressed. The ends of binding wire shall be lightly twisted together, bent over and pressed into the insulation. For mattresses, binding wire shall be used at intervals of 300mm. In the addition Aluminium bands shall also be provided at 300 mm intervals for diameters greater than 500mm. (Refer Drg No. PE-4-99-169-01.) 2.9 Where junctions between bodies of different diameters occur and difference in insulation thickness is specified, the greater thickness is to be continued for a length equal to one diameter of the smaller body and then smoothly tapered to the required smaller thickness over a length equal to two diameters of the small body.
2.10 The indicated thickness of insulation are minimum requirement which should be maintained. Any change in the thickness of the insulation should be done only after prior approval of the design engineer. 2.11 The day-to-day insulation work should be covered with suitable protective materials to prevent the rain water entry, if same is expected. 2.12 The insulation shall be cut to fit the piping O.D / equipment and shall be wrapped on the piping / equipments and held in position with proper support and wires. All the joints should be properly staggered and tightly butted and adjacent edges laced (Refer Drg No. PE-4-999/169/01) 2.13 The insulation of valves and flange joints shall be enclosed in a removable jacketing so that it may be removed without disturbing the concerned equipment or piping. The thickness of insulating shall be same as that of the pip line in which these valves and fittings are located. (Refer Drg No. PE-4-999-169-07.) 2.14 Steam / Air / Gas leakages in and around the pipes to be insulated with be attended before applying insulation. 2.15 In order to provide support to Aluminium cladding, support rings made out of 20 x 3 mm M.S. flats shall be fixed at equal intervals of approximately 850 mm spacing and at every circumferential joints. These rings shall be fixed with L
type lugs and shall be fabricated from 20 x 3 mm M.S flats. To reduce that conductivity through these lugs 20 mm x 3 mm size Ceramic mill board shall be used between rings and lugs (Refer Drg No. PE-4-999-169-04 and PE-4-999169-13). 2.16 Spacing between supporting rings for vertical piping shall be 3 mtrs. Support rings are to be provided only when the vertical height exceeds 3 mtrs. (Refer Drg No. PE-4-999-169-03-and PE-4-999-169-05). 2.17 For vertical pipes since support rings is provided ate every 3 mtrs interval, only two spacer rings shall be provided in between support rings. 2.18 Spacer rings shall be provided at both ends of elbows/bends, valves and flanges pipe having dia more than 89mm. 2.19 Wherever the end of hanger clamp assembly protrudes out of the insulation at the bottom suitable box structure are to be provided. Pipe hangers and supports should be covered in such a way that the moisture cannot penetrate into the insulation. 2.20 It is very important that sheet metal cladding should be done by a well experienced and competent fabricator. Person doing the job can alter the method of fixing of cladding sheet after consulting the concerned design engineer. 2.21 The longitudinal joint in the outer cladding sheet should always be at the lower half of the circumference for horizontal piping so that no rain water enters the insulation through the joints. (Refer Drg No. PE-4-999-169-01). 2.22 The joints of outer cladding should be staggered axially. 2.23 Inside surface of all Aluminium sheet will have two coats of Bituminous paint applied uniformly. 2.24 Aluminium sheets covering on outdoor horizontal pipes will be provided with 3 mm drain hole at the bottom center line at 6 mtr intervals. 2.25 The cladding sheet shall provides directly over the insulation/finishing cement (1F APPLICABLE). Suitable flashing and weather proofing shall be provided at all nozzles, manholes and other projections to prevent the entrance of water. 2.26 Loose wool can be taken from wool mattresses. Wherever gaps and voids have to be filled. 2.27 Sealing compound to be applied on Aluminum cladding sheet joints.
2.28 Support rings/spacer rings shall be provided if the insulation thickness > 40mm and pipe diameter > 89mm. 2.29 Equipments name plates shall not be insulated. 2.30 Clips made out of sheet be riveted inside the box for insulation of valves and flanges to hold the insulation in box. (Refer Drg No. PE-4-999-169-06). 2.31 The insulation local to the inspection points of the critical piping shall be removable. 3.00 For Thermal Insulation Material Specification related to the project refer Annexure 1. IMPORTANT POINTS TO BE TAKEN CARE DURING APPLICATION I) ii) iii) iv) v) vi) vii) viii) ix) Binding wires for all layers of insulation will be at distance of 300mm. In addition Aluminum bands/seals also to be provided at distance of 300 mm for sizes above 500mm. Aluminum bands/seals to be provided over aluminum sheets at distance of 500mm. Ceramic mill boards to be used between all L type lugs and the support rings. Inside surface of Aluminum sheets to have 2 coats of bituminous paint applied uniformly. Gaps to be properly filled with loose wool taken from mattresses. End of hanger clamp assembly protruding out of insulation at the bottom should be suitably boxed with Aluminum sheets. Valves to be insulated properly in box structure as given in enclosed drawings. Multilayer longitudinal and circumferential joints should be staggered.
ANNEXURE 1 1.0 1.1 Thermal insulating materials shall be per the details given below:Lightly Bonded Mineral (Rock) wool Mattresses of density 150 Kg / Cub. Mt with S.S. wire netting will be applied for the first layer of insulation where hot face temperature greater than 400 degree centigrade. For subsequent layers matters of density 150 Kg / Cub. Mtr with G.S. wire netting will be applied. Lightly Bonded Mineral (Rock) wool Mattresses of density 100 Kg/Cub. Mt with G.S. wire netting will be applied for all layers of insulation for host face temperature less than and equal to 400 degree centigrade. Binding and lacing wires: For insulation matters shall be of stainless steel for all insulation interface temperatures. Aluminum cladding sheet shall be provided over the Mattresses ad per details given below. 18 SWG (1.22 mm thk.) 20 SWG (0.91 mm thk.) 22 SEG (0.71 mm thk.) For pipes with dia over insulation above 450 MM. For pipes with dia over insulation above 150 MM and less than equal to 450MM. For pipes with dia over insulation less than equal to 150mm.
1.2
2.0 3.0
SECTION B

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NOTICE INVITING TENDER

at KAKATIYA THERMAL POWER PROJECT, CHELPUR VILLAGE, WARANGAL DISTRICT, AP

BHARAT HEAVY ELECTRICALS LIMITED

NOTICE INVITING TENDER

ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35 Date:

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Rev 01 1st Jun 2012

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Bharat Heavy Electricals Limited

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NOTICE INVITING TENDER (NIT)

Sub : NOTICE INVITING TENDER

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xii Latest updates

Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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S2-1, S2-2, S2-3, S2-4, S2-T2 S2

S3-1, S3-2, S3-3, S3-4, S3-T3 S3

S4-1, S4-2, S4-3, S4-4, S4-T4 S4

S5-1, S5-2, S5-3, S5-4, S5-T5 S5

SN-1, SN-2, --------SN-3, SN-4, SN-TN SN Sum () of columns (iii) to (ix) = ST

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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23.3 23.4 23.5

Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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PRE QUALIFYING CRITERIA

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Fill the details in Annexure-4 Fill the details in Annexure-4

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518

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Tender Specification BHEL PSSR SCT 1518