4. Vendor to quote '+' / '-' / Zero % on the Schedule of rates (A) mentioned in the following table.
5. Only single % is to be quoted for the complete set of Items/Services and not Item/Service wise.
Specifying more than single percentage (%) or quoting specific unit rates / Lumpsum rates
will make your offer rejected.
6. Prefix the % with, '+' for rates above the scheduled rate, '-' for rates below the scheduled rate.
Put Zero % if the scheduled rate itself are being offered.
7. The % is to be put in the space provided below the following table, both in figures and in words.
Please quote for the following items/service, as per the terms and conditions mentioned below and in
attachments :
DETAILS OF ITEMS / SERVICES
Deliver To : Maintenance-On Site, - . India.
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
1 1.000 Blinding &
Deblinding
of equip
Inch - Dia 99.00 Inch - Dia
2 2.000 Manway
opening and
head up of
Each 571.00 Each
3 3.000 Safety valve
dropping,
transpo
Each 864.00 Each
4 4.000 Safety valve
dropping &
instal
Each 571.00 Each
5 5.000 Drum manway Each 864.00 Each
Cont on next page . . 12000438 - HD - 46002
Page 2 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
opening &
headup
6 6.000 Removal &
re-fixing of
drum in
Lump Sum 2,928.00 Lump Sum
7 7.000 Economiser
tubes
cleaning
Lump Sum 2,495.00 Lump Sum
8 8.000 Drum & drum
internals
cleaning
Lump Sum 2,495.00 Lump Sum
9 9.000 Tubes
cleaning
Lump Sum 3,989.00 Lump Sum
10 10.000 Flue gas
path
cleaning
Lump Sum 3,989.00 Lump Sum
11 11.000 Cleaning of
burner, oil
gun et
Lump Sum 1,376.00 Lump Sum
12 12.000 CO inlet /
outlet ducts
inspec
Lump Sum 884.00 Lump Sum
13 13.000 Hydrotesting
of Boiler
Lump Sum 5,856.00 Lump Sum
Cont on next page . . 12000438 - HD - 46002
Page 3 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
14 14.000 Additional
hydrotest
Lump Sum 4,402.00 Lump Sum
15 15.000 Start up
coverage
Lump Sum 3,282.00 Lump Sum
16 16.000 Annual
Inspection
of Boilers
Lump Sum 157,214.00 Lump Sum
17 17.000 General
maintenance
of steam g
Lump Sum 57,973.00 Lump Sum
18 18.000 Repeat shell
test & tube
test
Lump Sum 22,206.00 Lump Sum
19 19.000 Repeat shell
test & tube
test
Lump Sum 11,005.00 Lump Sum
20 20.000 Retubing of
exchanger
tube (wi
Tube 246.00 Tube
21 21.000 Reaming of
exchanger
tube
Tube 77.00 Tube
22 22.000 Biennial / Lump Sum 137,562.00 Lump Sum
Cont on next page . . 12000438 - HD - 46002
Page 4 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
Annua IBR
Inspectio
23 23.000 Boiler tube
replacement
Tube 3,440.00 Tube
24 24.000 Sectional
replacement
of boile
Inch - Dia 1,454.00 Inch - Dia
25 25.000 Window patch
of tubes
Running
Feet
2,083.00 Running
Feet
26 26.000 Re-rolling
of Boiler
tubes
Joints 304.00 Joints
27 27.000 Seal welding
of boiler
tubes
Joints 433.00 Joints
28 28.000 Plug welding
of Boiler
tubes
Joints 433.00 Joints
29 29.000 Additional
hydrotest of
econom
Each 2,338.00 Each
30 30.000 Hydrotesting
of piping
Inch Meter 4.00 Inch Meter
Cont on next page . . 12000438 - HD - 46002
Page 5 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
31 31.000 Gauge glass
overhauling
Each 864.00 Each
32 32.000 Threaded
fittings
replacement
Inch - Dia 39.00 Inch - Dia
33 33.000 Gland
packing
replacement
Inch - Dia 22.00 Inch - Dia
34 34.000 Valve free
up / repair
Inch - Dia 39.00 Inch - Dia
35 35.000 Valve
replacement
Inch - Dia 158.00 Inch - Dia
36 36.000 Supply &
operation of
air comp
Hour 652.00 Hour
37 37.000 Supply &
operation of
diesel w
Hour 205.00 Hour
38 38.000 Scaffolding
of 3m x 3m x
3m bl
Each 609.00 Each
39 39.000 Grit
blasting
Square
Meters
766.00 Square
Meters
Cont on next page . . 12000438 - HD - 46002
Page 6 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
40 40.000 Copper slag
blasting
Square
Meters
334.00 Square
Meters
41 41.000 Solution
annealing of
anchors
Batch 14,727.00 Batch
42 42.000 Repairs to
economiser
tubes -
Inch - Dia 1,730.00 Inch - Dia
43 43.000 Repairs to
economiser
tubes -
Inch - Dia 571.00 Inch - Dia
44 44.000 Butt welding
-IBR X-ray
qualit
Inch - Dia 685.00 Inch - Dia
45 45.000 Butt welding
- IBR X-ray
quali
Inch - Dia 571.00 Inch - Dia
46 46.000 Butt welding
- X-ray
quality
Inch - Dia 434.00 Inch - Dia
47 47.000 Butt welding
- Non-X-ray
quali
Inch - Dia 315.00 Inch - Dia
48 48.000 Fillet Inch - Dia 448.00 Inch - Dia
Cont on next page . . 12000438 - HD - 46002
Page 7 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
welding -
IBR
quality(R
49 49.000 Fillet
welding -
IBR quality
Inch - Dia 374.00 Inch - Dia
50 50.000 Fillet
welding -
Non- IBR
qual
Inch - Dia 296.00 Inch - Dia
51 51.000 RF pad
replacement
jobs
Inch - Dia 689.00 Inch - Dia
52 52.000 Replacement
of Corrosion
pads
Inch - Dia 226.00 Inch - Dia
53 53.000 Replacement
of SS
anchors
Each 99.00 Each
54 54.000 Replacement
of CS
anchors
Each 55.00 Each
55 55.000 Replacement
of
insulation
Each 16.00 Each
Cont on next page . . 12000438 - HD - 46002
Page 8 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
Anch
56 56.000 Replacement
of hexmesh
(where
Square
Meters
8,800.00 Square
Meters
57 57.000 Replacement
of Hex Mesh
(where
Square
Meters
13,200.00 Square
Meters
58 58.000 Fin welding
between
adjacent
Meters 1,395.00 Meters
59 59.000 Fin welding
between
adjacent t
Meters 786.00 Meters
60 60.000 CS Overlay
Patch 6 to
12mm thk
Square
Feet
983.00 Square
Feet
61 61.000 CS Inlay
Patch 6 to
12mm thk f
Square
Feet
1,573.00 Square
Feet
62 62.000 SS Overlay
patch 6 to
12mm thk
Square
Feet
1,945.00 Square
Feet
63 63.000 SS Inlay
patch 6 to
Square
Feet
4,874.00 Square
Feet
Cont on next page . . 12000438 - HD - 46002
Page 9 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
12mm thk f
64 64.000 Weld repair
to old joint
Running
Feet
108.00 Running
Feet
65 65.000 Repairs to
drum cracks
- Depth
Inches 1,355.00 Inches
66 66.000 Repairs to
drum cracks
- Depth
Inches 2,653.00 Inches
67 67.000 Repairs to
drum cracks
- Depth
Inches 4,914.00 Inches
68 68.000 Weld build
up of 5 mm
Thk (fin
Square
Inches
99.00 Square
Inches
69 69.000 Structural
replacements
(Mater
Metric Ton 18,102.00 Metric Ton
70 70.000 WFMPT Inch - Dia 101.00 Inch - Dia
71 71.000 DP test Inch - Dia 73.00 Inch - Dia
72 72.000 Supply of CS
Welder
Shift 602.00 Shift
Cont on next page . . 12000438 - HD - 46002
Page 10 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
73 73.000 Supply of
gascutter or
grinder
Shift 463.00 Shift
74 74.000 Supply of
fabricator
or fitter
Shift 463.00 Shift
75 75.000 Supply of
rigger
Shift 392.00 Shift
76 76.000 Supply of
Mason
Shift 543.00 Shift
77 77.000 Supply of
Carpentor
Shift 543.00 Shift
78 78.000 Supply of
Gunman
Shift 1,111.00 Shift
79 79.000 Supply of
Nozzleman
Shift 1,111.00 Shift
80 80.000 Supply of
Helper
Shift 327.00 Shift
81 81.000 Mobilization
&
Demobilizati
on
Lump Sum 225,996.00 Lump Sum
Cont on next page . . 12000438 - HD - 46002
Page 11 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
82 82.000 Mobilization
&
Demobilizati
on
Lump Sum 45,199.00 Lump Sum
83 83.000 Chipping &
Removal of
Refracto
Square
Meters
689.00 Square
Meters
84 84.000 Refractory
Casting upto
3"
Square
Meters
3,930.00 Square
Meters
85 85.000 Chipping &
Removal of
Abrasion
Square
Meters
1,867.00 Square
Meters
86 86.000 Application
of abrasion
resist
Square
Meters
2,751.00 Square
Meters
87 87.000 Gunniting of
Refractory
upto 3
Square
Meters
3,243.00 Square
Meters
88 88.000 Painting -
Piping &
Pipe Fitti
Square
Meters
689.00 Square
Meters
89 89.000 Air cleaning
of FD fan
suction
Lump Sum 786.00 Lump Sum
Cont on next page . . 12000438 - HD - 46002
Page 12 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
90 90.000 Shifting of
tube bundle
of ste
Each 4,736.00 Each
91 91.000 Stress
Relieving
upto 1.5"
dia
Inch - Dia 590.00 Inch - Dia
92 92.000 Stress
Relieving
above 1.5"
an
Inch - Dia 504.00 Inch - Dia
93 93.000 Stress
Relieving
for all
sizes
Inch - Dia 335.00 Inch - Dia
94 94.000 Radiography
upto 1.5"
dia. (ap
Inch - Dia 718.00 Inch - Dia
95 95.000 Radiography
- above 1.5"
dia.
Inch - Dia 479.00 Inch - Dia
96 96.000 Radiography
- above 3"
dia. an
Inch - Dia 318.00 Inch - Dia
Cont on next page . . 12000438 - HD - 46002
Page 13 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
97 97.000 Radiography
for all
sizes (whe
Inch - Dia 214.00 Inch - Dia
98 98.000 Re-tubing of
Exchangers/S
ulphu
Tube 1,350.00 Tube
99 99.000 Hydrogen
Diffusion of
Exchange
Square
Feet
6,873.00 Square
Feet
100 100.000 Butt joint
AS/SS -
X-ray quali
Inch - Dia 1,116.00 Inch - Dia
101 101.000 Butt joint
AS/SS -
X-ray quali
Inch - Dia 973.00 Inch - Dia
102 102.000 Fillet joint
AS/SS with
TIG ro
Inch - Dia 429.00 Inch - Dia
103 103.000 Fillet joint
AS/SS with
TIG ro
Inch - Dia 372.00 Inch - Dia
104 104.000 SS/AS Weld
run jobs-
weld run
Running
Feet
743.00 Running
Feet
Cont on next page . . 12000438 - HD - 46002
Page 14 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
105 105.000 SS weld
build up
with
electric
Square
Inches
172.00 Square
Inches
106 106.000 SS weld
build up
with diesel
m
Square
Inches
200.00 Square
Inches
107 107.000 Supply of SS
/ AS / TIG
welder
Shift 1,073.00 Shift
108 108.000 Annual
Inspection
of WHB / Sul
Lump Sum 68,781.00 Lump Sum
109 109.000 Supply of
Hydra (10 T
capacity
Hour 893.00 Hour
110 110.000 Material
Handling
Trip 884.00 Trip
111 111.000 Replacement
of Casing
Plates o
Running
Feet
197.00 Running
Feet
Quoted % applicable to the schedule of rates specified in table above for all the Items/Services
Cont on next page . . 12000438 - HD - 46002
Page 15 ofSign and Seal of the Tenderer 99
XXXXXXXXXXXXX % (in figures) XXXXXXXXXXXXXXXXXXXXXXXX Percent (in words).
QUOTED DELIVERY PERIOD :
EXTRAS (TAXES,DUTIES & OTHERS) :
Details of taxes, duties, levies, etc., if to be paid extra to be filled in the space given below. The values specifically
mentioned below will only be considered for extra payments. The values to be filled below can be in percentage (%)
of unit rate or an add - on amount per unit rate. Vendor to specifically mention % or currency, after the value
(e.g. X% or X Rs/-), else the value having least impact to HPCL on the unit rate will only be considered.
DGS&D Rate Contract ( Y/N ) : __________
NSIC Unit ( Y/N ) : __________
PSE Unit ( Y/N ) : __________
SSI Unit ( Y/N ) : __________
Delivery Terms - Free to Destination location unless specified otherwise ____________________________________
Validity of offer - 120 days from the initial or extended Due Date for submission of Tender whichever is later unless: __________specified otherwise
Liquidated Damages accepted ( Y/N ) : __________
Payment Term ( 30 Days ), unless specified otherwise
NOTES / TERMS / CONDITIONS :
Please refer attached Tender Document.
Cont on next page . . 12000438 - HD - 46002
Page 16 ofSign and Seal of the Tenderer 99
DETAILED ITEM DESCRIPTION / SPECIFICATIONS :
Tendor Ref Tender Line
Number QuantityItem Description Line No Qty UOM
1.000 Blinding & Deblinding of
equip
Inch -
Dia
Blinding & Deblinding of equipments
The scope of job is as follows :
1. Fabricate and install necessary blinds in position as per operations requirement.
2. Initially blinds are to be installed in spread condition and after the line contents are
emptied, they are to be made up.
3. Remove the blinds after job completion and make up the flanges with new gaskets.
Rate: The rate payable is for Inch dia of blinding and deblinding done (put together), which
includes fabrication of blinds also.
2.000 Manway opening and head
up of
Each
Manway opening and head up of equipments
The scope of job is as follows :
1. Open all manways including wind box, fire box, super heater, economiser, stack, air inlet duct
and explosion door.
2. Break the refractory wall as per the advise of HPCL.
3. Make up the refractory wall and head up the manways opened after completion of the job.
Rate: The rate payable is lumpsum rate for each manway for the job scope as mentioned above.
3.000 Safety valve dropping,
transpo
Each
Safety valve dropping, transportation & installation
Cont on next page . . 12000438 - HD - 46002
Page 17 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. Drop all safety valves and install blind flanges in position, from where the safety valves
have been removed.
2. Transport these valves to HPCL valve section for servicing and take them back to the unit
after servicing. Servicing of the valves is excluded from this scope.
3. Remove the blind flanges and reinstall the valves. Make up the flanges with new gaskets and
obtain inspection clearance.
Rate: The rate payable is lumpsum for the entire job scope mentioned above for each safety
valve.
4.000 Safety valve dropping &
instal
Each
Safety valve dropping & installation
The scope of job is as follows :
1. Drop all safety valves and install blind flanges in position, from where the safety valves
have been removed.
2. Remove the blind flanges and reinstall the valves after job completion.
3. Transportation of the valve to HPCL workshop and back is excluded from this scope.
Rate:The rate payable is lumpsum for the entire job scope mentioned above for each safety valve.
5.000 Drum manway opening &
headup
Each
The scope of job is as follows :
1. Open all drum manways and head up after inspection clearance.
Rate: The rate payable is lumpsum for the entire job scope mentioned above for each manway.
Cont on next page . . 12000438 - HD - 46002
Page 18 ofSign and Seal of the Tenderer 99
6.000 Removal & re-fixing of
drum in
Lump Sum
Removal & re-fixing of drum internals
The scope of job is as follows :
1. Install air eductors as required for better air circulation.
2. Remove all internals and moisture separators.
3. Provide necessary assistance for carrying out vacuum testing.
Note : Towards this, supply and operation of air compressor, shall be paid separately.
4. Refix all internals in position and obtain HPCL clearance.
Rate: The rate payable is lumpsum for the entire job scope mentioned above for each drum.
7.000 Economiser tubes cleaning Lump Sum
The scope of job is as follows :
1. Clean the economiser tubes thoroughly as per Inspection.
2. Cleaning should done without using water unless it is permitted by HPCL.
Rate: The rate payable is lumpsum for the entire job scope mentioned above, for each economiser.
8.000 Drum & drum internals
cleaning
Lump Sum
The scope of job is as follows :
1. Clean the internals, moisture separators, steam drum and mud drums thoroughly and offer for
inspection.
Rate: The rate payable is lumpsum for the entire job scope mentioned above for each drum along
with its internals.
9.000 Tubes cleaning Lump Sum
The scope of job is as follows :
Cont on next page . . 12000438 - HD - 46002
Page 19 ofSign and Seal of the Tenderer 99
1. Clean all the tubes in fire box manually by wire brushing as per HPCL Inspection.
2. Carry out staging inside the firebox, if required, as per HPCL advise.
Rate:
1. The rate payable is lumpsum for the entire job scope as mentioned above.
2. If cleaning is advised to be carried out by hydrojetting, the same shall be paid, extra,
separately.
10.000 Flue gas path cleaning Lump Sum
The scope of job is as follows :
1. Clean the flue gas path thoroughly free from soot, from the fire box side as well as from the
transit box/superheater side.
2. Clean the connected ducts free of debris and free up all the dampers.
3. All the soot deposited in fire box, flue gas path and all corners of the boiler shall be
cleaned thoroughly.
4. Use Industrial vaccum cleaner for better cleaning and agency to mobilise the same.
Rate: The rate payable is lumpsum for the entire job scope as mentioned above.
11.000 Cleaning of burner, oil
gun et
Lump Sum
Cleaning of burner, oil gun etc
The scope of job is as follows :
1. Clean the burner throats, oil guns guides, wind box floor diffuser, peep holes glasses etc.
and offer for inspection.
Rate: The rate payable is lumpsum for the entire job scope as mentioned above.
12.000 CO inlet / outlet ducts
inspec
Lump Sum
Cont on next page . . 12000438 - HD - 46002
Page 20 ofSign and Seal of the Tenderer 99
CO inlet / outlet ducts inspection
The scope of job is as follows :
1. Provide approach facility for Inspection of CO inlet and outlet ducts and offer for
inspection.
Rate: The rate payable is lumpsum for the entire job scope as mentioned above.
13.000 Hydrotesting of Boiler Lump Sum
The scope of job is as follows :
1. Carry out hydrotest of boiler as per the advise of HPCL.
2. For this, clean the manways and box them up and connect the test pumps for pressurising.
3. Fill water in drums and economiser as per the advise of HPCL and pressurise to the designated
pressure and offer for inspection.
4. Provide standby manpower untill the hydrotest is completed and obtain inspection clearance.
Rate: The rate payable is lumpsum for the entire job scope as mentioned above for each hydrotest.
14.000 Additional hydrotest Lump Sum
The scope of job is as follows :
1. Carry out additional hydrotest, which excludes closing and opening of drum manways.
2. All other actvities required for hydrotest are to be carried out as per the previous item.
Rate: The rate payable is lumpsum for the entire job scope as mentioned above, for each
additional hydrotest.
15.000 Start up coverage Lump Sum
The scope of job is as follows :
1. Provide start up coverage to attend miscellaneous jobs like removing and refixing of ignitor,
to pull leaks if any, unplugging of lines etc. during start up of the unit.
2. Agency to provide necessary manpower as per the directions of the job engineer upto the
Cont on next page . . 12000438 - HD - 46002
Page 21 ofSign and Seal of the Tenderer 99
completion of start up.
Rate: The rate payable is lumpsum for the entire job scope as mentioned above.
16.000 Annual Inspection of
Boilers
Lump Sum
The scope of job is as follows :
1. Carry out necessary blinding as per Operations requirement for obtaining entry permit and for
carrying out hydrotesting.
2. On completion of the job carry out deblinding of the same.
3. Open all manways including wind box, fire box, super heater, economiser, stack, air inlet duct
and explosion door. Break the refractroy wall, if required.
4. Make up the refractory wall and head up the manways opened after completion of the job.
5. Drop all safety valves and install blind flanges at the removed locations.
6. Transport the valves to HPCL valve section for servicing.
7. Transport the valves back and reinstall the same in position, after removing the blind
flanges.
8. Open all drum manways and head up after completion of the job.
9. Install air eductors as required, to maintain fresh air circulation inside the equipment.
10. Remove and refix all the internals and moisture separators.
11. Provide necessary assistance to HPCL inspection for carrying out vacuum testing.
12. Clean the economiser tubes thoroughly as per Inspection. Cleaning shall be done without using
water, unless permitted by HPCL.
13. Clean all internals, moisture separators, steam drum, mud drum etc. thoroughly by wire brush
and buffing.
14. Clean all tubes in fire box manually by wire brushing as per Inspection. If required, carry
out staging inside fire box to facilitate inspection.
15. Clean the flue gas path thoroughly free from soot, from the fire box side as well as from the
transit box/superheater side.
16. Clean the connected duct, transit box, super heater free of debris and free up all dampers.
17. Clean burner throats, oil guns guides, wind box floor diffuser, peep hole glasses etc. and
offer for inspection.
18. Provide approach facility for Inspection of CO inlet and outlet duct.
19. Air clean FD Fan suction silencers after opening manways.
Cont on next page . . 12000438 - HD - 46002
Page 22 ofSign and Seal of the Tenderer 99
20. Hydrotest the boiler for annual inspection as per Inspection requirement (one preliminary
test for leaks identification, One test for HPCL Inspection (before IBR Inspection) and final
test in presence of IBR Inspector). All these three hydrotests are part of lumpsum scope.
21. Coordinate with Dy.Chief Inspector of Boilers for Inpection and certification.
22. Hydrotesting includes closing of drum manways, water filling in the equipment and economiser,
providing standby manpower and pressurising of boiler to the required pressure, providing
necessary connections for hydrotest pump etc.
23. Provide start up coverage to attend miscellaneous jobs like removing and refixing of ignitor,
to pull leaks if any, unplug lines etc. for a period of 24 hours. Agency to take the signature /
acknowledgement of the job engineer for the above coverage.
24. For any additional manpower supplied beyond the 24 hour period for start up coverage,
additional payment shall be made on manpower rates basis.
Rate:
1. The rate payable is lumpsum for the entire job scope as mentioned above per boiler.
2. In case cleaning is to be done by hydrojetting, as per the advise of HPCL, the same shall be
paid, extra, separately.
Note:
Incase of Heat Recovery Boilers (like HRSGs, DHDS Reformer circut, NHT-CCR circuit, D-SRU
Incinerator Circuit, etc), agency shall carry out necessary jobs as per site condition. (like
cpening of cover plates of coils, casing plate cuttings, staging for access to work, furnace
cleaning, etc).
This item is applicable for following Boilers / Heat Recovery Steam Generators of Refinery.
1. WIL-8 Boiler
2. BHPV Boiler
3. IBH-9 Boiler
4. IBH-10 Boiler
5. HRSG-I / II / III / IV / V / VI
6. D-SRU Tr-I/II Incinerator Steam Generation Circuit (65E002, 65E001 & 65V006 together)
7. D-SRU Tr-IIII Incinerator Steam Generation Circuit (79E002, 79E001 & 79V006 together)
8. New CO Boiler
9. Old CO Boiler
10. DHDS Reformer Steam Generation Cicuit (61D15, 61E12, 61CE11,13, 14 & 17 together)
Cont on next page . . 12000438 - HD - 46002
Page 23 ofSign and Seal of the Tenderer 99
11. NHT-CCR Steam Generation Cicuit (74F01, 02, 03 & 04 and 74V09 together)
12. 4V63 when taken with Heater (4F01) shutdown and Steam Coils Testing.
(Incase only drum (4V63 tested & inspection due to Heater outage problem, rate will be paid as
per item no.108).
17.000 General maintenance of
steam g
Lump Sum
General maintenance of steam generators
The scope of job is as follows :
1. Provide necessary flushing, steam connections etc. and install necessary blinds before opening
the equipment, as per Operations requirement.
2. Remove insulation over the flanges, to facilitate removal of bolts.
3. Drop all components viz., channel cover, shell cover, channel section and floating head cover
and erect staging as required, as per the directions of HPCL.
4. Drop all safety valves, and install blind flanges in position and transport these valves to
HPCL valve section.
5. Transport the valves from HPCL valve section and refix them in position after removal of
blind flanges.
6. Make proper arrangements for pulling the bundle out and pull out the bundle.
7. Clean the bundle externally by scraping, wire brushing, water washing etc.
8. Clean the tubes internally by rodding,water washing and air blowing.
9. Offer the equipment for inspection and obtain clearance.
10.Clean the shell and all other components thoroughly by wire brushing / buffing , water washing
and scraping.
11.Offer the shell and components for Inspection and obtain clearance.
12.Prove clear all shell nozzles.
13.Reinstall bundle in the dummy shell, shift & install the test jig in position and carry out
testing. Identify the leaky tubes by way of shell testing, carry out plugging or re-rolling of
tubes as instructed, re-do shell test followed by tube test.
14. Remove the bundle from dummy shell, re-install the same in the steam generator shell and
carryout shell test and obtain inspection clearance.
15. Remove the blinds and make up the flanges.
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Page 24 ofSign and Seal of the Tenderer 99
16. Maintain stand-by crew for hot bolting, pulling leaks etc. for a period of 24 hours (one
fitter + one helper).
17. For any additional manpower supplied beyond the 24 hour period, additional payment shall be
made on manpower rates basis.
Rate:
1. The rate payable is lumpsum for the entire job scope as mentioned above per Steam generator.
2. For any cleaning done by hydrojetting, as per the advise of HPCL, the same shall be paid,
extra, separately.
3. For any retubing or tube rolling done as per the advise of HPCL, the same shall be paid
extra, separately.
4. For any weld repairs to the shell and components, the same shall be paid extra, separately.
18.000 Repeat shell test & tube
test
Lump Sum
Repeat shell test & tube test with bundle pull out
The scope of job is as follows :
1. If any tube leaks are found while doing shell test inside steam generator shell, agency shall
pull the bundle out again to do the shell test and tube test in dummy shell for plugging or
re-rolling of the leaking tube / tubes.
Rate :
1. The rate payable is lumpsum for the entire job scope as mentioned above per Shell test and
tube test put together.
2. These charges are payable, only if the tube leak is at a new location. In case of leak is
arising from a tube location, which had been plugged by the same ageny previously, agency to
carry out the same at no extra cost.
19.000 Repeat shell test & tube
test
Lump Sum
Repeat shell test & tube test without bundle pull out
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Page 25 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. Incase of tube test failure in the dummy shell, shell test and tube test shall be repeated for
plugging or re-rolling of the leaking tubes.
Rate :
1. The rate payable is lumpsum for the entire job scope as mentioned above per shell test and
tube test put together.
2. These charges are payable, only if the tube leak is at a new location. In case of leak is
arising from a tube location, which had been plugged by the same agency, agency to carry out
repairs to the same at no extra cost.
20.000 Retubing of exchanger
tube (wi
Tube
Retubing of exchanger tube (without Seal Welding)
The scope of job is as follows :
1. Carry out re-tubing, as per the advsie of HPCL, by mobilisng the required resources including
equipment, tools and tackles and skilled manpower.
2. Obtain HPCL clearance for the job carried out.
Rate :
1. The rate payable is for PER TUBE BASIS for the job scope as mentioned above.
21.000 Reaming of exchanger tube Tube
The scope of job is as follows :
1. Clean tubes internally by reaming and offer for Inspection and obtain clearance.
Rate :
1. The rate payable is for PER TUBE BASIS for the job scope as mentioned above.
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22.000 Biennial / Annua IBR
Inspectio
Lump Sum
Biennial / Annua IBR Inspection of steam generators
The scope of job is as follows :
1. Provide necessary flushing, steam connections etc. and install necessary blinds before opening
the equipment, as per Operations requirement.
2. Remove insulation over the flanges, to facilitate removal of bolts.
3. Drop all components such as channel cover, shell cover, channel section and floating head
cover.
4. Erect staging as required, as per the directions of HPCL.
5. Drop all safety valves and install blind flanges in position and transport these valves to
HPCL valve section.
6. Transport the valves from HPCL valve section and refix them in position after removal of
blind flanges.
7. Make proper arrangements for pulling the bundle out and pull out the bundle.
8. Clean the bundle externally by scraping, wire brushing, water washing etc.
9. Clean the tubes internally by rodding,water washing and air blowing.
10. Offer the equipment for inspection and obtain clearance.
11. Clean the shell and all other components thoroughly by wire brushing / buffing , water
washing and scraping.
12. Offer the shell and components for Inspection and obtain clearance.
13. Prove clear all shell nozzles.
14. Reinstall bundle in the dummy shell, shift & install the test jig in position and carry out
testing. Identify the leaky tubes by way of shell testing, carry out plugging or re-rolling of
tubes as instructed, re-do shell test followed by tube test.
15. Remove the bundle from dummy shell, re-install the same in the steam generator shell and
carryout shell test and obtain incpection clearance.
16. Remove the blinds and make up the flanges
17. Maintain stand-by crew for hot bolting, pulling leaks, etc, for a period of 24 hours (one
fitter + one helper).
18. For any additional manpower supplied beyond the 24 hour period, additional payment shall be
made on manpower rates basis.
19. Coordinate with Dy.Chief Inspector of Boilers for inspection and certification and related
Cont on next page . . 12000438 - HD - 46002
Page 27 ofSign and Seal of the Tenderer 99
jobs and obtain clearance from DCIB.
Rate:
1. The rate payable is lumpsum for the entire job scope as mentioned above per Steam generator.
2. For any cleaning done by hydrojetting,or reaming as per the advise of HPCL, the same shall be
paid, extra, separately.
3. For any retubing or tube rolling done as per the advise of HPCL, the same shall be paid
extra, separately.
4. For any weld repairs to the shell and components, the same shall be paid extra, separately.
Note:
This item is applicable for following Steam Generators (Heat Exchangers)
1. CDU-I: 2-E-31
2. CDU-2: 12E10, 12E10A, 13E01A, 13E01B, 13E03A & 13E03
3. CDU-3/VBU: 42WHB-01 Circuit, 46E09A, 46E09B, 46E08
4. FCCU-I: 4E55A, 4E55B, 4E57 & 4E56
5. FCCU-2: 14E04B, 14E04C, 14E56, 14E07 & 14E04A
6. DHDS: 61E13A & 61E13B
23.000 Boiler tube replacement Tube
The scope of job for Boiler tube replacement is as follows :
1. Chip out refractory at the ends to facilitate removal of tube.
2. Cut and remove marked tubes.
3. Remove tube stubs from upper and lower drum holes.
4. Clean tube hole, remove burrs and weld build up in any pits that are found, as per Inspection.
5. Clean new tube internally and externally.
6. Install new tube in position and carry out field modification, if required for facilitating
replacement.
7. Roll the tube ends in the drums, offer for inspection and obtain clearance.
Rate :
1. The rate payable shall be for PER TUBE replacement as per the scope mentioned above.
2. Hydrotest if required as per HPCL will be paid extra, separately.
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24.000 Sectional replacement of
boile
Inch -
Dia
Sectional replacement of boiler tube
The scope of job for sectional Boiler tube replacement is as follows :
1. Chip out refractory at the ends to facilitate removal of tube.
2. Cut and remove marked section of the tube.
3. Fabricate a new section, carry out fit up and offer for inspection.
4. Weld the tube and obtain inspection clearance.
5. Stage wise DP test is included in the agency's scope.
Rate :
1. The rate payable shall be for PER INCH dia of sectional tube replacement, as per the scope
mentioned above.
2. Hydrotest if required as per HPCL, will be paid extra, separately.
25.000 Window patch of tubes Running
Feet
The scope of job for Window patch of tubes is as follows :
1. Clean tubes by buffing for inspection and marking of the patch area.
2. Cut window as marked, fabricate a new patch, fit up, weld in position, offer for inspection
and obtain clearance.
3.Stagewise DP test is in agency's scope.
Rate :
1. The rate payable shall be for Running foot of welding done for the tube, as per the scope
mentioned above.
2. Hydrotest if required as per HPCL will be paid extra. However, any leak arising out from the
repaired / replaced location, where the same agency worked earlier, shall be rectified with
repeat hydrotest without any extra cost.
3. Obtain inspection clearance.
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26.000 Re-rolling of Boiler
tubes
Joints
The scope of job is as follows :
1.Re-roll the leaking tubes as marked by inspection and obtain inspection clearance.
Rate :
1. The rate payable shall be for PER JOINT of tube rerolling as per the scope mentioned above.
27.000 Seal welding of boiler
tubes
Joints
The scope of job is as follows :
1. Seal weld the leaking marked roll joints in drums using E-7018 Electrodes or equivalent TIG
wire as advised by Inspection.
2. After welding, roll all the tubes around the seal welded tube and obtain inspection clearance.
3. DP test is inculded in the scope.
Rate :
1. The rate payable shall be for PER JOINT basis for the job scope as mentioned above.
2. No seperate payment shall be made for DP test of the weld joints.
28.000 Plug welding of Boiler
tubes
Joints
The scope of job is as follows :
1. Plug the leaking marked tubes and seal weld using E-7018 electrodes or equivalent TIG wire as
advised by Inspection.
2. After welding, roll all the tubes around the plugged tube.
3. DP test is included in the job scope.
Rate :
The rate payable shall be per JOINT for the job scope as mentioned above.
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29.000 Additional hydrotest of
econom
Each
Additional hydrotest of economiser/ GRE/CPH
The scope of job is as follows :
1. Carry out hydrotest of economiser as per the advise of HPCL and obtain inspection clearance.
Rate :
The rate payable shall be per hydrotest for each economiser/ GRE of boiler or CPH of HRSGs.
No seperate payment for blinding and deblinsing shall be made.
30.000 Hydrotesting of piping Inch
Meter
The scope of job is as follows :
1. Carry out hydrotesting of pipelines by filling water and pressurising to the specified test
pressure.
2. Clean the weld joints and offer for Inspection.
3. On clearance, depressurise, drain water and clean the area.
Rate :
1. The rate payable shall be per Inch meter of hydrotest done as per the scope mentioned above.
2. Separate rate shall be paid for blinding and deblinding jobs.
31.000 Gauge glass overhauling Each
The scope of job is as follows:
1. Overhaul the gauge glass including removal of guage glass assembly, installing blinds/ blind
flanges and dismantling of the gauge glass assembly, cleaning and assembly with necessary
replacements.
2. Fix back the assembly in position after removal of blind flanges.
Rate :
Cont on next page . . 12000438 - HD - 46002
Page 31 ofSign and Seal of the Tenderer 99
1. The rate payable shall be per EACH gauge glass assembly overhauled as per the scope mentioned
above.
32.000 Threaded fittings
replacement
Inch -
Dia
The scope of job is as follows :
1. Replace the Threaded fittings as per the advise of HPCL, offer for inspection and obtain
clearance.
Rate :
1. The rate payable shall be per Inch dia of threaded fittings replaced as per the scope
mentioned above.
33.000 Gland packing replacement Inch -
Dia
The scope of job is as follows :
1. Arrest valve gland leaks by add packing/repacking as per Inspection and obtain clearance.
Rate :
1. The rate payable shall be per Inch dia of gland packing replaced/ add packed, as per the
scope mentioned above.
34.000 Valve free up / repair Inch -
Dia
The scope of job is as follows :
1. Free up the valves by cleaning, servicing the valve components including opening and closing
of bonnet, greasing, etc and ensure trouble free operation.
Rate :
1. The rate payable shall be per Inch dia of valve free up done, as per the scope mentioned
above.
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Page 32 ofSign and Seal of the Tenderer 99
35.000 Valve replacement Inch -
Dia
The scope of job is as follows :
1. Replace the flanged valves which includes opening flanges, dropping old valves and installing
new valve by collecting them from warehouse or valve section, along with new gasket.
2. Shifting / transportation of valves from any location within the Refinery and returning the
old valves is included in the job scope.
Rate :
1. The rate payable shall be per Inch dia of valve replacement done, as per the scope mentioned
above.
36.000 Supply & operation of air
comp
Hour
Supply & operation of air compressor
The scope of job is as follows :
1. Supply and operate air compressor along with fuel and operator, for carrying out vacuum test
and other jobs related to boiler, as per the directions of HPCL.
2. Agency shall mobilise the compressor within 24 hrs from the time of notice given to them.
Rate :
1. The rate payable shall be per Hour of operation of air compressor, as per the scope
mentioned above.
2. No idle charges shall be paid.
37.000 Supply & operation of
diesel w
Hour
Supply & operation of diesel welding generators
Cont on next page . . 12000438 - HD - 46002
Page 33 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. Supply and operate diesel welding generator along with fuel and operator as and when advised
by HPCL.
2. Agency shall mobilise the equipment within 24 hrs from the time of notice given to them.
Rate :
1. The rate payable shall be per Hour of operation of the diesel generator, as per the scope
mentioned above.
2. No idle charges shall be paid.
38.000 Scaffolding of 3m x 3m x
3m bl
Each
Scaffolding of 3m x 3m x 3m block
The scope of job is as follows :
1. Provide scaffolding as directed by Job engineer at the designated locations.
2. Scaffolding shall be erected with 1-1/2" steel tubular pipe with suitable and safe clamping
arrangement.
3. Proper MS gratings to be laid on horizontal pipes and suitably tied by GI wire of minimum 10
gauge to ensure firm fastening.
4. Supply of all material including scaffolding pipes in standard sizes, clamps, gratings and
other resources is included in the agency's scope.
5. Remove the scaffolding after job completion, after getting clearance from HPCL.
6. Agency shall follow the existing standards followed in the refinery, for scaffolding jobs.
Rate :
1. The rate payable shall be per block of 3 metre x 3 metre x 3 metre of scaffolding done and
removed put together.
39.000 Grit blasting Square
Meters
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Page 34 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. The scope includes supply and mobilisation of all resources required like metallic grit, air
compressor with fuel and operator, copper slag blasting equipment and arrangements, skilled
manpower and everything required to complete the job in its entirety.
2. Carry out grit blasting to SA 2.5 and offer for inspection.
3. After grit blasting, the entire area shall be cleaned and waste material and metallic grit be
removed from the site and obtain clearance from HPCL inspection.
Rate :
1. The rate payable shall be per sq. meter of grit blasting done and approved by HPCL, as per
the scope mentioned above.
40.000 Copper slag blasting Square
Meters
The scope of job is as follows :
1. The scope includes supply and mobilisation of all resources required like copper slag , air
compressor with fuel and operator, copper slag blasting equipment and arrangements, skilled
manpower and everything required to complete the job in its entirety.
2. Carry out copper slag blasting to SA 2.5 and offer for inspection.
3. After copper slag blasting, the entire area shall be cleaned and waste material and copper
slag be removed from the site and obtain clearance from HPCL inspection.
Rate :
1. The rate payable shall be per sq. meter of copper slag blasting done and approved by HPCL, as
per the scope mentioned above.
41.000 Solution annealing of
anchors
Batch
The scope of job is as follows :
1. Carry out solution annealing of anchors, as per the directions of HPCL inspection.
2. For this, agency to take out the anchors, to the workshop located at Visakhapatnam - where
solution annealing is to be carried out and bring them back after job completion.
3. Submit the charts for HPCL inspection records and approval.
Cont on next page . . 12000438 - HD - 46002
Page 35 ofSign and Seal of the Tenderer 99
Rate :
1. The rate payable shall be per batch of anchors solution annealed, as per the scope mentioned
above.
42.000 Repairs to economiser
tubes -
Inch -
Dia
Repairs to economiser tubes - Root TIG and filler by SMAW
The scope of job is as follows :
1. Cut and remove the marked section of economiser tubes as per inspection.
2. Provide support, if necessary, for other sections.
3. Fabricate new section, carry out fit up and welding in position after HPCL Inspection
approval.
4. Root welding to be done by TIG and Filler runs by SMAW. Electrodes shall be as specified by
Inspection.
Rate :
1. The rate payable shall be per Inch Dia of welding done for the economiser tubes, as per the
scope mentioned above.
43.000 Repairs to economiser
tubes -
Inch -
Dia
Repairs to economiser tubes - Root and filler by SMAW
The scope of job is as follows :
1. Cut and remove the marked section of economiser tubes.
2. Provide support, if necessary, for other sections.
3. Fabricate new section, carry out fit up and welding in position after HPCL Inspection
approval.
4. Root welding and Filler runs to be done using SMAW. Electrodes shall be as specified by
Cont on next page . . 12000438 - HD - 46002
Page 36 ofSign and Seal of the Tenderer 99
Inspection.
Rate :
1. The rate payable shall be per Inch Dia of welding done for the tubes including root & final
weld DP test, as per the scope mentioned above.
44.000 Butt welding -IBR X-ray
qualit
Inch -
Dia
Butt welding -IBR X-ray quality (Root TIG + SMAW Filler)
The scope of job is as follows :
1. Prepare the arae for Hot work and keep the area ready for hot work.
2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of
pipes, fitups, welding, DP test, and / or radiography of weld joints (if required), stress
relieving, Hydrotesting of the entire section etc.
3. Erect scaffolding, wherever required, as per HPCL inspection advise.
4. Removal of existing section also is also inluded in the job scope.
5. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test,
as per the scope mentioned above.
2. Charges for RF pad, Corrosion pads, radiography, Stress relieving, hydrotesting, scaffolding,
threaded fittings & valves replacement shall be paid, extra, separately.
45.000 Butt welding - IBR X-ray
quali
Inch -
Dia
Butt welding - IBR X-ray quality
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Page 37 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. Prepare the arae for Hot work and keep the area ready for hot work.
2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of
pipes, fitups, welding, DP test, and / or radiography of weld joints, stress relieving,
Hydrotesting of the entire section etc.
3. Use IBR approved welder and HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing section also is also inluded in the jobs cope.
6. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test, as
per the scope mentioned above.
2. Charges for RF pad, Corrosion pads, radiography, Stress relieving, hydrotesting, scaffolding,
threaded fittings & valves replacement shall be paid, extra, separately.
46.000 Butt welding - X-ray
quality
Inch -
Dia
The scope of job is as follows :
1. Prepare the area for Hot work and keep the area ready for hot work.
2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of
pipes, fitups, welding, DP test, radiography of weld joints, stress relieving, Hydrotesting of
the entire section etc.
3. Use HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing section also is also inluded in the jobs cope.
6. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test, as
per the scope mentioned above.
2. Charges for RF pad, Corrosion pads, radiography, Stress relieving, hydrotesting, scaffolding,
threaded fittings & valves replacement shall be paid, extra, separately.
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Page 38 ofSign and Seal of the Tenderer 99
47.000 Butt welding - Non-X-ray
quali
Inch -
Dia
Butt welding - Non-X-ray quality
The scope of job is as follows :
1. Prepare the araes for Hot work and keep the area ready for hot work.
2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of
pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.
3. Use IBR approved welder and HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing section also is also inluded in the jobs cope.
6. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test,
as per the scope mentioned above.
2. Charges for RF pad, Corrosion pads, hydrotesting, scaffolding, threaded fittings & valves
replacement shall be paid, extra, separately.
48.000 Fillet welding - IBR
quality(R
Inch -
Dia
Fillet welding - IBR quality(Root TIG + SMAW Filler)
The scope of job is as follows :
1. Prepare the area for Hot work and keep the area ready for hot work.
2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of
pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.
3. Use IBR approved welder and HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing section also is also inluded in the job scope.
6. Offer the weld joints for HPCL inspection and obtain approval.
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Page 39 ofSign and Seal of the Tenderer 99
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test,
as per the scope mentioned above.
2. Charges for hydrotesting, scaffolding, threaded fittings & valves replacement shall be paid,
extra, separately.
49.000 Fillet welding - IBR
quality
Inch -
Dia
The scope of job is as follows :
1. Prepare the ares for Hot work and keep the area ready for hot work.
2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of
pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.
3. Use IBR approved welder and HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing section also is also inluded in the job scope.
6. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test, as
per the scope mentioned above.
2. Charges for hydrotesting, scaffolding, threaded fittings & valves replacement shall be paid,
extra,separately.
50.000 Fillet welding - Non- IBR
qual
Inch -
Dia
Fillet welding - Non- IBR quality
The scope of job is as follows :
1. Prepare the area for Hot work and keep the area ready for hot work.
2. Carry out replacement of pipelines, which includes cutting, grinding, beveling, laying of
pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.
Cont on next page . . 12000438 - HD - 46002
Page 40 ofSign and Seal of the Tenderer 99
3. Use HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing section also is also inluded in the job scope.
6. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test, as
per the scope mentioned above.
2. Charges for hydrotesting, scaffolding, threaded fittings & valves replacement shall be paid,
extra, separately.
51.000 RF pad replacement jobs Inch -
Dia
The scope of job is as follows :
1. Prepare the area for Hot work and keep the area ready for hot work.
2. Carry out replacement of RF pads, or laying of new RF pads, which includes cutting, grinding,
beveling, laying of pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.
3. Use IBR approved welder and HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing RF pad also is also included in the scope.
6. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of Branch piping, for jobs done including root & final
weld DP test as per the scope mentioned above.
2. Charges for hydrotesting, scaffolding, threaded fittings & valves replacement shall be paid,
extra,separately.
52.000 Replacement of Corrosion
pads
Inch -
Dia
The scope of job is as follows :
1. Prepare the area for Hot work and keep the area ready for hot work.
2. Carry out replacement of corrosion pads, which includes cutting, grinding, beveling, laying of
Cont on next page . . 12000438 - HD - 46002
Page 41 ofSign and Seal of the Tenderer 99
pipes, fitups, welding, DP test, Hydrotesting of the entire section etc.
3. Use IBR approved welder and HPCL approved electrodes.
4. Erect scaffolding, wherever required, as per HPCL inspection advise.
5. Removal of existing section also is also inluded in the job scope.
6. Offer the weld joints for HPCL inspection and obtain approval.
Rate :
1. The rate payable shall be per Inch Dia of welding done including root & final weld DP test, as
per the scope mentioned above.
2. Charges for hydrotesting, scaffolding, threaded fittings & valves replacement shall be paid,
extra, separately.
53.000 Replacement of SS anchors Each
The scope of job is as follows :
1. Carry out welding of anchors, of SS material using HPCL approved electrodes and welders, at a
specified pitch.
2. Offer the job for HPCL inspection and approval.
3. Removal of the existing anchors and cleaning the parent material surface also is included
in this scope.
Rate :
1. The rate payable shall be per anchor welding done including DPT.
54.000 Replacement of CS anchors Each
The scope of job is as follows :
1. Carry out welding of anchors, of CS material using HPCL approved electrodes and welders, at
a specified pitch.
2. Offer the job for HPCL inspection and approval.
3. Removal of the existing anchors and cleaning the parent material surface also is included
in this scope.
Rate :
1. The rate payable shall be per anchor welding done including DPT.
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55.000 Replacement of insulation
Anch
Each
Replacement of insulation Anchors
The scope of job is as follows :
1. Carry out welding of insulation anchors, of CS material using HPCL approved electrodes and
welders, at a specified pitch.
2. Offer the job for HPCL inspection and approval.
3. Removal of the existing anchors and cleaning the parent material surface also is included in
this scope.
Rate :
1. The rate payable shall be per anchor welding done.
56.000 Replacement of hexmesh
(where
Square
Meters
Replacement of hexmesh (where mesh is to be welded to studs)
The scope of job is as follows :
1. Gouge out and remove the existing hexmesh and clean the welding surface free of coke/weld
deposits etc., offer for inspection and obtain clearance.
2. Agency shall collect new Hex mesh panels from HPCL warehouse or any other designated location
inside the refinery as advised by the Engineer-in-charge and transport them to the work spot.
3. Carry out rolling of hex mesh panels to suit to the profile of the equipment, where it is to
be welded.
4. After surface is cleared for fit up, carry out fit up of the hexmesh panels and offer for
inspection.
5. Fabricate edge bars from 6 mm thick SS plate and ensure that edge bars are welded between
joints of every panel and corner tabs are welded at all corner areas.
6. Carry out welding of hex mesh as per EXXON Design welding scheme, or as advised by HPCL.
7. Carryout DP test of weld joints as advised by Inspection.
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Page 43 ofSign and Seal of the Tenderer 99
8. Chip and remove the weld slag completely and offer for Inspection and obtain clearance.
Rate :
1. The rate payable shall be per square meter of hex mesh replaced, for the entire job as per
the scope mentioned above.
57.000 Replacement of Hex Mesh
(where
Square
Meters
Replacement of Hex Mesh (where Hex Mesh is to be welded directly to the shell)
The scope of job is as follows :
1. Gouge out and remove the existing hexmesh and clean the welding surface free of coke/weld
deposits etc., offer for inspection and obtain clearance.
2. Agency shall collect new Hex mesh panels from HPCL warehouse or any other designated location
inside the refinery as advised by the Engineer-in-charge and transport them to the work spot.
3. Carry out rolling of hex mesh panels to suit to the profile of the equipment, where it is to
be welded.
4. After suface is cleared for fit up, carry out fit up of the hexmesh panels and offer for
inspection.
5. Fabricate edge bars from 6 mm thick SS plate and ensure that edge bars are welded between
joints of every panel and corner tabs are welded at all corner areas.
6. Carry out welding of hex mesh as per EXXON Design welding scheme, or as advised by HPCL.
7. Carryout DP test of weld joints as advised by Inspection.
8. Chip and remove the weld slag completely and offer for Inspection and obtain clearance.
Rate :
1. The rate payable shall be per square meter of hex mesh replaced, for the entire job as per
the scope mentioned above.
58.000 Fin welding between
adjacent
Meters
Fin welding between adjacent tubes on both sides (Inside & outside the boiler )
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Page 44 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. Cut and remove fins in between tubes as marked by HPCL inspection.
2. Fabricate new fins, fit up and weld fins after carrying out necessary tube replacement, repair
and inspection.
3. Offer the fin repairs and replacement for inspection and obtain clearance.
Rate :
1. The rate payable shall be per meter length of fin welding done on the finished job including
DPT, for the entire job as per the scope mentioned above.
59.000 Fin welding between
adjacent t
Meters
Fin welding between adjacent tubes on one side
The scope of job is as follows :
1. Cut and remove fins in between tubes as marked by HPCL inspection.
2. Fabricate new fins, fit up and weld fins after carrying out necessary tube replacement /
repair / inspection.
3. Offer the fin repairs and replacement for inspection and obtain clearance.
Rate :
1. The rate payable shall be per meter length of fin welding done on the finished job including
DPT, for the entire job as per the scope mentioned above.
60.000 CS Overlay Patch 6 to
12mm thk
Square
Feet
CS Overlay Patch 6 to 12mm thk for Pressure Parts
The scope of job is as follows :
Cont on next page . . 12000438 - HD - 46002
Page 45 ofSign and Seal of the Tenderer 99
1. Remove insulation as required and clean the surface area.
2. Cut and remove marked section of casing plate and fabricate new section using 6mm to 12 mm
thick CS plate.
3. Offer the plate fit up for inspection and carry out welding.
4. Carry out air testing of new welds at 1kg/sq. cm.
5. Carry out necessary repairs on identification of leaks during the test.
6. Use HPCL approved electrodes.
Rate :
1. The rate payable shall be per square foot of overlay patch jobs done including root & final
DPT, for the entire job as per the scope mentioned above.
2. This item is applicable only for Pressure parts like Boiler shell,Steam drums etc. but not for
Casing Plates
61.000 CS Inlay Patch 6 to 12mm
thk f
Square
Feet
CS Inlay Patch 6 to 12mm thk for Pressure Parts
The scope of job is as follows :
1. Remove insulation as required and clean the surface area.
2. Cut and remove marked section of casing plate and fabricate new section using 6mm to 12 mm
thick CS plate.
3. Offer the plate fit up for inspection and carry out welding.
4. DP test the welds and offer for inspection and obtain clearance.
5. Use HPCL approved electrodes.
Rate :
1. The rate payable shall be per square foot of inlay patch jobs done including root & final DPT,
for the entire job as per the scope mentioned above.
2. This item is applicable only for Pressure parts like Boiler shell,Steam drums etc. but not for
Casing Plates
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62.000 SS Overlay patch 6 to
12mm thk
Square
Feet
SS Overlay patch 6 to 12mm thk for Pressure Parts
The scope of job is as follows :
1. Remove insulation as required and clean the surface area.
2. Cut and remove marked section of casing plate and fabricate new section using 6mm to 12 mm
thick SS plate.
3. Offer the plate fit up for inspection and carry out welding.
4. Carry out air testing of new welds at 1kg/sq. cm.
5. Carry out necessary repairs on identification of leaks during the test.
6. Use HPCL approved electrodes.
Rate :
1. The rate payable shall be per square foot of overlay patch jobs done including root & final
DPT, for the entire job as per the scope mentioned above.
2. This item is applicable only for Pressure parts like Boiler shell,Steam drums etc. but not for
Casing Plates
63.000 SS Inlay patch 6 to 12mm
thk f
Square
Feet
SS Inlay patch 6 to 12mm thk for Pressure Parts
The scope of job is as follows :
1. Remove insulation as required and clean the surface area.
2. Cut and remove marked section of casing plate and fabricate new section using 6mm to 12 mm
thick SS plate.
3. Offer the plate fit up for inspection and carry out welding.
4. DP test the welds and offer for inspection and obtain clearance.
5. Use HPCL approved electrodes.
Rate :
Cont on next page . . 12000438 - HD - 46002
Page 47 ofSign and Seal of the Tenderer 99
1. The rate payable shall be per square foot of inlay patch jobs done including root & final DPT,
for the entire job as per the scope mentioned above.
2. This item is applicable only for Pressure parts like Boiler shell,Steam drums etc. but not for
Casing Plates
64.000 Weld repair to old joint Running
Feet
The scope of job is as follows :
1. Carry out air testing of old weld joint, repair old leaking casing weld joints as detected and
marked during air test.
2. After repairs air test again at 1kg/cm sq. and offer for inspection and obtain clearance.
3. Use HPCL approved electrodes.
Rate :
1. The rate payable shall be per running foot of weld repairs done for the finished job including
DPT, as per the scope mentioned above.
65.000 Repairs to drum cracks -
Depth
Inches
Repairs to drum cracks - Depth of crack upto 8 mm
The scope of job is as follows :
1. Identify the crack by means of magnetic particle testing.
2. Remove the tubes etc. for carrying out repairs around the cracked area.
3. Carry out grinding and MPT to find any further cracks on the area as marked by Inspection.
4. Form a V-Groove as advised by Inspection.
5. Carry out welding using E 7018 electrodes by IBR approved welders.
6. Dress up the area and the nearby tube holes etc.
7. Take radiography and submit the films for inspection and obtain approval from Inspection.
8. In case any defects found in the welding, carry out repairs as per Inspection advice.
9. Carry out radiography and obtain Inspection clearance.
10.Carry out the stress relieving of the weld affected zone, using sufficient number of
Cont on next page . . 12000438 - HD - 46002
Page 48 ofSign and Seal of the Tenderer 99
thermocouples, and as per approved procedure.
11. Carry out hardness test in this area and submit teh reports to Inspection.
12. Carry out re-radiography of the joint after stress relieving and if defects are found, carry
out repairs again.
13. Repeat the radiography and stress relieving after repairs and obtain inspection clearance.
Rate :
1. The rate payable shall be per Inch length of repairs done including DPT as per the scope
mentioned above.
66.000 Repairs to drum cracks -
Depth
Inches
Repairs to drum cracks - Depth of crack from 8 mm to 25mm
The scope of job is as follows :
1. Identify the crack by means of magnetic particle testing.
2. Remove the tubes etc. for carrying out repairs around the cracked area.
3. Carry out grinding and MPT to find any further cracks on the area as marked by Inspection.
4. Form a V-Groove as advised by Inspection.
5. Carry out welding using E 7018 electrodes by IBR approved welders.
6. Dress up the area and the nearby tube holes etc.
7. Take radiography and submit the films fro inspection and obtain approval from Inspection.
8. In case any defects found in the welding, carry out repairs as per Inspection advice.
9. Carry out radiography and obtain Inspection clearance.
10.Carry out the stress relieving of the weld affected zone, using sufficient number of
thermocouples, and as per approved procedure.
11. Carry out hardness test in this area and submit the reports to Inspection.
12. Carry out re-radiography of the joint after stress relieving and if defect are found, carry
out repairs again.
13. Repeat the radiography and stress relieving after repairs and obtain inspection clearance.
Rate :
1. The rate payable shall be per Inch length of repairs done including DPT as per the scope
Cont on next page . . 12000438 - HD - 46002
Page 49 ofSign and Seal of the Tenderer 99
mentioned above.
67.000 Repairs to drum cracks -
Depth
Inches
Repairs to drum cracks - Depth of crack above 25mm
The scope of job is as follows :
1. Identify the crack by means of magnetic particle testing.
2. Remove the tubes etc. for carrying out repairs around the cracked area.
3. Carry out grinding and MPT to find any further cracks on the area as marked by Inspection.
4. Form a V-Groove as advised by Inspection.
5. Carry out welding using E 7018 electrodes by IBR approved welders.
6. Dress up the area and the nearby tube holes etc.
7. Take radiography and submit the films fro inspection and obtain approval from Inspection.
8. In case any defects found in the welding, carry out repairs as per Inspection advice.
9. Carry out radiography and obtain Inspection clearance.
10.Carry out the stress relieving of the weld affected zone, using sufficient number of
thermocouples, and as per approved procedure.
11. Carry out hardness test in this area and submit the reports to Inspection.
12. Carry out re-radiography of the joint after stress relieving and if defect are found, carry
out repairs again.
13. Repeat the radiography and stress relieving after repairs and obtain inspection clearance.
Rate :
1. The rate payable shall be per Inch length of repairs done including DPT as per the scope
mentioned above.
68.000 Weld build up of 5 mm Thk
(fin
Square
Inches
Weld build up of 5 mm Thk (finish)
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Page 50 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. Clean the surface and prepare the weld buildup area.
2. Carry out weld buildup as marked using E-7018 electrode as advised by Inspection.
3. Flush grind the area and offer for inspection and obtain clearance.
Rate :
1. The rate payable shall be per Square Inch of finish weld build up done for 5 mm thickness
including DPT, as per the scope mentioned above.
2. For any variation in thickness on higher or lower side, the rate shall be proportionately
paid.
69.000 Structural replacements
(Mater
Metric
Ton
Structural replacements (Material supplied by HPCL)
The scope of job is as follows :
1. Provide additional supports or replace the existing supporting structurals, hand railings,
ladders, etc.
2. Dismantle the existing members is also includes in the job scope.
3. Carry out good housekeeping after job completion.
Rate :
1. The rate payable shall be per Metric tonne of structural steel jobs done and erected in the
field.
2. Material shall be supplied by HPCL free of cost and agency to submit the material
reconciliation sheet.
70.000 WFMPT Inch -
Dia
The scope of job is as follows :
1. Agency to carry out Wet Magnetic Particle Testing as advised by HPCL.
2. The scope includes mobilisation of all required resources and skilled manpower with
Cont on next page . . 12000438 - HD - 46002
Page 51 ofSign and Seal of the Tenderer 99
consumables to carry out and complete the job.
3. Obtain HPCL inspection clearance for jobs carried out.
Rate :
1. The rate payable shall be per Inch dia for the testing done, as per the scope mentioned
above.
71.000 DP test Inch -
Dia
The scope of job is as follows :
1. Agency to carry out Dye Penetrant test as advised by HPCL.
2. The scope includes mobilisation of all resources required like Magna Flux DP Kit along with
skilled manpower required to complete the job in its entirety.
3. The job scope also includes carrying out grinding / buffing required to facilitate DP test
prior to actual testing.
4. Obtain HPCL inspection clearance for jobs carried out.
Rate :
1. The rate payable shall be per Inch dia for the testing done, as per the scope mentioned
above.
72.000 Supply of CS Welder Shift
The scope of job as follows:
1. Supply of CS welder for carrying out miscellaneous jobs not covered under the unit rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
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Page 52 ofSign and Seal of the Tenderer 99
73.000 Supply of gascutter or
grinder
Shift
The scope of job as follows:
1. Supply of Gascutter/ Grinder for carrying out miscellaneous jobs not covered under the unit
rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is per 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
74.000 Supply of fabricator or
fitter
Shift
The scope of job as follows:
1. Supply of Fitter or fabricator for carrying out miscellaneous jobs not covered under the unit
rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
75.000 Supply of rigger Shift
The scope of job as follows:
1. Supply of rigger for carrying out miscellaneous jobs not covered under the unit rates.
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Page 53 ofSign and Seal of the Tenderer 99
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
76.000 Supply of Mason Shift
The scope of job as follows:
1. Supply of Mason for carrying out miscellaneous jobs not covered under the unit rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
77.000 Supply of Carpentor Shift
The scope of job as follows:
1. Supply of Carpentor for carrying out miscellaneous jobs not covered under the unit rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
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Page 54 ofSign and Seal of the Tenderer 99
78.000 Supply of Gunman Shift
The scope of job as follows:
1. Supply of Gunman for carrying out miscellaneous jobs not covered under the unit rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
79.000 Supply of Nozzleman Shift
The scope of job as follows:
1. Supply of nozzleman for carrying out miscellaneous jobs not covered under the unit rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
80.000 Supply of Helper Shift
The scope of job as follows:
1. Supply of Helper for carrying out miscellaneous jobs not covered under the unit rates.
2. All Manpower shall be supplied along with necessary tools and tackles, equipment, supervision
and consumables.
Rate:
1.Rate Payable is 8 hours shift.
Cont on next page . . 12000438 - HD - 46002
Page 55 ofSign and Seal of the Tenderer 99
2.For working beyond 8 hours and for working on HPCL defined holidays, the rate payable shall
be double the rates given under this head on pro-rata basis.
81.000 Mobilization &
Demobilization
Lump Sum
Mobilization & Demobilization Charges for Refractory Jobs - Agency from outside Visakhapatnam
This rate is payable if the agency is asked to mobilize specialised Refractory Contractors
approved by HPCL.
Agency shall engage experienced sub agencies such as M/s. Cape Industrial services, M/s. Rockwool
Insulations, M/s. Kafer Engineering, M/s Ciria India, M/s Furnace Fabrica, M/s Padmaja Systems &
Services or any other HPCL approved agencies.
The refractory agency shall be mobilized within 7 days of advice along with skilled manpower and
tools and tackles.
For the actual refractory jobs to be carried out, rates as applicable will be paid extra.
Agency shall mobilize enough manpower & equipments for carrying out various jobs assigned to the
party. Various types of skilled man power and equipments required for refractory jobs are given
below. The number of personnel and equipment shall be decided based the job requirement and in
consultation with HPCL.
Man Power:
1. Gunman
2. Nozzle man
3. Masons
4. Carpenters
5. Mixer Operators
6. Helpers
Equipment :
1. Paddle Mixers
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Page 56 ofSign and Seal of the Tenderer 99
2. Hobart Mixer
3. Gunniting Equipment with accessories
4. Needle vibrators with accessories
5. Shuttering equipments & and sufficient qty of plywood and other consumables
6. Tools for casting.
7. Rope & pulley arrangement for lifting of materials.
Rate : The rate payable shall be lumpsum for the mobilisation done.
82.000 Mobilization &
Demobilization
Lump Sum
Mobilization & Demobilization Charges for Refractory Jobs - Agency from within Visakhapatnam
This is payable if the agency is asked to mobilize various Refractory application equipments
(Gunniting equipments, Hobart Mixer, etc) if they own them or from local sources. The rate
include demobilization charges as well.
The refractory agency shall be mobilized within 7 days of advice along with skilled manpower and
tools and tackles.
For the actual refractory jobs to be carried out, rates as applicable will be paid extra.
Agency shall mobilize enough manpower & equipments for carrying out various jobs assigned to the
party. Various types of skilled man power and equipments required for refractory jobs are given
below. The number of personnel and equipment shall be decided based the job requirement and in
consultation with HPCL.
Man Power:
1. Gunman
2. Nozzle man
3. Masons
4. Carpenters
5. Mixer Operators
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Page 57 ofSign and Seal of the Tenderer 99
6. Helpers
Equipment :
1. Paddle Mixers
2. Hobart Mixer
3. Gunniting Equipment with accessories
4. Needle vibrators with accessories
5. Shuttering equipments & and sufficient qty of plywood and other consumables
6. Tools for casting.
7. Rope & pulley arrangement for lifting of materials.
Rate : The rate payable shall be lumpsum for the mobilisation done.
83.000 Chipping & Removal of
Refracto
Square
Meters
Chipping & Removal of Refractory upto 3"
The scope of job is given below :
The scope covers chipping and removal of existing refractory, cleaning the shell thoroughly free
of all scales by sand or grit blasting/power tool/manual cleaning as per the instructions of
HPCL.
Rate :
1. The rate payable shall be per sq. meter of refractory chipped and removed as per the scope
mentioned above.
2. For chipping and removal of any thickness other than than 3", (higher or lesser thickness) ,
the rate payable shall be on pro rata basis for each inch of thickness per unit area.
84.000 Refractory Casting upto
3"
Square
Meters
The scope of job is given below :
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Page 58 ofSign and Seal of the Tenderer 99
1. The scope of job includes drawing refractory materials from warehouse or any other designated
location inside the refinery premises as advised by the Engineer-in-charge and transportation of
these materials to the work spot.
2. Ensure that refractory material issued from HPCL warehouse is stored in a dry place at the
agency's work shed and covered with tarpaulin. Storage on dry concrete, asphalt or other
impervious surface will prevent moisture from the ground condensing under the plastic pallet
cover and wetting the bags of material which may result in loss of strength.
3. Carryout pre-qualification of masons for executing the job in coordination with HPCL
Inspection group prior to the commencement of job. Pre-qualification job test samples shall be
sent for testing for the required parameters by the agency at its own cost. HPCL's Inspection
department will issue Identity cards for all qualified masons which shall always be carried by
respective personnel while carrying out any refractory job at site. Test for qualification of
Masons shall be carried out prior to commencement of the job.
4. Mobilize all resources including Paddle type mixers required for refractory mixing, shuttering
and application as per the procedure recommended by the manufacturer/ Engineer-in-charge.
5. Agency shall carry out casting of refractory as per the procedure recommended by the
manufacturer/ Engineer-in-charge.
6. The following precautions shall be taken while preparation, mixing & application of refractory
material.
a.Use clean tools and equipment. Contamination can affect setting and strength of castables.
b.Water proof all forms and surfaces. Mold release agents may be used if required.
c.Use only clean water suitable for drinking.
d.A paddle type mechanical mixer shall be used.
e.Mix only as much castable as can be placed immediately. Under ideal conditions 20 minutes is
the maximum placement time. Material left in pails or mortar box may develop a "false" set making
it difficult to properly place.
f.Pre-dampen mixer prior to mixing first batch.
g.Add the dry material to the mixer. Then quickly add the minimum amount of specified water to
the mixer while mixing.
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Page 59 ofSign and Seal of the Tenderer 99
h.Mix for a "Preliminary Mix Time" as per the manufacturer's recommendation, then adjust water to
obtain the desired consistency. Excess water reduces the strength of the castable
proportionately.
i.After placement of refractory, cure either by spraying with a commercial curing compound or
water mist for at least 24 hours after casting. This shall prevent water evaporation required for
proper hydration and maximum properties.
7. Agency to note that welding of anchors is not in agency's scope.
Rate :
1. The rate payable shall be per sq. meter of refractory cast for 3" thickness, as per the scope
mentioned above.
2. For casting of thickness other than than 3", (higher or lesser thickness) , the rate payable
shall be on pro rata basis for each inch of thickness per unit area.
85.000 Chipping & Removal of
Abrasion
Square
Meters
Chipping & Removal of Abrasion resistant lining from Hexmesh
The scope of job is given below :
1. The scope of job includes chipping and removal of abrasion resistant lining from hex mesh and
cleaning the surface.
2. Agency to note that this lining shall be approx 1" thick and removal shall expose the
shell surface area.
3. Offer the cleaned / chipped arae for inspection and obtain clearance.
Rate :
1. The rate payable shall be per sq. meter of refractory chipped and removed.
86.000 Application of abrasion
resist
Square
Meters
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Page 60 ofSign and Seal of the Tenderer 99
Application of abrasion resistant refractory of hexmesh
The scope of job is given below :
1. The scope of job includes supply of all resources like Hobart mixer, wooden/rubber mallets,
trowels, Ice required for mixing and skilled manpower etc. to complete the job in its entirety.
2. Draw the refractory materials from warehouse or any other designated location inside the
refinery premises as advised by the Engineer-in-charge and transportation of these materials to
the work spot.
2. Ensure that refractory material issued from HPCL warehouse is stored in a dry place at the
agency's work shed and covered with tarpaulin. Storage on dry concrete, asphalt or other
impervious surface will prevent moisture from the ground condensing under the plastic pallet
cover and wetting the bags of material which may result in loss of strength.
3. Carryout pre-qualification of masons for executing the job in coordination with HPCL
Inspection group prior to the commencement of job. Pre-qualification job test samples shall be
sent for testing for the required parameters by the agency at its own cost. HPCL's Inspection
department will issue Identity cards for all qualified masons which shall always be carried by
respective personnel while carrying out any refractory job at site. Test for qualification of
Masons shall be carried out prior to commencement of the job.
4. Mobilize all resources including Paddle type mixers required for refractory mixing, shuttering
and application as per the procedure recommended by the manufacturer/ Engineer-in-charge.
5. Agency shall carry out casting of refractory as per the procedure recommended by the
manufacturer/ Engineer-in-charge.
6. The following precautions shall be taken while preparation, mixing & application of refractory
material.
a. Use clean tools and equipment. Contamination can affect setting and strength of castables.
b. Water proof all forms and surfaces. Mold release agents may be used if required.
Cont on next page . . 12000438 - HD - 46002
Page 61 ofSign and Seal of the Tenderer 99
c. Application surfaces must be clean and free of foreign (loose material, oil rust) matter.
d. Use only clean, cool (2-16deg.c.) Water suitable for drinking.
e. Use planetary, Hobart-type, mixer. The "B" flat agitator and mixing bowl should be made of
stainless steel. The maximum gap between the blade and the bowl at the bottom and sides should
be about 0.25inch (6mm). Mixing efficiency and product quality may be reduced if the clearances
are greater and if the mixing bowl is more than or less than 1/3 full.
f. Material and ambient temperatures should be (16-27deg.c.) during mixing, placing and setting.
g. Mix only as much material at one time as can be applied before material stiffens. Stiff
material becomes crumbly, loses plasticity, and does not knit together. Discard stiff material.
Do not remix.
h. Place the required amount of material into the mixing bowl. Dry blending at lower agitator
speeds, about 70 to 110 RPM. Consult the mixer manual for proper setting.
i. Add water to the dry material, starting at 4% by weight. The percent water used by RESCO or
other third party laboratories for qualification testing is a good guide to determine the amount
needed for mixing during installation. Increase the agitator speed to about 175 to 210 RPM.
Consult the mixer manual for proper setting. Slower or faster agitator speeds may change the
mixing times.
j. Adjust the water content to achieve a dough or putty-like consistency after 3 to 6 minutes of
mixing. Three or four distinct lumps of material will roll around in the bottom of the mixing
bowl. Use that same "final" water content on all batches or until a change in the appearance is
noted, if for example, the ambient temperature gets hotter or colder. If a change should occur,
adjust the water.
k. Add a little more water if the batch does not knit together easily on installation. The batch
will stick to the mixing bowl and blade if too much water is used.
l. Wash the mixing and placing equipment periodically with clean water and dry.
m. Pack the material into the area being lined, working it as needed to fill all holes and
eliminate air bubbles. Wood or rubber mallets, hammers, air rammers and trowels are commonly used
for this step.
n. Trim excess material, Be careful not to cut too deeply into the lining or pull the material
away from the anchor metal. Smooth the surface using a trowel, hardwood, or Teflon block or the
palm of the hand. DO NOT apply water.
o. Do not disturb lining during the first 24hour period after installation.
p. Do not spray water. A curing compound is also not required.
Cont on next page . . 12000438 - HD - 46002
Page 62 ofSign and Seal of the Tenderer 99
Rate :
1. The rate payable shall be per sq. meter of abrasion resistant refractory applied , as per the
scope mentioned above.
87.000 Gunniting of Refractory
upto 3
Square
Meters
Gunniting of Refractory upto 3"
The scope of job is given below :
1. The scope of job includes drawing refractory materials from warehouse or any other designated
location inside the refinery premises as advised by the Engineer-in-charge and transportation of
these materials to the work spot.
2. Ensure that refractory material issued from HPCL warehouse is stored in a dry place at the
agency's work shed and covered with tarpaulin. Storage on dry concrete, asphalt or other
impervious surface will prevent moisture from the ground condensing under the plastic pallet
cover and wetting the bags of material which may result in loss of strength.
3. Carryout pre-qualification of masons and gunmen for executing the job in coordination with
HPCL Inspection group prior to the commencement of job.
4. Pre-qualification job test samples shall be sent for testing for the required parameters by
the agency at its own cost. HPCL's Inspection department will issue Identity cards for all
qualified masons which shall always be carried by respective personnel while carrying out any
refractory job at site. Test for qualification of Masons shall be carried out prior to
commencement of the job.
5. Mobilize all resources including Paddle type mixers required for refractory mixing, shuttering
and application as per the procedure recommended by the manufacturer/ Engineer-in-charge.
6. Agency shall carry out gunniting of refractory as per the procedure recommended by the
manufacturer/ Engineer-in-charge.
Cont on next page . . 12000438 - HD - 46002
Page 63 ofSign and Seal of the Tenderer 99
7. The following precautions shall be taken while preparation, mixing & application of refractory
material.
a. Use clean tools and equipment. Contamination can affect setting and strength of castables.
b. Water proof all forms and surfaces. Mold release agents may be used if required.
c. Use only clean water suitable for drinking.
d. A paddle type mechanical mixer shall be used.
e. Mix only as much castable as can be placed immediately. Under ideal conditions 20 minutes is
the maximum placement time. Material left in pails or mortar box may develop a "false" set making
it difficult to properly place.
f. Pre-dampen mixer prior to mixing first batch.
g. Add the dry material to the mixer. Then quickly add the minimum amount of specified water to
the mixer while mixing.
h. Mix for a "Preliminary Mix Time" as per the manufacturer's recommendation, then adjust water
to obtain the desired consistency. Excess water reduces the strength of the castable
proportionately.
i. After placement of refractory, cure either by spraying with a commercial curing compound or
water mist for at least 24 hours after casting. This shall prevent water evaporation required for
proper hydration and maximum properties.
8. Agency to note that welding of anchors is not in their scope and shall be done separately,
by HPCL.
Rate :
1. The rate payable shall be per sq. meter of refractory gunnited for 3" thickness, as per the
scope mentioned above.
2. For gunniting of thickness other than than 3", (higher or lesser thickness) , the rate
payable shall be on pro rata basis for each inch of thickness per unit area.
88.000 Painting - Piping & Pipe
Fitti
Square
Meters
Painting - Piping & Pipe Fittings & Structurals
Cont on next page . . 12000438 - HD - 46002
Page 64 ofSign and Seal of the Tenderer 99
The scope of job is as follows :
1. Carry out surface preparation by copper slag blasting or manual cleaning to SA 2 1/2, as per
the directions of HPCL.
Manual cleaning is permitted only if copper slag blastng cannot be done and the decision of
HPCL shall be final and binding on the agency, in this regard.
2. Carry out Primer application of One Coat of Inorganic Zinc Silicate of DFT 65 Microns OR One
Coat of Zinc Rich Epoxy of DFT 50 Microns.
3. Application shall be done using airless spray or with air spray with bullows. Generally, for
hot lines Inorganic Zinc Silicate shall be applied and for cold lines & stucturals Zinc Rich
Epoxy shall be applied. However Job Engineer's instruction in this regard shall be final &
binding on the agency.
Rate : The rate payable shall be per square meter basis, as per the scope of job given above.
89.000 Air cleaning of FD fan
suction
Lump Sum
Air cleaning of FD fan suction silencer
The scope of job is as follows :
1.Air clean the FD fan suction silencers after opening the manways.
2.Opening and closing of manways is included in this scope.
Rate: The rate payable is lumpsum for the entire job scope mentioned above.
90.000 Shifting of tube bundle
of ste
Each
Shifting of tube bundle of steam generators- To & Fro
1. Supply of tractor-trailor with operator, other tools & tackles, nylon ropes, manpower
2. Transport the tube bundle from the unit to hydro-jetting yard and back to unit premises after
Cont on next page . . 12000438 - HD - 46002
Page 65 ofSign and Seal of the Tenderer 99
completion of hydrojetting.
NOTE:
1. Agency shall use only nylon ropes only for removal, loading and unloading the tube bundle.
2. Agency shall use Tractor Trailor only for shifting tube bundle.
91.000 Stress Relieving upto
1.5" dia
Inch -
Dia
Stress Relieving upto 1.5" dia. (applicable when no. of joints less than or equal to 5 nos.)
JOB SCOPE:
1. Supply all necessary tools & tackles, equipment, consumables.
2. Take the advise of Inspection/Job engineer on SR cycle
3. Stress relieve weld joints of shop fabricated / site fabricated / already installed pipe lines
at any elevation
4. Subimit the SR chart of Inspection/Job engineer.
5. Provide Hardness meter and check hardness of the metal near the weld joint after SR.
6. Submit hardness test report to Inspection and obtain clearance.
RATE PAYABLE:
Per Inch Dia. of weld joint of pipe sizes upto 1.5" dia.
NOTES:
1. In case of improper stress relieving, agency has to redo the entire job to the satisfaction of
Job engineer / Inspection engineer at no extra cost.
2. Electricity power shall be supplied by HPCL free of cost
3. This item is applicable only when the number of the weld joints to be stress relieved on a
respective line/loop is less than and upto 5 nos. If the no. of weld joints to be stress relieved
exceeds 5 nos., payment will be made as per Item no.93 and in such case, this item will not be
applicable.
4. This item is not operated inaddition to item no.93 for a particular job.
Cont on next page . . 12000438 - HD - 46002
Page 66 ofSign and Seal of the Tenderer 99
92.000 Stress Relieving above
1.5" an
Inch -
Dia
Stress Relieving above 1.5" and upto 3" dia. (applicable when no. of joints less than or equal to
5 nos.)
JOB SCOPE:
1. Supply all necessary tools & tackles, equipment, consumables.
2. Take the advise of Inspection/Job engineer on SR cycle
3. Stress relieve weld joints of shop fabricated / site fabricated / already installed pipe lines
at any elevation
4. Subimit the SR chart of Inspection/Job engineer.
5. Provide Hardness meter and check hardness of the metal near the weld joint after SR.
6. Submit hardness test report to Inspection and obtain clearance.
RATE PAYABLE:
Per Inch Dia. of weld joint of pipe sizes above 1.5" and upto 3" dia.
NOTES:
1. In case of improper stress relieving, agency has to redo the entire job to the satisfaction of
Job engineer / Inspection engineer at no extra cost.
2. Electricity power shall be supplied by HPCL free of cost
3. This item is applicable only when the number of the weld joints to be stress relieved on a
respective line/loop is less than and upto 5 nos. If the no. of weld joints exceeds 5 nos.,
payment will be made as per Item no.93 and in such case, this item will not be applicable.
4.This item is not operated inaddition to item no.93 for a particular job.
93.000 Stress Relieving for all
sizes
Inch -
Dia
Stress Relieving for all sizes (when no of joints exceeds 5)
JOB SCOPE:
Cont on next page . . 12000438 - HD - 46002
Page 67 ofSign and Seal of the Tenderer 99
1. Supply all necessary tools & tackles, equipment, consumables.
2. Take the advise of Inspection/Job engineer on SR cycle
3. Stress relieve weld joints of shop fabricated / site fabricated / already installed pipe lines
at any elevation
4. Subimit the SR chart of Inspection/Job engineer.
5. Provide Hardness meter and check hardness of the metal near the weld joint after SR.
6. Submit hardness test report to Inspection and obtain clearance.
RATE PAYABLE:
Per Inch Dia. of weld joint of pipe size above 3" dia.
NOTES:
1. In case of improper stress relieving, agency has to redo the entire job to the satisfaction of
Job engineer / Inspection engineer at no extra cost.
2. Electricity power shall be supplied by HPCL free of cost
3. In any case item nos. 91& 92 are not applicable for any job, this item is used irrespective of
size of weld joint/pipe including sizes less than 3" dia.
4. This item is not operated inaddition to item nos.91 & 92 for a particular job.
94.000 Radiography upto 1.5"
dia. (ap
Inch -
Dia
Radiography upto 1.5" dia. (applicable when no. of joints less than or equal to 5 nos.)
JOB SCOPE:
1. Supply of radigraphy films, equipment, skilled manpower, tools & tackles and all other
accessories
2. Carrying out radiography of weld joints as per standard procedure for all types and
thicknesses, at any elevation / location
RATE PAYABLE:
Per Inch Dia. of weld joint of pipe sizes less than and upto 1.5" dia.
Cont on next page . . 12000438 - HD - 46002
Page 68 ofSign and Seal of the Tenderer 99
NOTES:
1. In case of defective film, poor radiographic quality, non-readable film etc. agency shall redo
the radiography at no extra cost and agency will not be paid for any repeat radiography.
2. For any radiographic jobs carried out for straight lengths etc, the length shall be converted
to Inch dia and paid.
3. This item is applicable only when the number of the weld joints to be radiographed on a
respective line/loop is less than and upto 5 nos. If the no. of weld joints to be radiographed
exceeds 5 nos., payment will be made as per Item no.97 and in such case, this item will not be
applicable.
4.This item is not operated inaddition to item no.97 for a particular job.
95.000 Radiography - above 1.5"
dia.
Inch -
Dia
Radiography - above 1.5" dia. and upto 3" dia. (applicable when no. of joints less than or equal
to 5 nos.)
JOB SCOPE:
1. Supply of radigraphy films, equipment, skilled manpower, tools & tackles and all other
accessories
2. Carrying out radiography of weld joints as per standard procedure for all types and
thicknesses, at any elevation / location
RATE PAYABLE:
Per Inch dia. of weld joint of pipe sizes above 1.5" dia and upto 3" dia.
NOTES:
1. In case of defective film, poor radiographic quality, non-readable film etc. agency shall redo
the radiography at no extra cost and agency will not be paid for any repeat radiography.
2. For any radiographic jobs carried out for straight lengths etc, the length shall be converted
to Inch dia and paid.
3. This item is applicable only when the number of the weld joints to be radiographed on a
respective line/loop is less than and upto 5 nos. If the no. of weld joints to be radiographed
exceeds 5 nos., payment will be made as per Item no.97 and in such case, this item will not be
Cont on next page . . 12000438 - HD - 46002
Page 69 ofSign and Seal of the Tenderer 99
applicable.
4.This item is not operated inaddition to item no.97 for a particular job.
96.000 Radiography - above 3"
dia. an
Inch -
Dia
Radiography - above 3" dia. and upto 6" dia. (applicable when no. of joints less than or equal to
5 nos.)
JOB SCOPE:
1. Supply of radigraphy films, equipment, skilled manpower, tools & tackles and all other
accessories
2. Carrying out radiography of weld joints as per standard procedure for all types and
thicknesses, at any elevation / location
RATE PAYABLE:
Per Inch dia. of weld joint of pipe size above 3" and upto 6" dia.
NOTES:
1. In case of defective film, poor radiographic quality, non-readable film etc. agency shall redo
the radiography at no extra cost and agency will not be paid for any repeat radiography.
2. For any radiographic jobs carried out for straight lengths etc, the length shall be converted
to Inch dia and paid.
3. This item is applicable only when the number of the weld joints to be radiographed on a
respective line/loop is less than and upto 5 nos. If the no. of weld joints to be radiographed
exceeds 5 nos., payment will be made as per Item no.97 and in such case, this item will not be
applicable.
4.This item is not operated inaddition to item no.97 for a particular job.
97.000 Radiography for all sizes
(whe
Inch -
Dia
Radiography for all sizes (when no of joints exceeds 5)
Cont on next page . . 12000438 - HD - 46002
Page 70 ofSign and Seal of the Tenderer 99
JOB SCOPE:
1. Supply of radigraphy films, equipment, skilled manpower, tools & tackles and all other
accessories
2. Carrying out radiography of weld joints as per standard procedure for all types and
thicknesses, at any elevation / location
RATE PAYABLE:
Per Inch dia. of weld joint of pipe size above 6" dia.
NOTES:
1. In case of defective film, poor radiographic quality, non-readable film etc. agency shall redo
the radiography at no extra cost and agency will not be paid for any repeat radiography.
2. For any radiographic jobs carried out for straight lengths etc, the length shall be converted
to Inch dia and paid.
3. In any case item nos.94 to 96 are not applicable for any job, this item is used irrespective
of size of weld joint/pipe including sizes less than 6" dia.
4. This item is not operated inaddition to item nos.94, 95 & 96 for a particular job.
98.000 Re-tubing of
Exchangers/Sulphu
Tube
Re-tubing of Exchangers/Sulphur condensers Welded Tubes - Rate per tube of size upto 1" Dia. OD
Job Scope:
1. Remove the existing tubes of Exchanger/Sulphur condenser by grinding existing weld joints.
Make grooves at tube holes as per drawings and carry out DP testing of tube holes.
2. Clean tube sheet hole, remove burrs and weld build up in pits any pits that are found, as per
Inspection. Agency shall record and submit the internal diameters of tube sheet holes using a
calibrated dial gage. The tube shall be identified in the record basis row and tube number.
3. Clean new tube internally and externally.
4. Install new tube in position and carry out field modification, if required for facilitating
the replacement
5. Roll the tube ends as per requirement and obtain clerance from Inspection.
Cont on next page . . 12000438 - HD - 46002
Page 71 ofSign and Seal of the Tenderer 99
6. Seal weld the tube ends on both sides as per IWL using CS/SS electrode equivalent TIG filler
rod.
7. Offer root and final seal weld DP test to Inspection and obtain clerance.
8. Carryout Stress relieving of joints as advised by Job Engineer.
9. Co-ordinate with IBR in obtaining necessary certification for retubing jobs.
Rate Payable:
1. The rate payable shall be PER TUBE REPLACEMENT OF SIZE UPTO 1" OD as per scope mentioned
above.
2. Incase of variation in tube OD size, rate will be paid on pro-rata basis.
3. Charges for Stress Relieving/PWHT of seal weld joints shall be paid extra as per available
items
4. Carrying out the cutting the 2 to 3 nos. sample tubes into three sections (both ends and
middle) of one-foot length, splitting the tubes axially into two halves and handing over to
Inspection Engineer is part of the scope.
5. In case of requirement for 100% re-tubing of any bundle, cutting and removal the old tubes,
removing the tube stubs from the tube sheets and baffles, cleaning and offering the tube sheets
and cage for Inspection and re-tubing etc are part of the job scope.
99.000 Hydrogen Diffusion of
Exchange
Square
Feet
Hydrogen Diffusion of Exchanger/Sulphur Condenser Tube sheet / PWHT of exchanger tube seal weld
joints
Job Scope:
1. Remove the sulphur/HC deposits over the the tube sheet surface using wire brushes/scrapers.
2. Carry out Hydrogen diffusion of exchanger tube sheet using suitable equipments as per Heating
& Cooling cycle provided by HPCL.
3. Uniform heating/cooling shall be ensured across the tube sheet surface by installing adequate
no. of heating elements.
4. Adequate no. of thermo couples to be installed as per Inspection to record temperature at
various points simultaneously.
5. Take hardness of tube sheet at various location as marked by Inspection before & after
Cont on next page . . 12000438 - HD - 46002
Page 72 ofSign and Seal of the Tenderer 99
Hydrogen Diffusion/PWHT/SR.
6. After completion of job, submit Time-Temperature record graph and hardness test report to HPCL
Inspection and Obtain clearance.
7. In case above job is done mainly for stress relieving of tube seal weld joints on tube sheet,
ASR and BSR weld joint hardness test report shall be submitted to HPCL Inspection.
Rate Payable: The rate payable shall be PER SQUARE FEET OF TUBE SHEET AREA INCLUDING TUBE SEAL
WELDS Stress Relieved / Hydrogen diffusion done.
100.000 Butt joint AS/SS - X-ray
quali
Inch -
Dia
Butt joint AS/SS - X-ray quality weld joints with TIG weld at root and TIG/Arc weld for Filler
joint using diesel machine
Job Scope:
1. Carry out isolation and preparatory works for obtaining 'Hot work permit' such as isolation,
blinding, flushing, removal of insulation and all other preparatory works.
2. Preparation for welding:
Carry out cold/hot cutting and dismantling of old pipes / pipe fittings, providing
Hook-ups/Tie-in/Additional piping, shifting material from issue points to site, erection,
cutting, grinding, beveling, bending, laying of pipes and preparation of fit-ups
3. Welding:
Carry out welding of pipes, pipe fittings, stubs etc. as per Inspection.
4. Testing and commissioning assistance:
Carry out DP test, WFMPT and/or radiography of welds as required, stress releiving, hydro testing
of pipes of various sizes, thickness etc., capping vent drains, deblinding etc.
Rate:
Per inch dia. of joint for using Diesel welding machine of the agency with TIG filler wire for
root run and subsequent runs with electrodes/TIG filler wire, for all Alloy Steel, SS and IBR-X
Cont on next page . . 12000438 - HD - 46002
Page 73 ofSign and Seal of the Tenderer 99
ray joints.
NOTES:
1. All non-destructive testing of piping shall be as per EIL Standard specification 3655-6-44-16.
2. Follwing items are paid separately as per applicable items in the tender :
RF pad, corrosion pads, threaded joints, scaffolding, Radiography, WFMPT, UFDT, SR, hydrotesting,
Valves replacement, Painting, Civil and Structural items.
3. No separate payment shall be made for DP TEST as it is included in the job scope.
4. AS/SS X-ray quality weld joints with TIG at root and filler with Arc/TIG welding with agency's
diesel equipment. Consumables and suitable electrodes to be used for AS/SS welding as instructed
by the job engineer/ Inspection.
101.000 Butt joint AS/SS - X-ray
quali
Inch -
Dia
Butt joint AS/SS - X-ray quality weld joints with TIG weld at root and TIG/Arc weld for Filler
joint using electrical machine
Job Scope:
1. Carry out isolation and preparatory works for obtaining 'Hot work permit' such as isolation,
blinding, flushing, removal of insulation and all other preparatory works.
2. Preparation for welding:
Carry out cold/hot cutting and dismantling of old pipes / pipe fittings, providing
Hook-ups/Tie-in/Additional piping, shifting material from issue points to site, erection,
cutting, grinding, beveling, bending, laying of pipes and preparation of fit-ups
3. Welding:
Carry out welding of pipes, pipe fittings, stubs etc. as per Inspection.
Cont on next page . . 12000438 - HD - 46002
Page 74 ofSign and Seal of the Tenderer 99
4. Testing and commissioning assistance:
Carry out DP test, WFMPT and/or radiography of welds as required, stress releiving, hydro testing
of pipes of various sizes, thickness etc., capping vent drains, deblinding etc.
Rate Payable:
Per inch dia. of joint for using Electrical welding machine of the agency with TIG filler wire
for root run and subsequent runs with electrodes/TIG filler wire, for all Alloy Steel, SS and
IBR-X ray joints.
Notes:
1. All non-destructive testing of piping shall be as per EIL Standard specification 3655-6-44-16.
2. Follwing items are paid separately as per applicable items in the tender :
RF pad, corrosion pads, threaded joints, scaffolding, Radiography, WFMPT, UFDT, SR, hydrotesting,
Valves replacement, Painting, Civil and Structural items.
3. No separate payment shall be made for DP TEST as it is included in the job scope.
4. AS/SS X-ray quality weld joints with TIG at root and filler with Arc/TIG welding with agency's
Electrical welding equipment. Consumables and suitable electrodes to be used for AS/SS welding as
instructed by the job engineer/ Inspection.
102.000 Fillet joint AS/SS with
TIG ro
Inch -
Dia
Fillet joint AS/SS with TIG root using diesel machine
Job Scope:
1. Carry out isolation and preparatory works for obtaining 'Hot work permit' such as isolation,
blinding, flushing, removal of insulation and all other preparatory works.
2. Preparation for welding:
Carry out cold/hot cutting and dismantling of old pipes / pipe fittings, providing
Hook-ups/Tie-in/Additional piping, shifting material from issue points to site, erection,
cutting, grinding, beveling, bending, laying of pipes and preparation of fit-ups
3. Welding:
Cont on next page . . 12000438 - HD - 46002
Page 75 ofSign and Seal of the Tenderer 99
Carry out welding of pipes, pipe fittings, stubs etc. as per Inspection.
4. Testing and commissioning assistance:
Carry out DP test, hydro testing of pipes of various sizes, thickness etc., capping vent drains,
deblinding etc.
Rate:
1.Per inch dia. of joint for using Diesel welding machine of the agency with TIG filler wire,
for for Alloy steel, SS and IBR relevant joints.
Notes:
1. All non-destructive testing of piping shall be as per EIL Standard specification 3655-6-44-16.
2. Follwing items are paid separately as per applicable items in the tender :
RF pad, corrosion pads, threaded joints, scaffolding, Radiography, WFMPT, UFDT, SR, hydrotesting,
Valves replacement, Painting, Civil and Structural items.
3. No separate payment shall be made for DP TEST as it is included in the job scope.
4. Suitable electrodes shall be used as instructed by the Inspection/Job engineer.
103.000 Fillet joint AS/SS with
TIG ro
Inch -
Dia
Fillet joint AS/SS with TIG root using electrical machine
Job Scope:
1. Carry out isolation and preparatory works for obtaining 'Hot work permit' such as isolation,
blinding, flushing, removal of insulation and all other preparatory works.
2. Preparation for welding:
Carry out cold/hot cutting and dismantling of old pipes / pipe fittings, providing
Hook-ups/Tie-in/Additional piping, shifting material from issue points to site, erection,
cutting, grinding, beveling, bending, laying of pipes and preparation of fit-ups
3. Welding:
Carry out welding of pipes, pipe fittings, stubs etc. as per Inspection.
4. Testing and commissioning assistance:
Carry out DP test, hydro testing of pipes of various sizes, thickness etc., capping vent drains,
Cont on next page . . 12000438 - HD - 46002
Page 76 ofSign and Seal of the Tenderer 99
deblinding etc.
Rate:
1.Per inch dia. of joint for using electrical welding machine of the agency with TIG filler
wire, for for Alloy steel, SS and IBR relevant joints.
NOTES:
1. All non-destructive testing of piping shall be as per EIL Standard specification 3655-6-44-16.
2. Follwing items are paid separately as per applicable items in the tender :
RF pad, corrosion pads, threaded joints, scaffolding, Radiography, WFMPT, UFDT, SR, hydrotesting,
Valves replacement, Painting, Civil and Structural items.
3. No separate pyment shall be made for DP TEST as it is included in the job scope.
4. IBR quality welding shall be carried out by IBR approved welders only.
5. Suitable electrodes/filler wire shall be used as instructed by the Inspection/Job engineer.
104.000 SS/AS Weld run jobs- weld
run
Running
Feet
SS/AS Weld run jobs- weld run with SS/AS electrodes per running foot of 6mm thick
JOB SCOPE:
1. Collect the plate from warehouse and fabricate necessary patch plates/box(es) etc. as required
to be installed from plate material
2. Install patch/box on vessels/heaters/any equipment as advised by Job Engineer and carry out
welding as per standard procedure
3. DP test the patch plate welding and offer for inspection and obtain clearance.
RATE PAYABLE: Per Running Feet of welding done using SS/AS electrodes using electrical welding
machine.
NOTES:
1. Blinding, Scaffolding, Hydro testing etc. if carried out shall be payable , extra, seperately
as per respective line items.
2. For any variation in thickness of weld, pro-rata payment shall be made.
Cont on next page . . 12000438 - HD - 46002
Page 77 ofSign and Seal of the Tenderer 99
3. Incase Diesel welding machine is used, 10% extra rate will be paid and Qty. of item will be
fixed accordingly.
105.000 SS weld build up with
electric
Square
Inches
SS weld build up with electrical machine
Job Scope is as follows
1. Grind the surface where weld build up is to be carried out.
2. Weld build up using Stainlss Steel electrodes (E-308/309/310/309 MO),as advised by Job
engineer upto 5 mm thick.
3. Finish grind after deposition and DP test the weld built up area and offer for inspection.
Rate:
1.Per square inch of deposited area for 5 mm thick deposition with elecrical machine.
2. For any variation in thicknes of weld deposit, payment shall be made in pro-rata basis.
106.000 SS weld build up with
diesel m
Square
Inches
SS weld build up with diesel machine
Job scope is as follows::
1. Grind the surface where weld build up is to be carried out.
2. Weld build up using Stainlss Steel electrodes (E-308/309/310/309 MO),as advised by Job
engineer upto 5 mm thick.
3. Finish grind after deposition and DP test the weld built up area and offer for inspection.
Rate:
1.Per square inch of deposited area for 5 mm thick deposition with diesel machine.
2. For any variation in thicknes of weld deposit, payment shall be made in pro-rata basis.
Cont on next page . . 12000438 - HD - 46002
Page 78 ofSign and Seal of the Tenderer 99
107.000 Supply of SS / AS / TIG
welder
Shift
JOB SCOPE:
1.Supply a qualified SS / AS / TIG / IBR welder complying with statutory and safety stipulations
along with all tools & tackles, upervision, consumables (suitable electrodes) and safety
equipment to carry out the job at any location.
Rate:
1. Per 8 hour shift
2.Payment for working beyond 8 hrs shift and on sundays and Refinery holidays shall be made at
double the rate on prorata basis.
108.000 Annual Inspection of WHB
/ Sul
Lump Sum
Annual Inspection of WHB / Sulphur Condensers /
The scope of job is as follows :
1. Provide necessary flushing, steam connections etc. and install necessary blinds before opening
the equipment, as per Operations requirement.
2. Remove insulation over the flanges, to facilitate removal of bolts.
3. Open the channel covers and all manways including Thermal Reactor manways opening.
4. Erect staging as required, as per the directions of HPCL.
5. Drop all safety valves and install blind flanges in position and transport these valves to
HPCL valve section.
6. Transport the valves from HPCL valve section and refix them in position after removal of
blind flanges.
7. Clean the tubes internally by rodding,water washing and air blowing.
8. Clean the demister pads by water washing or using air.
9. Offer the components for Inspection and obtain clearance.
10. Prove clear all shell nozzles.
11. Carryout the shell test at the mentioned pressure and obtain inspection clearance.
Cont on next page . . 12000438 - HD - 46002
Page 79 ofSign and Seal of the Tenderer 99
12.Refix the demister pads and carry out refractory repair jobs, if any.
13.Fix the channel covers and box up all the manways.
14.Carry out tube test and offer to Inspection.
15. Remove the blinds and make up the flanges
16. Maintain stand-by crew for hot bolting, pulling leaks, etc, for a period of 24 hours (one
fitter + one helper).
17. For any additional manpower supplied beyond the 24 hour period, additional payment shall be
made on manpower rates basis.
18. Coordinate with Dy.Chief Inspector of Boilers for inspection and certification and related
jobs and obtain clearance from DCIB.
Rate:
1. The rate payable is lumpsum for the entire job scope as mentioned above per Sulphur Condensor
/ Waste Heat Recovery Boilers.
2. For any cleaning done by hydrojetting,or reaming as per the advise of HPCL, the same shall be
paid, extra, separately.
3. For any refractory chipping and application jobs done as per the advise of HPCL, the same
shall be paid extra, separately.
4. For any weld repairs to the shell and components, the same shall be paid extra, separately.
Note:
This item is applicable for the following condensers / waste heat Boiler / drums.
1. D-SRU Train-1: 65E101, 65E102 & 65E103
2. D-SRU Train-2: 65E201, 65E202 & 65E203
3. D-SRU Train-3: 79E301, 79E302 & 79E303
4. FCCU-I: 4V63 (without Heater S/D & coils testing).
109.000 Supply of Hydra (10 T
capacity
Hour
Supply of Hydra (10 T capacity) - Payment is applicable only for running hours
Job scope is as follows:
Cont on next page . . 12000438 - HD - 46002
Page 80 ofSign and Seal of the Tenderer 99
1. Supply Hydra along with all consumables (fuel) and accessories, operator and fuels etc
2. Operate them at site to shift material, components etc.
Rate:
Per running hour
110.000 Material Handling Trip
Job Scope is as follows
1. Mobilise necessary tools, tackles, chain pulley blocks, D-shakles, 6" x 6" wooden blocks of
required length, wire ropes etc. for carrying out the job.
2. Shift components like test jig, channel section, channel cover, floating head cover, tube
sheets, shell cover etc. from any location to any other location inside Refinery.
Rate :
1.Per component shifted (One Way) unsing tractor trailer.
Notes:
1. Agency to mobilise trailor/hand trolley, tools etc.
2. This rate is applicable only when using Jeep/Tractor to pull the trailor/trolley for shifting
of components.
2. This item rate is not applicable for shifting within the unit of work and is applicable only
when the components are shifted beyond the battery limits of the unit.
111.000 Replacement of Casing
Plates o
Running
Feet
Replacement of Casing Plates of Boilers/HRSGs/Ducts- applicable 6 mm to 12 mm thick plates
Scope of job is as follows
1.Plate replacement scope covers- Cut, remove and replace the existing casing plate entirely or
Cont on next page . . 12000438 - HD - 46002
Page 81 ofSign and Seal of the Tenderer 99
Attachment To HPCL Tender Enquiry No. 12000438 - HD - 46002 dated 25/9/2012
Format For Priced Bid
1. Schedule of rates are in INR unless otherwise specified.
2. Vendor to quote '+' / '-' / Zero % on the Schedule of rates (A) mentioned in the following table.
3. Only single % is to be quoted for the complete set of Items/Services and not Item/Service wise.
Specifying more than single percentage (%) or quoting specific unit rates / Lumpsum rates
will make your offer rejected.
4. Prefix the % with, '+' for rates above the scheduled rate, '-' for rates below the scheduled rate.
Put Zero % if the scheduled rate itself are being offered.
5. The % is to be put in the space provided below the following table, both in figures and in words.
Please quote for the following items/service, as per the terms and conditions mentioned below and in
attachments :
DETAILS OF ITEMS / SERVICES
Deliver To : Maintenance-On Site, - . India.
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
1 1.000 Blinding &
Deblinding
of equip
Inch - Dia 99.00 Inch - Dia
2 2.000 Manway
opening and
head up of
Each 571.00 Each
3 3.000 Safety valve
dropping,
transpo
Each 864.00 Each
Cont on next page . . 12000438 - HD - 46002
Page 84 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
4 4.000 Safety valve
dropping &
instal
Each 571.00 Each
5 5.000 Drum manway
opening &
headup
Each 864.00 Each
6 6.000 Removal &
re-fixing of
drum in
Lump Sum 2,928.00 Lump Sum
7 7.000 Economiser
tubes
cleaning
Lump Sum 2,495.00 Lump Sum
8 8.000 Drum & drum
internals
cleaning
Lump Sum 2,495.00 Lump Sum
9 9.000 Tubes
cleaning
Lump Sum 3,989.00 Lump Sum
10 10.000 Flue gas
path
cleaning
Lump Sum 3,989.00 Lump Sum
11 11.000 Cleaning of
burner, oil
gun et
Lump Sum 1,376.00 Lump Sum
12 12.000 CO inlet / Lump Sum 884.00 Lump Sum
Cont on next page . . 12000438 - HD - 46002
Page 85 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
outlet ducts
inspec
13 13.000 Hydrotesting
of Boiler
Lump Sum 5,856.00 Lump Sum
14 14.000 Additional
hydrotest
Lump Sum 4,402.00 Lump Sum
15 15.000 Start up
coverage
Lump Sum 3,282.00 Lump Sum
16 16.000 Annual
Inspection
of Boilers
Lump Sum 157,214.00 Lump Sum
17 17.000 General
maintenance
of steam g
Lump Sum 57,973.00 Lump Sum
18 18.000 Repeat shell
test & tube
test
Lump Sum 22,206.00 Lump Sum
19 19.000 Repeat shell
test & tube
test
Lump Sum 11,005.00 Lump Sum
20 20.000 Retubing of
exchanger
tube (wi
Tube 246.00 Tube
Cont on next page . . 12000438 - HD - 46002
Page 86 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
21 21.000 Reaming of
exchanger
tube
Tube 77.00 Tube
22 22.000 Biennial /
Annua IBR
Inspectio
Lump Sum 137,562.00 Lump Sum
23 23.000 Boiler tube
replacement
Tube 3,440.00 Tube
24 24.000 Sectional
replacement
of boile
Inch - Dia 1,454.00 Inch - Dia
25 25.000 Window patch
of tubes
Running
Feet
2,083.00 Running
Feet
26 26.000 Re-rolling
of Boiler
tubes
Joints 304.00 Joints
27 27.000 Seal welding
of boiler
tubes
Joints 433.00 Joints
28 28.000 Plug welding
of Boiler
tubes
Joints 433.00 Joints
29 29.000 Additional
hydrotest of
Each 2,338.00 Each
Cont on next page . . 12000438 - HD - 46002
Page 87 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
econom
30 30.000 Hydrotesting
of piping
Inch Meter 4.00 Inch Meter
31 31.000 Gauge glass
overhauling
Each 864.00 Each
32 32.000 Threaded
fittings
replacement
Inch - Dia 39.00 Inch - Dia
33 33.000 Gland
packing
replacement
Inch - Dia 22.00 Inch - Dia
34 34.000 Valve free
up / repair
Inch - Dia 39.00 Inch - Dia
35 35.000 Valve
replacement
Inch - Dia 158.00 Inch - Dia
36 36.000 Supply &
operation of
air comp
Hour 652.00 Hour
37 37.000 Supply &
operation of
diesel w
Hour 205.00 Hour
38 38.000 Scaffolding Each 609.00 Each
Cont on next page . . 12000438 - HD - 46002
Page 88 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
of 3m x 3m x
3m bl
39 39.000 Grit
blasting
Square
Meters
766.00 Square
Meters
40 40.000 Copper slag
blasting
Square
Meters
334.00 Square
Meters
41 41.000 Solution
annealing of
anchors
Batch 14,727.00 Batch
42 42.000 Repairs to
economiser
tubes -
Inch - Dia 1,730.00 Inch - Dia
43 43.000 Repairs to
economiser
tubes -
Inch - Dia 571.00 Inch - Dia
44 44.000 Butt welding
-IBR X-ray
qualit
Inch - Dia 685.00 Inch - Dia
45 45.000 Butt welding
- IBR X-ray
quali
Inch - Dia 571.00 Inch - Dia
46 46.000 Butt welding
- X-ray
quality
Inch - Dia 434.00 Inch - Dia
Cont on next page . . 12000438 - HD - 46002
Page 89 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
47 47.000 Butt welding
- Non-X-ray
quali
Inch - Dia 315.00 Inch - Dia
48 48.000 Fillet
welding -
IBR
quality(R
Inch - Dia 448.00 Inch - Dia
49 49.000 Fillet
welding -
IBR quality
Inch - Dia 374.00 Inch - Dia
50 50.000 Fillet
welding -
Non- IBR
qual
Inch - Dia 296.00 Inch - Dia
51 51.000 RF pad
replacement
jobs
Inch - Dia 689.00 Inch - Dia
52 52.000 Replacement
of Corrosion
pads
Inch - Dia 226.00 Inch - Dia
53 53.000 Replacement
of SS
anchors
Each 99.00 Each
54 54.000 Replacement Each 55.00 Each
Cont on next page . . 12000438 - HD - 46002
Page 90 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
of CS
anchors
55 55.000 Replacement
of
insulation
Anch
Each 16.00 Each
56 56.000 Replacement
of hexmesh
(where
Square
Meters
8,800.00 Square
Meters
57 57.000 Replacement
of Hex Mesh
(where
Square
Meters
13,200.00 Square
Meters
58 58.000 Fin welding
between
adjacent
Meters 1,395.00 Meters
59 59.000 Fin welding
between
adjacent t
Meters 786.00 Meters
60 60.000 CS Overlay
Patch 6 to
12mm thk
Square
Feet
983.00 Square
Feet
61 61.000 CS Inlay
Patch 6 to
12mm thk f
Square
Feet
1,573.00 Square
Feet
Cont on next page . . 12000438 - HD - 46002
Page 91 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
62 62.000 SS Overlay
patch 6 to
12mm thk
Square
Feet
1,945.00 Square
Feet
63 63.000 SS Inlay
patch 6 to
12mm thk f
Square
Feet
4,874.00 Square
Feet
64 64.000 Weld repair
to old joint
Running
Feet
108.00 Running
Feet
65 65.000 Repairs to
drum cracks
- Depth
Inches 1,355.00 Inches
66 66.000 Repairs to
drum cracks
- Depth
Inches 2,653.00 Inches
67 67.000 Repairs to
drum cracks
- Depth
Inches 4,914.00 Inches
68 68.000 Weld build
up of 5 mm
Thk (fin
Square
Inches
99.00 Square
Inches
69 69.000 Structural
replacements
(Mater
Metric Ton 18,102.00 Metric Ton
70 70.000 WFMPT Inch - Dia 101.00 Inch - Dia
Cont on next page . . 12000438 - HD - 46002
Page 92 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
71 71.000 DP test Inch - Dia 73.00 Inch - Dia
72 72.000 Supply of CS
Welder
Shift 602.00 Shift
73 73.000 Supply of
gascutter or
grinder
Shift 463.00 Shift
74 74.000 Supply of
fabricator
or fitter
Shift 463.00 Shift
75 75.000 Supply of
rigger
Shift 392.00 Shift
76 76.000 Supply of
Mason
Shift 543.00 Shift
77 77.000 Supply of
Carpentor
Shift 543.00 Shift
78 78.000 Supply of
Gunman
Shift 1,111.00 Shift
79 79.000 Supply of
Nozzleman
Shift 1,111.00 Shift
80 80.000 Supply of
Helper
Shift 327.00 Shift
Cont on next page . . 12000438 - HD - 46002
Page 93 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
81 81.000 Mobilization
&
Demobilizati
on
Lump Sum 225,996.00 Lump Sum
82 82.000 Mobilization
&
Demobilizati
on
Lump Sum 45,199.00 Lump Sum
83 83.000 Chipping &
Removal of
Refracto
Square
Meters
689.00 Square
Meters
84 84.000 Refractory
Casting upto
3"
Square
Meters
3,930.00 Square
Meters
85 85.000 Chipping &
Removal of
Abrasion
Square
Meters
1,867.00 Square
Meters
86 86.000 Application
of abrasion
resist
Square
Meters
2,751.00 Square
Meters
87 87.000 Gunniting of
Refractory
upto 3
Square
Meters
3,243.00 Square
Meters
88 88.000 Painting - Square 689.00 Square
Cont on next page . . 12000438 - HD - 46002
Page 94 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
Piping &
Pipe Fitti
Meters Meters
89 89.000 Air cleaning
of FD fan
suction
Lump Sum 786.00 Lump Sum
90 90.000 Shifting of
tube bundle
of ste
Each 4,736.00 Each
91 91.000 Stress
Relieving
upto 1.5"
dia
Inch - Dia 590.00 Inch - Dia
92 92.000 Stress
Relieving
above 1.5"
an
Inch - Dia 504.00 Inch - Dia
93 93.000 Stress
Relieving
for all
sizes
Inch - Dia 335.00 Inch - Dia
94 94.000 Radiography
upto 1.5"
dia. (ap
Inch - Dia 718.00 Inch - Dia
95 95.000 Radiography
- above 1.5"
Inch - Dia 479.00 Inch - Dia
Cont on next page . . 12000438 - HD - 46002
Page 95 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
dia.
96 96.000 Radiography
- above 3"
dia. an
Inch - Dia 318.00 Inch - Dia
97 97.000 Radiography
for all
sizes (whe
Inch - Dia 214.00 Inch - Dia
98 98.000 Re-tubing of
Exchangers/S
ulphu
Tube 1,350.00 Tube
99 99.000 Hydrogen
Diffusion of
Exchange
Square
Feet
6,873.00 Square
Feet
100 100.000 Butt joint
AS/SS -
X-ray quali
Inch - Dia 1,116.00 Inch - Dia
101 101.000 Butt joint
AS/SS -
X-ray quali
Inch - Dia 973.00 Inch - Dia
102 102.000 Fillet joint
AS/SS with
TIG ro
Inch - Dia 429.00 Inch - Dia
103 103.000 Fillet joint
AS/SS with
Inch - Dia 372.00 Inch - Dia
Cont on next page . . 12000438 - HD - 46002
Page 96 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
TIG ro
104 104.000 SS/AS Weld
run jobs-
weld run
Running
Feet
743.00 Running
Feet
105 105.000 SS weld
build up
with
electric
Square
Inches
172.00 Square
Inches
106 106.000 SS weld
build up
with diesel
m
Square
Inches
200.00 Square
Inches
107 107.000 Supply of SS
/ AS / TIG
welder
Shift 1,073.00 Shift
108 108.000 Annual
Inspection
of WHB / Sul
Lump Sum 68,781.00 Lump Sum
109 109.000 Supply of
Hydra (10 T
capacity
Hour 893.00 Hour
110 110.000 Material
Handling
Trip 884.00 Trip
111 111.000 Replacement Running 197.00 Running
Cont on next page . . 12000438 - HD - 46002
Page 97 ofSign and Seal of the Tenderer 99
Sr.
No.
Tender Line
Number
Ref
Line No
Item
Number
Item
Description
Quantity Qty
UOM
Schedule of
Rates (A)
Purchasing
UOM
of Casing
Plates o
Feet Feet
Cont on next page . . 12000438 - HD - 46002
Page 98 ofSign and Seal of the Tenderer 99
Quoted % applicable to the schedule of rates specified in table above for all the Items/Services
______________ % (in figures) ___________________________________________Percent (in words).
Signature :
Seal :
(Tenderer)
End of Document 12000438 - HD - 46002
Page 99 ofSign and Seal of the Tenderer 99
Page 1
VISAKH REFINERY
HINDUSTAN PETROLEUM CORPORATION LIMITED - VISAKH REFINERY
TENDER DOCUMENT
FOR
ANNUAL SERVICE CONTRACT FOR
OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS IN
VR
RFQ No.12000438-HD-46002/VNK
OFFICE OF DEUPTY GENERAL MANAGER (I/C) -
MATERIALS
MATERIALS DEPARTMENT – VISAKH REFINERY
ADMINISTRATIVE BLOCK - A, FIRST FLOOR, WEST WING
MALKAPURAM
VISAKHAPATNAM -- 530 011
ANDHRA PRADESH
Tel: 0-891 / 289.4309 & 289.4300
Fax: 0-891 / 257.7139 & 257.7824
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
Seal of the Vendor Page 2 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery
CONTENTS
PAGE NOs.
I. Important Dates & Events and Commercial Details 03 - 04
II. Bidding Procedure 05 - 08
III. Prequalification Criteria 09 - 11
IV. Scope of Job and Important Terms & Conditions 12 - 25
ANNEXURE:
Annexure I : FORMAT FOR BANK GUARANTEE IN LEIU OF EMD. Annexure II : DECLARATION Annexure III : GENERAL TERMS & CONDITIONS OF WORKS CONTRACTS Annexure IV : SAFETY REGULATIONS FOR CONTRACTTORS Annexure V : SWP-01 SPECIFICATION FOR PPE Annexure VI : SWP-02 MINIMUM PPE FOR VARIOUS ACTIVITIES Annexure VII : SWP-06 CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE Annexure VIII : SAFETY, HEALTH & ENVIRONMENT Annexure IX : FORMAT FOR WORKMEN PHYSICAL FITNESS CERTIFICATE Annexure X : PENALIES FOR NON-COMPLIANCE Annexure XI : FORMAT FOR ANTECEDENT VERIFICATION CERTIFICATE Annexure XII : RADIOGRAPHY RULES Annexure XIII : SPECIFICATIONS FOR FIRE RETARDANT CLOTH Annexure XIV : QUALIFICATION & CRITERIA FOR AGENCY’S SAFETY SUPERVISOR’S Annexure XV : MINIMUM RESOURCES TO BE MOBILIZED
* * * * * * * *
RFQ No. 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS
Seal of the Vendor Page 3 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery
IMPORTANT DATES &EVENTS
S.No. TIME & DATE EVENT SUBMISSION MODE REMARKS
1 11:00 a.m. on
02-Nov-2012
Due Date for
Submission of Tender
Fee, EMD, Unpriced &
Priced Offers
Tender Fees, EMD,
Unpriced Bid and Priced
Bid to be submitted in
separate Sealed
Envelopes
In 4 Separate Envelopes:
1. Tender Fees 2. EMD/ Exemption Details
3. UnPriced Bid 4. Priced Bid
All together in one sealed
envelope subscribed with
Tender No., Due Date &
Tender Description,
Tenderer’s Name & Address.
IMPORTANT NOTES:
1.0. This Tender Document can be Downloaded from the following websites: http://www.hindustanpetroleum.com.
1.1. Tenderer have a choice of either obtaining the documents from the office of DGM (I/C) - Materials (address given below at 1.9.) or by downloading the relevant tender documents from website indicated at 1.0. above.
1.2. All the Tenderers who download this Tender Document shall pay the Tender Fees of R5,000/- (Rupees Five Thousand Only) along with the submission Tender in a separate sealed envelope.
* * * * * * * * *
RFQ No. 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS IMPORTANT DATES & EVENTS AND COMMERCIAL DETAILS
Seal of the Vendor Page 4 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery
IMPORTANT COMMERCIAL DETAILS
1.0. TENDER FEES:
1.1. Tenderers shall submit the Tender Fees of R5,000/- (Rupees Five Thousand only) in the form of a Demand Draft issued by a Scheduled Bank (other than Co-Operative Banks) in favour of Hindustan Petroleum Corporation Limited, payable at Visakhapatnam. It is to be noted that Tender Fee is non-refundable.
1.2. Kindly note that all the Tenderers who download this Tender Document (whether interested to participate in the Bidding process or not) shall send us the Tender Fees of R5,000/- (Rupees Five Thousand only) as specified above, to the office of DGM(I/C)-Materials.
1.3. Tenderers registered with National Small Scale Industries Corporation (NSIC) are exempted from Tender Fees. For this purpose, a copy of the valid NSIC registration Certificate should be submitted. 1.4. Tenders received without Tender Fee will be rejected other than those who are exempted. 2.0. EMD (EARNEST MONEY DEPOSIT):
2.1. Tenderers should submit EMD (Earnest Money Deposit) of R1,70,000/- (Rupees One Lakh Seventy Thousand only).
2.2. EMD shall in the form of Demand Draft issued by a Scheduled Bank (other than Co-operative Banks) in favour of Hindustan Petroleum Corporation Limited, payable at Visakhapatnam (OR) in the form of Non-revocable Bank Guarantee on R100/- (Rupees One Hundred only) non-judicial stamp paper (as per format enclosed) issued by a Scheduled Bank (other than Co-Operative Banks).
2.3. Any Bank Guarantee submitted by a tenderer shall be confirmed by the Issuing Bank within 10 days of receipt of HPCL’s letter requesting for confirmation that it is genuine and validly issued in favor of HPCL.
2.4. Public Sector Enterprises and Tenderer registered with National Small Scale Industries Corporation (NSIC) are exempted from EMD. For this purpose, in the event of the tenderer being a Public Sector Enterprise, a declaration to that effect and in case of tenderers registered with NSIC, a copy of the registration Certificate should be submitted. 2.5. Tenders received without Earnest Money Deposit will be rejected other than those who are
exempted. NOTE: HPCL shall not be responsible for any expense incurred by tenderers in connection with the
preparation & acceptance of Bid and any other expenses incurred, for submission of bid.
* * * * * * * * *
RFQ No. 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
BIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDURE
Seal of the Vendor Page 5 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery Visakh Refinery
1.0. SUBMISSION OF OFFER/ MODE OF BIDDING: ============================================= 1.1. The Tenderer shall submit their offer in FOUR ENVELOPE System as detailed below: 1.2. Tenderer should submit the Tender Fee, EMD, Un-Priced and Priced Bid in separate sealed envelopes. All the envelopes should be superscribed with the RFQ No., RFQ Date, RFQ Due Date and Tenderer's Name & Address. 1.3. In case either (a) the Tenderer submits any two or more of above documents, in the same envelope, or (b) Documents are submitted in differently titled envelopes, or (c) Prices are mentioned in any of these envelopes, or (d) EMD and/ or Tender Fee is not submitted in separate sealed envelope but instead submitted along with Un-Priced Bid or the Priced Bid, such Offers shall be summarily REJECTED, WITHOUT ANY reference to and/ or correspondence with the Vendor.
1.4. TENDER FEE (Envelope No.1): =============================== 1.4.1. The Tender Fee shall be submitted in a separate envelope duly superscribed “Tender Fee” along with HPCL-VR’s RFQ No., RFQ Date, RFQ Due Date and Vendor’s Name & Address. 1.4.2. Please refer clause no.1.0. of Important Commercial Clauses for details of Tender Fees such as Amount as well as mode of payment of the same. 1.5. EARNEST MONEY DEPOSIT (Envelope No.2): ========================================== 1.5.1. The Earnest Money Deposit shall be submitted in a separate envelope duly superscribed “Earnest Money Deposit” along with HPCL-VR’s RFQ No., RFQ Date, RFQ Due Date and Vendor’s Name & Address. 1.5.2. Please refer clause no.2.0. of Important Commercial Clauses for details of Earnest Money Deposit such as Amount as well as mode of payment of the same. 1.6. UNPRICED BID (Envelope No.3): ================================== Please ensure to Submit, in duplicate, the following as Un-Priced Bid:
1) All the Notarised Documents in support of fulfilling their pre-qualification criteria (as specified under PRE-QUALIFICATION CRITERIA, clause no.2.0 to 2.5).
2) A Covering Letter, on Tenderer’s Letter Head, confirming unconditional acceptance to all the terms & conditions contained in HPCL's RFQ and WITHOUT any deviation except deviations if any, given in the deviation list specified at (5) below.
3) All pages of this Tender Document and all its Annexures, duly signed and stamped. 4) Declaration on your Letter Head, confirming that agency have not been banned or
delisted by any Government or Quasi Government agencies or Public Sector Undertakings / Enterprises.
RFQ No. 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
BIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDURE
Seal of the Vendor Page 6 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery Visakh Refinery
5) Deviation List: In case of any deviation, the tenderer has to mention the same in this document (titled as “Deviation List”) on their Letter Head. Deviation mentioned in any other place will not be considered. 1.7. PRICED BID (Envelope No.4): ============================= 1.7.1. Tenderer has to quote a SINGLE Percentage (above or below, + / - ) on the schedule of
rates specified by HPCL in this RFQ, in the Priced Bid Format. Please note that the same percentage shall be applicable for all items of this Enquiry, without exception.
1.7.2. The offer of Tenderers quoting separate / different rates and / or separate / different percentages for different items, shall be summarily rejected, without further reference / correspondence to the Tenderer.
1.7.3. The Percentage should be quoted in Figures as well as in Words. 1.7.3.1. If some discrepancies are found between the rate quoted in words and figures in the tender,
the rate as quoted in words shall be adopted. 1.7.4. The Rate(s) quoted shall be towards all cost including Mobilization and Demobilization,
Packing, Forwarding, Freight, Octroi and all Taxes & Duties (viz., Sales Tax, Works Contract Tax, Entry Tax, Excise Duty, Customs Duty, etc.), Cess and any other levies, etc. that are applicable during the execution of contract till completion of work, but EXCLUDING Service Tax and Cess on Service Tax. The rate thus quoted shall be FIRM during the entire period of the contract till completion of the job and no escalation in the rates for any reason whatsoever shall be payable by HPCL.
1.7.5. Please enter the applicable Service Tax and Cess on Service Tax, only in the UNPRICED/ TECHNO COMMERCIAL BID.
1.7.5.1. Any upward variation in Service Tax and Cess on Service Tax shall be reimbursed by HPCL provided any upward variation has come into existence after the opening of un-priced bid. Any downward variation in Service Tax and Cess on Service Tax occurring after opening of Un-Priced Bid shall be passed on to HPCL.
1.7.6. Please note that Service Tax and Cess on Service Tax, shall be payable only if the following conditions are fulfilled:
1.7.6.1. Service Tax shall be paid extra, in accordance with the rate prevailing (before the contractual date of completion) as per the Statutory Provisions and Rules relating to Service Tax.
1.7.6.2. The Tenderer should submit a photocopy of the Certificate from the Service Tax Authorities allocating them their unique 15-digit PAN based STC Number. And this 15-digit PAN based STC Number should be quoted on their Invoice.
1.7.6.3. The Tenderer should submit a photocopy of the Certificate of Registration with the Service Tax Authorities allocating their Registration Number. And this Registration Number should also be quoted on their Invoice.
1.7.6.4. In case of PO, the Tenderer should show the Service Tax component as a separate Item in their Invoice/ Bill/ Challan.
RFQ No. 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
BIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDURE
Seal of the Vendor Page 7 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery Visakh Refinery
1.7.6.5. In case of PO, whenever called for by HPCL, the Tenderer shall furnish documentary evidence of having paid the Service Tax payable against the PO, to the Service Tax Authorities.
1.7.6.6. The Tenderer shall provide all necessary documents to enable HPCL to avail the CENVAT credit, as per the prevailing guidelines of Service Tax authorities.
1.8. ESTIMATED FINANCIAL LIMIT: ================================== 1.8.1. The services shall be requisitioned as and when the need arises and the actual quantities shall
be communicated to the Agency, from time to time. 1.8.2. The Total Estimated Financial Limit of this job is R85,00,000/- (Rupees Eighty Five Lakhs),
which is proposed to be distributed between 2 agencies in the ratio of 60:40. The order will be placed on the lowest tenderer with the rate accepted by HPCL for 60% of the total ordered value. This lowest accepted rate will be counter offered to the L2 tenderer for their acceptance based on which the order will be placed for 40% of the total ordered value. However, HPCL reserves the right to allocate the Total Financial Limit to the lowest tenderer.
1.8.3. In case more than 1 tenderer quotes the same lowest (L-1) rate, the total ordered value will be equally apportioned between all such tenderers only.
1.8.4. In case only one tenderer quotes the lowest (L-1) rate and in case more than 1 tenderer quotes the same second lowest (L-2) rate, the remaining 40% of the total ordered value will be equally apportioned between all such tenderers only.
1.8.5. However, HPCL reserves the right to allocate the Total Financial Limit to the lowest tenderer and/or any other ratio.
Tenders received after the stipulated date and time for receipt of the tenders, due to any reasons whatsoever, shall be rejected. 1.9. ADDRESS FOR SUBMISSION OF BIDS: =====================================
The Bid should be submitted at the following address, before the Due Date and Time specified in the RFQ:
OFFICE OF DEPUTY GENERAL MANAGER (I/C) - MATERIALS MATERIALS DEPARTMENT – VISAKH REFINERY ADMINISTRATIVE BLOCK - A, FIRST FLOOR, WEST WING MALKAPURAM VISAKHAPATNAM -- 530 011 ANDHRA PRADESH
RFQ No. 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
BIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDUREBIDDING PROCEDURE
Seal of the Vendor Page 8 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery Visakh Refinery
Tel : 0-891 / 2894300 & 2894305 Fax : 0-891 / 257 7139 & 257 7824 E-Mail: [email protected], [email protected], [email protected] & [email protected]
• HPCL shall not be responsible for delay in receipt of the Tenders due to postal delays or any other reason whatsoever.
2.0. SEQUENCE OF OPENING OF ENVELOPES: ========================================= 2.1. The Envelopes shall be opened in the following order, on the due date for submission of
offers, i.e. on 02-Nov-2012 at 11 a.m. 2.1.1. Tender Fee 2.1.2. EMD 2.1.3. Un-Priced Bid
2.2. After the Tender Fee is established and found to be in order, the EMD/Exemption Details shall be opened. After EMD/Exemption Details are established and found to be in order, the Un-Priced Bid Envelope shall be opened.
* * * * * * * * * *
RFQ No.12000162-HD-46002/RD ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS PREPREPREPRE----QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA
Seal of the Vendor Page 9 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery
1.0. Tenderers intending to participate in this tender shall fulfill BOTH the qualification criteria, stipulated at 1.1. & 1.2. below.
1.1. FINANCIAL CRITERIA: Average Annual Financial Turnover during the last 3 years,
ending 31-March-2012, should be at least r25 Lakhs (Rupees Fifteen Lakhs Only). 1.2. TECHNICAL CRITERIA: Tenderers shall have experience of having successfully carried
out and completed similar work during the last 7 years ending 30-Sept-2012 which experience should be any one of the following:
(a) Three similar completed works, each costing not less than the amount equal to R34 Lakhs. OR
(b) Two similar completed works, each costing not less than the amount equal to R42 Lakhs. OR
(c) One similar completed work costing not less than the amount equal to R68 Lakhs.
"Similar Work" shall mean tenderers should have successfully carried out & completed Static Equipment (i.e., Exchanges, Furnaces, Pressure Vessels, Piping etc.) Maintenance Jobs in any Refineries/ Petrochemical/ Fertiliser Industries in India, of the value of work(s) indicated at 1.2 above. Also, for the purpose of experience the tenderer should have carried out and completed at least one job of any value of Boiler Erection/ Maintenance Jobs (repairs, testing, etc.) in any type of Industries in India.
2.0. Tenderer shall furnish the following documentary evidence in support of the above Financial and Technical Criteria for Pre-Qualification, duly attested by a Notary:
2.1. Copy of Purchase Order(s) in support of similar work of value(s) indicated at 1.2 above. 2.2. Copy of Purchase Order as a proof of having experience in Boiler Jobs of any value in any
type of industries in India. 2.3. Copy of valid IBR certificate for from Andhra Pradesh IBR Authorities for repairs or
Overhauling of Boilers/ Steam Generators. 2.4. Details of the IBR Welders whom agency is likely to deploy for this contract and their valid
IBR Certificates and credentials. 2.5. Annual reports containing audited balance sheets and profit & loss accounts statement.
3.0. The tenderers should submit all the documents in the first instance (i.e., along with Unpriced Bid) itself, in support of fulfilling their qualification criteria. Offer of Tenderer’s shall be liable for rejection, if the documents at s.nos.2.0. to 2.5 are not submitted along with the Un-Priced Bid.
3.1. HPCL reserves the right to complete the evaluation based on the details furnished along with the bid, without seeking any additional information.
3.2. HPCL reserves the right to use their in-house information for assessment of Tenderer’s capabilities.
RFQ No.12000162-HD-46002/RD ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS PREPREPREPRE----QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA
Seal of the Vendor Page 10 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery
3.3. HPCL also reserves the right to reject any tender without assigning any reasons whatsoever. 4.0. Parties who are affiliates of one another can decide which Affiliate will make a bid. Only one
affiliate may submit a bid. Two or more affiliates are not permitted to make separate bids directly or indirectly. If 2 or more affiliates submit a bid, then any one or all of them are liable for disqualification. However upto 3 affiliates may make a joint bid as a consortium, and in which case the conditions applicable to a consortium shall apply to them.
4.1. “Affiliate” of a Party shall mean any company or legal entity which: (a) controls either directly or indirectly a Party, or (b) which is controlled directly or indirectly by a Party; or (c) is directly or indirectly controlled by a company, legal entity or partnership which directly or
indirectly controls a Party. “Control” means actual control or ownership of at least a 50% voting or other controlling interest that gives the power to direct, or cause the direction of, the management and material business decisions of the controlled entity.
5.0. Bids may be submitted by: a) a single person/ entity (called sole bidder); b) a newly formed incorporated joint venture (JV) which has not completed 3 financial years
from the date of commencement of business; c) a consortium (including an unincorporated JV) having a maximum of 3 (three) members; d) an Indian arm of a foreign company. 6.0. Fulfillment of Eligibility criteria and certain additional conditions in respect of each of the
above 4 types of bidders is stated below, respectively: a) The sole bidder (including an incorporated JV which has completed 3 financial years after
date of commencement of business) shall fulfill each eligibility criteria. b) In case the bidder is a newly formed and incorporated joint venture and which has not
completed three financial years from the date of commencement of business, then either the said JV shall fulfill each eligibility criteria or any one constituent member/ promoter of such a JV shall fulfill each eligibility criteria. If the bid is received with the proposal that one constituent member/ promoter fulfills each eligibility criteria, then this member/promoter shall be clearly identified and he/it shall assume all obligations under the contract and provide such comfort letter/guarantees as may be required by Owner. The guarantees shall cover inter alia the commitment of the member/ promoter to complete the entire work in all respects and in a timely fashion, being bound by all the obligations under the contract, an undertaking to provide all necessary technical and financial support to the JV to ensure completion of the contract when awarded, an undertaking not to withdraw from the JV till completion of the work, etc.
c) In case the bidder(s) is/are a consortium (including an unincorporated JV), then the following conditions shall apply:
1) Each member in a consortium may only be a legal entity and not an individual person; 2) the Bid shall specifically identify and describe each member of the consortium;
RFQ No.12000162-HD-46002/RD ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS PREPREPREPRE----QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA QUALIFICATION CRITERIA
Seal of the Vendor Page 11 Signature & Name of the Authorised Signatory
with Date
Visakh Refinery Visakh Refinery
3) the consortium member descriptions shall indicate what type of legal entity the member is and its jurisdiction of incorporation (or of establishment as a legal entity other than as a corporation) and provide evidence by a copy of the articles of incorporation (or equivalent documents);
4) One participant member of the consortium shall be identified as the “Prime member” and contracting entity for the consortium;
5) this prime member shall be solely responsible for all aspects of the Bid/Proposal including the execution of all tasks and performance of all consortium obligations;
6) the prime member shall fulfill each eligibility criteria; 7) a commitment shall be given from each of the consortium members in the form of a letter
signed by a duly authorized officer clearly identifying the role of the member in the Bid and the member’s commitment to perform all relevant tasks and obligations in support of the Prime/lead member of the Consortium and a commitment not to withdraw from the consortium;
8) No change shall be permitted in the number, nature or share holding pattern of the Consortium members after pre-qualification, without the prior written permission of the Owner.
9) No change in project plans, timetables or pricing will be permitted as a consequence of any withdrawal or failure to perform by a consortium member;
10) No consortium member shall hold less than 25% stake in a consortium; 11) Entities which are affiliates of one another are allowed to bid either as a sole bidder or as a
consortium only; 12) Any person or entity can bid either singly or as a member of only one consortium. d) In case the bidder is an Indian arm (subsidiary, authorized agent, branch office or affiliate) of
a foreign bidder, then the foreign bidder shall have to fulfill each eligibility criteria. If such foreign company desires that the contract be entered into with the Indian arm, then a proper back to back continuing (parent company) guarantee shall be provided by the foreign company clearly stating that in case of any failure of any supply or performance of the equipment, machinery, material or plant or completion of the work in all respects and as per the warranties/ guarantees that may have been given, then the foreign company shall assume all obligations under the contract. Towards this purpose, it shall provide such comfort letter/guarantees as may be required by Owner. The guarantees shall cover inter alia the commitment of the foreign company to complete the entire work in all respects and in a timely fashion, being bound by all the obligations under the contract, an undertaking to provide all necessary technical and financial support to the Indian arm or to render the same themselves so as to ensure completion of the contract when awarded, an undertaking not to withdraw from the contract till completion of the work, etc.
* * * * * * * * *
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
SPECIAL CONDITIONS OF THE CONTRACT (SCC): ===========================================
This SCC should be read in conjunction with GTCWC (General Terms & Conditions of Works Contract) . In case of any contradiction between the said documents, SCC will be applicable only to the extent of such variance.
1.0. SCOPE OF JOB: ~~~~~~~~~~~~~~~~~~~~~ 1.1. Carrying out overhauling / annual / biennial Inspection of boilers & steam generators in the
Refinery as per scope mentioned against each item. 1.2. Carrying out various IBR piping replacement jobs in the Refinery 1.3. Coordination with IBR authorities for their stage wise approval for completion of the jobs i.e.
agency shall coordinate with IBR authorities for obtaining approvals for the jobs carried out by them inside HPCL. Agency to note that coordination for approval of drawings by IBR authorities for new schemes / modifications etc. is excluded from this scope.
1.4. Co-ordination with Director of Boilers, Hyderabad for obtaining approval / authorization for any repair / replacement job (for example exchanger re-tubing jobs) is excluded from agency’s scope. However, co-ordination for obtaining necessary Certification & Inspection from Inspector of Boilers & DCIB is included in agency’s scope and is part of scope of job. This clause is applicable to all the items of this order.
1.2. OTHER TERMS & CONDITIONS: ===================================== 1.2.1. HPCL's "General Terms & Conditions of Works Contracts" & "Safety Regulations for
Contractors" form an integral part of this order.
1.2.2. Agency to abide by the Refinery's safety rules and regulations without any deviation.
1.2.3. Good housekeeping forms part of the scope and is to be carried out on a daily basis.
1.2.4. The entire job at all stages will be subject to HPCL Inspection and approval.
1.2.5. Agency shall give two telephone nos., preferably of the owner and supervisor for passing on information regarding emergency jobs which may come up beyond normal working hours. On intimation party shall mobilize the resources within 2 hours. Failure to respond to calls from HPCL or failure to mobilize resources within time as informed by the job engineer will be viewed very seriously.
1.2.6. As this is an order to meet regular as well as emergency maintenance requirements of the refinery operations, agency shall be ready for carrying out assigned jobs round the clock.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
Agency shall mobilize the necessary material, manpower, tools, equipment etc., for carrying out the jobs immediately on intimation. Agency shall mobilize material in sufficient quantities in line with the schedule of the work.
1.2.6.1. Outstation agencies/organizations, located outside Visakhapatnam, have to open an office in Visakhapatnam with Two responsible contact persons based at Visakhapatnam for this job. These persons shall have valid mobile telephone numbers and shall be available on round the clock basis, without which the jobs cannot be awarded. They are required to submit an undertaking to that effect - that an office with necessary staffing, tools and tackles shall be opened at Visakhapatnam and will be operational throughout the period of this contract, with responsible persons posted to work on round the clock basis, as required. This undertaking shall be submitted along with the Unpriced Bid, failing which the offer shall be rejected.
1.2.7. In case the agency fails to carry out jobs as per the instructions of the concerned job engineer within the scheduled time, HPCL reserves the right to get the job done by any other agency of its choice and recover the differential expenditure and overheads from the agency.
1.2.8. Agency shall co-ordinate with other agencies working in the same area and working on associated jobs and works in a conducive environment during the course of work execution, towards expeditious and safe completion of jobs.
1.2.9. Agency shall prepare and obtain measurement certification for the jobs completed within 3 days of completion of jobs. Also agency shall prepare and submit schematic diagram of pipeline duly signed by the job engineer. The drawing shall provide minimum information of pipe size, length of pipe, pipe specification, no. of fittings, no. of prefabrication joints & field joints, no. of joints with diesel / electrical welding machine, etc. Both Job completion certificate and certified pipeline schematic diagram to be submitted along with monthly RA bills.
1.2.10. For the jobs completed, as per the duration for submission of bills agreed to, running bills should be numbered and dated, indicating clearly the period of measurement covered should be submitted every month in the Box provided in the Disbursement Section. Agency shall submit the bills to Maint.-Planning within stipulated time given (within first week of every month).
1.2.11. Material shall be brought inside Refinery through valid gate passes. Agency shall submit all these documents, weighment slips, material reconciliation statement duly signed by the Job engineer along with the bill, if requested by job engineer.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
1.2.12. Material under HPCL's scope of supply shall be issued from any location within the refinery including ATP. Transportation (includes loading & unloading) of required materials from any designated location to work site and vice versa as per the instructions of the job engineer is part of the scope. The area covered shall be within ATP & Refinery Area.
1.2.13. Transportation of scrap/debris from the work site, weighment and dumping at designated location as instructed by the job engineer is included in the job scope.
1.2.14. Agency shall carry out the jobs as instructed by the Job Engineer at any elevation. The agency shall provide required scaffolding for comfortable working and completion of the job.
Scaffolding to be erected with 1-1/2" dia. Steel tubular pipe with suitable and safe clamping arrangement. Distance between adjacent vertical members shall not be more than six feet and distance between adjacent horizontal members shall not be more than three feet. Proper MS Gratings to be laid on Horizontal pipe and the gratings must be tied to the Horizontal members by GI wire.
In all cases, rates for Scaffolding are included in the respective item rates, unless otherwise specified.
1.2.15. Agency has to ensure that all manpower deployed for the job shall be covered under the provision of all statutory acts like ESI, EPF, Minimum wages, etc. and agency shall submit proofs of the same on demand to the Manager Onsite. Agency's proprietor/authorized representative shall sign the temporary photo pass along with the concerned workmen which will be certified by CISF for entry into Refinery.
1.2.16. Unless otherwise specified, no idling charges are payable for any idling of agency's manpower & Equipment due to non-availability of inspection, non-availability of work permits due to operational constraints, non-availability of materials required for the job.
1.2.17. Corporation will arrange to dismantle control instruments or their components that interfere with the work of the agency and reinstall on completion of work. Agency shall inform the corporation about any such item interfering in their work.
1.2.18. HPCL reserves the right to split/off-load the job, if progress of work is found satisfactory at any stage and assign the same to any other agency as deemed fit and all the consequential expenses in this regard shall be borne by the agency.
1.219. Agency shall be prepared to cut gaskets from sheets in case of non-availability of gaskets
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
1.2.20. Agency shall be prepared to cut corroded bolts of the flanged joints and replace with new / serviced bolts during arresting flange leaks, blinding, de-blinding, etc. at no extra cost
Agency shall not resort to cutting the bolts to open the joint unless the threads are damaged / corroded.
1.2.21. Any damage to the HPCL's chain pulley blocks shall be repaired / replaced by the Agency free of cost. Also, agency shall thoroughly clean, grease the chain pulley blocks after and before handing over to HPCL. For opening of bigger size bolts, torque wrench shall be used, if required. Torque wrench shall be issued by HPCL. In case of damage to the torque wrench, the agency shall repair / replace free of cost.
1.2.22. A job is said to be completed only when housekeeping of that job area is completed. Unless housekeeping is not completed, respective job completion challan/certificate will not be approved/issued. Agency to segregate ferrous & non-ferrous scrap, as adviced by Job Engineer. Scrap/un- useful material shall be shifted immediately after completion housekeeping to respective scrap yard or designated area within Refinery/ATP as advised by Job Engineer.
Agency to submit material reconcilation sheet for each job along with job completion challan and upon advice of Job Engineer, agency to handover unused material to Warehouse.
1.2.23.In case any electrodes/filler wire/other consumables supplied by HPCL, when agency fails to arrange the same within specified time limit, amount equivalent to material supplied by HPCL and 15% handling charges will be deducted from monthly RA bills. However, it is considered as non-compliance to PO terms by agency and are not always entertained.
1.3. SAFETY, HEALTH & ENVIRONMENT: ===================================== 1.3.1. The agency shall provide all their personnel with the requisite personal protective equipment
like safety shoes, protective clothing, safety helmet, safety belts, gloves, safety goggles, adequate lighting in the work area. Failing to comply with this shall result in stoppage of work. Agency shall ensure to use minimum safety PPE as per IS specifications for all workmen engaged as applicable for the job (Refer Annexure-V: SWP-01 for IS Specifications). Details of minimum PPE required for various jobs are mentioned in Annexure-VI: SWP-02 and agency shall abide by the guidelines given in these Annexures. Agency may approach Maintenance Onsite Planning for details of suppliers of PPE conforming to IS standards, if required.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
1.3.2. Agency has to designate a safety supervisor, having minimum 3 years of refinery experience and well versed with Refinery Safety Procedures and Practices. The safety supervisor has to be certified by Fire & Safety Dept. Agency shall deploy such qualified safety supervisors during the course of work to ensure the jobs carried out are in compliance with Refinery safety requirement and as per procedure. Qualification and Criteria for Safety Supervisor are mentioned in Annexure-XIV attached with this enquiry. It may be noted that penalty shall be levied on the contractor for violation of safety for each incident. Penalty amount will be decided by HPCL and shall be binding on the agency.
1.3.3. Agency shall ensure to abide SHE (Safety, Health, Environment) guidelines described as per Annexure-IV which is attached along with this tender enquiry.
1.3.4. Agency shall ensure that the age of workmen deployed to carryout various jobs in the Refinery is in between 18 to 58 years. As per Factories act, workmen below 18 years are not allowed to work in Factory/Refinery. HPCL will not issue the gate passes for the workmen whose age is below 18 years and above 58 years to work in the Refinery.
1.3.5. Agency shall ensure that all the workmen employed by him are medically fit and will submit the Fitness certificate as per attachment (Physical Fitness Certificate Format (Annexure-IX) along with this tender enquiry. The fitness certificates shall be submitted while applying for gate passes. The certificate shall be issued by registered Doctor and the certificate shall be not older than 3 months to the date of submission of certificate.
1.3.6. Agency to abide by the up-to-date Refinery's safety rules and regulations as long as jobs are taken up. In case any deviation is taken by agency from prevailing Safety rules & regulations, penalty is levied on agency. The penalty amount is finalized by Job Engineer / F&S Officer based on the nature and severity of deviations taken or observed. The type of deviations and approx. penalty amounts are indicated in Annexure-X (attached along with this tender enquiry). This penalty amount is deducted from agency's RA bill or to be paid by agency in the form of DD/Cheque etc. upon advice of Job Engineer.
1.3.7. Agency shall submit the Antecedent Verification Report of his workmen from the respective Police Station and same should be submitted to HPCL, VR-HR department for obtaining the gate entry Photo passes to work in the Refinery. A specimen copy of letter addressed to Police Station (Annexure-XI) is enclosed along with this tender enquiry for agency's ready reference.
1.3.8. Agency's supervisor shall conduct a Safety pep talk in field with their workmen on daily basis and this Safety pep-talk shall consists of Safety rules and regulations to be followed while carrying out the assigned jobs. Agency shall maintain a record noting all the points discussed in Safety pep-talk on daily basis and that record shall be endorsed by all the workmen and Job Engineer.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
1.3.9. The maximum speed limit for motor vehicle within the Refinery premises is 25 KMPH. Vehicle and mobile equipment shall be driven cautiously and shall follow all traffic regulations and road signs. Vehicle driver shall have valid Refinery license issued by Fire & Safety Department.
1.3.10. Agency shall ensure to have a valid Refinery Driving License approved by F&S Dept. for all their Vehicle Drivers. To obtain new F&S approved driving license for their drivers, agency shall deposit a non-refundable amount of Rs.500/- in favour of F&S Dept., Visakh Refinery, HPCL and to do test drive in presence of F&S officer. Agency shall submit copies of Driving license issued RTA Dept. and Eye vision test certificate (duly endorsed by Refinery-Dispensary) to F&S for obtaining Refinery Driving License. Agency's vehicle drive shall always carry this valid License while driving the vehicle within Refinery premises.
1.3.11. Agency shall produce valid Vehicle Healthiness Certificate from RTA/authorised institution on the demand of HPCL for their vehicle engaged vide this order.
1.3.12. Agency shall ensure 100% compliance with Provisions of Atomic Energy (Radiation Protection) Rules-2004 for Radiography Agencies (Refer Annexure-XII for rules).
1.3.13. Agency shall ensure to have ready availability of fire extinguishers like DCP cylinders and fire retardant cloth of minimum 4 Sq.Mtr. for carrying out hot work jobs especially welding & gas cutting jobs. Stand by Fire hoses and nozzles for any hot work to be arranged by the agency. Specifications of Fire Retardant cloth & suggested vendors are mentioned in Annexure-XIII.
1.3.14. The agency shall arrange for lighting at work spots on its own and must ensure that adequate lighting is made available for carrying out the jobs on round the clock basis.
1.3.15. Agency shall use only those lifting tools and tackles (in their scope of supply) which are certified for intended usage by relevant statutory authority at any particular point of time Agency shall furnish test reports to that regard.
1.3.16. Agency shall strictly comply with electrical compliance requirement for its equipment and human safety. Agency shall ensure 100% compliance with following guidelines for usage of any electrical equipment¿s in allocated agency shed in the Refinery.
- Electrical Panel dummy holes shall always be plugged. - Sand buckets shall be provided near power panel. - Ensure proper glanding for incoming and outgoing cables. - Separate earthing to be done for each equipment. - Adequate lighting shall be provided in shed especially near electrical equipment¿s like
power panels. - Ensure the ELCBs used always in good condition. - Proper approach shall always be provided to reach panel and to operate the panel without
any obstructions.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
1.3.17. Agency's shall ensure stenciling of their company name & other details on each and every equipment owned by them. All equipment brought by the agency shall be subjected to pre-use checks with respect to safety, condition and usability. The agency shall be required to submit a statement regarding the same prior to use.
1.3.18. Use of Wood within the Refinery is prohibited. Agency shall use steel in place of wood wherever required for the jobs like shuttering, crane movement, etc. In case any job requires usage of only wood, approval of F&S to be taken for the same prior to use.
1.3.19. Agency shall 100% comply with following guidelines/requirements for grit blasting jobs in Blasting Yard. Agency shall not be permitted to work in blasting yard unless the below mentioned items are complied.
- Valid Permit to be displayed as long as work is in progress in yard. - Relevant test certificates with due date are to be available for Hopper, Fire Extinguisher,
etc. - Fire hose in charged condition laid on road shall be covered with metal ramp for vehicle
movement on the road. - Area to be barricaded to prevent dust. For this, canopy / shelter to be used. - Compressor being used shall have spark arrester. Agency shall ensure no oil/diesel leaks
from the compressor unit. - Slag blaster shall use hood - Helpers shall use all applicable PPE: Dust Masks, Goggles, Boiler suits, etc. - Fine dust shall be sieved from the slag 1.3.20. Agency shall ensure to deploy adequate no. of qualified & well experienced Job supervisors
& Safety supervisors to carryout out various jobs simultaneously at various locations in various units or in same unit. Agency's Job Supervisor(s) shall report daily Manager(s)-Onsite to schedule day to day jobs. HPCL will reserve the right to deduct applicable amount (at the rate of Rs.1000/- per 12 hr shift per supervisor) from agency's RA Bill(s) for no. of days Job Supervisor & Safety Supervisor are not deployed.
1.3.21. Agency shall ensure to pay Penalty levied towards taking safety deviation(s) within stipulated time. Incase penalty is not paid in time, double the penalty amount will be deducted from RA Bills without any further intimation to the agency. Agency shall ensure to avoid safety deviation which will be viewed very seriously by HPCL.
1.3.22. Agency shall possess & maintain minimum 2 nos. Trunk Radios/Walkie Talkies for communication purpose. Agency's site in-charge/Supervisor shall carry this Walkie Talky for communicating with HPCL in the Refinery. Also, agency shall maintain a valid email id for regular correspondence throughout the contract period.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
1.3.23. Proper confinement using Tin/GI & Gasket sheets covered with Fire Retardant cloths shall be made for hot work jobs like Welding, Gas cutting, Grinding, Chipping, etc. to eliminate fall of sparks on live lines/equipment/oily floors.
1.3.24. While working at heights, agency shall carry out their tools & tackles in the protective bags to avoid falling. Also, tools like spanners, screw drivers, etc. shall be tied to work cloth of workmen while working at heights.
1.3.25. Agency's workmen shall undergo 'VERTIGO" test and necessary certificate approved by Registered Doctor shall be submitted to the Refinery F&S prior working at heights. Only the workmen who passed VERTIGO test and obtained F&S approval are allowed to work at heights.
1.3.26. Agency shall ensure to report the any incident first to F&S Dept. and causalities if any are to be taken first to Refinery Dispensary. Also, agency shall report any safety deviation first to Job Engineer.
1.3.27. All workmen of agency shall wear 'Boiler Suit/Cover All' dress as long as they are working inside the Refinery.
1.3.28. All workmen of agency shall possess a valid "Safety Training Card" issued by F & S dept. after attending safety training conducted by F & S. Gate passes will be issued only to workers/personnel having this valid training card.
1.3.29. All safety belts/welding machines to be used by the agency should be submitted to F & S for approval and tagging. Safety belts and welding machines that are tagged by F & S will be allowed to be used in refinery.
1.3.30. CCOE approved spark arresters shall be fixed to the exhaust of equipment like Cranes, Hydras, Tractors, and Diesel Generators and other equipment (which are having Diesel Engines).
1.3.31. All contractor equipment, tools and tackles shall be offered to F & S for periodical inspection. Any defective Equipment, tools and tackles shall not be used and shall be removed from the Refinery. Details of Contractor Equipment Safety assurance plan is mentioned in Annexure-VII attached with this tender.
2.0. HPCL's SCOPE OF SUPPLY: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 2.1. HPCL shall supply the following free of cost: 2.1.1. CS & SS Plates 2.1.2. Piping and pipe fittings, boiler tubes, tube fittings, valves, plugs, ferrules along with
Gaskets and gasket sheets, gland packing material 2.1.3. CS, SS anchor rods, hexmesh, SS plate for strip fabrication, refractory and insulation
material.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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2.1.4. All hardware including bolts, nuts and washers. 2.1.5. Crane and forklift 2.1.6. Electrical power from the nearest available power source points. Agency to make necessary
arrangements for onward distribution to the work spot strictly as per our Electrical Department Rules and Regulations.
3.0. CONTRACTOR's SCOPE OF SUPPLY/WORK: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 3.1. Skilled manpower with round the clock supervision for carrying out jobs safely and as per
procedure/instructions of the job engineer. 3.2. All tools and tackles and all consumables required to complete the job. 3.3. Fire water fittings / hoses, water hoses, DCP, CO2 Cylinders as approved by HPCL fire and
safety 3.4. All personal protective equipment including safety helmets, safety belts (double harness
type), safety shoes, goggles, ear plugs, face masks and hand gloves etc. 3.5. Scaffolding material including 1.5" dia pipes and clamps, gratings etc. 3.6. All required Tools & tackles, Rigging equipment, Chain pulley blocks, Wire ropes, D
Shackles etc. Agency to note that all the lifting equipment shall have necessary statutory certification and the same are to be submitted to Maintenance department, prior to job commencement.
3.7. Graphite and holdtite 3.8. All required machinery including welding machines, grinding machines (both flexible and
angle), buffing machine, tube bending machine etc. 3.9. Gas cutting equipment sets with cylinders as required. 3.10. Air, water and steam hoses. 3.11. Grit blasting and copper slag blasting units (inclusive of grit material, copper slag, air
compressor, hoses, nozzles) with fuel and skilled operators and supervision. 3.12. Tube rolling equipment, hydrotest pumps, wire brushes etc. 3.13. CS & SS welding electrodes (list of electrodes to be used is attached with this PO), DP
testing kit, WFMPT Kit 3.14. All required resources for SR & radiography 3.15. Hand lamps with 24 V transformers, metallic switchboards with ELCB, welding / electrical
cables etc. 3.1.16. All electrical equipment like electric panels used for power connection shall be provided with
ELCB, Source sign writing, danger sign boards, plugs for dummy holes and to be properly earthed.
3.1.17. Bundle supports, sleepers, Nylon slings and vaccum testing equipment
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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3.1.18. All refractory chipping and application tools, equipment and appliances including Paddle mixers, Gunniting equipment, Industrial vaccum cleaner etc.
3.1.19. Diesel driven compressor with accessories, operator and diesel. Using of open type diesel tanks for running any compressor/pump is prohibited inside the refinery. Agency shall use compressors/pumps with closed type diesel tanks only.
3.1.20. Tractor Trailor, Jeep and trolleys and Hydra. Drivers/Operators of any vehicle should have valid license from Refinery Fire & Safety Department and non-compliance to this may force HPCL to take any action against agency at their risk and cost.
3.1.21. All other resources required to complete the job in its entirety. 4.0. VALIDITY OF THE ORDER: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 4.1. ONE YEAR from the date of LOA/ PO, whichever is earlier. 5.0. JOB TO COMMENCE: ~~~~~~~~~~~~~~~~~~~~~~~~~~ 5.1. As advised by HPCL. 6.0. MOBILISATION TIME: ~~~~~~~~~~~~~~~~~~~~~~~~~~ 6.1. Within 10 days from the date of LOA/ PO, whichever is earlier, for the initial mobilization.
Subsequent mobilizations shall be done as per the advice of HPCL. 7.0. JOB TO COMPLETE: ~~~~~~~~~~~~~~~~~~~~~~~~~ 7.1. As advised by HPCL. 8.0. PRICE REDUCTION CLAUSE: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 8.1. Not Applicable. 9.0. PAYMENT SCHEDULE / TERMS: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 9.1. Monthly RA Bills, payable through e-Payment.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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9.2. For the jobs completed, as per the duration for submission of bills agreed to (upto 25th of every month), running bills numbered, dated and indicating clearly the period of measurement covered, should be submitted in the Box provided in the Disbursement Section for every month during first week of month.
9.3. Incase no jobs are executed in any month; agency shall submit NIL statement for that month
to the Manager-Onsite Planning. Agency's RA Bills shall be in computerized format to aid faster checking and processing of the bills.
10.0. SECURITY DEPOSIT: ~~~~~~~~~~~~~~~~~~~~~~~~ 10.1. The tenderer, with whom the contract is decided to be entered into and intimation is so given will have to make a security deposit of one percent (1%) of the total contract value in the form of account payee crossed demand draft drawn in favour of the Owner, within 15 days from the date of intimation of acceptance of their tender, failing which the Owner reserves the right to cancel the Contract and forfeit the EMD. 10.2. 1% of PO/Contract value as Security deposit will be acceptable in the form of Demand draft up to Rs. 50,000/- and in the form of Demand draft / Bank guarantee beyond Rs. 50,000/-. 10.3. Composite PBG for 10% of PO value towards Security Deposit and Performance bank guarantee shall be accepted (in lieu of retention money); which shall be valid up to a period of 3 months beyond the expiry of Defect liability period. Demand Draft should be drawn on Scheduled Banks, other than co-operative bank. 11.0. GUARANTEE: ~~~~~~~~~~~~~~~~~ 11.1. Agency shall guarantee the work executed/material supplied for a period of 12 months from
the date of completion of the job. Any damage or defect that may arise or lie undiscovered at the time of completion of the job shall be rectified or replaced by the agency at their own cost. The decision of the Engineer In charge/Owner shall be the final and binding on the agency undertaking this job, as to whether the defect has to be rectified or replaced.
11.0. RETENTION: ~~~~~~~~~~~~~~~~~~~ 11.1. 10% of the total value of the Invoice will be deducted and retained by the Owner as retention
money on account of any damage/defect liability that may arise for the period covered under the defect liability period clause of the Contract free of interest. Any damage or defect that may arise or lie undiscovered at the time of issue of completion certificate connected in any way with the equipment or materials supplied by contractor or in workmanship shall be rectified or replaced by the contractor at his own expense failing which the Owner shall be
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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entitled to rectify the said damage/defect from the retention money. Any excess of expenditure incurred by the Owner on account of damage or defect shall be payable by the Contractor. The decision of the Owner in this behalf shall not be liable to be questioned but shall be final and binding on the Contractor.
12.0. WORKS CONTRACT TAX: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 12.1. If the Works Contract Tax (WCT) is included in the price, please specify the percentage of
WCT included in the rate quoted in the Un-Priced bid. In such cases, HPCL requires a valid Tax Invoice displaying WCT quantum and AP VAT Registration No.
13.0. CONTACT PERSONS: ============================
13.1. FOR TECHNICAL QUERIES: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Mr. V Rameshbabu, Senior Manager, Maintenance - Onsite. Tel: 0891-2894278 Fax: 0891-2577499 e-mail: [email protected] 13.2. FOR COMMERCIAL QUERIES: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Mr.A.K. Ganguly ;Sr.Manager - Materials / Mr.V. Naveen Kumar ; Officer - Purchase Materials Department Tel: 0-891 / 2894309 & 2894312 Fax: 0-891 / 2577139 E-Mail: [email protected] & [email protected] 14.0. NOTES TO TENDERES: ~~~~~~~~~~~~~~~~~~~~~~~~~~~ 14.1. HPCL-VR’s "General Terms and Conditions of Works Contracts" and "Safety Regulations
for Contractors" forms an integral part of this tender. 14.2. Tenderer's offer should be valid for a period of 120 DAYS from the date of opening of the
Unpriced Bids. 14.3. Tenderer's offer is liable for rejection if it does not comply with the RFQ format or if it is
incomplete.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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14.4. Women workforce are not allowed inside the Refinery. 14.5. Manual Transport of load is limited to a maximum weight of 50 Kgs. 14.6. Use of hand drawn trolleys by agencies to shift the materials is not permitted in the Refinery. 14.7. All workmen engaged by the Tenderer for working at height shall have Medical certificate of
fitness for working at heights. 14.8. HPCL reserves the right to suspend the execution of the Purchase Order, in the event of
strike, accidents or any other contingencies, which are beyond HPCL's control. 14.9. Purchase / Price Preference: Purchase / Price preference, as applicable, shall be given to
Central Government Public Sector Enterprises and NSIC registered Units (only those who forward valid NSIC certificate, which clearly indicates the items for which they are registered), as per the existing and prevailing government guidelines, rules and regulations.
14.9.1. The prevailing Government of India guidelines for units registered under NSIC regarding exemption of Tender Fees, EMD & Security Deposit and Price Preference will be applicable. However relevant supporting documents must be furnished for claiming the same.
14.9.2. The prevailing Government of India guidelines for Central Public Sector Undertakings regarding exemption of EMD & Purchase preferences shall be applicable.
14.10. HPCL takes no responsibility for delay of non-receipt of EMD/ Exemption Details sent by
post or by any other means. EMD/ Exemption Details received after the due date and time will be rejected. Telex / Fax / E-mail offers are not acceptable.
14.11. The Tenderer should furnish on their letter-head a Declaration that they have not been
banned or de-listed by any government or Quasi-Government agencies or PSUs. If this Declaration is not furnished / submitted, the Tenderer’s Bid will be considered as non-responsive, and the Bids of such Tenderers shall be rejected. This declaration should be uploaded along with the other Unpriced Bid documents. Format of declaration is provided in page no.31 of 37.
14.12. The EMD shall be refunded to the unsuccessful bidders. The EMD of the successful bidder
would be released on submission of Security Deposit. The Security Deposit shall be returned after satisfactory completion of entire contract.
14.13. The offers of the agencies not meeting the prequalification criteria shall be rejected.
RFQ No. 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
SCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONSSCOPE OF JOB & IMPORTANT TERMS & CONDITIONS
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Visakh Refinery Visakh Refinery
14.14. GRIEVANCE REDRESSAL: There is a Grievance Redressal Mechanism in the Corporation for Tenderers participating in the tender, the details of which are available on the Corporation's website.
14.15. Bills will be paid by e-payment. 14.15.1. For the purpose of e-payment [EFT], the Tenderer(s) shall ensure that all the requisite
details prescribed by the Finance Department of HPCL-VR have been submitted/ updated. The correspondence regarding the registration for e-payment, should be addressed to
Mr.LeeladharVemula; Officer- Finance (E-Mail:[email protected]), with a copy to Mr.S. Ramesh, Manager - Finance, (E-Mail: [email protected]) and
Mr.M Akbar; Sr. Manager - Finance (E-Mail:[email protected]).
* * * * *
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS Annexure I : Annexure I : Annexure I : Annexure I : FORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMD
Visakh Refinery Visakh Refinery
(On Non-Judicial stamp paper of appropriate value) TO : HINDUSTAN PETROLEUM CORPORATION LIMITED
VISAKH REFINERY Malkapuram Visakhapatnam - 530011
IN CONSIDERATION OF MESSRS. HINDUSTAN PETROLEUM CORPORATION LIMITED a Government of India Company registered under the Companies Act, 1956, having its registered office at 17, Jamshedji Tata Road, Bombay-20 (hereinafter called "The Corporation" which expression shall include its successor in business and assigns) issued a tender on Messrs. ............................................ a partnership firm/sole proprietor business/a company registered under the Companies Act, 1956 having its office at (hereinafter called "the Tenderer" which expression shall include its executors, administrators and assigns) against Tender No......................... dated ........... (hereinafter called "the tender" which expression shall include any amendments/ alterations to "the tender" issued by "the Corporation") for the supply of goods to/execution of services for "the Corporation" and "the Corporation" having agreed not to insist upon immediate payment of Earnest Money for the fulfillment of the said tender in terms thereof on production of an acceptable Bank Guarantee for an amount of R....... (Rupees ................................. only). 1. We, ................................................ Bank having office at ..................................(hereinafter referred to as "the Bank" which expression shall include its successors and assigns) at the request and on behalf of "the Tenderer" hereby agree to pay to the Corporation without any demur on first demand an amount not exceeding R...........(Rupees ...................................... only) against any loss or damage, costs, charges and expenses caused to or suffered by "the Corporation" by reason of non-performance and fulfillment or for any breach on the part of "the Tenderer" of any of theterms and conditions of the said "tender". 2. We, ......................... Bank further agree that "the Corporation" shall be sole Judge whether the said "Tenderer" has failed to perform or fulfill the said "tender" in terms thereof or committed breach of any of the terms and conditions of "the order" and the extent of loss,damage, cost, charges and expenses suffered or incurred or would be suffered or incurred by "the Corporation" on account thereof and we waive in favour of "the Corporation" all the rights and defences to which we as guarantors and/or "the Tenderer" may be entitled to. 3. We, ......................... Bank further agree that the amount demanded by "the Corporation" as such shall and binding on "the Bank" as to "the Bank" 's liability to pay and the amount demanded and "the Bank" to undertake to pay "the Corporation" the amount so demanded on first demandand without any demur notwithstanding any dispute raised by "the Tenderer" or any suit or other legal proceedings including arbitration pending before any court, tribunal orarbitrator relating thereto, our liability under this guarantee being absolute and unconditional.
Page 1 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS Annexure I : Annexure I : Annexure I : Annexure I : FORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMDFORMAT FOR BANK GUARANTEE IN LIEU OF EMD
Visakh Refinery Visakh Refinery
4. We, ......................... Bank furtheragree with "the Corporation" that "the Corporation" shall have the fullest liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the terms and conditions of the said "tender"/or to extend time of performance by "the Tenderer" from time totime or to postpone for any time to time any of the powersexercisable by "the Corporation" against "the Tenderer" andto forbear to enforce any of the terms and conditions relating to "the tender" and we shall not be relieved from our liability by reason of any such variation or extension being granted to "the Tenderer" or for any forbearance, actor ommission on the part of "the Corporation" or any indulgence by "the Corporation" to "the tenderer" or by any such matter or things whatsoever which under the law relatingto sureties would but for this provision have the effect of relieving us. 5. NOTWITHSTANDING anything hereinbefore contained, our liability under this Guarantee is restricted to R .........(Rupees......................... only). Ourliability under this guarantee shall remain in force until expiration of six months from the due date of opening of thesaid "tender". Unless a demand or claim under this guarantee is made on us in writing within said period, that is, on orbefore .................................... all rights of"the Corporation" under the said guarantee shall be forfeitedand we shall be relieved and discharged from all liabilities thereunder. 6. We, ......................... Bank further undertake not to revoke this guarantee during its currency except with the previous consent of "the Corporation" in Writing. 7. We, ......................... Bank lastlyagree that "the Bank"'s liability under this guarantee shall not be affected by any change in the constitution of "the Tenderer". 8. "The Bank" has power to issue this guarantee in favour of "the Corporation" in terms of the documents and/or the Agreement/Contract or MOU entered into between "the Tenderer" and "the Bank" in this regard. IN WITNESS WHEREOF the Bank has executed this document on this ............ day of .................
For ........................ Bank
(by its constituted attorney)
(Signature of a person authorised to sign on behalf of "the Bank")
* * * * * * * * *
Page 2 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS Annexure II : DECLARATIONAnnexure II : DECLARATIONAnnexure II : DECLARATIONAnnexure II : DECLARATION
Seal of the Vendor Signature & Name of the Authorised
Signatory with Date
Visakh Refinery Visakh Refinery
We, ____________________________________________ (Name of the company) hereby
declare that we have not been banned or delisted by any Indian Government or Quasi – India
Government agencies or Indian Public Sector Undertakings / Enterprises.
Sign
Name & Company Stamp
Note 1: If the Tenderer has been banned or delisted by any Indian Government or Quasi –
Indian Government agencies or Indian Public Sector Undertakings / Enterprises, this fact must
be clearly stated.
Note 2: If this declaration is not given, the bid will be rejected as non-responsive.
* * * * * * * * *
Page 3 of 209
Annexure - III to RFQ: 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
GENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTS
Seal of the Vendor
Signature & Name of the Authorised Signatory with Date
Visakh Refinery
1. PRELIMINARY
1.1 This is a Contract for execution of __________________ work at Visakh Refinery. (Please fill up the
blanks)
1.2 The tenderer for the abovementioned item of work is____________________________. (please give the
name and address of the tenderer)
1.3 The terms and conditions mentioned hereunder are the terms and conditions of the Contract for the
execution of the work mentioned under item 1.1 above.
1.4 It is the clear understanding between Hindustan Petroleum Corporation Limited and the tenderer
______________________________________ that (name and address of the tenderer) in case the tender of
____________________________________________________ ______________________ is (name and address
of the tenderer) accepted by Hindustan Petroleum Corporation Limited and an intimation to that effect is so issued
and also a Purchase Order is placed with _____________________________________________
________________________ (name and address of the tenderer) this document will be termed as a Contract
between the parties and terms and conditions hereunder would govern the parties interest.
1.5 Interpretation of Contract Documents: All documents forming part of the Contract are to be taken
mutually explanatory. Should there be any discrepancy, inconsistency, error or omission in the contract, the
decision of the Owner/Engineer-in-Charge/Site-in-Charge shall be the final and the contractor shall abide by the
decision. The decision shall not be arbitrable. Works shown upon the drawings but not mentioned in the
specification or described in the specifications without being shown on the drawings shall nevertheless be deemed
to be included in the same manner as if they are shown in the drawings and described in the specifications.
1.6 Special conditions of Contract: The special conditions of contract, if any provided and whenever and
wherever referred to shall be read in conjunction with General Terms and Conditions of contract, specifications,
drawings, and any other documents forming part of this contract wherever the context so requires.
Notwithstanding the subdivision of the documents into separate sections, parts, volumes, every section, part or
volume shall be deemed to be supplementary or complementary to each other and shall be read in whole. In case
of any misunderstanding arising the same shall be referred to decision of the Owner/ Engineer-in-Charge/Site-in-
Charge and their decision shall be final and binding and the decision shall not be arbitrable. It is the clear
understanding that wherever it is mentioned that the Contractor shall do/perform a work and/or provide facilities
for the performance of the work, the doing or the performance or the providing of the facilities is at the cost and
expenses of the work not liable to be paid or reimbursed by the Owner.
2. DEFINITIONS
In this contract unless otherwise specifically provided or defined and unless a contrary intention appears from the
contract the following words and expressions are used in the following meanings;
2.1 The term "Agreement" wherever appearing in this document shall be read as "Contract".
2.2 The "Authority" for the purpose of this Contract shall be the Chairman and Managing Director or any
other person so appointed or authorised.
2.3 The "Chairman and Managing Director" shall mean the Chairman and Managing Director of HINDUSTAN
PETROLEUM CORPORATION LIMITED or any person so appointed, nominated or designated and holding the office
of Chairman & Managing Director.
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2.4 The "Change Order" means an order given in writing by the Engineer-in-Charge or by Owner to effect
additions to or deletion from or alterations into the Work.
2.5 The "Construction Equipment" means all appliances and equipment of whatsoever nature for the use in
or for the execution, completion, operation or maintenance of the work except those intended to form part of the
Permanent Work.
2.6 The "Contract" between the Owner and the Contractor shall mean and include all documents like enquiry,
tender submitted by the contractor and the purchase order issued by the owner and other documents connected
with the issue of the purchase order and orders, instruction, drawings, change orders, directions issued by the
Owner/Engineer-in-Charge/Site-in-Charge for the execution, completion and commissioning of the works and the
period of contract mentioned in the Contract including such periods of time extensions as may be granted by the
owner at the request of the contractor and such period of time for which the work is continued by the contractor
for purposes of completion of the work.
2.7 "The Contractor" means the person or the persons, firm or Company whose tender has been accepted by
the Owner and includes the Contractor's legal heirs, representative, successor(s) and permitted assignees.
2.8 The "Drawings" shall include maps, plans and tracings or prints thereof with any modifications approved
in writing by the Engineer-in-Charge and such other drawings as may, from time to time, be furnished or approved
in writing by the Engineer-in-Charge.
2.9 The "Engineer-in-Charge or Site-in-Charge" shall mean the person appointed or designated as such by the
Owner and shall include those who are expressly authorized by the owner to act for and on its behalf.
2.10 "The Owner" means the HINDUSTAN PETROLEUM CORPORATION LIMITED incorporated in India having
its Registered office at PETROLEUM HOUSE, 17, JAMSHEDJI TATA ROAD, BOMBAY – 400020 and Marketing office
at ____________________________________________ or their successors or assignees.
2.11 The "Permanent Work" means and includes works which form a part of the work to be handed over to
the Owner by the Contractor on completion of the contract.
2.12 The "Project Manager" shall mean the Project Manager of HINDUSTAN PETROLEUM CORPORATION
LIMITED, or any person so appointed, nominated or designated.
2.13 The "Site" means the land on which the work is to be executed or carried out and such other place(s) for
purpose of performing the Contract.
2.14 The "Specifications" shall mean the various technical and other specifications attached and referred to in
the tender documents. It shall also include the latest editions, including all addenda/corrigenda or relevant Indian
Standard Specifications and Bureau Of Indian Standards.
2.15 The "Sub-Contractor" means any person or firm or Company (other than the Contractor) to whom any
part of the work has been entrusted by the Contractor with the prior written consent of the Owner/Engineer-in-
Charge/Site-in-Charge and their legal heirs, representatives, successors and permitted assignees of such person,
firm or Company.
2.16 The "Temporary Work" means and includes all such works which are a part of the contract for execution
of the permanent work but does not form part of the permanent work confirming to practices, procedures
applicable rules and regulations relevant in that behalf.
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2.17 The "Tender" means the document submitted by a person or authority for carrying out the work and the
Tenderer means a person or authority who submits the tender offering to carry out the work as per the terms and
conditions.
2.18 The "Work" shall mean the works to be executed in accordance with the Contract or part thereof as the
case may be and shall include extra, additional, altered or substituted works as maybe required for the purposes of
completion of the work contemplated under the Contract.
3. SUBMISSION OF TENDER
3.1 Before submitting the Tender, the Tenderer shall at their own cost and expenses visit the site, examine
and satisfy as to the nature of the existing roads, means of communications, the character of the soil, state of land
and of the excavations, the correct dimensions of the work facilities for procuring various construction and other
material and their availability, and shall obtain information on all matters and conditions as they may feel
necessary for the execution of the works as intended by the Owners and shall also satisfy of the availability of
suitable water for construction of civil works and for drinking purpose and power required for fabrication work etc.
Tenderer, whose tender may be accepted and with whom the Contract is entered into shall not be eligible and be
able to make any claim on any of the said counts in what so ever manner for what so ever reasons at any point of
time and such a claim shall not be raised as a dispute and shall not be arbitrable.
A pre-bid meeting may be held as per the schedule mentioned in the tender.
3.2 The Tenderer shall be deemed to have satisfied fully before tendering as to the correctness and
sufficiency of his tender for the works and of the rates and prices quoted in the schedule of quantities which rates
and prices shall except as otherwise provided cover all his obligations under the contract.
3.3 It must be clearly understood that the whole of the conditions and specifications are intended to be
strictly enforced and that no work will be considered as extra work and allowed and paid for unless they are clearly
outside the scope, spirit, meaning of the Contract and intent of the Owner and have been so ordered in writing by
Owner and/or Engineer-in-Charge/Site-in-Charge, whose decision shall be final and binding.
3.4 Before filling the Tender the Contractor will check and satisfy all drawings and materials to be procured
and the schedule of quantities by obtaining clarification from the Owner on all the items as may be desired by the
Tenderer. No claim for any alleged loss or compensation will be entertained on this account, after submission of
Tender by the Tenderer/Contractor and such a claim shall not be arbitrable.
3.5 Unless specifically provided for in the tender documents or any Special Conditions, no escalation in the
Tender rates or prices quoted will be permitted throughout the period of contract or the period of actual
completion of the job whichever is later on account of any variation in prices of materials or cost of labour or
due to any other reasons. Claims on account of escalation shall not be arbitrable.
3.6 The quantities indicated in the Tender are approximate. The approved schedule of rates of the contract
will be applicable for variations upto plus or minus 25% of the contract value. No revision of schedule of rates will
be permitted for such variations in the contract value, including variations of individual quantities, addition of new
items, alterations, additions/deletions or substitutions of items, as mentioned above. Quantities etc. mentioned
and accepted in the joint measurement sheets shall alone be final and binding on the parties.
3.7 Owner reserve their right to award the contract to any tenderer and their decision in this regard shall be
final. They also reserve their right to reject any or all tenders received. No disputes could be raised by any
tenderer(s) whose tender has been rejected.
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3.8 The Rates quoted by the Tenderer shall include Costs and expenses on all counts viz. cost of materials,
transportation of machine(s), tools, equipments, labour, power, Administration charges, price escalations, profits,
etc. etc. except to the extent of the cost of material(s), if any, agreed to be supplied by Owner and mentioned
specifically in that regard in condition of Contract, in which case, the cost of such material if taken for preparation
of the Contractor's Bill(s) shall be deducted before making payment of the Bill(s) of the Contractor. The description
given in the schedule of quantities shall unless otherwise stated be held to include wastage on materials, carriage
and cartage, carrying in and return of empties, hoisting, setting, fitting and fixing in position and all other expenses
necessary in and for the full and complete execution and completion of works and in accordance with good
practice and recognised principles in that regard.
3.9 Employees of the State and Central Govt. and employees of the Public Sector Undertakings, including
retired employees are covered under their respective service conditions/rules in regard to their submitting the
tender. All such persons should ensure compliance to the respective/applicable conditions, rules etc. etc. Any
person not complying with those rules etc. but submitting the tender in violation of such rules, after being so
noticed shall be liable for the forfeiture of the Earnest Money Deposit made with the tender, termination of
Contract and sufferance on account of forfeiture of Security Deposit and sufferance of damages arising as a result
of termination of Contract.
3.10 In consideration for having a chance to be considered for entering into a contract with the Owner, the
Tenderer agrees that the Tender submitted by him shall remain valid for the period prescribed in the tender
conditions, from the date of opening of the tender. The Tenderer shall not be entitled during the said validity
period, to revoke or cancel the tender without the consent in writing from the Owner.
In case the tenderer revokes or cancels the tender or varies any of terms of the tender without the Consent of the
Owner, in writing, the Tenderer forfeits the right to the refund of the Earnest Money paid along with the tender.
3.11 The prices quoted by the Tenderer shall be firm during the validity period of the bid and Tenderer
agrees to keep the bid alive and valid during the said period. The Tenderers shall particularly take note of this
factor before submitting their tender(s).
3.12 The works shall be carried out strictly as per approved specifications. Deviations, if any, shall have to be
authorised by the Engineer-in-Charge/Site-in-Charge in writing prior to implementing deviations. The price
benefit, if any, arising out of the accepted deviation shall be passed on to the Owner. The decision of Engineer-in-
Charge shall be final in this matter.
3.13 The contractor shall make all arrangements at his own cost to transport the required materials outside
and inside the working places and leaving the premises in a neat and tidy condition after completion of the job to
the satisfaction of Owner. All materials except those agreed to be supplied by the Owner shall be supplied by the
contractor at his own cost and the rates quoted by the Contractor should be inclusive of all royalties, rents, taxes,
duties, octroi, statutory levies, if any, etc. etc.
3.14 The Contractor shall not carry on any work other than the work under this Contract within the Owner’s
premises without prior permission in writing from the Engineer-in-Charge/Site-in-charge.
3.15 The Contractor shall be bound to follow and ensure compliance to all the safety and security regulations
and other statutory rules applicable to the area. In the event of any damage or loss or sufference caused due to
non-observance of such rules and regulations, the contractor shall be solely responsible for the same and shall
keep the Owner indemnified against all such losses and claims arising from the same.
3.16 At any time after acceptance of tender, the Owner reserves the right to add, amend or delete any work
item, the bill of quantities at a later date or reduce the scope of work in the overall interest of the work by prior
discussion and intimation to the Contractor. The decision of Owner, with reasons recorded therefor, shall be final
and binding on both the Owner and the Contractor. The Contractor shall not have right to claim compensation or
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damage etc. in that regard. The Owner reserves the right to split the work under this contract between two or
more contractors without assigning any reasons.
3.17 Contractor shall not be entitled to sublet, sub contract or assign, the work under this Contract without the
prior consent of the Owner obtained in writing.
3.18 All signatures in tender document shall be dated as well as all the pages of all sections of the tender
documents shall be initialled at the lower position and signed, wherever required in the tender papers by the
Tenderer or by a person holding Power of Attorney authorising him to sign on behalf of the tenderer before
submission of tender.
3.19 The tender should be quoted in English, both in figures as well as in words. The rates and amounts
tendered by the Tenderer in the Schedule of rates for each item and in such a way that insertion is not possible.
The total tendered amount should also be indicated both in figures and words with the signature of tenderer.
If some discrepancies are found between the rates given in words and figures of the amount shown in the tender,
the following procedure shall be applied:
(a) When there is a difference between the rates in figures and words, the rate which corresponds to the
amount worked out by the tenderer shall be taken as correct.
(b) When the rate quoted by the tenderer in figures and words tallies but the amount is incorrect, the rate
quoted by the tenderer shall be taken as correct.
(c) When it is not possible to ascertain the correct rate in the manner prescribed above the rate as quoted in
words shall be adopted.
3.20 All corrections and alterations in the entries of tender paper will be signed in full by the tenderer with
date. No erasures or over writings are permissible.
3.21 Transfer of tender document by one intending tenderer to the another one is not permissible. The
tenderer on whose name the tender has been sent only can quote.
3.22 The Tender submitted by a tenderer if found to be incomplete in any or all manner is liable to be rejected.
The decision of the Owner in this regard is final and binding. In case of any error/discrepancy in the amount
written in words and figures, the lower amount between the two shall prevail.
4. DEPOSITS
a) EARNEST MONEY DEPOSIT (EMD)
The tenderer will be required to pay a sum as specified in the covering letter, as earnest money deposit along with
the tender either thru a crossed demand draft or a non-revokable Bank Guarantee in favour of Hindustan
Petroleum Corporation Limited, from any Scheduled Bank (other than a Co-Operative Bank) payable at Mumbai in
favour of Hindustan Petroleum Corporation Limited, Mumbai in the proforma enclosed. The earnest money
deposit will be refunded after finalisation of the contract.
Note: Public sector enterprises and small scale units registered with National Small Scale Industries are exempted
from payment of Earnest Money Deposit. Small scale units registered with National Small Scale Industries should
enclose a photocopy of their registration certificate with their quotation to make their quotation eligible for
consideration. The Registration Certificate should remain valid during the period of the contract that may be
entered into with such successful bidder. Such tenderers should ensure validity of the Registration Certificate for
the purpose.
b) SECURITY DEPOSIT:
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The tenderer, with whom the contract is decided to be entered into and intimation is so given will have to make a
security deposit of one percent (1%) of the total contract value in the form of account payee crossed demand draft
drawn in favour of the Owner, within 15 days from the date of intimation of acceptance of their tender, failing
which the Owner reserves the right to cancel the Contract and forfeit the EMD.
1% of PO/Contract value as Security deposit will be acceptable in the form of Demand draft up to Rs.50,000/- and
in the form of Demand draft / Bank guarantee beyond Rs.50,000/-.
Composite Performance Bank Guarantee (CPBG) for 10% of PO value towards Performance Bank Guarantee
inclusive of Security Deposit shall be accepted (in lieu of deduction of retention money); such CPBG shall be valid
up to a period of 3 months beyond the expiry of defect liability period.
Demand Draft should be drawn on Scheduled Banks, other than co-operative bank.
5. EXECUTION OF WORK
All the works shall be executed in strict conformity with the provisions of the contract documents and with such
explanatory details, drawings, specifications and instructions as may be furnished from time to time to the
Contractor by the Engineer-in-Charge/ Site-in-Charge, whether mentioned in the Contract or not. The Contractor
shall be responsible for ensuring that works throughout are executed in the most proper and workman-like
manner with the quality of material and workmanship in strict accordance with the specifications and to the entire
satisfaction of the Engineer-in- Charge/Site-in-Charge.
The completion of work may entail working in monsoon also. The contractor must maintain the necessary work
force as may be required during monsoon and plan to execute the job in such a way the entire project is
completed within the contracted time schedule. No extra charges shall be payable for such work during monsoon.
It shall be the responsibility of the contractor to keep the construction work site free from water during and off the
monsoon period at his own cost and expenses.
For working on Sundays/Holidays, the contractor shall obtain the necessary permission from Engineer
Incharge/Site Incharge in advance. The contractor shall be permitted to work beyond the normal hours with prior
approval of Engineer-In-Charge/Site-In-Charge and the contractors quoted rate is inclusive of all such extended
hours of working and no extra amount shall be payable by the owner on this account.
5.a. SETTING OUT OF WORKS AND SITE INSTRUCTIONS
5.a.1. The Engineer-in-Charge/Site-in-Charge shall furnish the Contractor with only the four corners of the work
site and a level bench mark and the Contractor shall set out the works and shall provide an efficient staff for the
purpose and shall be solely responsible for the accuracy of such setting out.
5.a.2. The Contractor shall provide, fix and be responsible for the maintenance of all necessary stakes,
templates, level marks, profiles and other similar things and shall take all necessary precautions to prevent their
removal or disturbance and shall be responsible for consequences of such removal or disturbance should the same
take place and for their efficient and timely reinstatement. The Contractor shall also be responsible for the
maintenance of all existing survey marks, either existing or supplied and fixed by the Contractor. The work shall be
set out to the satisfaction of the Engineer-in-Charge/Site-in-Charge. The approval thereof or joining in setting out
the work shall not relieve the Contractor of his responsibility.
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5.a.3. Before beginning the works, the Contractor shall, at his own cost, provide all necessary reference and
level posts, pegs, bamboos, flags ranging rods, strings and other materials for proper layout of the work in
accordance with the scheme, for bearing marks acceptable to the Engineer-in-Charge/Site-in-Charge. The Centre
longitudinal or face lines and cross lines shall be marked by means of small masonary pillars. Each pillar shall have
distinct marks at the centre to enable theodolite to be set over it. No work shall be started until all these points are
checked and approved by the Engineer-in-Charge/Site-in-Charge in writing. But such approval shall not relieve the
contractor of any of his responsibilities. The Contractor shall also provide all labour, materials and other facilities,
as necessary, for the proper checking of layout and inspection of the points during construction.
5.a.4. Pillars bearing geodetic marks located at the sites of units of works under construction should be
protected and fenced by the Contractor.
5.a.5. On completion of works, the contractor shall submit the geodetic documents according to which the work
was carried out.
5.a.6. The Engineer-in-Charge/Site-in-Charge shall communicate or confirm his instructions to the contractor in
respect of the executions of work in a "work site order book" maintained in the office having duplicate sheet and
the authorised representative of the contractor shall confirm receipt of such instructions by signing the relevant
entries in the book.
5.a.7. All instructions issued by the Engineer-in-Charge/Site-in-Charge shall be in writing. The Contractor shall
be liable to carry out the instructions without fail.
5.a.8. If the Contractor after receipt of written instruction from the Engineer-in-Charge/ Site-in-Charge requiring
compliance within seven days fails to comply with such drawings or 'instructions' or both as the Engineer-in-
Charge/Site-in-Charge may issue, owner may employ and pay other persons to execute any such work whatsoever
that may be necessary to give effect to such drawings or `instructions' and all cost and expenses incurred in
connection therewith as certified by the Engineer-in-Charge/ Site-in-Charge shall be borne by the contractor or
may be deducted from amounts due or that may become due to the contractor under the contract or may be
recovered as a debt.
5.a.9. The Contractor shall be entirely and exclusively responsible for the horizontal and vertical alignment, the
levels and correctness of every part of the work and shall rectify effectually any errors or imperfections therein.
Such rectifications shall be carried out by the Contractor, at his own cost.
5.a.10. In case any doubts arise in the mind of the Contractor in regard to any expressions, interpretations,
statements, calculations of quantities, supply of material rates, etc. etc., the contractor shall refer the same to the
Site-in-Charge/ Engineer-in-Charge for his clarification, instructions, guidance or clearing of doubts. The decision
of the Engineer-in-Charge/Site-in-Charge shall be final and the contractor shall be bound by such a decision.
5.a.11. "The Contractor shall take adequate precautions, to ensure that his operations do not create nuisance or
misuse of the work space that shall cause unnecessary disturbance or inconvenience to others at the work site".
5.a.12. "All fossils, coins articles of value of antiquity and structure or other remains of geological or
archaeological discovered on the site of works shall be declared to be the property of the Owner and Contractor
shall take reasonable precautions to prevent his workmen or any other persons from removing or damaging any
such articles or thing and shall immediately inform the Owner/ Engineer-in-Charge/Site-in-Charge."
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5.a.13. "Contractor will be entirely and exclusively responsible to provide and maintain at his expenses all lights,
guards, fencing, etc. when and where even necessary or/as required by the Engineer-in-Charge/Site-in-Charge for
the protection of works or safety and convenience to all the members employed at the site or general public."
5.b. COMMENCEMENT OF WORK
The contractor shall after paying the requisite security deposit, commence work within 15 days from the date of
receipt of the intimation of intent from the Owner informing that the contract is being awarded. The date of
intimation shall be the date/day for counting the starting day/date and the ending day/date will be accordingly
calculated. Penalty, if any, for the delay in execution shall be calculated accordingly.
Contractor should prepare detailed fortnightly construction programme for approval by the Engineer-in-Charge
within one month of receipt of Letter Of Intent. The work shall be executed strictly as per such time schedule. The
period of Contract includes the time required for testing, rectifications, if any, re-testing and completion of work in
all respects to the entire satisfaction of the Engineer-in-Charge. A Letter of Intent is an acceptance of offer by the
Owner and it need not be accepted by the contractor. But the contractor should acknowledge a receipt of the
purchase order within 15 days of mailing of Purchase Order and any delay in acknowledging the receipt will be a
breach of contract and compensation for the loss caused by such breach will be recovered by the Owner by
forfeiting earnest money deposit/bid bond.
5.c. SUBLETTING OF WORK
5.c.1. No part of the contract nor any share or interest thereof shall in any manner or degree be transferred,
assigned or sublet, by the Contractor, directly or indirectly to any firm or corporation whatsoever, without the
prior consent in writing of the Owner.
5.c.2. At the commencement of every month the Contractor shall furnish to the Engineer-in-charge/Site-in-
Charge list of all sub-contractors or other persons or firms engaged by the Contractor.
5.c.3 The contract agreement will specify major items of supply or services for which the Contractor proposes
to engage sub-Contractor/sub-Vendor. The contractor may from time to time propose any addition or deletion
from any such list and will submit the proposals in this regard to the Engineer-in-charge/Designated officer-in-
charge for approval well in advance so as not to impede the progress of work. Such approval of the Engineer-in-
charge/Designated officer-in-charge will not relieve the contractor from any of his obligations, duties and
responsibilities under the contract.
5.c.4. Notwithstanding any sub-letting with such approval as resaid and notwithstanding that the Engineer-in-
Charge shall have received copies of any sub-contract, the Contractor shall be and shall remain solely to be
responsible for the quality and proper and expeditious execution of the works and the performance of all the
conditions of the contract in all respects as if such subletting or sub-contracting had not taken place and as if such
work had been done directly by the Contractor.
5.c.5 Prior approval in writing of the Owner shall be obtained before any change is made in the constitution of
the contractor/Contracting agency otherwise contract shall be deemed to have been allotted in contravention of
clause entitled “sub-letting of works” and the same action may be taken and the same consequence shall ensue as
provided in the clause of “sub- letting of works”.
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5.d EXTENSION OF TIME
1) If the Contractor anticipates that he will not be able to complete the work within the contractual
delivery/ completion date (CDD), then the Contractor shall make a request for grant of time extension clearly
specifying the reasons for which he seeks extension of time and demonstrating as to how these reasons were
beyond the control of the contractor or attributable to the Owner. This request should be made well before the
expiry of the Contractual Delivery/ Completion Date (CDD). If such a request for extension is received with a
Bank Guarantee for the full
2) Liquidated Damages amount calculated on the Total Contract Value, the concerned General Manager of
the Owner shall grant a Provisional extension of time, pending a decision on the request.
3) The concerned General Manager of the Owner shall expeditiously decide upon the request for time
extension and decide the levy of liquidated damages within a maximum period of 6 months from the CDD or
date of receipt of the request, whichever is later.
4) Grant of any extension of time shall be by means of issuance of a Change Order.
5) In order to avoid any cash crunch to the Contractor, a Bank Guarantee could be accepted against LD, as
stated above. Once a decision is taken, the LD shall be recovered from any pending bills or by encashment of
the BG. Any balance sum of Contractor or the BG (if LD is fully recovered from the bills) shall be promptly
refunded/returned to the Contractor.
5.e. SUSPENSION OF WORKS
5.e.1. Subject to the provisions of this contract, the contractor shall if ordered in writing by the Engineer- in-
Charge/Site-in-Charge for reasons recorded suspend the works or any part thereof for such period and such time
so ordered and shall not, after receiving such, proceed with the work therein ordered to suspended until he shall
have received a written order to re-start. The Contractor shall be entitled to claim extension of time for that
period of time the work was ordered to be suspended. Neither the Owner nor the Contractor shall be entitled to
claim compensation or damages on account of such an extension of time.
5.e.2. In case of suspension of entire work, ordered in writing by Engineer-in-Charge/Site-in-Charge, for a period
of 30 days, the Owner shall have the option to terminate the Contract as provided under the clause for
termination. The Contractor shall not be at liberty to remove from the site of the works any plant or materials
belonging to him and the Employer shall have lien upon all such plant and materials.
5.e.3. The contract shall, in case of suspension have the right to raise a dispute and have the same arbitrated
but however, shall not have the right to have the work stopped from further progress and completion either by the
owner or through other contractor appointed by the owner.
5.f. OWNER MAY DO PART OF WORK
Not withstanding anything contained elsewhere in this contract, the owner upon failure of the Contractor to
comply with any instructions given in accordance with of entire work, place additional labour force, tools,
equipment and materials on such parts of the work, as the Owner may decide or engage another Contractor to
carryout the balance of work. In such cases, the Owner shall have the right to deduct from the amounts payable to
the Contractor the difference in cost of such work and materials with ten percent overhead added to cover all
departmental charges. Should the total amount thereof exceed the amount due to the contractor, the Contractor
shall pay the difference to the Owner within 15 days of making demand for payment failing which the Contractor
shall be liable to pay interest at 24% p.a. on such amounts till the date of payment.
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5.g. INSPECTION OF WORKS
5.g.1. The Engineer-in-Charge/Site-in-Charge and Officers from Central or State Government will have full power
and authority to inspect the works at any time wherever in progress, either on the site or at the Contractor's
premises/workshops of any person, firm or corporation where work in connection with the contract may be in
hand or where the materials are being or are to be supplied, and the Contractor shall afford or procure for the
Engineer-in-Charge/Site-in-Charge every facility and assistance to carryout such inspection. The Contractor shall,
at all times during the usual working hours and at all other times at which reasonable notice of the intention of the
Engineer-in-Charge/Site-in-Charge or his representative to visit the works shall have been given to the Contractor,
either himself be present to receive orders and instructions, or have a responsible agent, duly accredited in
writing, present for the purpose. Orders given to the Contractor's agent shall be considered to have the same
force as if they had been given to the Contractor himself. The Contractor shall give not less than seven days notice
in writing to the Engineer-in-Charge/Site-in-Charge before covering up or otherwise placing beyond reach of
inspection and measurement any work in order that the same may be inspected and measured. In the event of
breach of above, the same shall be uncovered at Contractor's expense for carrying out such measurement and/or
inspection.
5.g.2. No material shall be removed and despatched by the Contractor from the site without the prior approval
in writing of the Engineer-in-charge. The contractor is to provide at all times during the progress of the work and
the maintenance period proper means of access with ladders, gangways, etc. and the necessary attendance to
move and adapt as directed for inspection or measurements of the works by the Engineer-in-Charge/Site-in-
Charge.
5.h. SAMPLES
5.h.1. The contractor shall furnish to the Engineer-in-charge/Site-in-Charge for approval when requested or
required adequate samples of all materials and finishes to be used in the work.
5.h.2. Samples shall be furnished by the Contractor sufficiently in advance and before commencement of the
work so as the Owner can carry out tests and examinations thereof and approve or reject the samples for use in
the works. All material samples furnished and finally used/applied in actual work shall fully be of the same quality
of the approved samples.
5.i. TESTS FOR QUALITY OF WORK
5.i.1. All workmanship shall be of the respective kinds described in the contract documents and in accordance
with the instructions of the Engineer-in-Charge / Site-in- Charge and shall be subjected from time to time to such
tests at Contractor's cost as the Engineer-in-Charge/Site-in-Charge may direct at the place of manufacture or
fabrication or on the site or at all or any such places. The Contractor shall provide assistance, instruments, labour
and materials as are normally required for examining, measuring and testing any workmanship as may be selected
and required by the Engineer-in-Charge/Site-in-Charge.
5.i.2. All the tests that will be necessary in connection with the execution of the work as decided by the
Engineer-in- charge/Site-in-Charge shall be carried out at the contractors cost and expenses.
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5.i.3. If any tests are required to be carried out in connection with the work or materials or workmanship to be
supplied by the owner, such tests shall be carried out by the Contractor as per instructions of Engineer-in-
Charge/Site-in-Charge and expenses for such tests, if any, incurred by the contractor shall be reimbursed by the
Owner. The contractor should file his claim with the owner within 15 (fifteen) days of inspection/test and any
claim made beyond that period shall lapse and be not payable.
5.j. ALTERATIONS AND ADDITIONS TO SPECIFICATIONS, DESIGNS AND WORKS
5.j.1. The Engineer-in-Charge/Site-in-Charge shall have powers to make any alterations, additions and/or
substitutions to the schedule of quantities, the original specifications, drawings, designs and instructions that may
become necessary or advisable or during the progress of the work and the Contractor shall be bound to carryout
such altered/extra/new items of work in accordance with instructions which may be given to him in writing signed
by the Engineer-in-Charge/Site- in-Charge. Such alterations, omissions, additions or substitutions shall not
invalidate the contract. The altered, additional or substituted work which the Contractor may be directed to
carryon in the manner as part of the work shall be carried out by the Contractor on the same conditions in all
respects on which he has agreed to do the work. The time for completion of such altered added and/or
substituted work may be extended for that part of the particular job. The rates for such additional altered or
substituted work under this Clause shall, be worked out in accordance with the following provisions:
5.j.2. If the rates for the additional, altered or substituted work are specified in the contract for similar class of
work, the Contractor is bound to carryout the additional, altered or substituted work at the same rates as are
specified in the contract.
5.j.3. If the rates for the additional, altered or substituted work are not specifically provided in the contract for
the work, the rates will be derived from the rates for similar class of work as are specified in the contract for the
work. In the opinion of the Engineer-in- Charge/Site-in-Charge as to whether or not the rates can be reasonably so
derived from the items in this contract, will be final and binding on the Contractor.
5.j.4. If the rates for the altered, additional or substituted work cannot be determined in the manner specified
above, then the Contractor shall, within seven days of the date of receipt of order to carry out the work, inform
the Engineer-in-Charge/ Site-in-Charge of the rate at which he intends to charge for such class of work, supported
by analysis of the rate or rates claimed and the Engineer-In-Charge/ Site-in-Charge shall determine the rates on the
basis of the prevailing market rates for both material and labour plus 10% to cover overhead and profit of labour
rates and pay the Contractor accordingly. The opinion of the Engineer-in-Charge/Site-in-Charge as to current
market rates of materials and the quantum of labour involved per unit of measurement will be final and binding on
the contractor.
5.j.5. The quantities indicated in the Tender are approximate. The approved schedule of rates of the contract
will be applicable for variations of up to +25% of the estimated contract value. No revision of schedule of rates will
be permitted for such variations in the contract value, even for variations of individual quantities, addition of new
items, alterations, additions/deletions or substitutions of items, as mentioned above.
(Already covered under Clause No. 3.6)
5.j.6. In case of any item of work for which there is no specification supplied by the Owner and is mentioned in
the tender documents, such work shall be carried out in accordance with Indian Standard Specifications and if the
Indian Standard Specifications do not cover the same, the work should be carried out as per standard Engineering
Practice subject to the approval of the Engineer-in-Charge/ Site-in-Charge.
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5.k. PROVISIONAL ACCEPTANCE
Acceptance of sections of the works for purposes of equipment erection, piping, electrical work and similar usages
by the Owner and payment for such work or parts of work shall not constitute a waiver of any portion of this
contract and shall not be construed so as to prevent the Engineer from requiring replacement of defective work
that may become apparent after the said acceptance and also shall not absolve the Contractor of the obligations
under this contract. It is made clear that such an acceptance does not indicate or denote or establish to the fact of
execution of that
5.l. COMPLETION OF WORK AND COMPLETION CERTIFICATE
As soon as the work is completed in all respects, the contractor shall give notice of such completion to the site in
charge or the Owner and within thirty days of receipt of such notice the site in charge shall inspect the work and
shall furnish the contractor with a certificate of completion indicating:
a) defects, if any, to be rectified by the contractor
b) items, if any, for which payment shall be made in reduced rates
c) the date of completion.
5.m. USE OF MATERIALS AND RETURN OF SURPLUS MATERIALS
5.m.1. Not withstanding anything contained to the contrary in any or all of the clauses of this contract, where
any materials for the execution of the contract are procured with the assistance of Government either by issue
from Government stocks or purchase made under orders or permits or licences issued by Government, the
contractor shall use the said materials economically and solely for the purpose of the contract and shall not
dispose them of without the permission of the Owner.
5.m.2. All surplus (serviceable) or unserviceable materials that may be left over after the completion of the
contract or at its termination for any reason whatsoever, the Contractor shall deliver the said product to the
Owner without any demur. The price to be paid to the Contractor, if not already paid either in full or in part,
however, shall not exceed the amount mentioned in the Schedule of Rates for such material and in cases where
such rates are not so mentioned, shall not exceed the CPWD scheduled rates. In the event of breach of the
aforesaid condition the contractor shall become liable for contravention of the terms of the Contract.
5.m.3. The surplus (serviceable) and unserviceable products shall be determined by joint measurement. In case
where joint measurement has failed to take place, the Owner may measure the same and determine the quantity.
5.m.4. It is made clear that the Owner shall not be liable to take stock and keep possession and pay for the
surplus and unserviceable stocks and the Owner may direct the Contractor to take back such material brought by
the Contractor and becoming surplus and which the Owner may decide to keep and not to pay for the same.
5.n. DEFECT LIABILITY PERIOD
The contractor shall guarantee the work executed for a period of 12 months from the date of completion of the
job. Any damage or defect that may arise or lie undiscovered at the time of completion of the job shall be rectified
or replaced by the contractor at his own cost. The decision of the Engineer In-charge/Site-Incharge/Owner shall be
the final in deciding whether the defect has to be rectified or replaced.
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Equipment or spare parts replaced under warranty/guarantees shall have further warranty for a mutually agreed
period from the date of acceptance.
The owner shall intimate the defects noticed in writing by a Registered A.D. letter or otherwise and the contractor
within 15 days of receipt of the intimation shall start the rectification work and complete within the time specified
by the owner failing which the owner will get the defects rectified by themselves or by any other contractor and
the expenses incurred in getting the same done shall be paid by the Contractor under the provision of the
Contract.
Thus, defect liability is applicable only in case of job/works contract (civil, mechanical, electrical, maintenance etc. )
where any damage of defect may arise in future (i.e. within 12 months from the date of completion of job) or lie
undiscovered at the time of completion of job.
In other words, in case of service contracts (like car hire etc.) where there is no question of damage or defect
arising in future, the defect liability clause is not applicable.
5.o. DAMAGE TO PROPERTY
5.o.1. Contractor shall be responsible for making good to the satisfaction of the Owner any loss of and any
damage to all structures and properties belonging to the Owner or being executed or procured by the Owner or of
other agencies within the premises of the work of the Owner, if such loss or damage is due to fault and/or the
negligence or willful acts or omission of the Contractor, his employees, agents, representatives or sub-contractors.
5.o.2. The Contractors shall indemnify and keep the Owner harmless of all claims for damage to Owner's
property arising under or by reason of this contract.
6. DUTIES AND RESPONSIBILITIES OF CONTRACTOR
6.a. EMPLOYMENT LIABILITY TOWARDS WORKERS EMPLOYED BY THE CONTRACTOR
6.a.1 The Contractor shall be solely and exclusively responsible for engaging or employing persons for the
execution of work. All persons engaged by the contractor shall be on Contractor's payroll and paid by Contractor.
All disputes or differences between the Contractor and his/their employees shall be settled by Contractor.
6.a.2. Owner has absolutely no liability whatsoever concerning the employees of the Contractor. The
Contractor shall indemnify Owner against any loss or damage or liability arising out of or in the course of his/their
employing persons or relation with his/their employees. The Contractor shall make regular and full payment of
wages and on any complaint by any employee of the Contractor or his sub-contractor regarding non-payment of
wages, salaries or other dues, Owner reserves the right to make payments directly to such employees or sub-
contractor of the Contractor and recover the amount in full from the bills of the Contractor and the contractor
shall not claim any compensation or reimbursement thereof. The Contractor shall comply with the Minimum
Wages Act applicable to the area of work site with regard to payment of wages to his employees and also to
employees of his sub contractor.
6.a.3. The Contractor shall advise in writing or in such appropriate way to all of his employees and employees of
sub-contractors and any other person engaged by him that their appointment/employment is not by the Owner
but by the Contractor and that their present appointment is only in connection with the construction contract with
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Owner and that therefore, such an employment/appointment would not enable or make them eligible for any
employment/appointment with the Owner either temporarily or/and permanent basis.
6.b. NOTICE TO LOCAL BODIES
The contractor shall comply with and give all notices required under any Government authority, instruction, rule or
order made under any act of parliament, state laws or any regulations or by-laws of any local authority relating to
the works.
6.c. FIRST AID AND INDUSTRIAL INJURIES
6.c.1. Contractor shall maintain first aid facility for his employees and those of his sub-contractors.
6.c.2. Contractor shall make arrangements for ambulance service and for the treatment of all types of injuries.
Names and telephone numbers of those providing such services shall be furnished to Owner prior to start of
construction and their name board shall be prominently displayed in Contractor's field office.
6.c.3. All industrial injuries shall be reported promptly to owner and a copy of contractor's report covering each
personal injury requiring the attention of a physician shall be furnished to the Owner.
6.d. SAFETY CODE
6.d.1. The Contractor shall at his own expenses arrange for the Safety provisions as may be necessary for the
execution of the work or as required by the Engineer-in-Charge in respect of all labours directly or indirectly
employed for performance of the works and shall provide all facilities in connections therewith. In case the
contractor fails to make arrangements and provide necessary facilities as aforesaid, the Owner shall be entitled to
do so and recover the cost thereof from the Contractor.
6.d.2. From the commencement to the completion of the works, the contractor shall take full responsibility for
the care thereof and of all the temporary works (defined as meaning all temporary works of every kind required in
or for the execution, completion or maintenance of the works). In case damage, loss or injury shall happen to the
works or to any part thereof or to temporary works or to any cause whatsoever repair at his (Contractor's) own
cost and make good the same so that at the time of completion, the works shall be in good order and condition
and in conformity in every respect with the requirement of the contract and Engineer-in-Charge's instructions.
6.d.3. In respect of all labour, directly or indirectly employed in the work for the performance of the
Contractor's part of this agreement, the contractor shall at his own expense arrange for all the safety provisions as
per relevant Safety Codes of C.P.W.D Bureau of Indian Standards, the Electricity Act/I.E. Rules. The Mines Act and
such other Acts as applicable.
6.d.4. The Contractor shall observe and abide by all fire and safety regulations of the Owner. Before starting
construction work, the Contractor shall consult with Owner's Safety Engineer or Engineer-in-Charge/Site-in-Charge
and must make good to the satisfaction of the Owner any loss or damage due to fire to any portion of the work
done or to be done under this agreement or to any of the Owner's existing property.
6.d.5. The Contractor will be fully responsible for complying with all relevant provisions of the Contract Labour
Act and shall pay rates of Wages and observe hours of work/conditions of employment according to the rules in
force from time to time.
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6.d.6. The Contractor will be fully responsible for complying with the provision including documentation and
submission of reports on the above to the concerned authorities and shall indemnify the Corporation from any
such lapse for which the Government will be taking action against them.
6.d.7. Owner shall on a report having been made by an inspecting Office as defined in the Contract Labour
Regulations have the power to deduct from the money due to the Contractor any sum required or estimated to be
required for making good the loss suffered by a worker(s) by reasons of non-fulfillment of conditions of contract
for the benefit of workers no-payment of wages or of deductions made from his or their wages which are not
justified by the terms of contract or non observance of the said contractor's labour Regulation.
6.e. INSURANCE AND LABOUR
Contractor shall at his own expense obtain and maintain an insurance policy with a Nationalised Insurance
Company to the satisfaction of the Owner as provided hereunder.
6.e.1. EMPLOYEES STATE INSURANCE ACT
i. The Contractor agrees to and does hereby accept full and exclusive liability for the compliance
with all obligations imposed by Employees State Insurance Act,1948, and the Contractor further
agrees to defend indemnify and hold Owner harmless from any liability or penalty which may be
imposed by the Central, State or local authority by reason of any asserted violation by
Contractor, or sub-contractor of the Employees' State Insurance Act, 1948 and also from all
claims, suits or proceedings that may be brought against the Owner arising under, growing out of
or by reason of the work provided for by this contract whether brought by employees of the
Contractor, by third parties or by Central or State Government authority or any political sub-
division thereof.
ii. The Contractor agrees to file with the Employees State Insurance Corporation, the Declaration
forms and all forms which may be required in respect of the Contractor's or sub-contractor's
employee whose aggregate emuneration is within the specified limit and who are employed in
the work provided or those covered by ESI Act under any amendment to the Act from time to
time.
The Contractor shall deduct and secure the agreement of the sub-contractor to deduct the employee's
contribution as per the first schedule of the Employee's State Insurance Act from wages and affix the employee's
contribution cards at wages payment intervals. The Contractor shall remit and secure the agreement of the sub
contractor to remit to the State Bank of India, Employee's State Insurance Corporation Account, the Employee's
contribution as required by the Act.
iii. The Contractor agrees to maintain all records as required under the Act in respect of employees
and payments and the Contractor shall secure the agreement of the sub contractor to maintain
such records. Any expenses incurred for the contributions, making contribution or maintaining
records shall be to the Contractor's or sub-contractor's account.
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iv. The Owner shall retain such sum as may be necessary from the total contract value until the
Contractor shall furnish satisfactory proof that all contributions as required by the Employees
State Insurance Act, 1948, have been paid.
v. WORKMAN'S COMPENSATION AND EMPLOYEE'S LIABILITY INSURANCE
Provide Insurance for all the Contractor's employees engaged in the performance of this contract. If any of the
work is sublet, the Contractor shall ensure that the sub-contractor provides workmen's compensation and
Employer's Liability Insurance for the latter's employees who are not covered under the Contractor's insurance.
vi. AUTOMOBILE LIABILITY INSURANCE
Contractor shall take out an Insurance to cover all risks to Owner for each of his vehicles plying on works of this
contract and these insurances shall be valid for the total contract period. No extra payment will be made for this
insurance. Owner shall not be liable for any damage or loss not made good by the Insurance Company, should
such damage or loss result from unauthorised use of the vehicle. The provisions of the Motor Vehicle Act would
apply.
vii. FIRE INSURANCE
Contractor shall within two weeks after award of contract insure the Works, Plant and Equipment and keep them
insured until the final completion of the Contract against loss or damage by accident, fire or any other cause with
an insurance company to be approved by the Employer/Consultant in the joint names of the Employer and the
Contractor (name of the former being placed first in the Policy). Such Policy shall cover the property of the
Employer only.
6.e.2. ANY OTHER INSURANCE REQUIRED UNDER LAW OR REGULATION OR BY OWNER
i. Contractor shall also provide and maintain any and all other insurance which may be required
under any law or regulations from time to time. He shall also carry and maintain any other
insurance which may be required by the Owner.
ii. The aforesaid insurance policy/policies shall provide that they shall not be cancelled till the
Engineer-in-Charge has agreed to their cancellation.
iii. The Contractor shall satisfy to the Engineer-in-Charge/Site-in-Charge from time to time that he
has taken out all insurance policies referred to above and has paid the necessary premium for
keeping the policies alive till the expiry of the defects liability period.
iv. The contractor shall ensure that similar insurance policies are taken out by his sub-contractor (if
any) and shall be responsible for any claims or losses to the Owner resulting from their failure to
obtain adequate insurance protections in connection thereof. The contractor shall produce or
cause to be proceed by his sub-contractor (if any) as the case may be, the relevant policy or
policies and premium receipts as and when required by the Engineer-in-Charge/Site-in-Charge.
6.e.3. LABOUR AND LABOUR LAWS
i. The contractor shall at his own cost employ persons during the period of contract and the
persons so appointed shall not be construed under any circumstances to be in the employment
of the Owner.
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ii. All payments shall be made by the contractor to the labour employed by him in accordance with
the various rules and regulations stated above. The contractor shall keep the Owner indemnified
from any claims whatsoever inclusive of damages/costs or otherwise arising from injuries or
alleged injuries to or death of a person employed by the contractor or damages or alleged
damages to the property.
iii. No labour below the age of eighteen years shall be employed on the work. The Contractor shall
not pay less than what is provided under the provisions of the contract labour (Regulations and
Abolition) Act, 1970 and the rules made thereunder and as may be amended from time to time.
He shall pay the required deposit under the Act appropriate to the number of workman to be
employed by him or through sub contractor and get himself registered under the Act. He shall
produce the required Certificates to the Owner before commencement of the work. The Owner
recognises only the Contractor and not his sub contractor under the provisions of the Act. The
Contractor will have to submit daily a list of his workforce. He will also keep the wage register at
the work site or/and produce the same to the Owner, whenever desired. A deposit may be taken
by the Owner from the Contractor to be refunded only after the Owner is satisfied that all
workmen employed by the Contractor have been fully paid for the period of work in Owner's
premises at rates equal to or better than wages provided for under the Minimum Wages Act.
The contractor shall be responsible and liable for any complaints that may arise in this regard and
the consequences thereto.
iv. The Contractor will comply with the provisions of the Employee's Provident Fund Act and the
Family Pension Act as may be applicable and as amended from time to time.
v. The Contractor will comply with the provisions of the payment of Gratuity Act, 1972, as may be
applicable and as amended from time to time.
vi. IMPLEMENTATION OF APPRENTICES ACT, 1961
The Contractor shall comply with the provisions of the Apprentices Act, 1961 and the Rules and Orders issued
thereunder from time to time. If he fails to do so, his failure will be a breach of the contract and the Engineer-in-
Charge may, at his discretion, cancel the contract. The Contractor shall also be liable for any pecuniary liability
arising on account of any violation by him of the provision of the Act.
vii. MODEL RULES FOR LABOUR WELFARE
The Contractor shall at his own expenses comply with or cause be complied with Model rules for Labour Welfare
as appended to those conditions or rules framed by the Government from time to time for the protection of health
and for making sanitary arrangements for worker employed directly or indirectly on the works. In case the
contractor fails to make arrangements as aforesaid the Engineer-in-Charge/Site-in-Charge shall be entitled to do so
and recover the cost thereof from the contractor.
6.f. DOCUMENTS CONCERNING WORKS
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6.f.1. All documents including drawings, blue prints, tracings, reproducible models, plans, specifications and
copies, thereof furnished by the Owner as well as all drawings, tracings, reproducibles, plans, specifications design
calculations etc. prepared by the contractor for the purpose of execution of works covered in or connected with
this contract shall be the property of the Owner and shall not be used by the contractor for any other work but are
to be delivered to the Owner at the completion or otherwise of the contract.
6.f.2. The Contractor shall keep and maintain secrecy of the documents, drawings etc. issued to him for the
execution of this contract and restrict access to such documents, drawings etc. and further the Contractor shall
execute a SECRECY agreement from each or any person employed by the Contractor having access to such
documents, drawings etc. The Contractor shall not issue drawings and documents to any other agency or individual
without the written approval by the Engineer-in-Charge/Site-in- Charge.
6.f.3. Contractor will not give any information or document etc. concerning details of the work to the press or a
news disseminating agency without prior written approval from Engineer-in-charge/Site-in-Charge. Contractor
shall not take any pictures on site without written approval of Engineer-in-Charge/Site-in-Charge.
7. PAYMENT OF CONTRACTOR'S BILLS
7.1. Payments will be made against Running Accounts bills certified by the Owner's Engineer-in-Charge/Site-in-
Charge within 15 days from the date of receipt of the bill.
7.2. Running Account Bills and the final bill shall be submitted by the Contractor together with the duly signed
measurements sheet(s) to the Engineer-in-Charge/ Site-in-Charge of the Owner in quadruplicate for certification.
The Bills shall also be accompanied by quantity calculations in support of the quantities contained in the bill along
with cement consumption statement, actual/theoretical, wherever applicable duly certified by the Engineer-in-
Charge/ Site-in-Charge of the Owner.
7.3. All running account payments shall be regarded as on account payment(s) to be finally adjusted against
the final bill payment. Payment of Running Account Bill(s) shall not determine or affect in any way the rights of the
Owner under this Contract to make the final adjustments of the quantities of material, measurements of work and
adjustments of amounts etc.etc. in the final bill.
7.4. The final bill shall be submitted by the Contractor within one month of the date of completion of the work
fully and completely in all respects. If the Contractor fails to submit the final bill accordingly Engineer-in-
Charge/Site-in-Charge may make the measurement and determine the total amount payable for the work carried
out by the Contractor and such a certification shall be final and binding on the Contractor. The Owner/Engineer-
in-Charge/Site-in-Charge may take the assistance of an outside party for taking the measurement, the expenses of
which shall be payable by the Contractor.
7.5. Payment of final bill shall be made within 30 days from the date of receipt of the certified bill by the
Disbursement Section of the owner.
7.6. Wherever possible, payment shall be tendered to the contractor in electronic mode (e-payment) through
any of the designated banks. The contractor will comply by furnishing full particulars of Bank account (mandate)
to which the payments will be routed. Owner reserves the right to make payment in any alternate mode also.
7.a. MEASUREMENT OF WORKS
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7.a.1. All measurements shall be in metric system. All the works will be jointly measured by the representative
of the Engineer-in-Charge/Site-in-Charge and the Contractor or their authorised agent progressively. Such
measurement will be recorded in the Measurement Book/Measurement Sheet by the Contractor or his authorized
representative and signed in token of acceptance by the Owner or their authorised representative.
7.a.2. For the purpose of taking joint measurement, the Contractor/representative shall be bound to be present
whenever required by the Engineer-in-Charge/Site-in-Charge. If, however, they are absent for any reasons
whatsoever, the measurement will be taken by the Engineer-in-Charge/Site-in-Charge or his representative and
the same would be deemed to be correct and binding on the Contractor.
7.a.3. In case of any dispute as to the mode of measurement for any item of work, the latest Indian Standard
Specifications shall be followed. In case of any further dispute on the same the same shall be as per the
certification of an outside qualified Engineer/ Consultant. Such a measurement shall be final and binding on the
Owner and the Contractor.
7.b. BILLING OF WORKS EXECUTED
The Contractor will submit a bill in approved proforma in quadruplicate to the Engineer-in-Charge/Site-in-Charge
of the work giving abstract and detailed measurement for the various items executed during a month, before the
expiry of the first week of the succeeding month. The Engineer-in-Charge/Site-in-Charge shall take or cause to be
taken the requisite measurements for the purpose of having the bill verified and/or checked before forwarding the
same to the disbursement office of the Owner for further action in terms of the Contract and payment thereafter.
The Engineer-in-Charge/Site-in-Charge shall verify the bills within 7 days of submission of the Bill by the
Contractor.
7.c. RETENTION MONEY
10% of the total value of the Running Account and Final Bill will be deducted and retained by the Owner as
retention money on account of any damage/defect liability that may arise for the period covered under the defect
liability period clause of the Contract free of interest. Any damage or defect that may arise or lie undiscovered at
the time of issue of completion certificate connected in any way with the equipment or materials supplied by
contractor or in workmanship shall be rectified or replaced by the contractor at his own expense failing which the
Owner shall be entitled to rectify the said damage/defect from the retention money. Any excess of expenditure
incurred by the Owner on account of damage or defect shall be payable by the Contractor. The decision of the
Owner in this behalf shall not be liable to be questioned but shall be final and binding on the Contractor.
Thus, deduction towards retention money is applicable only in case of job/works contracts (civil, mechanical,
electrical, maintenance etc.) where any damage or defect may arise in future (i.e. within 12 months from the date
of completion of job) or lie undiscovered at the time of issue of completion certificate.
7.d. STATUTORY LEVIES
7.d.1. The Contractor accepts full and exclusive liability for the payment of any and all taxes, duties, octroi,
rates, cess, levies and statutory payments payable under all or any of the statutes etc.
Variations of taxes and duties arising out of the amendments to the Central / State enactments, in respect of
sale of goods / services covered under this bid shall be to HPCL’s account, so long as :
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• They relate to the period after the opening of the price bid, but before the contracted completion
period ( excluding permitted extensions due to delay on account of the contractors, if any) or the
actual completion period, whichever is earlier; and
• The vendor furnishes documentary evidence of incurrence of such variations, in addition to the
invoices/documents for claiming Cenvat /Input Tax credit, wherever applicable.
All contributions and taxes for unemployment compensation, insurance and old age pensions or annuities now or
hereafter imposed by Central or State Governmental authorities which are imposed with respect to or covered by
the wages, salaries or other compensations paid to the persons employed by the Contractor and the Contractor
shall be responsible for the compliance with all obligations and restrictions imposed by the Labour Law or any
other law affecting employer-employee relationship and the Contractor further agrees to comply and to secure the
compliance of all sub-contractors with all applicable Central, State, Municipal and local laws, and regulations and
requirements of any Central, State or Local Government agency or authority.
Contractor further agrees to defend, indemnify and hold harmless from any liability or penalty which may be
imposed by the Central, State or Local authorities by reason of any violation by Contractor or sub-contractor of
such laws, regulations or requirements and also from all claims, suits or proceedings that may be brought against
the Owner arising under, growing out of, or by reasons of the work provided for by this contract by third parties, or
by Central or State Government authority or any administrative sub-division thereof. The Contractor further
agrees that in case any such demand is raised against the Owner, and Owner has no way but to pay and
pays/makes payment of the same, the Owner shall have the right to deduct the same from the amounts due and
payable to the Contractor. The Contractor shall not raise any demand or dispute in respect of the same but may
have recourse to recover/receive from the concerned authorities on the basis of the Certificate of the Owner
issued in that behalf.
7.d.2. The rates quoted should be inclusive of all rates, cess, taxes and sales tax on works contracts wherever
applicable. However, wherever the sales tax on works contract is applicable and is to be deducted at source, the
same will be deducted from the bills of the Contractor and paid to the concerned authorities. The proof of such
payments of sales tax on works contract will be furnished to the contractor.
7.d.3. Income tax will be deducted at source as per rules at prevailing rates, unless certificate, if any, for
deduction at lesser rate or nil deduction is submitted by the Contractor from appropriate authority.
7.d.4. The contractor shall provide accurate particulars of PAN number as required, to enable issuance of TDS
(Tax Deduction at Source) certificate.
7.e. MATERIALS TO BE SUPPLIED BY CONTRACTOR
7.e.1. The Contractor shall procure and provide the whole of the materials required for construction including
tools, tackles, construction plant and equipment for the completion and maintenance of the works except the
materials viz. steel and cement which may be agreed to be supplied as provided elsewhere in the contract. The
contractor shall make arrangement for procuring such materials and for the transport thereof at their own cost
and expenses.
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7.e.2. The Owner may give necessary recommendation to the respective authority if so desired by the
Contractor but assumes no responsibility of any nature. The Contractor shall procure materials of ISI
stamp/certification and supplied by reputed suppliers borne on DGS&D list.
7.e.3. All materials procured should meet the specifications given in the tender document. The Engineer-in-
charge may, at his discretion, ask for samples and test certificates for any batch of any materials procured. Before
procuring, the Contractor should get the approval of Engineer-in-Charge/Site-in-Charge for any materials to be
used for the works.
7.e.4. Manufacturer's certificate shall be submitted for all materials supplied by the Contractor. If, however, in
the opinion of the Engineer-in-Charge/Site-in-Charge any tests are required to be conducted on the material
supplied by the Contractor, these will be arranged by the Contractor promptly at his own cost.
7.f. MATERIALS TO BE SUPPLIED BY THE OWNER
7.f.1. Steel and Cement maybe supplied by the Owner to the contractor against payment by Contractor from
either godown or from the site or within work premises itself and the contractor shall arrange for all transport to
actual work site at no extra cost.
7.f.2. The contractor shall bear all the costs including loading and unloading, carting from issue points to work
spot storage, unloading, custody and handling and stacking the same and return the surplus steel and cement to
the Owner's storage point after completion of job.
7.f.3. The contractor will be fully accountable for the steel and cement received from the Owner and contractor
will give acknowledgement/receipt for quantity of steel and cement received by him each time he uplifts cement
from Owner's custody.
7.f.4. For all computation purposes, the theoretical cement consumption shall be considered as per CPWD
standards.
7.f.5. Steel and Cement as received from the manufacturer/stockists will be issued to the contractor.
Theoretical weight of cement in a bag will be considered as 50 Kg. Bags weighing upto 4% less shall be accepted by
the contractor and considered as 50 Kg. per bag. Any shortage in the weight of any cement bag by more than 4%
will be to the Owner's account only when pointed out by the Contractor and verified by Engineer-in-Charge/Site in
Charge at the time of Contract or taking delivery.
7.f.6. The contractor will be required to maintain a stock register for receipt, issuance and consumption of steel
and cement at site. Cement will be stored in a warehouse at site. Requirement of cement on any day will be taken
out of the warehouse. Cement issued shall be regulated on the basis of FIRST RECEIPT to go as FIRST ISSUE.
7.f.7. Empty cement bag shall be the property of the Contractor. Contractor shall be penalised for any
excess/under consumption of cement. The penal rate will be twice the rate of issue of cement for this work.
7.f.8. All the running bills as well as the final bills will be accompanied by cement consumption statements
giving the detailed working of the cement used, cement received and stock-on-hand.
7.f.9. The Contractor will be fully responsible for safe custody of cement once it is received by him and during
transport. Owner will not entertain any claims of the contractor for theft, loss or damage to cement while in their
custody.
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7.f.10. The contractor shall not remove from the site any cement bags at any time.
7.f.11. The Contractor shall advise Engineer-in-charge/Site-in-charge in writing atleast 21 days before exhausting
the Cement stocks already held by Contractor to ensure that such delays do not lead to interruptions in the
progress of work.
7.f.12. Cement shall not be supplied by the Owner for manufacturing of mosaic tiles, precast cement jali and any
other bought out items which consume cement and for temporary works.
7.f.13. Cement in bags and in good usable condition left over after the completion of work shall be returned by
the contractor to the Owner. The Owner shall make payment to the Contractor at the supply rate for such stocks
of cement they accept and receive. Any refused stock of cement shall be removed by the Contractor from the site
at his cost and expenses within 15 days of completion of the work.
8. PAYMENT OF CLAIMS AND DAMAGES
8.1. Should the Owner have to pay money in respect of claims or demands as aforesaid the amount so paid
and the costs incurred by the Owner shall be charged to and paid by the Contractor and the Contractor shall not be
entitled to dispute or question the right of the Owner to make such payments notwithstanding the same may have
been without his consent or authority or in law or otherwise to the contrary.
8.2. In every case in which by virtue of the provisions of Workmen's Compensation Act, 1923, or other Acts,
the Owner is obliged to pay Compensation to a Workman employed by the Contractor in execution of the works,
the Owner will recover from the Contractor the amount of compensation so paid and without prejudice to the
rights of Owner under the said Act. Owner shall be at liberty to recover such amount or any part thereof by
deducting it from the security deposit or from any sum due to the Contractor whether under this contract or
otherwise. The Owner shall not be bound to contest any claim made under Section 12 sub section (1) of the said
Act, except on the written request of the Contractor and upon his giving to the Owner full security for all costs for
which the owner might become liable in consequence of contesting such claim.
8.a. ACTION AND COMPENSATION IN CASE OF BAD WORK
If it shall appear to the Engineer-in-Charge/Site-in-Charge that any work has been executed with bad, imperfect or
unskilled workmanship, or with materials, or that any materials or articles provided by the Contractor for
execution of the work are not of standards specified/inferior quality to that contracted for, or otherwise not in
accordance with the contract, the CONTRACTOR shall on demand in writing from the Engineer-in-Charge/Site-in-
Charge or his authorised representative specifying the work, materials or articles complained of, notwithstanding
that the same may have been inadvertently passed, certified and paid for, forthwith rectify or remove and
reconstruct the work so specified and at his own charge and cost and expenses and in the event of failure to do so
within a period of 15 days of such intimation/ information/knowledge, the Contractor shall be liable to pay
compensation equivalent to the cost of reconstruction by the Owner. On expiry of 15 days period mentioned
above, the Owner may by themselves or otherwise rectify or remove and re-execute the work or remove and
replace with others, the materials or articles complained of as the case may be at the risk and expenses in all
respects of the Contractor. The decision of the Engineer-in- Charge/ Site-in-Charge as to any question arising
under this clause shall be final and conclusive and shall not be raised as a dispute or shall be arbitrable.
8.b. INSPECTION AND AUDIT OF CONTRACT AND WORKS
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This project is subject to inspection by various Government agencies of Government of India. The contractor shall
extend full cooperation to all the Government and other agencies in the inspection of the works, audit of the
Contract and the documents of Contract Bills, measurements sheets etc. etc. and examination of the records of
works and make enquiries interrogation as they may deem fit, proper and necessary. Upon inspection etc. by such
agencies if it is pointed out that the contract work has not been carried out according to the prescribed terms and
conditions as laid down in the tender documents and if any recoveries are recommended, the same shall be
recovered from the contractors running bills/final bill/from ordered/suggested Security Deposit/retention money.
The Contractor shall not rise any dispute on any such account and the same shall not be arbitrable.
9. CONTRACTOR TO INDEMNIFY THE OWNER
The Contractor shall indemnify the Owner and every member, officer and employee of the Owner, also the
Engineer-in-Charge/Site-in-Charge and his staff against all the actions, proceedings, claims, demands, costs,
expenses, whatsoever arising out of or in connection with the works and all actions, proceedings, claims, demands,
costs, expenses which may be made against the Owner for or in respect of or arising out of any failure by the
Contractor in the performance of his obligations under the contract. The Contractor shall be liable for or in respect
of or in consequence of any accident or injury to any workmen or other person in the employment of the
Contractor or his sub contractor and Contractor shall indemnify and keep indemnified the Owner against all such
damages, proceedings, costs, charges and expenses whatsoever in respect thereof or in relation thereto.
10. LIQUIDATED DAMAGES
i) In case of any delay in completion of the work beyond the CDD, the Owner shall be entitled to
be paid Liquidated Damages by the Contractor. The liquidated damages shall be initially at the
rate of 0.5% (half percent) of the total contract value for every week of the delay subject to a
maximum of 5% of the total contract value. The liquidated damages shall be recovered by the
Owner out of the amounts payable to the Contractor or from any Bank Guarantees or Deposits
furnished by the Contractor or the Retention Money retained from the Bills of the Contractor,
either under this contract or any other contract.
ii) The Contractor shall be entitled to give an acceptable unconditional Bank Guarantee in lieu of
such a deduction if Contractor desires any decision on a request for time extension.
iii) Once a final decision is taken on the request of the Contractor or otherwise, the LD shall be
applicable only on the basic cost of the contract and on each full completed week(s) of delay
(and for part of the week, a pro-rata LD amount shall be applicable).
iv) This final calculation of LD shall be only on the value of the unexecuted portion/quantity of
work as on the CDD.
v) Contractor agrees with the Owner, that the above represents a genuine pre-estimate of the
damages which the Owner will suffer on account of delay in the performance of the work by
Contractor. The Contractor further agrees that the LD amount is over and above any right
which owner has to risk purchase under Clause 12.4 and any right to get the defects in the
work rectified at the cost of the contractor.
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11. DEFECTS AFTER TAKING OVER OR TERMINATION OF WORK CONTRACT BY OWNER
The Contractor shall remain responsible and liable to make good all losses or damages that may occur/appear to
the work carried out under this Contract within a period of 12 months from date of issue of the Completion
Certificate and/or the date of Owner taking over the work, which ever is earlier. The Contractor shall issue a Bank
Guarantee to the Owner in the sum of 10% of the work entrusted in the Contract, from any nationalised Bank
acceptable to the Owner and if however, the Contractor fails to furnish such a Bank Guarantee the Owner shall
have right to retain the Security Deposit and Retention Money to cover the 10% of the Guarantee amount under
this clause and to return/refund the same after the expiry of the period of 12 months without any interest
thereon.
12. TERMINATION OF CONTRACT
12.1. The owner may terminate the contract at any stage of the construction for reasons to be recorded in the
letter of termination.
12.2. The Owner inter alia may terminate the Contract for any or all of the following reasons that the contractor
a) has abandoned the work/Contract.
b) has failed to commence the works, or has without any lawful excuse under these conditions suspended
the work for 15 consecutive days.
c) has failed to remove materials from the site or to pull down and replace the work within 15 days after
receiving from the Engineer written notice that the said materials or work were condemned and/or rejected by the
Engineer under specified conditions.
d) has neglected or failed to observe and perform all or any of the terms acts, matters or things under this
Contract to be observed and performed by the Contractor.
e) has to the detriment of good workmanship or in defiance of the Engineer's instructions to the contrary
sub-let any part of the Contract.
f) has acted in any manner to the detrimental interest, reputation, dignity, name or prestige of the Owner.
g) has stopped attending to work without any prior notice and prior permission for a period of 15 days.
h) has become untraceable.
i) has without authority acted in violation of the terms and conditions of this contract and has committed
breach of terms of the contract in best judgement of the owner.
j) has been declared insolvent/bankrupt.
k) in the event of sudden death of the Contractor.
12.3. The owner on termination of such contract shall have the right to appropriate the Security Deposit,
Retention Money and invoke the Bank Guarantee furnished by the contractor and to appropriate the same
towards the amounts due and payable by the contractor as per the conditions of Contract and return to the
contractor excess money, if any, left over.
12.4. In case of Termination of the contract, Owner shall have the right to carry out the unexecuted portion
of the work either by themselves or through any other contractor(s) at the risk and cost of the Contractor. In
view of paucity of time, Owner shall have the right to place such unexecuted portion of the work on any
nominated contractor(s). However, the overall liability of the Contractor shall be restricted to 100 % of the total
contract value.
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12.5. The contractor within or at the time fixed by the Owner shall depute his authorised representative for
taking joint final measurements of the works executed thus far and submit the final bill for the work as per joint
final measurement within 15 days of the date of joint final measurement. If the contractor fails to depute their
representative for joint measurement, the owner shall take the measurement with their Engineer-in-Charge/Site-
in-Charge or any other outside representatives. Such a measurement shall not be questioned by the Contractor
and no dispute can be raised by the Contractor for purpose of Arbitration.
12.6. The Owner may enter upon and take possession of the works and all plant, tools, scaffoldings, sheds,
machinery, power operated tools and steel, cement and other materials of the Contract at the site or around the
site and use or employ the same for completion of the work or employ any other contractor or other person or
persons to completion of the work or employ any other contractor or other person or persons to complete the
works. The Contractor shall not in any way object or interrupt or do any act, matter or thing to prevent or hinder
such actions, other Contractor or other persons employed for completing and finishing or using the materials and
plant for the works. When the works shall be completed or as soon thereafter the Engineer shall give a notice in
writing to the Contractor to remove surplus materials and plant, if any, and belonging to the Contractor except as
provided elsewhere in the Contract and should the Contractor fail to do so within a period of 15 days after receipt
thereof the Owner may sell the same by public auction and shall give credit to the contractor for the amount
realised. The Owner shall thereafter ascertain and certify in writing under his hand what (if anything) shall be due
or payable to or by the Owner for the value of the plant and materials so taken possession and the expense or loss
which the Owner shall have been put to in procuring the works, to be so completed, and the amount if any, owing
to the Contractor and the amount which shall be so certified shall thereupon be paid by the Owner to the
Contractor or by the Contractor to the Owner, as the case may, and the Certificate of the Owner shall be final and
conclusive between the parties.
12.7. When the contract is terminated by the Owner for all or any of the reasons mentioned above the
Contractor shall not have any right to claim compensation on account of such termination.
13. FORCE MAJEURE
13.1. Any delay in or failure of the performance of either part hereto shall not constitute default hereunder or
give rise to any claims for damage, if any, to the extent such delays or failure of performance is caused by
occurrences such as Acts of God or an enemy, expropriation or confiscation of facilities by Government authorities,
acts of war, rebellion, sabotage or fires, floods, explosions, riots, or strikes. The Contractor shall keep records of
the circumstances referred to above and bring these to the notice of the Engineer-in-Charge/Site-in-Charge in
writing immediately on such occurrences. The amount of time, if any, lost on any of these counts shall not be
counted for the Contract period. Once decision of the Owner arrived at after consultation with the Contractor,
shall be final and binding. Such a determined period of time be extended by the Owner to enable the Contractor
to complete the job within such extended period of time.
13.2. If Contractor is prevented or delayed from the performing any of its obligations under this Agreement by
Force Majeure, then Contractor shall notify Owner the circumstances constituting the Force Majeure and the
obligations performance of which is thereby delayed or prevented, within seven days of the occurrence of the
events.
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14. ARBITRATION
14.1 All disputes and differences of whatsoever nature, whether existing or which shall at any time arise
between the parties hereto touching or concerning the agreement, meaning, operation or effect thereof or to the
rights and liabilities of the parties or arising out of or in relation thereto whether during or after completion of the
contract or whether before after determination, foreclosure, termination or breach of the agreement (other than
those in respect of which the decision of any person is, by the contract, expressed to be final and binding) shall,
after written notice by either party to the agreement to the other of them and to the Appointing Authority
hereinafter mentioned, be referred for adjudication to the Sole Arbitrator to be appointed as hereinafter provided.
14.2. The appointing authority shall either himself act as the Sole Arbitrator or nominate some officer/retired
officer of Hindustan Petroleum Corporation Limited (referred to as owner or HPCL) or a retired officer of any
other Government Company in the Oil Sector of the rank of Ch. Manager & above or any retired officer of the
Central Government not below the rank of a Director, to act as the Sole Arbitrator to adjudicate the disputes
and differences between the parties. The contractor/vendor shall not be entitled to raise any objection to the
appointment of such person as the Sole Arbitrator on the ground that the said person is/was an officer and/or
shareholder of the owner, another Govt. Company or the Central Government or that he/she has to deal or had
dealt with the matter to which the contract relates or that in the course of his/her duties, he/she has/had
expressed views on all or any of the matters in dispute or difference.
14.3. In the event of the Arbitrator to whom the matter is referred to, does not accept the appointment, or is
unable or unwilling to act or resigns or vacates his office for any reasons whatsoever, the Appointing Authority
aforesaid, shall nominate another person as aforesaid, to act as the Sole Arbitrator.
14.4. Such another person nominated as the Sole Arbitrator shall be entitled to proceed with the arbitration
from the stage at which it was left by his predecessor. It is expressly agreed between the parties that no person
other than the Appointing Authority or a person nominated by the Appointing Authority as aforesaid, shall act
as an Arbitrator. The failure on the part of the Appointing Authority to make an appointment on time shall only
give rise to a right to a Contractor to get such an appointment made and not to have any other person
appointed as the Sole Arbitrator.
14.5. The Award of the Sole Arbitrator shall be final and binding on the parties to the Agreement.
14.6. The work under the Contract shall, however, continue during the Arbitration proceedings and no payment
due or payable to the concerned party shall be withheld (except to the extent disputed) on account of initiation,
commencement or pendency of such proceedings.
14.7. The Arbitrator may give a composite or separate Award(s) in respect of each dispute or difference
referred to him and may also make interim award(s) if necessary.
14.8. The fees of the Arbitrator and expenses of arbitration, if any, shall be borne equally by the parties unless
the Sole Arbitrator otherwise directs in his award with reasons. The lumpsum fees of the Arbitrator shall be
Rs.40,000/- per case for transportation contracts and Rs.60,000/- for engineering contracts and if the sole
Arbitrator completes the arbitration including his award within 5 months of accepting his appointment, he shall
be paid Rs.10,000/- additionally as bonus. Reasonable actual expenses for stenographer, etc. will be
reimbursed. Fees shall be paid stagewise i.e. 25% on acceptance, 25% on completion of
pleadings/documentation, 25% on completion of arguments and balance on receipt of award by the parties.
14.9. Subject to the aforesaid, the provisions of the Arbitration and Conciliation Act, 1996 or any statutory
modification or re-enactment thereof and the rules made thereunder, shall apply to the Arbitration proceedings
under this Clause.
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Annexure - III to RFQ: 12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
GENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTSGENERAL TERMS & CONDITIONS OF WORKS CONTRACTS
Seal of the Vendor
Signature & Name of the Authorised Signatory with Date
Visakh Refinery
14.10. The Contract shall be governed by and constructed according to the laws in force in India. The parties
hereby submit to the exclusive jurisdiction of the Courts situated at Visakhapatnam for all purposes. The
Arbitration shall be held at Visakhapatnam and conducted in English language.
14.11. The Appointing Authority is the Functional Director of Hindustan Petroleum Corporation Limited.
15. GENERAL
15.1. Materials required for the works whether brought by the or supplied by the Owner shall be stored by the
contractor only at places approved by Engineer-in-Charge/Site-in-Charge. Storage and safe custody of the material
shall be the responsibility of the Contractor.
15.2. Owner and/or Engineer-in-Charge/Site-in-Charge connected with the contract, shall be entitled at any
time to inspect and examine any materials intended to be used in or on the works, either on the site or at factory
or workshop or at other place(s) manufactured or at any places where these are laying or from which these are
being obtained and the contractor shall give facilities as may be required for such inspection and examination.
15.3. In case of any class of work for which there is no such specification supplied by the owner as is mentioned
in the tender documents, such work shall be carried out in accordance with Indian Standard Specifications and if
the Indian Standard Specifications do not cover the same the work should be carried out as per standard
Engineering practice subject to the approval of the Engineer-in-Charge/Site-in-Charge.
15.4. Should the work be suspended by reason of rain, strike, lockouts or other cause the contractor shall take
all precautions necessary for the protection of the work and at his own expense shall make good any damages
arising from any of these causes.
15.5. The contractor shall cover up and protect from injury from any cause all new work also for supplying all
temporary doors, protection to windows and any other requisite protection for the whole of the works executed
whether by himself or special tradesmen or sub- contractors and any damage caused must be made good by the
contractors at his own expense.
15.6. If the contractor has quoted the items under the deemed exports, then it will be the responsibility of the
contractor to get all the benefits under deemed exports from the Government. The Owner’s responsibility shall
only be limited to the issuance of required certificates. The quotation will be unconditional and phrases like
“subject to availability of deemed exports benefit” etc. will not find place in it.
16. Integrity Pact: Effective 1st
September, 2007, all tenders and contracts shall comply with the
requirements of the Integrity Pact (IP) if the value of such tenders or contracts exceed Rs.1 crore. Failure to sign
the Integrity Pact shall lead to outright rejection of bid.
17. Grievances of parties participating or intend to participate in the tender shall be addressed in writing to the
officer designate of the Grievance Redressal Cell where the tenders have to be submitted within the stipulated
period. Detailed mechanism of Grievance Redressal is available on the HPCL website
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SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS
FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
ANNEXURE - IV
HINDUSTAN PETROLEUM CORPORATION LIMITED
VISAKH REFINERY
VISAKHAPATNAM
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INDEX
INTRODUCTION ............................................................................................. 3
1. ORIENTATION MEETING ........................................................................ 4
2. GENERAL RULES .................................................................................... 4
3. SECURITY CONTROLS: .......................................................................... 6
4. CHANGE HOUSE AND TOILET FACILITIES ........................................... 7
5. CAFETERIA FACILITIES .......................................................................... 8
7. SMOKING REGULATIONS ....................................................................... 9
8. BATTERY OPERATED EQUIPMENT & ELECTRICAL ITEMS ............... 9
9. PHOTOGRAPHY ...................................................................................... 9
10. TRAFFIC REGULATIONS ........................................................................ 9
11. CONTRACTOR’S EQUIPMENT ............................................................. 11
12. HOUSE KEEPING .................................................................................. 15
13. WORK PERMIT SYSTEM ....................................................................... 15
14. PERSONAL PROTECTIVE EQUIPMENT............................................... 18
15. REPORTING OF ACCIDENTS/ INCIDENTS .......................................... 19
16. FIRST AID FACILITY .............................................................................. 20
17. FIRE FIGHTING EQUIPMENT ................................................................ 20
18. REPORTING OF FIRE / EMERGENCY PROCEDURES:....................... 21
19. SAFETY PRACTICES AT WORK PLACES ........................................... 23
20. PENALTY FOR NON-COMPLIANCE ..................................................... 52
21. SAFETY MANAGEMENT SYSTEM FOR CONTRACTORS ................... 54
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SAFETY REGULATIONS FOR CONTRACTORS
INTRODUCTION Safety of personnel and property is of prime importance to the management of HPCL, Visakh Refinery. In order to achieve this objective, rules and procedures have been established to prevent accidents that may result in injury to persons or damage to property. The rules and procedures summarized below will assist the contractors in protecting their own employees and property as well as to the HPCL employees and property. This booklet is a part of ‘Contractor Safety Management System’ of HPCL, Visakh Refinery and shall form part of every work order. Some of the important work procedures and safe practices to be followed by contractors while working in the Visakh Refinery Operational area of Hindustan Petroleum Corporation Limited (hereinafter called Company) are listed out in this manual.
The term contractors covers all agencies / persons who render service to the company within its premises in effecting supplies of any description, operating transport or heavy equipment, performing work of any nature or engaging in any activity in response to orders placed by or at the invitation of the company.
It should be clearly understood that all regulations applicable to contractor given herein, are only typical but not exhaustive. Contractors should obtain specific instructions pertaining to their jobs as and when necessary from concerned company officer. The contractor shall comply with the Safety Manual in addition to this booklet. The contractor will have access to the Safety Manual, which is available with the sponsoring department. On demand company will supply copy of Safety Manual.
These safety regulations are treated as an integral part of the contract document and the contractor shall be held responsible for their and their sub contractor’s employees concerning familiarization, strict adherence to these regulations and any additional safety requirements. . It is the responsibility of the contractor to ensure that all their workers thoroughly familiarize with these procedures and strictly follow them.
Any violation of the safety regulations by the contractor may lead to infringement, penalties or cancellation of the contract if, corrective measures are not taken immediately after having been informed of the same by the Company.
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1. ORIENTATION MEETING
Prior to commencement of the work, key personnel of the contractor and his sub-contractors shall attend an orientation meeting with the representatives from sponsoring dept. and HPCL- Fire & Safety to discuss matters related to safety aspects of the job. Contractor to mobilize their crew and workmen two days advance to attend the safety training conducted by HPCL.
2. GENERAL RULES
2.1. The contractor shall be responsible for all employees working for him and should explain to them the Safety Regulations and other relevant company procedures.
2.2. The contractors shall abide by the applicable statutes viz., the factories act, E.S.I. act, MSIHC rules, gas cylinder rules, workmen’s compensation act, and other central/state government rules pertaining to contractor’s work in a continuous process chemical industry
2.3. The contractor will follow Refinery safety systems and regulations as advised
2.4. The contractor shall maintain their activities in Environment friendly manner and assist HPCL to maintain established systems under ISO 14001 programme.
2.5. The contractor and/or his authorized supervisor shall :
2.5.1. Take instructions from the concerned company supervisor before starting any work in the company premises.
2.5.2. The contractor should submit the detailed execution scheme for critical/ high risk job and get it approved by concerned company supervisors before execution.
2.5.3. Consult the concerned company supervisor in the event of difficulty or problem relating to the assigned job or for any clarification pertaining to company procedures.
2.5.4. Ensure that all personnel working under him work safely and do not create any hazard, panic, un authorized propaganda, etc.
2.5.5. Contractor is held responsible not only for employees working for him (Ref. 3.1) but also persons calling on him or doing business with him in the company premises, Ex. Sub contractors, technical consultants, vendors etc.
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2.5.6. Be responsible for explaining all company instructions related to the persons mentioned in (3.3.4&3.3.5) above and ensuring their compliance.
2.5.7. Be responsible for explaining to his sub-contractors/agents and ensuring their compliance with Safety Rules and practices contained herein.
2.5.8. Ensure that all persons under his responsibility and connected with his work confine to the designated work place only.
2.5.9. In case of electrical work specifically in sub-stations the job should be done in the presence of company electrical section representative.
2.5.10. If two contractor agencies are working within 6 meters radius then they should bring to the notice of permit issuer. This is to ensure safety of workers and equipment.
2.6. Prior to commencement of work, contractor shall furnish his office and home addresses and telephone numbers to the company supervisor to facilitate urgent communication in case of emergency.
2.7. Contractor shall not employ any person below the age of 18 years and above the age of 58 years on company assigned jobs and above the age of 45 for carrying out jobs at height (>12m)
2.8. To avoid confusion arising from multiplicity of instructions, contractor shall receive instruction only from the designated Company Supervisor, except in situation of emergency.
2.9. The contractor shall maintain Attendance / leave Record and other records as given in “The Factories Act” and be able to produce them on demand.
2.10. Contractor shall ensure that the skilled manpower, as per job requirement, are employed and job supervisor is experienced and is minimum diploma holder in his discipline (Mechanical, Electrical/ Civil/ Instrumentation etc.)
2.11. Contractor shall ensure that all the workmen and supervisors working under him are covered under ESI scheme.
2.12. Contractor shall ensure that all the workmen employed by him are medically fit and will submit the Fitness certificate on demand. The fitness for working at height would cover medical certification of health assessment parameters in the format given in annexure –I.
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2.13. Contractor shall not engage any worker for more than 16 hours of continuous duty on a day/
2.14. Identification/ Information/ cautions tags affixed to any system/ equipment are not to be tampered or removed under any circumstances.
2.15. Compressed air or any hydrocarbon shall not be used for cleaning clothes.
2.16. Female workers are not to be employed by the contractor.
2.17. Company representative and F&S officer are authorized to correct any conditions which they may consider hazardous. In case of emergency however, all company supervisors are authorized to act directly with contractor supervisor or workmen. \
2.18. The contractor has to provide identification badge to the persons working under him. A blue colour helmet, safety shoe and boiler suits to be used by contractor personnel.
2.19. The contractor has to provide a board at the worksite giving the details as per “The Labor act.”
3. SECURITY CONTROLS:
3.1. Contractor’s personnel are permitted within Refinery premises only on possession of valid security pass.
3.2. It is the responsibility of the contractor or his supervisor to collect the required number of security passes each day/shift from the security office, distribute them to the personnel assigned for work.
3.3. Organize and regulate the entry of security pass-holders in an orderly fashion at the security gate.
3.4. Contractor’s personnel shall be in possession of the issued security personnel passes while inside the company premises and shall produce the same immediately on demand.
3.5. Security passes are not transferable.
3.6. The contractor shall ensure that his workmen do not trespass though the Operating areas. Trespassing through tank dikes, operating areas and unauthorized areas would be considered as violation and a fine of Rs. 100/- would be laid on the person. If the trespassing is repeated the contractor would be taken for penal action.
3.7. Contractor shall be responsible for safe conduct and orderly behavior of his personnel while inside company premises.
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3.8. Entry or exit of contractors property, be it materials, tools or equipment, into or from company premises shall be regulated by suitable documentation in the Material Movement Register maintained by the company at the security gate. Gate passes are not issued for outgoing item belonging to the contractor.
3.9. Security of Contractor’s materials, tools and equipment and company issued items shall be the responsibility of the contractor.
3.10. Separate Vehicle/equipment passes shall be obtained by the contractor from the security office for his equipment for entering into company premises.
3.11. Company representative will authorize issuance of required number of security passes to contractors, at least 24 hours prior intimation is required for issuance of additional passes. Passes are valid for specific period for which they are issued.
3.12. Passes issued in the name of one contractor shall not be used by workmen belonging to any other contractor.
3.13. At the commencement of each month, Contractors shall submit to the Company’s Security Manager a list of names of workmen employed by him with address and ESI number for arranging gate passes. These lists shall be kept updated throughout the month. On completion of the job or at the time specified, contractor shall return all the passes to company security manager and account for losses if any.
3.14. Mobile phones, pagers, cameras, laptops and data storage devises like pen drives are strictly not allowed inside the refinery. Only walkie talkies are allowed inside the refinery with prior permission
4. CHANGE HOUSE AND TOILET FACILITIES
4.1. Change house and toilet facilities designated for company personnel are not available to contractor’s personnel.
4.2. Maintenance of contractor’s Change room and Toilet facilities meant for contract workmen shall be the responsibility of the contractors.
4.3. Contractor’s personnel shall not wear loose/fluttering clothes like lungi or dhotis and their dress shall be free from oil or chemicals.
4.4. Open areas, pipe tracks, drains etc shall not be used for Toilets. Contractors shall advise their workers to use designated toilet facility.
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5. CAFETERIA FACILITIES
5.1. Company cafeteria facilities are not available to contractors’ personnel. The contractor worker may utilize the cafeteria facility, which is earmarked for them on payment basis.
5.2. Contractors’ personnel are permitted to bring their food inside the Refinery; however, their dining shall be restricted to the designated area. The contractor shall be responsible for keeping the dining area clean and tidy.
5.3. Contractor personnel should not use the pipe tracks, OWS pits and operating areas etc as dining and rest areas. Contractor to ensure the same.
6. CONTRACTOR SHELTER & YARDS
6.1. Contractor's Shelter, Storage yard or any temporary facility within HPCL Premises shall comply with the following conditions:
6.2. It should be a prefabricated portable metallic bunker and prior approval from HPCL to be taken before placing the bunker .
6.3. Similarly prior approval must be taken from HPCL before placing any metallic tool box and the tool box shall clearly indicate the name of the contractor, address, contact number along with HPCL’s supervisor name and contact details. Usage of non metallic bunkers/tool boxes is strictly prohibited.
6.4. At all times the contractor's assigned area shall be kept clean and tidy, waste is to be disposed to designated facilities with in refinery daily so as not to create any unsafe conditions.
6.5. The material to be stacked in neat and orderly manner preventing any blockage to the contractors shed. Access way to be clear and unobstructed.
6.6. The Contractor at his own cost shall provide fire, safety and first aid appliances as per The Factories Act requirements. The adequacy quality and prevails will be verified by the HPCL Personal. The contractor to ensure that F&S equipment are checked and certified by HPCL.
6.7. The Company shall have the right to inspect the facility at any time, even after working hours in case it is required for safety reasons.
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6.8. Contractor shall display a signboard at their Office/shed indicating company name, contract number, title, and period and sponsoring HPCL division/department.
6.9. Contractor shall maintain his shed in proper order and ensure that all flammable materials are stored properly. Contractor shall ensure that power is switched off to his shed before leaving company premises.
6.10. All electrical fittings in the contractors shed should be should be suitable for use as per the area classification, they should be maintained well, No loose electrical wiring is permitted .
7. SMOKING REGULATIONS
Smoking is prohibited inside company premises. Safety matches and cigarette lighters are not permitted inside the refinery. These are to be deposited at Security gate.
8. BATTERY OPERATED EQUIPMENT & ELECTRICAL ITEMS
8.1. Non-intrinsically safe battery operated items e.g. flash lights, mobile telephones; pagers etc. are not permitted inside the refinery by the contractor personnel. The same to be deposited at gate before entry into refinery.
8.2. Electrically operated tools and equipment should be suitable for use as per the area classification. Non explosion proof or non-intrinsically safe equipment shall not be used without a hot work permit.
9. PHOTOGRAPHY
Photography by the Contractor personnel is prohibited in refinery premises.
10. TRAFFIC REGULATIONS
10.1. Use of vehicles in side refinery is strictly on need basis. All contract drivers would have to attend driving test for obtaining refinery driving permit. A driver coming for a refinery driving permit should approach F&S with a recommendation letter from his head of the department that the vehicle is required for Project / maintenance work. He shall be submitting the following documents.
10.1.1. Original RTA license for verification
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10.1.2. Photocopy of the RTA license
10.1.3. Copy of gate pass
10.1.4. Clearance from company medical officer
10.1.5. Pay a one time processing fee of Rs. 500/- to finance and bring the challan.
10.1.6. Two stamp sized colour photos.
10.2. All vehicles entering or leaving the Refinery premises shall come to a complete halt at the security gates and shall be offered for checking by the security personnel.
10.3. The maximum speed limit for motor vehicles within the company premises is 25 KMPH Vehicles and mobile equipment shall be driven cautiously and shall follow all traffic regulations and road signs.
10.4. Contractors’ vehicles or mobile equipment shall not enter refinery operating units unless authorized by a hot work permit, strictly on need base approach.
10.5. Two wheelers are not allowed inside Refinery premises.
10.6. Transport vehicles permitted inside the refinery premises shall have flame/spark arrestors of CCOE approved design or manufacturer
10.7. Transport vehicles permitted inside the refinery premises shall be parked in the designated parking area only.
10.8. Vehicles or other mobile equipment shall not be parked in any manner that will block fire hydrant, fire equipment, building exists and walkways etc.
10.9. It shall be the responsibility of the contractor to ensure that materials are properly stacked in the transport vehicles to avoid items dropping from the vehicle while in transit.
10.10. Transporting of materials / equipment which project beyond the periphery of the transport vehicles shall have exclusive company permit and cautionary tags like red flag shall be conspicuously display on the projecting items. Proper supporting/tied covering to be made so that loading material does not fall.
10.11. Loitering inside Refinery premises is strictly prohibited.
10.12. Walk on walkway wherever provided, in the absence of which walk on the left side of the road.
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10.13. Bicycle may be allowed to ply inside the refinery strictly on need basis; double riding on bicycle is not permitted.
10.14. Contractor’s vehicles and bicycles shall normally be parked outside the main gate, company assume no responsibility for the security for contractor vehicles in case of theft.
10.15. Contractor‘s vehicles shall be allowed inside the refinery premises only if, in possession of a valid vehicle pass. Vehicle passes shall be issued by Security on approval by company representative.
10.16. Contractor vehicle drivers shall obtain necessary refinery driving license from Fire & Safety Department while driving inside the refinery
10.17. Crane, Hydra Operator should not allow anybody to sit on vehicle body. They should necessarily have reversing horn.
10.18. Materials being shifted by Trailer truck should be tied properly.
10.19. Men and material shall not be transported together on the same vehicle.
10.20. Contractor to ensure that road is not blocked up at any point of time due to vehicle movement, loading and unloading activities. Necessary road closure permit to be obtained from F&S. Always open up the roads in case of emergency sirens, ensure space for the movement of emergency vehicles. Blockage of roads without valid permit would call for penal action.
11. CONTRACTOR’S EQUIPMENT
11.1. Agency shall follow the Annexure IV – SWP06 : ‘Contractor Jobs equipment safety assurance ’ for bringing the various equipments, tools and tackles inside HPCL-VR.
11.2. All mobile and stationary equipment, tools, safety appliances and machinery under contractors’ control and operating in the company premises shall have valid certification applicable to each of them and equipment shall be in healthy working condition for safe operation. On demand by company Supervisor, Company Supervisor having right to reject equipment and that rejected equipment should be transported out of refinery, the contractor shall produce the test certificate of his equipment.
11.3. Use of equipment involving power, hoisting, and towing, pushing, carrying, high temperature/pressure shall be subject to prior permission from the company supervisor before actual application.
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11.4. Written company permits where indicated, shall be obtained without fail prior to any action or operation.
11.5. Preparation for any equipment activity, where indicated, shall be performed as stipulated by the company supervisor.
11.6. Equipment fitted with pneumatic or solid rubber tyres only shall be permitted on Refinery roads. Vehicle’s equipment fitted with steel tyres are not permitted on Refinery roads.
11.7. Use of Company Equipment
11.7.1. Contractor shall not use company equipment and tools without obtaining permission from the supervisor responsible for the equipment or tool.
11.7.2. Contractors shall assume full responsibility for proper care of company equipment and tools which are made available to them for the execution of their work and return such equipment and tools in good working order.
11.7.3. In case of any damage to the equipment company shall recover from contractors full cost of repairs / cost of replacement.
11.8. Handling of Cylinders
11.8.1. A Gas cylinder is a closed metal container intended for storage and transportation of compressed gas, designed not to be fitted to a special transport or under carriage, and having a volume exceeding 500 ml. but not exceeding 1000 litres. The following has to be taken into consideration while handling the cylinders.
11.8.2. Marking on cylinders – every gas cylinder should be clearly and permanently marked in accordance with the following particulars
11.8.2.1. Owner’s and Inspector’s marking and rotation number
11.8.2.2. Specification to which manufactured
11.8.2.3. Symbol to indicate nature of heat treatment
11.8.2.4. Date of last hydrostatic test or hydrostatic stretch test.
11.8.2.5. Working pressure and test pressure
11.8.2.6. Tare weight inclusive of valve weight
11.8.2.7. Water capacity
11.8.2.8. Manufactured by
11.8.2.9. Gas cylinder for
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11.8.2.10. Quantity & Srl. Nos
11.8.3. Cylinder colour – Cylinder should be painted with the appropriate identification colour
11.8.4. Following warning messages should be displayed on the cylinder.
11.8.4.1. Do not change the colour of the cylinder
11.8.4.2. This cylinder should not be filled with any gas other than the one it now contains.
11.8.4.3. No flammable material should be stored in the immediate vicinity or in the store room in which it is kept.
11.8.4.4. No oil or similar lubricant should be used at the valve or other fittings of this cylinder
11.8.4.5. Look for the next date of test, which is marked on a metal ring inserted between the valve and the neck of the cylinder and if this date is over, the cylinder shall not be accepted.
11.8.5. Prohibition of smoking, fire, lights and dangerous substances –There should be no smoking, no fire or hot work, no matches, fires or other appliances which cause ignition/ explosion at anytime in proximity to a place where any cylinder for any flammable gas is being filled, stored or handled.
11.8.6. Handling and use of cylinders
11.8.6.1. Cylinders should be handled with care and properly supported
11.8.6.2. They should not be allowed to fall on one another.
11.8.6.3. Trolleys’ with end cradles of adequate strength should be used
11.8.6.4. Sliding, dropping or playing with cylinder is prohibited.
11.8.6.5. LPG cylinders should always be kept in an upright position and so placed that they cannot be knocked over.
11.8.6.6. Cylinders used in horizontal position should be secured against rolling.
11.8.6.7. There should be no flame, light, fire, welding or smoking in proximity to any cylinder.
11.8.6.8. Working places should not be classified as places for purposes of licensing.
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11.8.7. Storage of cylinders
11.8.7.1. Cylinders should be stored in a cool, dry, ventilated space under cover, away from boilers, open flames, steam pipes or any potential sources oh heat,and such source of storage shall be easily accessible.
11.8.7.2. The storage shed /room should be of fire proof construction.
11.8.7.3. Thin walled cylinders like LPG cylinders and DI cylinders should not be stacked in horizontal position.
11.8.7.4. Cylinders containing flammable and toxic gases shall be kept separated from each other.
11.8.7.5. Cylinders should not be stored under conditions which will cause corrosion.
11.8.7.6. Cylinders should not be stored along with any combustible material.
11.8.7.7. Empty cylinders should be segregated from the filled ones and all the valves should be tightly shut.
11.8.8. Transportation of cylinders
11.8.8.1. Cylinders filled with any compressed gas should not be transported by bicycle or any other two wheeled mechanically propelled vehicle.
11.8.8.2. Cylinders should not project beyond the slides or ends of the vehicle by which they are transported.
11.8.8.3. Cylinders filled with any compressed gas should not be transported along with any other articles of highly flammable or corrosive nature.
11.8.8.4. Cylinders should be adequately secured to prevent their falling off vehicle.
11.8.8.5. Cylinders containing flammable gases should not be transporting along with the cylinders containing any other type of permanent gases.
11.8.8.6. Cylinders containing toxic or corrosive gas should not be transported along with food stuffs
11.8.8.7. Valves of cylinders should be adequately protected against damage with valve caps rings, etc, while in transit.
11.8.8.8. Transportation of leaking cylinders is prohibited.
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11.8.8.9. Use trolleys for minor movements within the yard or unit.
12. HOUSE KEEPING
12.1. Maintain good house keeping around work area.
12.2. Always keep work place clean and orderly, good housekeeping help to prevent accidents.
12.3. While transferring flammable / toxic material from one container to another, avoid spilling; however, should there be any spillage, it shall be disposed off as directed by the Company Supervisor.
12.4. On completion of work, all surplus materials / equipment / tools shall be removed from site. Company supplied surplus items to be returned to warehouse and site should be thoroughly cleaned.
12.5. Throughout any job, housekeeping at Contractor’s work spots shall be of a standard acceptable to company.
12.6. Following completion of work, contractor shall clean up job sites to Company’s satisfaction. And obtain certificate from operations department as per format attached along with tender.
12.7. Debris shall be disposed off at designated location(s). Metal scrap and other salvageable materials belonging to the company shall be moved to the Refinery Salvage Yard.
12.8. In case the agency/contractor fails to move the scrap to refinery scrap yard, twice the cost of moving the material shall be back charged on vendor apart from other penalties at the discretion of the HPCL Supervisor.
12.9. Unauthorized dumping of the scrap will attract a penalty of Rs 10,000/- in each instance.
13. WORK PERMIT SYSTEM
The purpose of a permit is to give written permission to contractor to carry out a particular job at specific location on a particular equipment or facility. Company representative after ensuring that the equipment /area is safe to carry out the specified work will issue a permit to work within the specified time. For detail about “Work permit system”, please refer our manual on the said subject.
13.1. Cold work permit
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Cold work permits are issued for carrying out work that is Non hazardous and does not pose the danger of fire or danger of life by asphyxiation , electrocution , exposure to gases/chemicals or working at heights under difficult conditions.
13.2. Hot work permit
13.2.1. Performance of work which (i) constitutes a potential fire hazard or (ii) interferes with normal fire fighting operations (iii) poses danger of life shall require a hot work permit.
13.2.2. Typical examples of hot work permits are:
13.2.2.1. Arc welding equipment, gas cutting and welding torches, soldering equipment, any type of electric heating devices, blow torches.
13.2.2.2. Usage of diesel generator
13.2.2.3. Grinding wheels
13.2.2.4. Electric drills and other electric equipment including non-explosion proof lights, connections and extension cords.
13.2.2.5. Shot and grit blasting and similar spark producing surface preparation
13.2.2.6. Stress relieving pre heating and induction heating
13.2.2.7. Location and operating welding equipment, internal combustion engines or any other equipment which may create a source of ignition in hazardous area.
13.2.2.8. Concrete chipping
13.2.2.9. Making entry for inspection, cleaning or repairs inside
13.2.2.9.1. storage tanks
13.2.2.9.2. Process and yard vessels, towers, drums, exchanger shells etc.
13.2.2.9.3. Furnace and boilers
13.2.2.9.4. Excavations, dyke cutting, valve box, sewer or sump where a man’s head may be below grade level
13.2.2.9.5. Sumps in oil separator system
13.2.2.10. Driving any automotive equipment inside process and utility areas, tank farm, adjacent to any sumps in the oil separator and
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adjacent to the hydrocarbon pump houses and flare stack areas.
13.2.2.11. Entry into or hot work on vessel , drums, sections of the pipelines etc. that contained oil , chemicals or toxic products even at approved area.
13.2.2.12. Going to the roof of floating roof tanks when product level is below three meters from top of tank
13.2.2.13. Radiography
13.2.2.14. Rock blasting
13.2.2.15. Stopping of steam leaks on live line by using Pneumatic drill
13.2.2.16. Hot tapping
13.2.2.17. Working under water, Ex: Dredging / shell cleaning at HLPH/LLPH
13.3. Extended Work Permit
A permit issued for maximum of 30 days is called as “Extended Permit”. Extended work permits for longer duration may be issued where the work is of a continuous nature and long duration subject to the area / plant having been positively isolated and facilities declared gas free.
Example: Tank repairs, Project Works away from operating area.
13.4. GUIDELINE ON WORK PERMIT SYSTEM
13.4.1. All activities within Company premises except in exempted areas like Offices, Maintenance shop including garage need authorization by company and work shall not commence without a written valid work permit.
13.4.2. Work permits are to be signed by the supervisor responsible for the operation of the equipment / unit or area concerned as Issuer and concerned company supervisor as Receiver.
13.4.3. The contractor shall ask the company representative for issuing the permit.
13.4.4. Each permit will have details about the nature of work and validity. If the contractor supervisor is in doubt he may ask for
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additional information regarding safe working procedure to the Issuer / Receiver of the permit.
13.4.5. Permits are valid only if all check list items in the permit are covered and signed by the authorized company supervisor and their validity holds good only for the duration specified.
13.4.6. If work is to be continued beyond specified time, permit shall be revalidated.
13.4.7. Permit shall be in the possession of contractors’ personnel in plastic folder at work site , for display in multiple locations, photocopies in plastic folder should be available at each site for entire duration of work.
13.4.8. All conditions and precautions stipulated in the permit shall be strictly adhered to, by the contractors’ personnel.
13.4.9. In the event of a hazardous situation developing during the course of work, the matter shall be immediately reported to the nearest company employee and permit returned to the issuing authority and there is any change in plan/methodology involving execution should inform to issuer and receiver. Work shall recommence only on restoration of the permit by the same authority.
13.4.10. In the event of an emergency at work site, any company employee is authorized to withdraw the permit and hand it over to the issuing authority.
13.4.11. On completion of work or on expiry of validity, the permit shall be returned to the issuing authority.
13.4.12. If the Contractor personnel found working without a valid permit, a serious action as deemed fit will be taken.
13.4.13. While all job need a safety review by contract safety supervisor permit issue will some times depends on a detailed job safety / hazard analysis for critical item performed by company. The out come of JSA take precautions, PPE and timely of the job is to be adhered to periodic checks by contractor safety supervisor should be submitted.
14. PERSONAL PROTECTIVE EQUIPMENT
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14.1. Agency shall strictly follow Annexure II - ‘SWP02 :Requirement of basic minimum PPE’ & Annexure I - ‘SWP01 : Specification of PPEs’
14.2. All necessary personal safety equipment as considered adequate by the company supervisor should be made available for the use to the persons employed at the site. These should be maintained in a condition suitable for immediate use. The contractor should take adequate steps to ensure proper use of equipment by those concerned. Contractor to submit the list of equipment and take the approval from company supervisor. Agency shall strictly follow Annexure II, ‘SWP02 :Requirement of basic minimum PPE’ & Annexure I ‘SWP01 : Specification of PPEs’
14.3. Those engaged in welding and cutting works shall be provided with protective equipment such as Welder’s helmet, leather hand gloves etc.
14.4. Proper training shall be provided to workers for usage of Personal protective equipment.
14.5. Personal protective and safety equipment shall conform to HPCL PPE Specifications and sample to be produced to HPCL Fire & Safety department for approval if asked.
14.6. Contractor to ensure the safety equipment are checked and certified for condition by F&S personnel.
14.7. Boiler suits
14.7.1. All workers engaged for T&I shall wear boiler suits of contractor specific color approved by HPCL.
14.7.2. Boiler suits shall be made of good quality pure cotton cloth like Aravind mills, alpha or of similar quality.
14.7.3. The boiler suit cloth shall be 100% cotton
14.7.4. Reflectors shall be stitched on the boiler suits
14.8. Over and above all the specified safety regulations, job specific PPE stipulated by the permit are mandatory.
15. REPORTING OF ACCIDENTS/ INCIDENTS
15.1. All the accidents/ incidents minor/ major and near misses shall be immediately reported in writing to the company supervisor.
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15.2. All formality as per statutory regulations shall be carried out by the contractor where warranted.
15.3. Contractor shall assist the company supervisor in investigating the accident/ incident and furnish all details regarding the accident/ incident.
15.4. Contractor shall pay all incidental and medical expenses for the injured and compensation, as per Govt.rules, in case of injury or fatality.
16. FIRST AID FACILITY
16.1. In the event of an injury to contractor personnel in company premises, injured shall be brought to company dispensary. Subsequent medical treatment and /or hospitalization shall be arranged by the contractor at his expenses.
16.2. Company Ambulance is not available for injured or sick persons of the contractor except with prior permission from HOD- Fire & Safety/ Manager- Production (shifts).
16.3. In the event of hospitalization of any contractor personnel, the contractor shall inform the details about the treatment being given to the company supervisor and shift Fire & Safety officer on telephone no. 2894851
16.4. Contractor supervisor shall accompany the worker to the dispensary in case of any injury to the worker. The details of the injured worker are to be produced to F&S.
17. FIRE FIGHTING EQUIPMENT
17.1. The contractor has to provide adequate fire fighting equipment as specified by the company supervisor at work site carrying out hot work.
17.2. ISI marked DCP extinguisher of 10 KG capacity, charged fire water hose of 38 mm size with spray nozzle are the general types of fire fighting equipment to be provided at work site
17.3. The fire fighting equipment available at site shall be in good working condition and periodically tested / checked as specified by Fire & Safety personnel of the refinery.
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17.4. The fire fighting equipment shall have a mark of identification of the contractor. DCP/ CO2 extinguishers shall be marked with the name of the contractor, date of last HT and HT due date.
17.5. 18.5 The fire fighting equipment shall be tested and certified by HPCL. Contractor to ensure the same.
18. REPORTING OF FIRE / EMERGENCY PROCEDURES:
18.1. In case of fire are spotted in the refinery premises, it shall be immediately reported to the nearest company employee who in turn shall dial “77” and inform about fire.
18.2. In the absence of any company employee, contractor supervisor shall dial phone “77”revealing the person’s identity and report about the fire, its location and nature.
18.3. Contractor personnel can also report a fire through Manual Call Points (MCP) provided at various locations round the refinery. MCP unit comprises of a micro switch enclosed in a box. The whole assembly is covered from all sides except from the front side. The front side is sealed with a breakable glass cover. The glass cover is fixed in such a way that the actuating micro cover is kept depressed so long as the glass cover is intact.
18.4. In case of fire emergency, the MCP box has to be opened up, the glass cover of the micro switch is to be broken, open the telephone box and use the telephone. The telephone communication can be made using hand set provided in the MCP box.
18.5. Communicate the fire emergency in the way given.
18.5.1. Lift the hand set and wait for acknowledgement from Fire house.
18.5.2. Caller to identify himself (Name, Contractor, Designation etc.)
18.5.3. Give the exact location and description of fire emergency.
18.5.4. Wait till Fire house repeats the message.
18.5.5. Caller to confirm the accuracy of the message (location of fire) as repeated by the Fire house person.
18.6. Fire emergency is sounded in wailing fashion for one minute. On sounding of refinery fire alarm, the contractor personnel shall stop their work immediately secure the place and move to the nearest assembly
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point away from refinery equipment keeping the road clear for free movement of emergency vehicles and persons. Wait for the sounding of all clear siren.
18.7. Assembly points are located at the following areas in Refinery and ATP area. Contractor supervisor should communicate the nearest assembly point to workers daily before the start of work
18.8. Assembly points – Refinery
18.8.1. SOUTH OF OLD ADMIN BUIDLING 18.8.2. SOUTH OF MAINTENANCE SHOP 18.8.3. SOUTH EAST OF CDU-III 18.8.4. SOUTH WEST OF HLPH PUMPS 18.8.5. SOUTH WEST OF SS-50 18.8.6. SOUTH OF IFO TANKS 18.8.7. NORTH OF CRWETP (NEAR ATP GATE) 18.8.8. REFINERY FIRE HOUSE 18.8.9. NORTH OF FABRICATION YARD (NORTH BOUNDARY) 18.8.10. SOUTH OF ETP-IV 18.8.11. SOUTH WEST OF TANK-D5 18.8.12. NORTH WEST OF SS-12A 18.8.13. NORTH OF BLOCK-B 18.8.14. EAST OF SS-14 18.8.15. WEST OF SS-6B 18.8.16. SOUTH OF LPG C/R 18.8.17. SOUTH OF TANK-191 18.8.18. EAST OF NEW ADMIN BUILDING 18.8.19. BLOCK-A 18.8.20. BLOCK-C 18.8.21. DM PLANT 18.8.22. MS BLOCK 18.8.23. FIRE&SAFETY 18.8.24. MOI CONTROL ROOM
18.9. Assembly points – ATP
18.9.1. NORTH OF VVPL OFFICE 18.9.2. SOUTH EAST OF TANK-211 18.9.3. NORTH WEST OF TANK- 120-T-213 B (NORTH
BOUNDARY) 18.9.4. NORTH WEST OF TANK- 120-T-210 (WEST BOUNDARY) 18.9.5. SOUTH WEST OF TANK- 120-T-209 A 18.9.6. NORTH WEST OF TANK- 120-T-206 A (WEST
BOUNDARY) 18.9.7. NORTH WEST OF TANK- 120-T-201 D (CRUDE TANK) 18.9.8. NORTH EAST OF TANK- 120-T-201 C (CRUDE TANK)
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18.9.9. NORTH OF REFINERY TO ATP GATE (SOUTH BOUNDARY)
18.10. Cold work should also be stopped in affected unit, but in all other processing units cold work can continue. They shall remain there till instructions for leaving the area are issued by company supervisor.
18.11. Fire emergency siren repeated 3 times after a gap of 30 seconds constitutes onsite emergency siren.
18.12. In case of Onsite emergency (disaster siren), contractor personnel shall stop their work, secure the work place and move towards the nearest assembly point. At the assembly point there would be a head count followed by evacuation. Contractor should evacuate his employees from the refinery premises using company arranged or own vehicle from the assembly point.
18.13. The All clear signal is the steady sounding of the refinery siren for one minute. After the all clear is signaled contractor personnel can resume back to work.
18.14. In case of emergency siren, all the vehicles should be immediately stopped by moving to the side of the road with out blocking any fire hydrant points and ensure sufficient space is available for the moment of fire tenders & rescue vehicles.
19. SAFETY PRACTICES AT WORK PLACES
19.1. Precautions against the fall of materials, persons, collapse of structures and precautions for working in confined space:
19.2. Precautions should be taken such as the provision of fencing, look-out men or barriers to protect any person against injury by the fall of materials, Proper access ladder, working plat form scaffolding railing use of safety nets, tools or such other equipment as necessary must be used.
19.3. Where necessary to prevent danger, guys, stays or supports should be used or other effective precautions should be taken to prevent the collapse of structures or parts of structures that are being erected, maintained, repaired, dismantled or demolished.
19.4. All openings through which workers are liable to fall shall be kept effectively covered or fenced and displayed prominently.
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19.5. As far as practicable, guardrails and toe-boards should be provided to protect workers materials and tools from falling from elevated workplaces.
19.6. Adequate rescue arrangements like ladders, ropes, baskets, ambulance, breathing apparatuses, etc. is to be made available and rescue drill conducted by contract personnel in presence of HPCL representative.
19.7. CONFINED SPACE :
19.7.1. A confined space is any vessel which has the following characteristics
19.7.1.1. Limited openings for entry and exit
19.7.1.2. Unfavorable natural ventilation
19.7.1.3. Not designed for continuous occupancy
19.7.1.4. Presence of contaminants and lack of oxygen
19.7.2. examples include towers, drums, tanks, large line, Vessels, boilers, storage tanks, large diameter piping etc, manhole, sewer or valve box, sump , excavation more than 1.2 meter deep, entry on floating roof tanks when the roof is more than 3 meter down from the top, space located below ground level such as pits, drains, channels etc.
19.7.3. Before entry into any confined space the contractor to ensure the vessel is positively isolated by means of blinds, made HC / Toxic gas free by depressurizing, steam purging, nitrogen purging, water wash etc. All electrical sources disconnected, switches removed locked and tagged, Belt and chain drives, mechanical linkages on shaft driven equipment disconnected, Mechanical moving parts inside the confined space secured.
19.7.4. Proper ventilation must be provided to get minimum 19.5% of oxygen in air.
19.7.5. Confined space must be tested for the presence of percentage of oxygen in air and the concentration of toxic gases and HC in air. The testing to be carried out prior to entry as well as during the course of the work. Continuous gas monitoring to be do incase of JSA recommendations. The gas test readings are to be entered in a register for future reference.
19.7.6. Hot work permit is required to be obtained prior to entry into a confined space.
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19.7.7. A standby person must be assigned and always be present at the entrance of the confined space. A record of all work permits issued and number of authorized entrants in the confined space has to be maintained with the stand by personnel. A stand by personnel should not have any other jobs other than being stand by. He must be trained in the emergency procedures and should be well versed with the emergency contact numbers.
19.7.8. All the Emergency equipment, must be readily available and in good working condition.
19.7.9. When entering from the top, and if this is the only means of access, a lifeline must be worn by the person entering into confined space.
19.7.10. There shall be no Hydrogen sulfide or any other toxic gases present, Carbon monoxide shall not exceed 5 PPM.
19.7.11. No hot work should be permitted unless the Explosive meter reading is zero. Vessel entry, where no hot work is to be carried out, may be permitted under extra precautionary measures based on the careful analysis of the potential hazards if combustible gases are up-to 5% of lower explosive limit (LEL). Entry with an air supplied mask may be permitted with LEL of up to 20%. The oxygen level should be at least 19.5 % vol. and the concentration of toxic gases below the threshold limits.
19.7.12. Electrical lamps with guard and voltage limited to 24 V shall be used for lighting.
19.7.13. Before entering gas test (presence of Hydrocarbon vapors, CO, H2S, other toxic gases, Oxygen deficiency shall be carried out by the Operations technician to ensure that concentrations of such gases are below the allowable limit. The allowable limits are as follows:
19.7.13.1. HC -20% of LEL ( Max)
19.7.13.2. CO -5 P PM( Max)
19.7.13.3. H2S -2 PPM ( Max)
19.7.13.4. O2- Not less than 19.5 % in air
19.7.14. Special precautions like wetting with water must be taken where there are materials like pyrophoric iron (Iron sulphide), Acetylides or polymers present which may ignite spontaneously.
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19.8. WORKING IN CONFINED SPACES
19.8.1. Following safety practices for working in confined space like towers, columns, tanks, pits and other vessels should be followed in addition to the safety guidelines for specific jobs like scaffolding, cutting/welding etc.
19.8.2. Ensure proper and accessible means of exit before entry inside a confined space.
19.8.3. The number of persons allowed inside the vessel should be limited to avoid overcrowding.
19.8.4. When the work is going on in the confined space, there should always be one man standby (attendant) at the nearby man way.
19.8.5. Ensure adequate ventilation or use respiratory devices.
19.8.6. Depending upon need, necessary respirator system, like BA set, air line respirators etc. shall be worn by the contractor employees. these equipment shall be arranged by company.
19.8.7. Use 24V flameproof lamp fittings only for illumination.
19.8.8. The gas cylinders used for cutting/welding shall be kept outside.
19.8.9. All cables, hoses, welding equipment etc., shall be removed from confined space at end of each work day, even if the work is to be resumed in the same space the next day.
19.8.10. Communication should be always maintained between the worker and the attendant.
19.8.11. A checklist should be prepared and used to check the safety and functional aspects of the equipment and the concerned activity. The check listing activity should be carried out prior to the commencement of the job.
19.9. LIGHTING
19.9.1. Where natural lighting is not adequate, working light fittings or portable hand-lamps should be provided at workplace on the construction site where a worker will do a job.
19.9.2. Emergency lighting should be provided for personnel safety during night time to facilitate standby lighting source, if normal system fails.
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19.9.3. Artificial lighting should not produce glare or disturbing shadows.
19.9.4. Lamps should be protected by guards against accidental breakage.
19.9.5. The cables of portable electrical lighting equipment should be of adequate size & characteristics for the power requirements and of adequate mechanical strength to withstand severe conditions in construction operations.
19.9.6. No loose or open cable joints are allowed.
19.9.7. Portable lights
19.9.7.1. All single fixtures portable hand lamp shall be of weather proof type.
19.9.7.2. Only the standard approved string lights may be used where Hot Work is authorized, either by a Hot Work Permit or by designing of the area as open for Hot Work at all times.
19.9.7.3. PORTABLE electric single or multitude outlet extension cords (plug boards) hand lights and string lights should be inspected at regular intervals.
19.9.7.4. AUTHORIZED person must make all repairs to refinery flashlights only.
19.9.7.5. ONLY 24volts portable lamps with guard shall be used in confined spaces.
19.10. PLANT, MACHINERY, EQUIPMENT AND HAND TOOLS
19.10.1. General Provisions
19.10.1.1. Plant, machinery and equipment including hand tools, both manual and power driven, should:
19.10.1.2. be of proper design and construction, taking into account health, Safety and ergonomic principles.
19.10.1.3. be maintained in good working order;
19.10.1.4. be used only for work for which they have been designed.
19.10.1.5. be operated only by workers who have been authorized and given appropriate training.
19.10.1.6. be provided with protective guards, shields or other devices as required.
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19.10.1.7. Adequate instructions for safe use should be provided.
19.10.1.8. Safe operating procedures should be established and used for all plant, machinery and equipment.
19.10.1.9. Where trailing cables or hose pipes are used they should be kept as short as practicable and not allowed to create a hazard.
19.10.1.10. All moving parts of machinery and equipment should be enclosed or adequately guarded.
19.10.1.11. Every power-driven machine and equipment should be provided with adequate means, immediately accessible and readily identifiable to the operator, of stopping it quickly and preventing it from being started again inadvertently.
19.10.1.12. Operators of plant, machinery, equipment and tools should be provided with PPEs, including suitable ear protection where ever necessary.
19.10.2. Hand Tools:
19.10.2.1. Hand tools should be repaired by competent persons.
19.10.2.2. Heads of hammers and other shock tools should be dressed or ground to a suitable radius on the edge as soon as they begin to mushroom or crack.
19.10.2.3. When not in use and while being carried or transported sharp tools should be kept in sheaths, shields, chests or other suitable containers.
19.10.2.4. Only insulated or non conducting tools should be used on or near live electrical installations.
19.10.2.5. Only non-sparking tools should be used near or in the presence of flammable or explosive dusts or vapours.
19.10.2.6. Do not carry hand tools by hand while climbing up the ladder or to height always use tool bags.
19.10.2.7. Crowbars and spaded used for excavtion activity are to be of insulated and non conducting type.
19.10.3. Pneumatic Tools:
19.10.3.1. Operating triggers on portable pneumatic tools should be:
19.10.3.1.1. So placed as to minimize the risk of accidental starting of the machine.
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19.10.3.1.2. So arranged as to close the air inlet valve automatically when the pressure of the operator's hand is removed.
19.10.3.2. Hose and hose connections for compressed air supply to portable pneumatic tools should be:
19.10.3.2.1. Designed and tested for the pressure and service for which they are intended;
19.10.3.2.2. Fastened securely on the pipe outlet and equipped with the safety chain, as appropriate.
19.10.3.3. Pneumatic shock tools should be equipped with safety clips or retainers to prevent dies and tools from being accidentally expelled from the barrel.
19.10.3.4. Pneumatic tools should be disconnected from power and the pressure in hose lines released before any adjustment or repair is made.
19.10.3.5. All the tools should be placed in toolbox and protected unit area can not be used as storage.
19.10.4. Hydrojetting machine
19.10.4.1. Work permit system manual shall be followed and stipulated work permit
19.10.4.2. Wearing Safety shoes and helmet is mandatory for working in the refinery. The jet operator and the foot pedal operator both shall use face shield with helmet , PVC hand gloves , gum shoes and apron while working
19.10.4.3. Tarpaulin sheets shall be tied on all three sides with the help of temporary structural members to prevent any injury to the surrounding personnel during actual blasting
19.10.4.4. The rigid lance shall be used along with the gun type trigger and flexible lance with foot operated valve and at no point they will be bypassed
19.10.4.5. In case of any abnormal sound during operation, the machine shall be stopped immediately and the matter informed to the Job Engineer.
19.10.4.6. Proper barricading shall be done to prevent anyone from coming into the vicinity of the high pressure jet if this operation is carried out outside the hydro jetting yard.
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19.10.5. Electrical Tools:
19.10.5.1. All portable electrical tools shall be provided with ELCB. The ELCB to be checked up regularly by contractor’s electrician and a record of the same to be maintained.
19.10.5.2. All electrical tools should be earthed, unless they are "all insulated" or "double insulated" tools which do not require earthing.
19.10.5.3. All electrical tools should get inspected and maintained on a regular basis by a competent electrician and complete records kept.
19.10.6. Engines:
19.10.6.1. Engines should:
19.10.6.1.1. Be installed so that they can be started safely and the maximum safe speed cannot be exceeded.
19.10.6.1.2. Have controls for limiting speed.
19.10.6.1.3. Have devices to stop them from a safe place in an emergency.
19.10.6.2. IC engines should not be run in confined spaces.
19.10.6.3. Engine exhausts to be fitted with spark arrestors to prevent any spark propagation.
19.10.6.4. Do not try to fill fuel when engine is in running condition.
19.10.6.5. Do not leave the engines unattended and in running condition. All the rotating parts in the engines are to be provided with guards. Do not try to open the radiators when the engine is running, this may cause spillage of hot water.
19.10.6.6. Ensure mufflene arrangement integrated fuel tanks in use with the engines.
19.10.7. Ladder & Stairways:
19.10.7.1. Ladders must be visually inspected by the user for defects prior to commencement of the job. Defective ladders must not be used and must be tagged as defective and put out of use until repaired.
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19.10.7.2. A straight ladder must be placed with its feet approximately 1/4th of the ladder length away from the line that is vertical with the top support.
19.10.7.3. Straight ladders must be secured at the bottom and tied at the top to prevent slipping.
19.10.7.4. When ascending or descending ladders, the user must face the ladder and keep a firm grip on the rungs. Always maintain a three point contact with the ladder.
19.10.7.5. Only non-metallic ladders shall be used in electrical substations and when working in close proximity to exposed electrical circuits.
19.10.7.6. Ladders must not be placed in front of doors, in passage ways, or in the vicinity of vehicular traffic unless appropriate barriers and warning signs are erected.
19.10.7.7. Portable ladders must be taken out and stored properly when the job is over
19.10.7.8. To permit visual inspection for defects, ladders must not be painted or varnished.
19.10.7.9. Do not carry tools and materials while ascending or descending ladders. Instead use tool bags.
19.11. EXCAVATION
19.11.1. All excavation work should be planned and the method of excavation and the type of support work required should be decided considering the following:
19.11.2. the stability of the ground;
19.11.3. the effect of excavation on the adjoining buildings, structures or roadways;
19.11.4. to prevent hazard, the gas, water, electrical and other public utilities should be shut off or disconnected, if necessary;
19.11.5. presence of underground pipes, cable conductors, etc.,
19.11.6. the position of culvert/bridges, temporary roads and spoil heaps should be determined;
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19.11.7. Before digging begins on site, all excavation work should be planned and the method of excavation and the type of support work required decided.
19.11.8. All excavation work should be supervised.
19.11.9. While excavating trenches exceeding 1.5m depth proper slope shall be provided. Proper shoring shall be provided to prevent cave-in or slides for deep excavation more than 2 meters in depth.
19.11.10. As far as possible, excavated earth should not be placed within one meter of the edge of the trench or depth of trench whichever is greater.
19.11.11. Adequately anchored stop blocks and barriers should be provided to prevent vehicles being driven into the excavation.
19.11.12. Barricade at 1m height (with red & white band/self glowing caution board) should be provided for excavations. Provide proper access to all excavation. For trenches of 4 feet or more in depth shall be provided with one access ladder.
19.11.13. Necessary precautions should be taken for underground utility lines like cables, sewers etc. and necessary approvals/clearances from the concerned authorities shall be obtained before commencement of the excavation job.
19.11.14. Water shall be pumped/bailed out, if any accumulates in the trench. Necessary precautions should be taken to prevent entry of surface water in trenches.
19.11.15. During rains, the soil becomes loose. Additional precaution against collapse of side wall shall be taken.
19.11.16. In case of mechanized excavation, precaution shall be taken to not to allow anybody to come within one meter of extreme reach of the mechanical shovel. The mechanized excavator shall be operated by a well-trained experienced operator.
19.11.17. When not in operation, the machine shall be kept on firm leveled ground with mechanical shovel resting on ground. Wheel or belt shall be suitably jammed to prevent any accidental movement of the machine. Suitable precautions as per manufacturer guidelines should be taken for dozers, graders and other heavy machines.
19.11.18. Before operating mechanical excavators always ensure ground stability. Do not park or move vehicle in loose soil.
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19.11.19. In case of blasting, IS: 4081-1986 & Indian Explosive Act and rules for storage, handling and carrying of explosive materials and execution of blasting operation shall be strictly followed.
19.12. ELECTRICAL
19.12.1. Only persons having valid licenses should be allowed to work on electrical facilities.
19.12.2. No person should be allowed to work on live circuit. The same, if unavoidable, special care and authorization need to be taken.
19.12.3. Treat all circuits as "LIVE" unless ensured otherwise.
19.12.4. Electrical "Tag Out" procedure "MUST" be followed for carrying out maintenance jobs.
19.12.5. Display voltage ratings prominently with "Danger" signs.
19.12.6. Put caution/notice signs before starting the repair works.
19.12.7. Proper grounding to be ensured for all switch boards and equipment including Portable ones prior to taking into service.
19.12.8. Make sure that electrical switch boards, portable tools, equipments (like grinding machine etc.) don't get wet during their usage. If it happens, stop the main supply, make the tools dry and then only use them. Check proper earthing.
19.12.9. Don't overload the electrical system, Use only proper rated HRC fuses
19.12.10. Industrial type extension boards and Plug sockets are only to be used.
19.12.11. ELCB of tripping current rating of 30 mA shall be used for all connections. Use insulated 3-pin plug tops.
19.12.12. All power supply cables should be laid properly and neatly so that they don't cause hindrance to persons working and no physical damage also takes place to the cables during various construction activities.
19.12.13. All Power cables to be properly terminated using glands and lugs of proper size and adequately crimped.
19.12.14. Spark-proof/flame proof type electrical fittings shall be used in Fire Hazard zones.
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19.12.15. Check installations of steel plates/pipes to protect underground cables at crossings.
19.12.16. Don't make any unsafe temporary connections, naked joints/wiring etc.
19.12.17. Ensure that temporary cables are free from cuts, damaged insulation, kinks or improper insulated joints.
19.12.18. Check at periodic intervals the condition of electrical equipment, ELCB’s, earthing and record for the same to be maintained by the electrician.
19.12.19. All switchboards should be of MS structure only and incoming source should be marked.
19.12.20. Hand lamps should not be of more than 24V rating.
19.12.21. Fire extinguishers and sand buckets (DCP/CO2) should be kept near temporary switch boards.
19.12.22. All parts of electrical installations should be so constructed, installed and maintained as to prevent danger of electric shock, fire and external explosion.
19.12.23. Cable marking and routing to be clearly marked. No loose cables are allowed at the electrical panels.
19.12.24. Electrical panel rooms and sheds should not be used as store house. Do not store any other combustible materials, work cloths, tools and tackles in the electrical panel sheds.
19.12.25. Good house keeping to be ensured at temporary electrical panels and sheds.
19.12.26. SPECIFICATIONS FOR USAGE OF WELDING MACHINES:
19.12.26.1. The ON/OFF switch of the machine shall be in good operable condition and shall be of correct size.
19.12.26.2. The terminal box shall be properly housed so that water entry is avoided
19.12.26.3. The welding cable connecting studs on the machine shall be in good condition.
19.12.26.4. The machine shall have a distinct earthing provision to which a separate cable shall be connected securely at one end and to the mains grid at the other end.
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19.12.26.5. The name- plate of the machine shall be clear.
19.12.26.6. The input cable shall not have joints and shall be in healthy condition.
19.12.26.7. The machine shall be overhauled thoroughly once in six months and the date of overhaul shall be displayed prominently on the machine.
19.12.27. NOTES TO SPECIFICATIONS FOR WELDING M/C :
19.12.27.1. All unwanted entries to the machine shall be properly sealed.
19.12.27.2. When the machine is used in running units / hazardous locations, flame proof plugs of correct size shall be used.
19.12.27.3. If water falls on the machine, input power shall be switched off and the machine shall be thoroughly checked and megger tested before energizing the machine.
19.12.28. SPECIFICATIONS FOR SWITCH BOARDS :
19.12.28.1. The board shall be made of totally non flammable material MS.
19.12.28.2. All the entries and sides of the board shall be securely sealed with Moniplast compound.
19.12.28.3. The top cover of the board shall be properly secured on all sides with adequate number of screws.
19.12.28.4. The top cover and bottom box shall be in healthy condition i.e. without cracks, pinholes etc.
19.12.28.5. The input flexible copper cable shall be of three-core type with appropriate color code (red, black and green), in good condition and of adequate size such that it can safely carry a min load of 16AMPS.
19.12.28.6. The cable entry shall be properly sealed with correct size of gland.
19.12.28.7. At the input there shall be an ELCB of continuous rating 16Amps and leakage current of size 30 mA.
19.12.28.8. There shall be an earthing point welded to the inside of the board to which all the individual earths of all the sockets
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shall be connected. The green lead of the input cable shall be connected securely to this earthing point. The other end of the green lead shall be connected to the mains earthing grid.
19.12.28.9. All the plugs and sockets shall be of industrial type, metal clad. 3 pin of size 10A/20A. There shall be a separate earthing lead connected to the earthing pin of the plug.
19.12.28.10. There shall not be more than three outgoing points and the cables shall be of standard wire like Finolex and connected securely and dressed neatly.
19.12.29. NOTES TO SPECIFICATIONS FOR SWITCH BOARDS
19.12.29.1. When not in use the input power to the board shall be kept in off condition.
19.12.29.2. The board shall not be used in rains and near water sprays. If water/liquid enters the board, it should be ensured that the inside of the board is totally dry and shall be megger tested before energizing the board.
19.12.29.3. The outgoing points, which are not in use, shall be fully covered.
19.12.30. FOR TEMPORARY ELECTRICAL PANELS
19.12.30.1. Provide RCCB and ELCB for each panel.
19.12.30.2. Should provide rubber sheet for shock protection. All electrical panels should be marked and identified, a record of the same to be maintained.
19.12.30.3. Fire Extinguisher (DCP / CO2) and sand bucket should be provided at every electrical panel.
19.12.30.4. Every electrical panel should be adequately protected from rain by means of weather guard.
19.12.30.5. Test lamp should be provided at the panel for ELCB checking.
19.12.30.6. ELCB checking register should be maintained at each and every electrical panel by the contractor’s electrician.
19.12.30.7. Ensure electrical panel is earthed and earthing is OK.
19.12.30.8. Access way to the electrical panels should be clear. Do not use panel room for storage of materials.
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19.12.30.9. Request for temporary power supply.
REQUEST FOR TEMPORARY POWER SUPPLY:
(TO BE FILLED BY THE JOB ENGINEER AND TO BE APPROVED BY THE CONCERNED
MANAGER. SEPARATE FORMS TO BE FILLED FOR DIFFERENT TEMPORARY POWER
PANELS.)
1.0 TEMPORARY
POWER REQUIRED
AT:
2.0 AGENCY TO WHOM
POWER IS TO BE
GIVEN:
M/S.
3.0 IS POWER TO BE
GIVEN FREE OF
COST:
YES* / NO
( * IF POWER IS TO BE GIVEN ON CHARGEABLE BASIS, CONTRACTOR
SHOULD BRING THREE PHASE ENERGY METER WITH VALID CALIBRATION
CERTIFICATE.)
4.0 POWER
REQUIREMENT**
(IN KW / VA / AMPERES)
THREE PHASE:_________________
SINGLE PHASE:_________________
** IF THE LOAD
REQUIREMENT IS
MORE THAN 63A / 36KW, 3-PHASE, PLEASE ENTER
THE DETAILS
HERE.
WELDING MACHINES:_________NOS. RATING:_________
HYDRO-JETTING M/C: _________NOS. RATING:_________
DRILLING M/C : ____________ _NOS. RATING:_________
NO. OF HANDLAMPS : ________ NOS. RATING:_________
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OTHERS (PL. SPECIFY) : _______________________________
_______________________________
5.0 JOB FOR WHICH
POWER IS TO BE
GIVEN:
6.0 HPCL PO NO. AND DATE:
7.0 TEMPORARY
POWER
REQUESTED BY:
(JOB ENGINEER)
(SIGNATURE WITH DATE:)
8.0 REQUEST
APPROVED BY:
(MANAGER)
(SIGNATURE WITH DATE:)
9.0 WO NO. AND
DATE:
WO PRIORITY: 0 / 1 / 2 / 3
CHECKLIST FOR TEMPORARY POWER SUPPLY:
(TO BE FILLED DURING JOINT SITE VISIT AFTER COMPLIANCE TO THE CONDITIONS, BY
THE CONTRACTOR.)
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1
Panel Condition (Physical Checkup)
CHECK IF PANEL BODY IS RUSTED, STRUCTURE IS OK, ALL COMPONENTS
ARE FIRMLY CONNECTED TO THE BODY, ETC.
Panel Structure : RUSTED / NOT RUSTED
Panel Components: RUSTED / NOT RUSTED
Connections: TIGHT / LOOSE
2 Components used are acceptable make:
General make of the components to be in line with acceptable vendors (GEC, ALSTOM, L&T, DATAR, SIEMENS)
STANDARD MAKE / NON-STANDARD MAKE
3
Proper fuses are used as per rating of feeder
(Wire fuses shall not be used. Fuse rating should match with the power requested under Sl. No.4.0 of Part-1 and should be able to take care of any downstream overload/fault. )
FUSE MAKE:_________________________
FUSE RATING: _______ A
FUSE BASE RATING: _______ A
SWITCH RATING: _______ A
4 Proper earthing is provided for the temporary panel. (Two distinct earthing to be provided for the panel, which should be connected to the earthing grid from the power source. The earth conductor size should be at-least half the size of the main power cable.)
SIZE OF MAIN CONDUCTOR:_______________
SIZE OF EARTH CABLE: _________________
NO. OF EARTHS
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PROVIDED: _________ nos.
5 Shed is provided over the temporary power panel to prevent rain water directly falling on panel. (All outdoor panels are to be provided with shed.)
YES / NO
6 All the opening in the panel are plugged/sealed.
YES / NO
7 Danger board is provided on the panel. (Standard DANGER sign with the symbol of skull and bones and the voltage rating (415V) to be provided. The word DANGER should be in English, Hindi and Telugu.)
YES / NO
8 Sand bucket & fire extinguisher is provided. (Not required in fabrication yard, where the same is available in the Contractor’s shed.)
YES / NO / NOT REQUIRED
9 Rubber mats are provided in front of the panel of safely standing on them for operating the switches.
YES / NO
10 Contractor has provided Electrician with valid wire man license, for monitoring the temporary panel.
(Copy of the wire-man license should be attached to this format.)
YES / NO
11 30mA leakage rating ELCBs are provided in the outgoing feeders. (if outgoing feeders are not having ELCBs, the incomer should be an RCBO/RCCB of adequate load rating and 30mA leakage rating.)
YES / NO
12 Lamp is provided for indication and illumination in the temporary panel shed.
YES / NO
13 No other material is stored in the shed.
YES / NO
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We have jointly inspected the temporary panel & the shed and found it to be complying / not complying with the above safety regulations and conditions.
(Contractor)
(Job Engineer)
(Maint. Electrical)
19.13. LIFTING EQUIPMENT: Following are the general guidelines to be followed with regard to all types of handling and lifting equipment in addition to the guidelines for specific type of equipments dealt later on.
19.13.1. There should be a well-planned safety programme to ensure that all the lifting appliances and lifting gear are selected, installed, examined, tested, maintained, operated and dismantled with a view to preventing the occurrence of any accident;
19.13.2. All lifting appliances shall be examined by competent persons at frequencies as specified in "The Factories act". Copies of test certificate shall be produced to sponsoring department and fire & safety.
19.13.3. Check thoroughly quality, size and condition of all lifting tools like chain pulley blocks, slings, U-clamps, D-shackles etc. before putting them in use.
19.13.4. Safe lifting capacity of all lifting & handling equipment, tools and shackles should be got verified and certificates obtained from competent authorities before its use. The safe working load shall be marked on them.
19.13.5. Check periodically the oil, brakes, gears, horns and tyre pressure of all moving equipments like cranes, forklifts, trailers etc as per manufacturer's recommendations working of controls, switches etc.
19.13.6. Check the weights to be lifted and accordingly decide about the crane capacity, boom length and angle of erection.
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19.13.7. Allow lifting slings as short as possible and check for packings at the friction points.
19.13.8. While lifting/placing of the load, no unauthorized person shall remain within the radius of the boom and underneath the load.
19.13.9. Prior to lifting, check the condition of earth, soil/concrete for its fitness to lift the load
19.13.10. While loading, unloading and stacking of pipes, proper wedges shall be placed to prevent rolling down of the pipes.
19.13.11. Control longer jobs being lifted up from both ends using guide ropes.
19.13.12. Only trained operators and riggers should carry out the job. While the crane is moving or lifting the load, the trained rigger should be there for keeping a vigil against hitting any other object.
19.13.13. During high wind conditions and nights, lifting of heavy equipments should be avoided. If unavoidable to do erection in night, operator and rigger should be fully trained for night signaling. Also proper illumination should be there.
19.13.14. Allow crane to move on hard, firm and leveled ground.
19.13.15. Crane and Hydra should not be used for material movement.
19.13.16. When crane is in idle condition for long periods or unattended, crane boom should either be lowered or locked as per manufacturer's guidelines.
19.13.17. Hook and load being lifted shall remain in full visibility of crane operators, while lifting, to the extent possible.
19.13.18. Don't allow booms or other parts of crane to come within 3 meters reach of overhead electrical cables.
19.13.19. No structural alterations or repairs should be made to any part of a lifting appliance, which may affect the safety of the appliance without the permission and supervision of the competent person.
19.13.20. Crane operators and riggers certificate & experience to be provided to HPCL.
19.13.21. Do not do any alterations to load in movement or while load is being lifted.
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19.13.22. All the lifting equipment such as wire ropes, web slings, chains etc are to be physically checked for any visible damage prior to every use.
19.13.23. Always ensure job plan is present while carrying out any critical lifting and heavy loads.
19.14. WORKING AT HEIGHTS
19.14.1. While working at a height of more than 2 meters, ISI marked full body safety harness with double lanyard shall be used. Condition of the safety belt shall be checked before each use of the belt and record of the same to be maintained.
19.14.2. Safety belts should be of the following specifications.
19.14.3. IS: 3521 marked full-body safety belt with double harness, belt made of nylon with 40 mm x 3 mm shoulder strap having double folded stitches , o-ring buckles made of stainless steel and 2.5 meter long two polyamide ropes of 12 mm dia with self closing hook of stainless steel attached to it for anchoring with scaffold pipe of # 50mm .
19.14.4. Worker should be well trained on usage of safety belt especially about the usage of the two harnesses at the time of ascending/descending.
19.14.5. Safety belts should be well maintained cleaned up regularly of oil, grease and dirt. Damaged safety harnesses should be identified and removed from usage.
19.14.6. Do not carry tools while ascending and descending to heights. All tools should be carried in tool kits to avoid their falling.
19.14.7. If the job is on fragile/sloping roof, roof walk ladders shall be used. F& S department should be informed prior to doing job to ensure that adequate safety precautions are taken.
19.14.8. Provide lifeline wherever required.
19.14.9. Additional safety measures like providing Fall Arrestor type Safety belt, fire retardant safety net proper access and scaffolding working platform with hand rails etc., should be provided depending upon site conditions, job requirements as mentioned by HPCL time to time.
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19.14.10. Don't throw or drop material/equipment from height, instead of that lower the materials and vice versa.
19.14.11. When hauling /lifting operations are in progress, the grade area to be barricaded with red and white colour caution tape.
19.14.12. Avoid working at two elevations at the same locations, if needed to perform proper safety review and precautions undertaken to be approved by HPCL.
19.14.13. Refinery standard to be strictly adhered to while laying scaffolding for work at heights.
19.14.14. Access ladder, work platform, hand railing and guard railing to be provided with scaffolding that is erected. Scaffolding pipes should not be dropped from height while dismantling or erection.
19.14.15. Do not use scaffolding clamps as steps for climbing a scaffold. Always hook up the safety belt to the pipe above your height, so that in case of a fall there will be no swinging and hitting against near by structure.
19.15. RADIOGRAPHY
19.15.1. Whenever a contract for industrial radiography is awarded to any industrial radiography agency, the Contractor shall ensure that:
19.15.1.1. The radiography agency is duly authorized by RSD, AERB to work at the particular site of Contractor
19.15.1.2. The radiography agency carries out the radiography work by adhering to requirements of AERB Safety Code on Industrial Radiography (AERB/SC-IR, 2001)
19.15.1.3. The radiographer who will be engaged by radiography agency for carrying out radiography work of radiography agency is certified by BARC/AERB
19.15.1.4. the radiographer has a functional radiation survey meter and makes use of it during radiograph
19.15.1.5. The radiographer cordons sufficient area to control access of unauthorized person during radiography at the site.
19.15.1.6. The radiography work is supervised by Radiological Safety Officer (RSO)/site-in-charge, if any, of the Contractor.
19.15.2. During field radiography, all the area which falls in the radiation zone as per survey meter readings has to be barricaded
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and people evacuated from the area. A flickering light and caution notice should be displayed.
19.15.3. The Contractor shall be responsible for providing adequate illumination, scaffolding and other facilities required to facilitate the safe radiography work by radiography agency.
19.15.4. Special permission/permit should be taken for radiography from area-in-charge.
19.15.5. As far as possible, field radiography should be done only during night time when there is little or no occupancy there.
19.15.6. Radiation warning signals should be pasted all along the cordoned off area.
19.15.7. Entry into the restricted area by unauthorized persons should be strictly prohibited during exposure. Ensure contractor supervisors presence at the barricading area for warning trespassers.
19.15.8. The radiation level along with the cordon should be monitored by a suitable and well-calibrated radiation survey meter. Radiation level outside the storage room should not exceed 0.25 mR/hr.
19.15.9. All personnel working with radiography sources should wear dosi meters and appropriate protective equipment and film badges issued by BARC.
19.15.10. Protection facilities such as radiation hazard placards and means of cordon off shall be available at each site.
19.15.11. The Contractor shall verify that the radiography agency has emergency plans, preparedness and contact numbers in case of emergency/incidents involving radiography devices.
19.15.12. The package containing radiography cameras and sources should never be carried by public transport like bus, train etc.
19.15.13. The Contractor shall ensure that the radiography devices (camera(s)) with source are brought in or moved out of the site with appropriate gate pass mentioning details of the equipment. The proper records of incoming and out going of radiography devices are maintained at storage room and at security department.
19.15.14. Radiography material, source and cameras should not be stored inside the refinery. On completion of radiography the
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contractor should take back the source and cameras, transportation as per BARC instructions.
19.15.15. In case of an accident (due to loss or of damage to radiography source), action should be taken in line with BARC Safety Rules/Guidelines.
19.15.16. Radiography should be carried out under the supervision and control of Radiation Safety Officers (RSO).
19.16. GRIT/SHOT BLASTING
19.16.1. Grit/sort blasting should be used only after approval from competent person.
19.16.2. Air Compressor used for sand/shot blasting/painting should have guard and positioned away from the work place.
19.16.3. Exhaust of the prime mover, if IC engine is used, should be directed away from the work place and should not damage any other equipment, cables, and structures. Spark arrestor should be fixed on the exhaust.
19.16.4. In case of motor driven compressor, the body of the motor as well as the compressor to be properly earthed.
19.16.5. The hoses used for compressed air should be of proper quality, and health of the same to be ensured through regular check/ test.
19.16.6. The operator of sand/shot blasting/painting should wear suitable PPE's including hood with air connection.
19.16.7. Covering eduction arrangement etc., measures to be taken to suppress dust/spray particle.
19.16.8. When these activities are done in confined places, adequate measure to be taken for proper ventilation. The compressor, engines shall be located outside the confined space and only the hoses taken in.
19.16.9. The hopper used for sand/short blasting should be tested once in a year for 1.5 times of normal operating pressure by compitent person and Test certificates to be maintained.
19.16.10. All the rotating parts in the equipment shall be provided with guards.
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19.16.11. The sand blasting area to be covered on four sides so that dust does not spread over. All workmen to be provided with dust masks.
19.17. GAS CUTTING, WELDING, brazing
19.17.1. Ensure that only approved and well-maintained apparatus, such as torches, manifolds, regulators or pressure reducing valves, and acetylene generators, be used.
19.17.2. The work piece should be connected directly to Power supply, and not indirectly through pipelines/structures/equipments etc.
19.17.3. All cables, including welding and ground cables, shall be checked for any worn out or cracked insulation before starting the job. Ground cable should be separate without any loose joints.
19.17.4. All gas cylinders shall be properly secured in upright position.
19.17.5. Acetylene cylinder key for opening valve shall be kept on valve stem, while cylinder is in use, so that the acetylene cylinder could be quickly turned off in case of emergency. Use flash back arrestors at cutting torch to prevent back-fire in acetylene/oxygen cylinder.
19.17.6. Use trolleys for oxygen & acetylene cylinder and chain them.
19.17.7. proper colour code shall be used for oxygen and acetylene cylinders and hoses.
19.17.8. Ensure that hoses are free from burns, cuts and cracks and properly clamped.
19.17.9. During cutting/welding, use proper type goggles/face shields.
19.17.10. The first cut or weld to be undertaken in the presence of company supervisor.
19.17.11. Liquefied petroleum gas cylinders and cylinders containing liquefiable gases shall always be kept in an upright position and shall be so placed that they cannot be knocked over.
19.17.12. A hammer should never be used for opening cylinder valves
19.17.13. If a leak in the valve cannot be rectified by tightening the gland nut or the spindle, the cylinder shall be removed to an open
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space where it is least dangerous to life and property and the filler shall be informed. In the case of LPG cylinder, the safety cap shall be fixed to arrest the leak and the cylinder shall be moved to an open space.
19.17.14. Domestic LPG Cylinders shall not be used for gas welding/cutting job. Only industrial LPG cylinders/private LPG cylinders to be used.
19.17.15. Cylinders heads should be protected when not in use.
19.17.16. Keep regulators, hoses, torches and other fittings free from grease, oil or other combustible substances.
19.17.17. Never use lubricants on oxy fuel gas equipment.
19.17.18. Never substitute oxygen for compressed air.
19.17.19. Make sure a confined area is well ventilated and gas freed before entry. Never carry any cylinders into a confined area.
19.17.20. Cylinders should not be subjected to falls, shock or undue heating.
19.17.21. Acetylene cylinders shall not be allowed to pass through a copper rich material as it forms explosive substances.
19.17.22. Do not take fuel gas Cylinders in trenches.
19.17.23. Proper regulator with pressure gauge shall be used for both Fuel gas and Oxygen cylinders.
19.17.24. Make sure Jubilee clamps are used for fixing hoses. GI wires should not be used for tying, as tubes will get cut.
19.17.25. Adequate and proper ventilation should be provided to keep the fuel gas concentration below the danger limit and to avoid prolonged exposure to fumes.
19.17.26. Flash back: If the tip of the nozzle is obstructed oxygen can flow back into the acetylene pipe and likely to cause explosion. Always keep the tip of the nozzle unobstructed.
19.17.27. Prior to commencement of the job, tubes, cutting torch condition should be checked and any damages/faulty equipment should be replaced.
19.17.28. The cutting torch shall be serviced monthly basis. Ensure that only approved and well-maintained apparatus, such as torches, manifolds, regulators or pressure reducing valves, and acetylene generators, be used.
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19.17.29. The work piece should be connected directly to Power supply, and not indirectly through pipelines / structures / equipment etc.
19.17.30. Domestic LPG cylinders shall not be used for gas welding/cutting job. Only industrial LPG cylinders/private LPG cylinders to be used.
19.18. BARRICADING
19.18.1. Contractor shall erect and maintain barricades required in connection with his operation to guard the followings.
19.18.1.1. Excavations
19.18.1.2. Hoisting areas
19.18.2. Areas adjudged hazardous by Contractors’ or Owner’s Inspectors.
19.18.3. Contractor’s employee and those of its sub-contractors shall become acquainted with Owner’s barricading practice and shall respect the provision thereof.
19.18.4. Barricades and hazards adjacent to but not located in normal routes of travel shall be marked by red flasher lanterns at nights.
19.18.5. Demolition of Buildings:
19.18.5.1. Before taking up the demolition work, a comprehensive site survey must be carried out considering the protection of the surrounding buildings/structures/equipment/utilities and service etc.
19.18.5.2. The electrical power supply to the building shall be disconnected prior to starting demolition.
19.18.5.3. All gas, water and steam service lines shall be positively isolated.
19.18.5.4. The structure to be demolished should be adequately fenced and cordoned off and suitable boards shall be provided warning the public about the danger.
19.18.5.5. For demolition of the building, the glasses in door and windows, loose objectives, projected parts shall be removed first.
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19.18.5.6. Scaffolding used for the demolition operation should be independent of the structure to be demolished.
19.18.5.7. Stair with hand railing should be kept in position as long as possible to provide access.
19.18.5.8. Workers should strictly use Safety belts while working at height, Safety helmets, Safety shoes and other safety gears like safety gloves etc.
19.18.5.9. The demolished materials should not be thrown from height, it should be lowered by the hoist and winch.
19.18.5.10. If the demolitions are carried out by the machines like power shovels, bulldozer etc., safety measures relevant to the operation and use of such machines should be adhered to.
19.18.5.11. The cold work permit shall be taken.
19.19. Hot Work on all Welded Lines
Prior to starting work on welded line (Ex. product shipping lines) which cannot be blinded close to the point where the hot work is to be performed, the following procedure must be observed.
19.19.1. The line must be properly cleared of products and isolated from other operating equipment by blanking. If there is any doubt about the presence within the line, a pilot hole must be drilled by cold cutting.
19.19.2. When it has been determined that there is no pressure, the line must be cold cut, unless specifically authorized by the operations supervisor to do otherwise.
19.19.3. Once a section of the line has been cut out and removed and the line vented, plugs must be inserted in each of the open ends of the pipe, at the cut before hot work is performed. A proper plug must seal the pipe completely.
19.19.4. An alternate method of plugging the end of a pipe line for hot work is to insert, blocks or pieces of solid carbon dio oxide (dry ice) into the container. The dry ice gives off CO2 gas, which makes the atmosphere in the pipe incapable of supporting combustion. In addition, the dry ice cools any residual oil in the pipe below the point where it can give off combustive vapors. The plug must be at least six feet long and must be at least five feet back from the point of hot
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work. Necessary care shall be taken so that the temperature of pipeline does not drop below sub zero during dry ice blanketing.
19.19.5. A vent must be provided through each plug as described above to prevent any pressure build-up. The vent must discharge at least 20 feet away from the plug end.
19.19.6. Plugs must be inspected during the course of job, especially if any hammering is being done, to make sure that they completely block the pipe at all times.
19.20. Tank Repairs:
19.20.1. General:
19.20.1.1. There will be a detailed hydrocarbon & water presenting of tank by HPCL Operations followed by blinding.
19.20.1.2. Necessary hazard related instructions given by the HPCL Operations and Maintenance engineer should be considered while tank repair.
19.20.1.3. Work Permit system should be rigidly followed for all work of tank cleaning and repairs.
19.20.1.4. Respiratory protective equipment should be maintained in good operating condition.
19.20.1.5. Ensure that gas-testing equipment is in good operating condition and proper. Procedures for testing are followed.
19.20.2. Entry into Tank.
19.20.2.1. No entry should be permitted inside the tank, until all lines the tank are blinded / isolated.
19.20.2.2. Every effort should be made to clean the tank from outside, to the extent possible.
19.20.2.3. Appropriate respiratory protective equipment, personal protective equipment and clothing should be used during cleaning operations.
19.20.2.4. No-entry should be permitted if the hydrocarbon gas presence is above 5% of Lower Explosive Limit and oxygen percentage less than 19.5% by volume in air with hydrocarbon gases.
19.20.2.5. While men are working inside a tank, a standby should be posted outside at the manhole, to keep a close watch and call for any assistance that may be required.
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19.20.2.6. Air blower must continue during cleaning operation.
19.20.3. Hot Work.
19.20.3.1. Prior to hot work, all combustibles, liquid hydrocarbons, sludge, scales, deposits etc should be completely removed. Carefully examine linings, pontoons and tank bottoms and legs for trapped oil.
19.20.3.2. Combustible gas indicator should read zero.
19.20.4. Closing Tank.
19.20.4.1. When the tank is to be buttoned up after the work is completed, ensure that no one is left inside the tank and no material is left behind.
19.20.4.2. The tank should be offered for inspection prior to buttoning up. For this purpose a specific permit for buttoning up to be made.
20. PENALTY FOR NON-COMPLIANCE
The penalty system is instituted to ensure safety compliance (HPCL- Fire & Safety shall decide whether an infringement is minor or major for violations which, are not listed below).
20.1. Violations: The penalty system is divided into two categories, Minor and Major. (HPCL - Fire & Safety shall decide whether an infringement is minor or major for violations which are not listed below). Examples given are situation specific and what is minor in a particular context may be a major deviation in another situation.
20.1.1. Minor violation: Examples
20.1.1.1. Not wearing personal protective equipment (PPE) at work site.
20.1.1.2. Minor traffic violation (wrong parking, over speeding)
20.1.1.3. Blocking of emergency equipment or exits.
20.1.1.4. Using unapproved scaffolding Etc.
20.1.2. Major violation: Examples
20.1.2.1. Smoking in the refinery, carrying matches or lighter and mobile telephone.
20.1.2.2. Working without valid work permit.
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20.1.2.3. Not wearing proper breathing apparatus when instructed.
20.1.2.4. Not providing shoring / sloped excavation for the deep pits.
20.1.2.5. Not providing fire extinguisher / fire hoses for hot work.
20.1.2.6. Repeating minor violations more than twice.
20.1.2.7. Major traffic violation.
20.1.2.8. Found guilty negligent driving resulting in a vehicle accident.
20.1.2.9. Entering classified area without permit.
20.1.2.10. Not complying with written instruction on the work permit.
20.2. Infringement Report Procedure:
Manager and above of Fire & Safety department are authorized to issue infringement report to the sponsoring department
The sponsoring department shall take action and provide feedback to fire & safety (If more or less severe action was taken other than recommended, details of same shall be provided.)
20.3. TABLE OF PENALTY STAGES
VIOLATION FIRST SECOND THIRD
MINOR Caution Notice Penalty Rs. 1000 /-
Penalty Rs. 3000/-
MAJOR Penalty Rs. 3000/-
Penalty Rs. 10,000/-
on holiday list
( duration will be decided by General Manager- Opns / Proj. )
Major accident /
Penalty Rs, 1 lakhs
Penalty Rs. 5 lakhs
on holiday list
( duration will be
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fire decided by General Manager- Opns / Proj. )
Note : HPCL reserves the right to impose more severe penalty, i.e. suspend/terminate the contract / employee, his supervisor or the site manager.
21. SAFETY MANAGEMENT SYSTEM FOR CONTRACTORS
The contractors shall have well defined Safety Management System as given below.
21.1. Written Safety Program
21.1.1. Contractors must have a written safety program. A written safety program need not be lengthy, but should include following items:
21.1.1.1. Safety Policy Statement
21.1.2. Safety Goals & Objectives
21.1.3. The program should establish the safety goals and objectives of the firm and a method of measuring it. Action plans should be developed for use in achieving the goals and objectives.
21.1.4. Site Safety Organization and Responsibilities
The program should establish responsibilities for managers, supervisors, safety representatives, and the employees. There should be at least one qualified and experienced Safety Engineer /Supervisor depending on the size of the organization exclusively responsible for safety implementation/Co-ordination. He shall be free from any other responsibility. And safety representative qualification will be verified by the Fire and Safety department. Depending upon the nature and size of the job, minimum strength of the safety personnel shall be as follows:
EMPLOYEE STRENGTH
(including sub-contractor)
SAFETY STAFF
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NO OF EMPLOYEES UPTO 30 ONE ( 1 ) SAFETY SUPERVISOR
NO. OF EMPLOYEES : 30 TO 75
ONE (1) SAFETY ENGINEER AND ONE (1) SUPERVISOR
NO. OF EMPLOYEES : 75-250
ONE (1) SAFETY ENGINEER + TWO (2) SAFETY SUPERVISOR
NO. OF EMPLOYEES : > 250 -500
TWO (2) SAFETY ENGINEERS + THREE (3) SAFETY SUPERVISORS
NO OF EMPLOYEES > 500 DEPLOYMENT WILL BE MORE THAN THE
REQUIREMENTS SPECIFIED ABOVE AND
CONTRACTOR TO PROPOSE DEPENDING
LOCATION AND MOBILISATION AND TAKE
PRIOR APPROVAL OF HPCL.
a) No. of employees mentioned above represent the maximum number employees estimated to be engaged at the site on any day by the Contractor and their sub-contractor(s)
b) A major contractor is one who has employed more than 60 workers engaged in a Project or maintenance activity. The contractors shall have well defined Safety Management System as given below.
c) Contractor shall provide additional Safety Personnel and fire watches as directed by HPCL depending upon need. Safety personnel should be identifiable and should wear green jacket.
d) Each contractor should have a safety supervisor as a minimum irrespective of no of workmen
e) For every 30 workmen a safety supervisor should be appointed and present for multiple location job with in a radius of 50 meter.
f) Effective communication system shall be maintained by all contractors using intrinsically safe walkie-talkies
g) All Safety Officers and supervisors will be having recognized qualification and experience. HPCL would verify their credentials by checking documents and also personal interaction.
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h) No job will be attempted without a job safety analysis by contract safety officers/supervisor and contract job engineers. Each safety supervisors will be reporting near misses and personally supervise corrections undertaken and ensure preventive measures to prevent recurrence.
21.2. Orientation of New Employees
21.2.1. Each employee should receive a safety orientation prior to beginning work. The orientation should include provisions of the written safety program and procedures applicable to the proposed work. The orientation also should include the following :
21.2.2. Clarification of the safety responsibilities for contractor, subcontractor, employee and all construction site personnel.
21.2.3. Clarification of safety expectations from the employee.
21.2.4. Safety rules - explain the company rules.
21.2.5. First aid facilities - state where first aid facilities are located and how first aid facilities are to be utilized.
21.2.6. Accident reporting - explain the procedure for reporting accidents and injuries.
21.2.7. Tool box meetings- state when and where held, who is to attend, and that attendance at meetings is mandatory.
21.2.8. Personal protective equipment - when such equipment is specified for a work assignment, its use in mandatory and not optional.
21.2.9. Reporting unsafe acts or conditions - employees should be encouraged to report unsafe acts or conditions to their supervisors so these may be corrected.
21.2.10. On completion of Orientation Training program, contractor employee to pass the test. The successful candidate only will be issued the “Safety training card”.
21.3. Safety Rules Enforcement Procedure:
21.3.1. There must be a procedure for enforcing safety rules. This procedure should be written, and should be enforced equally among supervisors, managers, workers and other parties on the site. It should spell out what situations will result in immediate discharge and what actions will be taken on first or subsequent incidents involving violations of a less serious nature.
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21.3.2. There should be a written notice when a safety violation occurs. If disciplinary action is involved, each violation should be written up in detail, discussed with the disciplined employee.
21.4. Training to Contractor Supervisor :
21.4.1. HPCL – Fire & Safety Department will be organizing Fire & Safety training program for the Contractor Supervisors on regular basis. It is the responsibility of the contractor to ensure that the concerned supervisors / Safety Engineer / Safety Supervisor attend the training. All these training programs will be organized at the cost of HPCL, Training cards will be issued by Fire & Safety dept. The content of the program is
21.5. Training & Tool box/Safety Meetings:
21.5.1. Contractor Management responsibilities include establishing practices and procedure and ensuring that each employee is trained regarding work hazards and the methods by which these hazards can be controlled.
21.5.2. On some safety subjects, toolbox meetings are the primary source of safety training for employees. They should conform to the following basic guidelines :
21.5.3. The meetings should be conducted daily, before work begins for the day or shift. It should last from 5-10 minutes. Additional meetings also may be warranted during the week.
21.5.4. The subject material to be discussed should be typed, reproduced and recorded & feedback taken from workmen.
21.5.5. The subject material should be pertinent to the type of work being performed.
21.5.6. The meeting should be conducted, for each craft by their supervisor at a predetermined place, using the subject material provided.
21.5.7. When deemed appropriate, the craft supervisor should add particularly relevant topics to the discussion, gathered from accidents, lessons learnt etc. in consultation with Safety Engineer.
21.5.8. Employees speaking different languages Telugu, English, Hindi will be identified and grouped. Information shall be communicated to them accordingly in appropriate language for better communication.
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21.5.9. The project manager and/or safety manager/engineer should regularly attend these meetings to audit and visually display their support for safety on the job.
21.5.10. In addition to toolbox meetings, Contractor should conduct periodical Safety Training all employees. The training program shall at least include the following;
21.5.10.1. Safe Work Procedure & Practices
21.5.10.2. Work Permit System
21.5.10.3. Entry into Confined Space
21.5.10.4. Use of Personal Protective Equipment
21.5.10.5. Working at Height
21.5.10.6. First Aid
21.5.10.7. Fire Fighting
21.5.10.8. Hazardous Material (chemicals & toxic gases)
21.5.10.9. Emergency Response Action and Alarms Including Evacuation Procedure.
21.5.11. The Contractor shall arrange the training of their own and maintain documentation of the same. The documentation should include the names of those trained, course content, date & time and the names of the instructors HPCL will periodically review the Contractor’s training record to verify that training is being conducted which meets the criteria.
21.6. Job Site Inspections:
21.6.1. Job safety inspections are visible signs to employees that safety is working. In addition, they provide for the identification of areas of potential loss and can be used to constantly monitor the effectiveness of the Accident Prevention Program. As with all safety activities, the inspection process needs to have well-defined objectives and designated participants as follows.
21.6.2. Contractor should make a safety audit of the work area at least once a week using an inspection CHECK LIST.
21.6.3. All safety personnel, including designated safety representatives, should make daily inspection of the work area. The
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inspection should be routine, planned, and designed to include communications with specific people in the work place, rather than just a visual site check.
21.6.4. Job supervisors also should make daily inspection of their work areas for the specific purpose of correcting unsafe acts or hazardous condition.
21.6.5. Regularly planned inspection should go beyond routine visual site checks. The result of these inspections should be used for setting goals for future improvements.
21.6.6. These inspections should make use of detailed checklists, developed for each item such as electrical facilities, lock-out systems, scaffolding, fire prevention, personal protective equipment, hazardous material handling, housekeeping, hand and power tools, maintenance practices and machine or equipment guarding. There should be effective systems for monitoring the progress on action plan developed based on the audits.
21.7. Accident Investigation Procedure:
21.7.1. An effective accident investigation and a reporting procedure is an essential part of any effective safety program.
21.7.2. Contractor should have his own accident investigation procedure in addition to his responsibilities as per HPCL Accident Reporting/Investigation Procedure.
21.7.3. The procedure outlined in the safety program should call for an inspection by the immediate supervisor of the person involved in the accident. A form should be completed that indicates what happened, the basic cause of the accident and action taken to prevent the recurrence of similar incident.
21.7.4. Corrective action should be taken as soon as practical after the investigation is complete.
21.8. Contractor Responsibility for Supervision
21.8.1. Upon award of the contract and prior to commencement of job, the contractor shall furnish “BIO DATA “ of all their Supervisors and skilled or un-skilled workers. All personnel deployed by contractor for the job must have completed safety training in HPCL Safety Dept.
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21.8.2. Contractor shall deploy qualified and experienced supervisor and other man power, which are well conversant with the safety regulations of the refinery the electricians to be deployed on the job should have Wireman License.
21.8.3. Contractor all supervisor must be given safety training/demonstration with the help of our Fire & Safety Dept. and should acquire knowledge of fire prevention and should be able to make use of Fire Extinguishers
21.8.4. Contractor shall route the application for Gate passes for their Supervisors though concerned department to safety section and obtain gate passes from CISF contractors to take clearance from Fire & safety section to ensure that all their supervisors are properly trained.
21.8.5. Contractor shall deploy adequate no. of supervisors including specific safety supervisor during the period of execution of the contracts awarded to him.
21.8.6. Contractor must familiarize him self from HPCL Engineer In-Charge about all known potential fire, explosion toxic release hazards related to his contract. He in turn will ensure that same information has been passed to his supervisor and workmen Proper record of such dissemination of information must be made by the contractor and submit to the Engineer-In-Charge failing which further continuation of work may be withheld.
21.8.7. Contractor must ensure that all his supervisors are properly trained. Document is to be maintained showing that each employee has received and understood from his supervisor necessary training The record should contain the supervisor’s name who has provided training to the employees, employees name who has received training, date of training, topic and the means used to verify that the employee has understood the training.
21.8.8. Contractor must provide at least one full time on site safety coordinator when the contractor has engaged manpower in excess of 50 in contract activities in the refinery. If the manpower is less then 50, the onsite safety co-ordination responsibilities shall be assumed by any one of the contractor’s other supervisory staff. In both cases, the contractor must specify in writing the name of such persons to the Engineer-In-Charge.
21.8.9. Contractor safety coordinator or his supervisor responsible for safety as the case may be shall conduct at his work site, and
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ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
document formal safety inspections and audits at least once in a week. Such documents shall be submitted to Engineer-In-Charge for his review and record.
21.8.10. Contractors, supervisors must attend all scheduled safety meetings as would be intimated to him by Engineer-In-Charge.
21.8.11. Before stating work under any contract , the contractor must ensure that a job specific safety procedures/ field practices as required over and above the safety permit conditions are prepared and followed He should also ensure that all supervisors and workers involved understand and follow these procedures/field practices.
21.8.12. Contractor must ensure that in his work site:
21.8.12.1. Appropriate display boards are put displaying sign for site safety, potential hazards and precautions required.
21.8.12.2. Safety performance display boards are provided.
21.8.12.3. Housekeeping/Scrap removed is done on daily basis.
21.8.13. Contractor shall put all efforts to deploy minimum manpower to execute the jobs in stipulated time by using modern techniques and mechanization. The contractor deploying minimum manpower will be given preference.
21.9. Restrictions in use of man power, and normal timings for work.
21.9.1. Contractor shall put all efforts to deploy minimum man power to execute the work awarded to their in stipulated time by using modern techniques & mechanization.
21.9.2. Contractors deploying minimum manpower will be given due weights while renewing his registration.
21.9.3. No contractor employee shall normally work for more then 8 hours a day and not more then 48 hours in a week of seven days . After every 48 hours of a working, an employee must get one full day rest.
21.9.4. The normal duty timings for contractor employees shall be between 8.00 AM and 4-15 PM.
21.9.5. Contractor employees would not be allowed to work on Sunday and refinery holidays.
21.9.6. Any deviation from above shall be with express permission from the Engineer-In-Charge.
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ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
21.10. Injury Notification and Investigation
21.10.1. Contractor must report to HPCL supervisor on the job any injury sustained by any of his employees or any near miss or any hazardous /dangerous incident at his work site with in the refinery premises. Hiding of any accident or near miss would be viewed as serious misconduct.
21.10.2. Arrange to provide FIRST AID immediately to the injured employee.
21.10.3. Keep and maintain proper records of all such incidents in respect of personnel /work site.
21.10.4. Submit to the engineer-in-charge a first information report as per prescribed Performa with in 4 hours of the incident.
21.10.5. Arrange to immediately investigate the incident and furnish with in 24hours a written investigation report in prescribed performs to HPCL Engineer-in –charge.
21.11. Requirement during Submission of Tender:
21.11.1. Complete work injury records per year for the last three years and total man hours worked per year for the last three years.
21.11.2. Safety assurance plan
21.11.3. Quotation must clearly indicate the number of Supervisors and skilled workers, which will be deployed for the job, from time to time during execution of the contract.
21.11.4. The above information will be taken in to view during tender evaluation.
21.12. Display Boards at Site:
21.12.1. Contractor must provide and maintain Display boards in the work site.
21.12.2. Appropriate display board displaying information as per HPCL “Work Site Display Board” Specification.
21.12.3. Safety Performance score board.
21.13. Participation in Safety Activities:
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ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
21.13.1. Contractor must attend all scheduled safety meetings as would be intimated to him by the Engineer- in-Charge.
21.13.2. Contractor also must ensure that al his employees participated in safety promotional activities organized in the refinery
Note :
• Every employee other than HPCL employee or a casual visitor entering in the refinery would be governed by the above conditions.
• The term supervisor would mean any person who oversees the work of a group of workmen. All other persons would be considered as workmen.
• Violation of any of the special conditions of safety would attract penal actions including termination of the contract/ registration.
• Meticulous adherence to these requirements would be documented by the engineer-in-charge on conclusion of the work and placed in the dosser of the contractor. This performance would be given adequate weights at the time of renewal of the registration.
• Any dispute arising out of these conditions shall be referred by the engineers-in –charge to the head of the refinery fire and safety department.
21.14. Record Keeping:
21.14.1. Records are required to support activities of Contractor safety programs for both control and audit purposes. Records to be maintained at the job site should include the following:-
21.14.2. First aid log of all first aid cases reported and treated, showing date, name of injured, job nature of injury and type of treatment given.
21.14.3. Accident investigation report for each accident.
21.14.4. Safety meetings or toolbox meeting records or minutes showing date of meeting, who attended, the subjects discussed and who conducted the meeting.
21.14.5. Job site inspection reports and status of the action plans.
21.14.6. Records to show dates, name of participants and subject of training programs.
21.14.7. Crane or equipment inspection / test records.
Page 93 of 209
OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS RFQ 12000438-HD-46002/VNK
ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
21.14.8. Fire fighting equipment inspection / test record
21.15. FIRST AID & MEDICAL SERVICES
21.15.1. It is good practice for at least one person on each project to possess a first aid card.
21.15.2. First aid boxes shall be available at contractor sheds.
CONTRACTORS' MONTHLY SAFETY REPORT
FOR(MONTH-YR):
CONTRACTOR:
CONTRACT DETAILS :
CONTRACT
START DATE:
DATE OF LAST
LTA:
THIS MONTH CUMULATIVE
TOTAL SINCE LAST
LTA
MAN-HOURS
CODE THIS MONTH CUMULATIVE
TOTAL
LOST TIME ACCIDENT LTA
LOST WORK DAYS LWD
NO LOST TIME ACCIDENT NLTA
Page 94 of 209
OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS RFQ 12000438-HD-46002/VNK
ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
DANGEROUS OCCURRENCES DO
NEAR-MISS INCIDENTS NM
INFRINGEMENT
NOTIFICATIONS
TOOLBOX MEETING
SAFETY TRAINING
SAFETY AUDIT
SAFETY INSPECTIONS
CARRIED OUT
DETAILS OF ACCIDENT, NEAR-MISS OR DANGEROUS OCCURRENCE
Page 95 of 209
OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS RFQ 12000438-HD-46002/VNK
ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
PHYSICAL FITNESS CERTIFICATE
1. NAME OF THE AGENCY / SUB
CONTRACTOR
2. NAME OF THE EMPLOYEE
3. AGE / SEX
4. PRESENT HEALTH HISTORY
5. PREVIOUS HEALTH HISTORY
6 MEASUREMENTS
HEIGHT IN CMS.
WEIGHT IN KGS.
CHEST
INSPIRATION
EXPIRATION
_____________________________
_____________________________
_____________________________
_____________________________
7. BLOOD PRESSURE
8. HEART
9. LUNGS
10. ABDOMEN
LIVER
SPLEEN
_____________________________
_____________________________
11. LIMPTH GLANDS
12. HYDROCELE
13. HERNIA
14. VERICOSITY
15. EYES:
WITHOUT GLASSES WITH GLASSES
RIGHT EYE LEFT EYE RIGHT EYE LEFT EYE
FAR VISION 6/ 6/ 6/ 6/
NEAR VISION P P P P
16. PHYSICAL DEFORMITIES
Page 96 of 209
OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS RFQ 12000438-HD-46002/VNK
ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
REMARKS OF THE DOCTOR :
SIGNATURE / STAMP WITH REGISTRATION NO.
All the contractors/agencies shall take the responsibility of ensuring that all of its workers/supervisors/employees are aware of the location of assembly points
Page 97 of 209
OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS RFQ 12000438-HD-46002/VNK
ANNEXURE-IV SAFETYSAFETYSAFETYSAFETY REGULATIONSREGULATIONSREGULATIONSREGULATIONS FORFORFORFOR CONTRACTORSCONTRACTORSCONTRACTORSCONTRACTORS
HINDUSTAN PETROLEUM CORPORATION LTD.
VISAKH REFINERY
INFRINGEMENT REPORT
From : Manager- Fire & Safety Date :
To : Manager- ………………………….
GIVEN BELOW ARE VIOLATION DETAILS OF SAFETY REGULATIONS / SITE INSTRUCTIONS
COMMITTED BY AN EMPLOYEE/CONTRACTOR WORKING FOR YOUR DIVISION. NAME: EMP. NO :
OCCUPATION: COMPANY :
LOCATION: COMPANY CODE :
DATE: TIME:
SUPERVISOR NAME/JOB TITLE:
DETAILS OF INFRINGEMENT:
IMMEDIATE ACTION TAKEN:
Previous violations:
This violation is: Minor (First/Second/Third) Major (First/Second/Third)
Action recommended: Written warning Penalty Rs. ____________
Other_______________________________________
Please advise action taken as per the penalties for Safety Violations on or before ………..
MANAGER- FIRE & SAFETY
CC: DEPT. HEAD CC : CASH OFFICE I/C , PLEASE COLLECT THE CASH UNDER A/C. 46000100.582190. .
NOTE : COMPANY CODE OF THE EMPLOYEE/ CONTRACTOR SHALL BE GIVEN BY THE
CONCERNED MANAGER.
Page 98 of 209
fg-e^-tdM U'f
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-01Ref. F&S/SMRev.ODate: May 24, 2010Page: Page 1 of 3
SAFE WORK PRACTICESSPECIFICATION OF PERSONAL PROTECTIVE
EQUIPMENT
1.0 OBJECTIVE:
The objective of this SWP is to specify the standard for Personal ProtectiveEquipment (PPE) to be used in the Refinery premises.
2.0 SCOPE:
This SWP is applicable to all the Personal Protective Equipment.
3.0 RESPONSIBILITY:
a. The respective Executing Department is responsible to ensure that the PPE asspecified by this SWP is used by all the personnel (company employees andcontractor employees) involved in the jobs handled by the department.
b. PPE not conforming to the standard specified by this SWP is not permitted tobe used. Respective Departments are required to ensure this.
4.0 SPECIFICATION OF THE PERSONAL PROTECTIVE EQUIPMENT
In Visakh Refinery premises the Personal Protective equipment used shall beconforming to the Specifications as per the respective Standard provided in the Tablebelow:
SI. No.
4.14.1.1
4.1.2
4.2
4.2.1
4.2.2
PPE TYPE
Head ProtectionSafety Helmet
Welder's Helmet integrated with faceshield fitted with filter glassEye protection (For protection againstflying particles & fragments, materialand molten metal splashes, harmfuldust, gases or vapors and aerosols,harmful radiation)Dust proof goggles (Clear - Plaingoggles / Dark - Smoked goggles)Chemical goggles (Panoramic viewgoggles)
SPECIFICATION ASPER
IS:2925
IS: 1 1 79 & IS 5983
IS: 5983 /EN 166 /ANSI Z 87.1)
IS: 5983 /EN 166 /ANSI Z 87.1)
Page 99 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-01Ref. F&S/SMRev.ODate: May 24, 2010Page: Page 2 of 3
SAFE WORK PRACTICESSPECIFICATION OF PERSONAL PROTECTIVE
EQUIPMENT
SI. No.
4.2.3
4.2.4
4.2.5
4.34.3.1
4.44.4.1
4.4.2
4.4.3
4.54.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
4.64.6.1
4.6.2
4.74.7.1
4.8
PPE TYPE
Eye cup goggles (Gas cutting / Furnacegoggles)Welding goggles (Electric Arc weldinggoggles)Cover all goggles (Zero powered safetygoggles)Ear ProtectionEar Muffs/Ear Plugs
Face ProtectionFace Shield
Electrical Arc Flash Protection Face shieldHelmet with face shield
Hand ProtectionGeneral purpose hand gloves (Withleather inner)Electrical hand gloves
Neoprene hand gloves for chemicalhandlingWelders leather gloves
PVC hand glovesHy flex hand glovesKevlar hand glovesFoot ProtectionSafety Shoe with PVC sole
Safety shoe with PU sole (light weight)
Fall ProtectionFull body harness (Double lanyard)
Body Protection
SPECIFICATION ASPER
IS: 5983 /EN 166 /ANSI Z 87.1)
IS: 5983 /EN 166 /ANSI Z 87.1)
IS: 5983 / EN 1 66 /ANSI Z 87.1)
IS: 9167
IS:8521
CE markedIS:8521
IS:6994 / CE marked
IS:4770
CE marked
IS 6994 / CE marked
CE markedCE markedCE marked
18:14544
IS: 15298 (Parti& Part 2)
IS:3521
Page 100 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-01Ref. F&S/SMRev.ODate: May 24, 2010Page: Page 3 of 3
SAFE WORK PRACTICESSPECIFICATION OF PERSONAL PROTECTIVE
EQUIPMENT
SI. No.
4.8.1
4.8.2
4.8.3
4.8.4
PPE TYPE
PVC hood Acid & Alkali proof
PVC yellow color splash proof coat andpant
Full body apron with hood
PVC gum boots
SPECIFICATION ASPER
HOOD PVC withprotected Ventilatorbreathers and replicableacrylic visor acid andalkali proof.
PVC yellow color SplashProof Coat And Pant
Full body apron withhood suitable for theperson of height 173 to178cmAcceptable Brands andMake:1) Dupont make modelTychem-TF145T6/CS2) Microgard makemodel Microchem -3000
PVC Gum Boot, WhiteColor.
PreparedBy
ApprovedBy
Sign
NameDesignationSignNameDesignation
c^^-yyya— r-rr'K.V.Singh
Senior Manager-F&Stt )C£xf Q/-l%C» C£^ '
V.V.R.NarasifflharnGM-Operations
(Appointed as Factory Manager as perClause 7 of Factories Act 1948)
Page 101 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 1 of 8
SAFE WORK PRACTICESMINIMUM PERSONAL PROTECTIVE EQUIPMENT
FOR VARIOUS ACTIVITIES
1.0 OBJECTIVE:
To specify the minimum Personal Protective Equipment (PPE) required for variousactivities and operations.
2.0 DESCRIPTION OF THE OBJECTIVE
• This SWP specifies the minimum PPE required for an activity or operation. Theminimum here means "at least". It does not mean that the minimum is enough bydefault.
• Depending on the environmental conditions and circumstances of carrying outthat activity or operation, additional or modified PPE may be required to be used.This assessment should be done through a "Job Hazard Analysis" prior to startingthe activity or the operation.
• The quality & specification of the PPE shall be as specified in SWP-01.
3.0 SCOPE:
a. This SWP is applicable to all the activities and operations carried out inthe premises of Visakh Refinery.
b. This SWP is limited to specifying the PPEs for the common activities.
c. For special activities which are not mentioned in this SWP, the PPErequirement is to be developed during the Job hazard Analysis inconsultation with F&S.
d. This SWP does not provide all the precautions for the mentioned activities.It only provides PPE required. For other precautions for an activity, referto the relevant Standing Instruction, Advisory, MSDS or the OperatingManual.
4.0 DEFINITIONS
a. The phrases operation, maintenance are used in generic sense and there is noreference to any specific department. No role definition is intended to be made inthis SWP from that perspective. At various times the activities could be performedby different departments to a lower or higher extent depending on thecircumstances. Whosoever does that activity must use the required PPE.
Page 102 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 2 of 8
SAFE WORK PRACTICESMINIMUM PERSONAL PROTECTIVE EQUIPMENT
FOR VARIOUS ACTIVITIES
b. Basic Minimum PPE (BM - PPE):
In the refinery for entering any Plant or carrying out any activity in the field, threeminimum PPE are required. These PPE are:
BM - PPEs
1.2.3.
Safety Helmet.Safety Shoes.Hand Glovesleather palm.
with
These PPE must be always used.
c. Additional PPE (A - PPE):
These are the PPEs which are to be used in addition to the BMPPE based on thejob, environment and circumstances.
d. Modified PPE (M - PPE):
In activities where the BM-PPE or A-PPE quality, material or shape is to be of adifferent kind to suit the requirements of that activity. This normally is areplacement of the corresponding PPE of either BM-PPE or A-PPE.
5.0 RESPONSIBILITY:
a. The responsibility of ensuring the usage of the adequate PPE lies with therespective Department and the individual involved in the activity.
b. In case any activity is not covered in this SWP, the respective Division Headshould seek advice from F&S Department giving details of the specificrequirements.
6.0 ACTIVITIES & MINIMUM PPE REQUIREMENT:
TABLE - 6.1
SI No.
6.16.1.1
ACTIVITY PPE TO BE USED FOR THE ACTIVITYBASIC - PPE A - P P E M - P P E
OPERATIONALWalk around in thePlant Area except and
BM - PPE Dust proofgoggles (Clear -
Page 103 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 3 of 8
SAFE WORK PRACTICES
MINIMUM PERSONAL PROTECTIVE EQUIPMENTFOR VARIOUS ACTIVITIES
SI No.
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.1.9
ACTIVITY
declared High NoiseAreas
Walk around in thePlant Area includingHigh Noise areas
Operational activity(excluding those specifically
mentioned in this table) in
Plant except in declaredHigh Noise Area.Operational activity(excluding those specifically
mentioned in this table) in
declared High NoiseArea.
Burners removal,installation in Furnaces(or in any Direct FiredEquipment)Observing of Fire boxflames (or any directfired equipment)Hot Liquid Sampling
Draining of liquid, gas,unplugging of bleeders.
Chemicals storage,
PPE TO BE USED FOR THE ACTIVITYBASIC - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
A -PPEPlain goggles /Dark - Smokedgoggles)a. Dust proof
goggles (ClearPlain
goggles / DarkSmoked
goggles)b. Ear Muffs /
Ear PlugsDust proofgoggles (ClearPlain goggles /Dark - Smokedgoggles)a. Dust proof
goggles (ClearPlain
goggles / DarkSmoked
goggles)b. Ear Muffs /
Ear PlugsEar Muffs / EarPlugs
Ear Muffs / EarPlugs
Additional PPE as
M-PPE
a. Helmet withface Shield
b. Kevlar HandGloves
Helmet with faceShield
a. Helmet withface Shield
b. Kevlar HandGloves
Helmet with faceShield
a. Neoprene
Page 104 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 4 of 8
SAFE WORK PRACTICES
MINIMUM PERSONAL PROTECTIVE EQUIPMENTFOR VARIOUS ACTIVITIES
SI No.
6.1.10
6.1.11
6.26.2.1
6.2.2
6.2.3
ACTIVITY
dispensing, pumpingand other handlingoperations
Fresh caustic , spentcaustic and otherchemical vessels orequipment purging,steaming, venting,draining operations (toatmos)Powder form catalysthandling
PPE TO BE USED FOR THE ACTIVITYBASIC - PPE
BM - PPE
BM - PPE
A -PPEper respectiveMSDS
ChemicalCartridgeRespirator
a. Dust proofgoggles (Clear- Plain goggles)
b. Dust maskC. Additional PPF.
as per respectiveMSDS
M-PPE
hand Glovesb. Helmet With
face Shield
Helmet with faceShield
MAINTENANCE ACTIVITIESWalk around in thePlant Area except anddeclared High NoiseAreas
Walk around in thePlant Area includingHigh Noise areas
Tightening of anyjoints on piping system,column, exchanger,vessel. Declared highnoise area. ( Whileequipment in service)
BM - PPE
BM - PPE
BM - PPE
Dust proofgoggles (Clear -Plain goggles /Dark - Smokedgoggles)a. Dust proof
goggles (Clear -Plain goggles /Dark - Smokedgoggles)
b. Ear Muffs /Ear Plugs
a. Dust proofgoggles (Clear- Plain goggles)
b. Ear Muffs /Ear Plugs
a. Helmet Withface Shield
b. In case ofchemical service:Neoprene handgloves
c. In case ofservice above50 degree C :Kevlar handgloves
Page 105 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 5 of 8
SAFE WORK PRACTICESMINIMUM PERSONAL PROTECTIVE EQUIPMENT
FOR VARIOUS ACTIVITIES
SI No.
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.2.9
6.2.10
6.2.11
6.2.12
6.2.13
ACTIVITY
Opening of joints forsegregation blinding ofany piping, column,exchanger or any otherequipment systemWelding operations
Gas cutting operations
Grinding operations
Workshop Operationslike lathe machine,hammering, turning,and drilling.Positioning at 2 metersabove ground or abovea permanent platform.Repairs and Maintenancejobs on pumps and otherequipment in Rotarysection within workshop.
Hydro testing activity
Hydro-jetting activity
Isolation andenergisation of panels
PPE TO BE USED FOR THE ACTIVITYBASIC - PPE
BM - PPE
BM - PPE
BM-PPE
BM - PPE
BM-PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
A -PPE
Eye cup goggles
Dust proofgoggles (Clear /Plain goggles)
Full body safetyharness withdouble lanyard.
PVC coat and pant
M-PPEHelmet with faceshield
a. Welders Helmetintegrated withface shield fittedwith filter glass.
b. Welder's leatherhand gloves.
Welder's leatherhand glovesa. Helmet with
face shield,b. Welders leather
hand Gloves.Ansell Protufhand gloves orDotted handgloves
Ansell Protufhand gloves orDotted handglovesHelmet with faceshield
Helmet with faceshielda. Electrical arc flash
protection handgloves
b. Electric Arc Flashprotection Faceshield with helmet
Page 106 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 6 of 8
SAFE WORK PRACTICESMINIMUM PERSONAL PROTECTIVE EQUIPMENT
FOR VARIOUS ACTIVITIES
SI No.
6.2.14
6.2.15
6.2.16
6.2.17
6.2.18
6.2.19
6.2.20
6.2.21
6.2.22
6.2.23
ACTIVITY
Panel PM checks
Motor PM checks
Motor PM checks(High noise area)
IR testing
IR testing (High noisearea)
Excavations in cablepresence
132 KV switch yardisolator opening
Instrumentation worksin workshopInstrumentation worksin fieldHandling of debris/scraps - by hand
PPE TO BE USED FOR THE ACTIVITYBASIC - PPEBM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
A -PPE
Dust proofgoggles (Clear -Plain)a. Dust proof
goggles(Clear - Plaingoggles),
b. Ear Muffs /Ear Plugs
Ear Muffs / EarPlugs
Dust proofgoggles (ClearPlain goggles)Full body safetyharness withdouble lanyard
a. Dust proofgoggles (Clear -Plain goggles)
b. Dust Mask.
M-PPEa. Electrical arc
flash protectionhand gloves,
b. Electric Arc Flashprotection Faceshield withhelmet
Hy flex handgloves
Hy flex handgloves
Electric Arc Flashprotection FaceshieldElectric Arc Flashprotection FaceshieldPVC gum boot
a. Electrical arcflash protectionhand gloves
b. Electrical arc flashprotection face shield
Hy flex handgloves
Hy flex handgloves
a. PVC gum bootsb.PVC hand gloves
with inner cottonlining
Page 107 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 7 of 8
SAFE WORK PRACTICES
MINIMUM PERSONAL PROTECTIVE EQUIPMENTFOR VARIOUS ACTIVITIES
SI No.
6.2.24
6.2.25
6.2.26
6.2.27
6.2.286.2.29
6.2.30
6.2.31
6.2.32
6.2.33
6.2.34
6.2.35
ACTIVITY
Scrap area works
P2 wrapping usingblow lamp for heatingpurpose to carry out P2Wrapping of pipelinesDry handling of bricks,mud, mortar etc.Wet handling of bricks,mud, mortar etc.
Excavation jobsConcrete chipping jobsManualConcrete chipping jobs(Pneumatic)Fixing of Aluminumsheets for insulationpurpose
Insulation Mineralwool handling jobs
Painting jobs at gradelevel
Painting jobs at heightmore than 2 meters.
Shot / Grit blasting
PPE TO BE USED FOR THE ACTIVITYBASIC - PPEBM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPEBM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
BM - PPE
A -PPE
a. Dust proofgoggles (Clear -Plain goggles)
b. Dust Mask.
Ear Muffs
a. Dust proofgoggles (Clear -Plain goggles)
b. Dust maska. Dust proof
goggles (Clear -Plain goggles)
b. Dust maska. Dust proof
goggles (ClearPlain goggles)
b. Dust maska. Full body
safety harnesswith doublelanyard
b. Dust proofgoggles (ClearPlain goggles)
c. Dust mask
M-PPE
Helmet with Faceshield.
PVC gum boots
a. PVC gum boots,b. PVC handgloves with innercotton lining.PVC gum bootsHelmet with faceshieldHelmet with faceshield
Shot blasting hoodand suit with air
Page 108 of 209
VISAKH REFINERYFIRE & SAFETYDEPARTMENT
Doc. No. SWP-02Ref. F&S - Safety ManualRev.lDate: October 5, 2010.Page: Page 8 of 8
SAFE WORK PRACTICESMINIMUM PERSONAL PROTECTIVE EQUIPMENT
FOR VARIOUS ACTIVITIES
SI No. ACTIVITY PPE TO BE USED FOR THE ACTIVITYBASIC - PPE A -PPE M-PPE
line supplyconnected tovortex air cooler.
PreparedBy
ApprovedBy
SignNameDesignationSignNameDesignation
^a^AU-rrr-HCV.Siligh
Senior Manager-F&Sf^OTW^c^ _.
V.V.R.NarasirnHatnGM-Operations
(Appointed as Factory Manager as perClause 7 of Factories Act 1948)
Page 109 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
SWP – 06 CONTRACTOR JOB EQUIPMENT
SAFETY ASSURANCE
HINDUSTAN PETROLEUM CORPORATION LTD. VISAKH REFINERY
POST BOX – 15, MALKAPURAM VISAKHAPATNAM – 530011
(ANDHRA PRADESH) INDIA
Page 110 of 209
VISAKH REFINERY FIRE & SAFETY DEPARTMENT
Doc. No. SWP - 06 Rev. 0 Date : 08/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
TABLE OF CONTENTS
DOCUMENT NO. TITLE LATEST
REV. NO. REV. DATE
NO OF PAGES
CATEGORY - 1 : MATERIAL HANDLING EQUIPMENT
SWP – 06 Contractor job equipment safety assurance 0 08/03/11 6 SWP – G
6.1 Manual of Equipment Checklist Formats
0 08/03/11 4
CL – 1.1 Manual of equipment checklist – Hydra 0 08/03/11 2 CL – 1.2 Manual of equipment checklist – Crane 0 08/03/11 2 CL – 1.3 Manual of equipment checklist – JCB / Proclainer 0 08/03/11 2 CL – 1.4 Manual of equipment checklist – Fork Lift 0 08/03/11 2 CL – 1.5 Manual of equipment checklist– Chain Pulley Block 0 08/03/11 1 CL – 1.6 Manual of equipment checklist – Wire rope sling 0 08/03/11 1 CL – 1.7 Manual of equipment checklist – Synthetic web sling 0 08/03/11 1 CL – 1.8 Manual of equipment checklist – Manila rope 0 08/03/11 1
CATEGORY - 2 : MATERIAL TRANSPORT EQUIPMENT
CL – 2.1 Manual of equipment checklist – Tractor 0 08/03/11 2 CL – 2.2 Manual of equipment checklist – Chemical Tanker 0 08/03/11 2 CL – 2.3 Manual of equipment checklist – Tyre mounted trolley 0 08/03/11 1 CL – 2.4 Manual of equipment checklist – Trailer 0 08/03/11 1 CL – 2.5 Manual of equipment checklist – Truck 0 08/03/11 2 CL – 2.6 Manual of equipment checklist – LMV 0 08/03/11 2
CATEGORY - 3 : WELDING & GRINDING EQUIPMENT
CL – 3.1 Manual of equipment checklist – Diesel generator 0 08/03/11 1 CL – 3.2 Manual of equipment checklist – Welding Machine 0 08/03/11 1 CL – 3.3 Manual of equipment checklist – Welding cables 0 08/03/11 1 CL – 3.4 Manual of equipment checklist – Welding holder 0 08/03/11 1 CL – 3.5 Manual of equipment checklist - Temporary electrical
panel 0 08/03/11 1
CL – 3.6 Manual of equipment checklist – Electrical Switch board 0 08/03/11 1 CL – 3.7 Manual of equipment checklist – Grinding machine 0 08/03/11 1
CATEGORY - 4 : GAS CUTTING EQUIPMENT
CL – 4.1 Manual of equipment checklist – Gas cutting torch 0 08/03/11 1 CL – 4.2 Manual of equipment checklist – Gas supply hose 0 08/03/11 1 CL – 4.3 Manual of equipment checklist – Gas cylinder regulator 0 08/03/11 1 CL – 4.4 Manual of equipment checklist – Gas cylinder 0 08/03/11 1 CL – 4.5 Manual of equipment checklist – Gas cylinder trolley 0 08/03/11 1
CATEGORY - 5 : ACCESS & EGRESS EQUIPMENT
CL – 5.1 Manual of equipment checklist – Scaffolding pipe and its fittings
0 08/03/11 1
CL – 5.2 Manual of equipment checklist – Portable Step Ladder 0 08/03/11 1 CL – 5.3 Manual of equipment checklist – Ladder
0
08/03/11 1
Page 111 of 209
VISAKH REFINERY FIRE & SAFETY DEPARTMENT
Doc. No. SWP - 06 Rev. 0 Date : 08/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
TABLE OF CONTENTS
DOCUMENT NO. TITLE LATEST
REV. NO. REV. DATE
NO OF PAGES
CATEGORY - 6 : FIRE FIGHTING EQUIPMENT
CL - 6.1 Manual of equipment checklist – DCP extinguisher 0 08/03/11 1 CL – 6.2 Manual of equipment checklist – CO2 extinguisher 0 08/03/11 1 CL – 6.3 Manual of equipment checklist – Fire hose 0 08/03/11 1 CL – 6.4 Manual of equipment checklist – Firefighting nozzle 0 08/03/11 1
CATEGORY - 7 : HAND TOOLS & TACKLES
CL - 7.1 Manual of equipment checklist – All Types of Wrenches & Spanners
0 08/03/11 1
CL - 7.2 Manual of equipment checklist – Chisel 0 08/03/11 1 CL - 7.3 Manual of equipment checklist – Hammer 0 08/03/11 1 CL - 7.4 Manual of equipment checklist – Screw Driver 0 08/03/11 1 CL - 7.5 Manual of equipment checklist – Plier 0 08/03/11 1 CL - 7.6 Manual of equipment checklist – Spreader 0 08/03/11 1 CL - 7.7 Manual of equipment checklist – Crimping Tool 0 08/03/11 1 CL - 7.8 Manual of equipment checklist – Jack Hammer 0 08/03/11 1 CL - 7.9 Manual of equipment checklist – Driller 0 08/03/11 1
CATEGORY - 8 : CIVIL WORKS EQUIPMENT
CL - 8.1 Manual of equipment checklist – Crow bar 0 08/03/11 1 CL - 8.2 Manual of equipment checklist – Shovel 0 08/03/11 1 CL - 8.3 Manual of equipment checklist – Spade 0 08/03/11 1 CL - 8.4 Manual of equipment checklist – Gamela 0 08/03/11 1 CL - 8.5 Manual of equipment checklist – Concrete mixer 0 08/03/11 1
CATEGORY - 9 : MISCELLANEOUS EQUIPMENT
CL - 9.1 Manual of equipment checklist – Hydro testing pump 0 08/03/11 1 CL - 9.2 Manual of equipment checklist – Blow Lamp 0 08/03/11 1 CL - 9.3 Manual of equipment checklist – De-watering pump 0 08/03/11 1 CL - 9.4 Manual of equipment checklist – Air Compressor 0 08/03/11 1 CL - 9.5 Manual of equipment checklist – Jack 0 08/03/11 1 CL - 9.6 Manual of equipment checklist- Grass cutting machine 0 08/03/11 1 CL - 9.7 Manual of equipment checklist – Fire proof Tarpaulin 0 08/03/11 1
SWP- F 6.1 List of equipment, tools & tackles planned for use in HPCL-VR
0 08/03/11 1
SWP- F 6.2 Equipment, tools & tackles gate entry plan 0 08/03/11 1 SWP- F 6.3 Equipment safety clearance certificate 0 08/03/11 1 SWP- R 6.1 Contact address of Fire & Safety department 0 08/03/11 1
Page 112 of 209
VISAKH REFINERYFIRE & SAFETY DEPARTMENT
Doc. No. SWP-06Ref. F&S-SM
Date: March, 2011Date:
Page: Page 1 of 6
SAFE WORK PRACTICES
CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
1.0 OBJECTIVE:
To ensure that the Job-Equipment available with all the contractors are safe for use.
2.0 DESCRIPTION OF THE OBJECTIVE
a. Contractors employed by the Visakh Refinery use equipment, tools and tackles of different makeand age. It is required to ensure that these equipment are safe for use and do not cause injuries tothe personnel and other untoward incidents.
b. It is required that the contractors ensure that all features and safety mechanisms of theirequipment, tools and tackles are in order and meet the required standards.
c. It is required to ensure that at the time of allowing entry into the Refinery, all the Job-Equipmentshould be checked to conform to the required standards. The non conforming equipment shouldnot be allowed into the Refinery.
d. Also, the Job-Equipment must be offered for periodic inspection to HPCL (or an agencyappointed by HPCL). Deficiencies must be corrected and usage of defective equipment, tools &tackles shall be discontinued and removed from the refinery premises.
e. This SWP is intended to lay down the process to achieve the objective.
3.0 SCOPE & APPLICABILITY
a. This SWP is applicable to all the Contractors of Visakh Refinery.
b. This SWP is applicable to the equipment, tools and tackles used by the Contractor within
HPCL - VR premises.
4.0 RESPONSIBILITY :
The responsibility of ensuring the implementation of the elements of this SWP is as detailed in the"Process" below.
Page 113 of 209
VISAKH REFINERYFIRE & SAFETY DEPARTMENT
Doc. No. SWP-06Ref. F&S-SMRev .0Date: March, 2011Page: Page 2 of 6
SAFE WORK PRACTICES
CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
5.0 PROCESS
SI No. ACTIVITY
REFERENCE
RESPONSIBILITY
5.1 ASSURANCE OF COMPULSORY REQUIREMENTS OF CONTRACTOR JOB
EQUIPMENT, TOOLS & TACKLES5.1.1 The contractor shall ensure that the equipment,
tools and Tackles which is planned to be used inHPCL premises shall meet all the requirements asper
the
"Manual
of
Equipment
ChecklistFormats"
SWP-G-6.1 Contractor
5.1.2 •
Each Equipment, Tools & Tackle shall bechecked against the Checklists provided inthe
"Manual
of
Equipment
ChecklistFormats" before bringing for entry into the
SWP-G-6.1 Contractor
Refinery premises .•
This Manual is provided to the contractor tohelp in ensuring that all features are provided,repaired as necessary before the equipment isbrought to the HPCL Gate and offered forInspection. This will help in efficient entry ofthe equipment.
•
The
contractor
should
prepare
additionalcopies as required and use one checklist foreach equipment.
•
At the entry point only visual check of all therequired features will be done by HPCL. Thefunctionality of the feature will need to bechecked prior to entry by the contractor.
5.2 PLANNING FOR EQUIPMENT FIRST TIME ENTRY INTO THE REFINERY
ON AWARD OF PURCHASE ORDER5.2.1 •
The equipment, Tools and Tackles plannedfor entry into HPCL-VR premises is checkedand ensured that it satisfies the requirement asper
Satisfaction
wrt
the
"Manual
ofEquipment Checklist Formats ",
•
After the above, following documents areprepared and submitted to HPCL :
a.
"List of Equipment Tools & TacklesPlanned for Use in HPCL-VR " on theletter Head of the Contractor. (Morethan one such lists can be given withnumbering)
b.
"Equipment, Tools &Tackles GateEntry Plan".
c.
Filled checklist of each equipment asper "Manual of Equipment ChecklistFormats"
SWP-G-6.1
SWP-F-6.1
SWP-F-6.2
SWP-G-6.1
Contractor
Page 114 of 209
VISAKH REFINERYFIRE & SAFETY DEPARTMENT
Doc. No. SWP-06Ref. F&S-SMRev.0Date: March, 2011Page: Page 3 of 6
SAFE WORK PRACTICES
CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
Si No. ACTIVITY REFERENCE RESPONSIBILITY5.2.2 The
above
documents
can
be
submitted
infollowing modes :
a.
Signed Scanned Copies by e-mail.b.
Signed copies by Fax.c.
Signed Copies by Post , courier.d.
Signed copies delivery in person to Fireand Safety Office. (Either the main office orthe office at the Equipment Entry Gate)
However, in all cases they must reach at least 3
Contractor
working days before the planned entry date.5.2.3 "Contact Address of Fire & Safety Department"
is available. In case of change, the Contractor isinformed.
SWP-R-6.1 By HPCL F&S.
5.2.4 On receipt of the Documents HPCL will provideacknowledgement through e-mail or on a copy ofthe submitted documents if provided.
By HPCL F&S
5.3 FIRST TIME ENTRY INTO THE REFINERY5.3.1 The first entry of the equipment should always be
done on a working day between 09.00 hrs to15.00 hrs only. Prior planning shall be done toensure this.
Contractor
5.3.2 One day confirmatory advance Notice shall begiven to HPCL intimating the arrival of theequipment either by e-mail, Fax, Telephone to theFire and Safety Office.
SWP-R-6.1 Contractor
5.3.3 As the Equipment arrives at the gate, the gateOffice
Fire
and
Safety
personnel
shall
beinformed by Telephone or in person.
Contractor
5.3.4 HPCL will verify that all the equipment broughtto the
gate
is
as
per the
already
submitted"Equipment, Tools &Tackles Gate Entry Plan"and "List of Equipment Tools & Tackles Plannedfor Use in HPCL-VR".
SWP-F-6.1SWP-F-6.2
HPCL F&S
5.3.5 The equipment shall be inspected just outside theequipment entry gate.
SWP-G-6.1 HPCL F&S withContractor support.
5.3.6 Appropriate
Tagging,
stickering
(as
proof ofinspection) shall be carried out by HPCL for theequipment, Tools and tackles. The accepted andrejected equipment will be tagged or stickereddifferently.
For information to theContractor
5.3.7 Only those equipment, tools and tackles whichconform
to
the
features
of their
respectivechecklists provided in the "Manual of EquipmentChecklist Formats" will be allowed to be takeninto the Refinery
SWP-G-6.1 For information to theContractor
Page 115 of 209
VISAKH REFINERYFIRE & SAFETY DEPARTMENT
Doc. No. SWP-06Ref. F&S-SMRev.ODate: March, 201 1Page: Page 4 of 6
SAFE WORK PRACTICES
CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
Sl No. ACTIVITY REFERENCE RESPONSIBILITY5.3.8 Equipment, tools and tackles not conforming to
the
respective
checklist
in
the
"Manual
ofEquipment
Checklist
Formats"will
not
beallowed entry into the Refinery.
SWP-G-6.1 For information to theContractor
5.3.9 For the Equipment, Tools and Tackles which areallowed entry, HPCL will issue a "EquipmentSafety Clearance Certificate".
Note :
SWP-F-6.3 For information to theContractor
This safety Clearance is not sufficient for final gateentry. Subsequent security clearance is also to beobtained.
5.3.10 After
the
clearance,
further
entry
for
theequipment is to be done with necessary Securityprocedures of HPCL. The "Equipment SafetyClearance Certificate" is to be attached with theGate Pass for equipment entry (MDF). (Withoutthis, the equipment, tools and tackles will not beallowed entry)
Note :
1.
HPCL will not allow any entry of the equipment,tools and tackles which do not conform to theirrespective checklists.
2.
The rejected equipment, tools and tackles will hestickered, tagged with different colour stickers orTags.
3.
It is in the interest of the contractor to ensure thatbefore bringing the equipment to the Entry gate, allrequirements
should
he
met
to
avoidinconvenience.
4.
This safety Clearance is not sufficient for final gateentry. Subsequent security clearance is also to beobtained.
SWP-F-6.3 For information to theContractor
5.4 QUARTERLY INSPECTION OF THE EQUIPMENT TOOLS & TACKLES5.4.1 Once inside the Refinery and on the job, HPCL
will carry out quarterly "on-location " inspectionof the equipment, tools and tackles. For eachinspection one week advance notice shall begiven.
For information to thecontractor
5.4.2 As preparation for the Inspection, on receipt ofthe
notice,
the
contractor
shall
advise
thelocations
of the
equipment
through
the jobsupervisor.
For information to thecontractor
•.yJ td in 4C^
Page 116 of 209
VISAKH REFINERYFIRE & SAFETY DEPARTMENT
Doc. No. SWP-06Ref. F&S-SMRev.ODate: March, 2011Page: Page 5 of 6
SAFE WORK PRACTICES
CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
Si No. ACTIVITY REFERENCE RESPONSIBILITY5.4.3 For each Inspection, Contractor representative
shall accompany the HPCL officer to each of theequipment, tool, tackles location and facilitate theinspection. This inspection shall be done wrt thecorresponding
"Equipment
Safety
ClearanceCertificate" which were issued and the checklistsprovided in the "Manual of Equipment ChecklistFormats"
SWP-F-6.3SWP-G-6.1
For information to thecontractor
5.4.4 Re-tagging and stickering will be done for theequipment tools and tackles found fit for use.
For information to thecontractor
5.4.5. In case of any equipment, tool and tackle, unfitfor usage during this inspection, HPCL will stopthe usage of the equipment.
For information to thecontractor
5.4.6 The equipment so identified will be tagged "Unfitfor use" and cannot be used from that instant. Therespective
HPCL
user
department
will
beinformed
accordingly
in
person
and through"Internal Memo"
For compliance byContractor
5.4.7 The Contractor will be given notice for repairingand restoring normalcy wrt to the equipmentwithin a time of maximum one week. In case ofnon-rectification within this period, the respectiveequipment will need to be taken out of thecompany premises within a days notice.
For compliance bycontractor
5.4.8 Contractor should ensure that all the equipment,tools
and
tackles
are
maintained
in
goodcondition.
For compliance bycontractor
5.5 ADDITIONAL ENTRY REQUIREMENTS DU RING JOB EXECU TION5.5.1 This approach is to be used after the first entry of
equipment.
There
could
be
requirement
ofequipment
entry
item
by
item
subsequentlydepending on the job requirements. This is to beused for that purpose.
Contractor
5.5.2 Each Equipment, Tools & Tackle planned forentry and use in HPCL-VR" shall be checkedagainst the Checklists provided in the "Manual ofEquipment Checklist Formats"
SWP-G-6.1 Contractor
5.5.3 One Day advance Notice on Contractors letterHead shall be given for the equipment tools andtackles entry. Following information should beincluded in the letter---- Name of the equipment-Tool-tackle, Make, I.D.No., Quantity.
Contractor
5.5.4 As the Equipment arrives at the gate, Fire andSafety
gate
Office
shall
be
informed
byTelephone or in person.
SWP-R-6.1 Contractor
Page 117 of 209
VISAKH REFINERYFIRE & SAFETY DEPARTMENT
Doc. No. SWP-06Ref. F&S-SMRev.0Date: March, 2011Page: Page 6 of 6
SAFE WORK PRACTICES
CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
SI No. ACTIVITY REFERENCE RESPONSIBILITY5.5.5 The equipment shall be offered for inspection at
the area outside the gate.Contractor
5.5.6 Appropriate
Tagging,
stickering
(as
proof ofinspection) shall be carried out by HPCL for theequipment,
Tools
and
tackles.
Accepted
andrejected equipment will have different type oftagging or stickering.
For information to theContractor
5.5.7 Only those equipment, tools and tackles whichconform
to
the
features
of their
respectivechecklists provided in the "Manual of EquipmentChecklist Formats" will be allowed to be takeninto the Refinery.
SWP-G-6.1 For information to theContractor
5.5.8 Equipment, tools and tackles not conforming tothe
respective
checklist
in
the
"Manual
ofEquipment
Checklist
Formats"
will
not
beallowed entry into the Refinery.
SWP-G-6.1 For information to theContractor
5.5.9 For the Equipment, Tools and Tackles which areallowed entry, HPCL will issue a "EquipmentSafety Clearance Certificate".Note :
This safety Clearance is not sufficient for final gateentry. Subsequent security clearance is also to beobtained.
SWP-F-6.3 For information to theContractor
5.5.10 Further entry for the equipment is to be done withnecessary Security procedures of HPCL. The"Equipment Safety Clearance Certificate" is to beattached with the Gate Pass for equipment entry(MDF). (Without this, the equipment, tools andtackles will not be allowed entry)
Note :
1.
HPCL will not allow entry of the equipment, toolsand
tackles
which
do
not
conform
to
theirrespective checklists.
2.
It is in the interest of the contractor to ensure thatbefore bringing the equipment to the Entry gate, allrequirements
should
be
met
to
avoidinconvenience.
SWP-F-6.3 For information to theContractor
P drepareBy
Sign
Name K.V.Smgh
Designation Senior Mana er-F&S
ApprovedBy
Sign C_^Q
GNU _^Name V.V.R.Narasim am
Designation GM-Operations(Appointed as Factory Manager as perClause 7 of Factories Act 1948)
Page 118 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: SWP-G-6.1 Ref Doc : SWP -06 Rev. : 0 Date : 15/3/2011 Page 1 of 4
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST FORMATS
1.0 OBJECTIVE:
a. This guideline specifies the minimum safety requirements of different Equipment, Tools & Tackles being used inside refinery by the contractor during the course of execution of the job.
b. Equipment are permitted inside the refinery provided they meet the requirements set in the Guideline.
c. This manual contains safety checklists for different equipment that will be used by the contractor during the course of execution of job inside refinery.
d. The responsibility of adhering to the requirements of the guide line lies with the contractor.
2.0 SCOPE & APPLICABILITY
2.1 Equipment Category and coverage Following equipment and their categories are covered in this guideline: Category Description Names of the Equipment Covered No. of
Equipment Covered
1 Material Handling Equipment
Hydra, Crane, JCB/ Poclain, Fork Lift Chain Pulley Block, Wire Rope Sling, Synthetic Web Sling, Manila Rope
8
2 Material Transport Equipment
Tractor, Chemical tanker, Tyre Mounted Trolley, Trailer, Truck, LMV.
6
3 Welding & Grinding Equipment.
Diesel generator, Welding Machine, Welding cable, Welding Holder, Temporary Electrical Panel, Electrical Switch Board, Grinding Machine.
7
4 Gas Cutting Equipment. Gas Cutting Torch, Gas Supply Hose, Gas Cylinder Regulator, Gas Cylinder, Gas Cylinder Trolley.
5
5 Access & Egress Equipment
Scaffolding Pipes & Fittings, Portable Step Ladder, Ladder.
3
6 Fire Fighting Equipment DCP Extinguisher, CO2 Extinguisher, Fire Hose, Fire Fighting Nozzle
4
7 Hand Tools and Tackles All types of Wrenches and Spanners, Chisels, Hammers, Screw drivers, Pliers, Spreaders, Crimping tool, Jack Hammer, Driller
9
8 Civil Works Equipment Crow bar, Shovel, Spade, Gamela, Concrete Mixer
5
9 Miscellaneous Equipment Hydro-testing Pump, Blow lamp, De-watering Pump, Air compressor, Jack, Grass cutting machine, Fire proof tarpaulin
7
Page 119 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: SWP-G-6.1 Ref Doc : SWP -06 Rev. : 0 Date : 15/3/2011 Page 2 of 4
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST FORMATS
2.2 Applicability of this guideline
a. At any point of time, the latest revision of this Guideline will be applicable.
b. HPCL will revise this guideline from time to time. The contractors will be informed through mail or e-mail and Notice Boards at gate & Fabrication Yard.
3.0 Abbreviations: 4.0 MANUAL OF EQUIPMENT CHECKLIST FORMATS
S.NO Checklist Number Equipment Category - 1 : Material handling Equipment
1 CL-1.1 Hydra 2 CL-1.2 Crane 3 CL-1.3 JCB or Poclain 4 CL-1.4 Forklift 5 CL-1.5 Chain Pulley block 6 CL-1.6 Wire rope Sling 7 CL-1.7 Synthetic web sling 8 CL-1.8 Manila Rope
Category - 2 : Material Transport Equipment
9 CL-2.1 Tractor 10 CL-2.2 Chemical Tanker 11 CL-2.3 Tyre Mounted Trolley 12 CL-2.4 Trailer 13 CL-2.5 Truck 14 CL-2.6 LMV
Category - 3 : Welding & Grinding Equipment
15 CL-3.1 Diesel Generator 16 CL-3.2 Welding Machine 17 CL-3.3 Welding Cable 18 CL-3.4 Welding Holder 19 CL-3.5 Temporary Electrical Panel 20 CL-3.6 Electrical Switch board 21 CL-3.7 Grinding machine
Page 120 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: SWP-G-6.1 Ref Doc : SWP -06 Rev. : 0 Date : 15/3/2011 Page 3 of 4
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST FORMATS
S.NO Checklist Number Equipment Category - 4 : Gas Cutting Equipment
22 CL-4.1 Gas cutting torch 23 CL-4.2 Gas Supply hose 24 CL-4.3 Gas cylinder regulator 25 CL-4.4 Gas cylinder 26 CL-4.5 Gas cylinder Trolley
Category - 5 : Access & Egress Equipment
27 CL-5.1 Scaffolding pipes & fittings 28 CL-5.2 Portable step Ladder 29 CL-5.3 Ladder
Category - 6 : Fire Fighting Equipment
30 CL-6.1 DCP Extinguisher 31 CL-6.2 CO2 Extinguisher 32 CL-6.3 Fire Hose 33 CL-6.4 Firefighting nozzle
Category - 7 : Hand Tools & Tackles
34 CL-7.1 All Types of Wrenches & Spanners 35 CL-7.2 Chisel 36 CL-7.3 Hammer 37 CL-7.4 Screw Driver 38 CL-7.5 Plier 39 CL-7.6 Spreader 40 CL-7.7 Crimping Tool 41 CL-7.8 Jack Hammer 42 CL-7.9 Driller
Category - 8 : Civil Works Equipment
43 CL-8.1 Crow bar 44 CL-8.2 Shovel 45 CL-8.3 Spade 46 CL-8.4 Gamela 47 CL-8.5 Concrete Mixer
Page 121 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: SWP-G-6.1 Ref Doc : SWP -06 Rev. : 0 Date : 15/3/2011 Page 4 of 4
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST FORMATS
S.NO Checklist Number Equipment Category - 9 : Miscellaneous Equipment
48 CL-9.1 Hydro-testing Pump 49 CL-9.2 Blow Lamp 50 CL-9.3 De-watering Pump 51 CL-9.4 Air Compressor 52 CL-9.5 Jack 53 CL-9.6 Grass cutting machine 54 CL-9.7 Fire proof Tarpaulin
* * *
Page 122 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 1
MATERIAL HANDLING EQUIPMENT
S.NO Format Number Equipment 1 CL-1.1 Hydra 2 CL-1.2 Crane 3 CL-1.3 JCB or Poclain 4 CL-1.4 Forklift 5 CL-1.5 Chain Pulley block 6 CL-1.6 Wire rope Sling 7 CL-1.7 Synthetic web sling 8 CL-1.8 Manila Rope
Page 123 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL- 1.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECK LIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3 Load Test Certificate (Submit a copy of each item)
4 Load test certificate for lifting tools and tackles (Submit a copy of each item)
5 Heavy vehicle license for hydra driver (Submit a copy to HPCL-VR F&S)
6 Refinery driving permission for hydra driver
Safety features: 7 Load test date marked on the body
8 Safe working load marked near each hook
9 Latching of hydra hooks in working condition
HYDRA
MATERIAL HANDLING EQUIPMENT
Page 124 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL- 1.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST S.NO CHECK LIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
10 Guarding to rotating parts a. Pulley belt b. Radiator fan
11 Body physical condition in good condition: a. Driver seat b. Body cover well maintained with painting. c. Top cover above driver seat. d. Tyres are not bald and without retreading. e. Tools box physically good and lockable. f. No engine oil leakage.
12 Self-ignition in working condition.
13 PESO approved spark arrester fixed to the exhaust.
14 Horn and lights are in working conditions
15 Good housekeeping in Hydra operator cabin
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
Page 125 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
CRANE
MATERIAL HANDLING EQUIPMENT Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECK LIST STATUS IDENTIFIED
DEFECTS/ REMARKS
OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3 Load Test Certificate (Submit a copy of each item)
4 Load test certificate for lifting tools and tackles (Submit a copy of each item)
5 Heavy vehicle license for Crane driver (Submit a copy to HPCL-VR F&S)
6 Refinery driving permission for Crane driver
Safety features: 7 Load test date marked on the body
8 Guarding to rotating parts: a. Pulley belt b. Radiator fan
9 Latching of Crane hooks in working condition
Page 126 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS/ REMARKS
OK NOT OK
10
Self-ignition in working condition.
11 Body physical condition in good condition: a. Driver seat b. Body cover well maintained with painting. c. Top cover above driver seat. d. Tyres are not bald and without retreading. e. Tools box physically good and lockable. f. No engine oil leakage.
12 PESO approved spark arrester fixed to the exhaust.
13 Jacks in working condition and no physical damage.
14 Crane limit switches in working condition
15 Horn and lights are in working conditions
16 Good housekeeping in Crane operator
cabin
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
Page 127 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3 Load Test Certificate (Submit a copy of each item)
4 Load test certificate for lifting tools and tackles (Submit a copy of each item)
5 Heavy vehicle license for JCB or Poclain driver (Submit a copy to HPCL-VR F&S)
6 Refinery driving permission for JCB or Poclain driver
Safety features: 7 Load test date marked on the body
8 Safe working load marked near each hook
JCB/POCLAIN
MATERIAL HANDLING EQUIPMENT
Page 128 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
9 Guarding to rotating parts a. Pulley belt b. Radiator fan
10 Latching of JCB / Poclain hooks in working condition
11 Body physical condition in good condition: a. Driver seat b. Body cover well maintained with painting. c. Top cover above driver seat. d. Tyres are not bald and without retreading. e. Tools box physically good and lockable. f. No engine oil leakage.
12 Self-ignition in working condition.
13 PESO approved spark arrester fixed to the exhaust.
14 Horn and lights are in working conditions
15 Good housekeeping in JCB or Poclain cabin
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
Page 129 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3 Load Test Certificate (Submit a copy of each item)
4 Load test certificate for lifting tools and tackles. (Submit a copy of each item)
5 Heavy vehicle license for Forklift driver (Submit a copy to HPCL-VR F&S)
6 Refinery driving permission for Forklift driver
Safety features: 7 Load test date marked on the body
8 Safe working load marked near each hook
9 Latching of Forklift hooks in working condition
FORKLIFT
MATERIAL HANDLING EQUIPMENT
Page 130 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
10 Guarding to rotating parts: a. Pulley belt b. Radiator fan
11 Body physical condition in good condition: a. Driver seat b. Body cover well maintained with painting. c. Top cover above driver seat. d. Tyres are not bald and without retreading. e. Tools box physically good and lockable. f. No engine oil leakage.
12 Self-ignition in working condition.
13 PESO approved spark arrester fixed to
the exhaust.
14 Horn and lights are in working conditions
15 Good housekeeping in Forklift operator
cabin
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
Page 131 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.5 Ref Doc : SWP -06 Rev. : 0 Date: 18/03/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Documents: 1 Test Certificate of Chain pulley block
available (Submit copy to HPCL-VR F&S)
Safety Features: 2 Chain pulley block shall be IS 3832
2005 marked.
3 Chain pulley blocks to be numbered and identified
4 Load test date and SWL marked on the chain pulley block
5 Latching provided to chain pulley block hook in working condition.
6 Chain to be free on ant signs of damage, Wear & tear.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
CHAIN PULLEY BLOCK
MATERIAL HANDLING EQUIPMENT
Page 132 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.6 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Documents: 1 Load test Certificate of wire rope sling
available (Submit copy to HPCL-VR F&S)
Safety Features: 2 Wire rope sling to be numbered and
identified.
3 Load test date and SWL marked on the body of the rope
4 Wire rope sling to be free of any signs of physical damage, wear & tear etc.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
WIRE ROPE SLING
MATERIAL HANDLING EQUIPMENT
Page 133 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-1.7 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Documents: 1 Load test certificates of synthetic web
sling (Submit copy to HPCL-VR F&S)
Safety Features: 2 Synthetic web sling to be numbered and
identified
3 Load test date and SWL to be marked on the web sling.
4 Synthetic web slings to be free from signs of wear and tear, physical damage and chemical burns etc.
5 Evidence of any acid or caustic burns, charring on any part of surface
6 Broken or worn out stitches
7 Condition of eye lets
(Check for any worn out signs)
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
SYNTHETIC WEB SLING
MATERIAL HANDLING EQUIPMENT
Page 134 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL - 1.8 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 All Manila ropes numbered and
identified
2 Physical condition of the rope free from defects
3 Rope free from broken strands, wear & tear, punctures, snags
4 Evidence of any acid or caustic burns, charring on any part of surface
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
MANILA ROPE
MATERIAL HANDLING EQUIPMENT
Page 135 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 2
MATERIAL TRANSPORT EQUIPMENT
S.NO Format Number Equipment 1 CL-2.1 Tractor 2 CL-2.2 Chemical Tanker 3 CL-2.3 Tyre Mounted Trolley 4 CL-2.4 Trailer 5 CL-2.5 Truck 6 CL-2.6 LMV
Page 136 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-2.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3 Heavy vehicle license for tractor driver (Submit a copy to HPCL-VR F&S)
4 Refinery driving permission for tractor driver
Safety Features: 5 Guarding to rotating parts
a. Pulley belt b. Radiator fan
6 Self-ignition in working condition.
7 PESO approved spark arrester fixed to the exhaust.
8 Horn and lights are in working conditions.
TRACTOR
MATERIAL TRANSPORT EQUIPMENT
Page 137 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL-2.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
9 Good housekeeping in operator’s cabin.
10 Physical conditions: a. Driver seat b. Body cover is well maintained and sound in construction. c. Top cover above driver seat. d. Tyres are not bald and without retreading. e. Tools box physically good and lockable f. No engine oil leakage.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
Page 138 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3 Driver carrying dangerous or hazardous goods holds a driving license as per provisions of rule 9 of Central Motor Vehicle Rules. (Submit a copy to HPCL-VR F&S)
Safety Features: 4 Display of distinct class Label of the
hazardous material being transported with the following details:
a. The name and telephone number of the emergency services to be contacted
b. The name and telephone number of the consignor of the dangerous or hazardous goods.
5
Guarding to rotating part of radiator fan
6 Self-ignition in working condition.
CHEMICAL TANKER
MATERIAL TRANSPORT EQUIPMENT
Page 139 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS/ REMARKS
OK NOT OK
7 Physical conditions: a. Tanker frame sound in construction and no make shift arrangement. b. Tanker control valves are in good working condition. c. Tanker lids with gaskets and without leaks. d. Tyres are not bald and without retreading. e. No engine oil leakage.
8 PESO approved spark arrester fixed to the exhaust.
.
9 Horn and lights are in working conditions.
10 Good housekeeping in driver’s cabin.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
Page 140 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Documents: 1 RTO Registration document.
(Submit copy to HPCL-VR F&S)
2 RTO fitness certificate. (Submit copy to HPCL-VR F&S)
Safety Features: 3 Physical Condition:
Body frame sound in construction and no make shift arrangement
Safety features:
4 Body is fully covered with metal sheet
5 Body side frame is fitted with provision
for fixing metal pipe in order to guide loaded materials
6 Tyres are not bald and without retreading.
7 Attached toeing hook is sound in construction
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
TYRES MOUNDED TROLLEY
MATERIAL TRANSPORT EQUIPMENT
Page 141 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
Safety Features: 3 Physical conditions:
Body frame sound in construction and no make shift arrangement.
4 Body is fully covered with metal sheet.
5 Body side frame is fitted with provision
for fixing metal pipe in order to guide loaded materials.
6 Tyres are not bald and without retreading.
7 Attached toeing hook is sound in construction.
TRAILER
MATERIAL TRANSPORT EQUIPMENT
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
Page 142 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.6 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3 Light vehicle license for LMV driver (Submit a copy to HPCL-VR F&S)
4 Refinery driving permission for LMV driver.
Safety Features: 5 Guarding to rotating parts
a. Radiator fan
6 Physical conditions: a. Driver seat b. Body cover is well maintained and sound in construction. c. Tyres are not bald and with out retreading. d. Tools box physically good and lockable e. No engine oil leakage.
LMV
MATERIAL TRANSPORT EQUIPMENT
Page 143 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.6 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
7 Self-ignition in working condition.
8 PESO approved spark arrester fixed to the exhaust
9 Horn and lights are in working conditions.
10 Good housekeeping in operator’s cabin.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
Page 144 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.5 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
\ Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Documents: 1 RTO Registration document
(Submit a copy of each item)
2 RTO fitness certificate (Submit a copy of each item)
3
Heavy vehicle license for truck driver (Submit copy to HPCL-VR F&S)
4 Refinery driving permission for truck driver.
Safety Features: 5 Guarding to rotating parts radiator fan
6 Physical conditions: a. Body frame sound in construction and no make shift arrangement. b. Body is fully covered with metal sheet. c. Body back door sound in construction. d. Tyres are not bald and without retreading. e. No engine oil leakage.
TRUCK
MATERIAL TRANSPORT EQUIPMENT
Page 145 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 2.5 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 2 of 2
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
7 Self-ignition in working condition.
8 PESO approved spark arrester fixed to the exhaust.
9 Horn and lights are in working conditions.
10 Good housekeeping in operator’s cabin.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
Page 146 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 3
WELDING & GRINDING EQUIPMENT
S.NO Format Number Equipment 1 CL-3.1 Diesel Generator 2 CL-3.2 Welding Machine 3 CL-3.3 Welding Cable 4 CL-3.4 Welding Holder 5 CL-3.5 Temporary Electrical Panel 6 CL-3.6 Electrical Switch board 7 CL-3.7 Grinding machine
Page 147 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 3.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety features: 1 Diesel generator body physical condition:
a. Body cover
b. Plug points
c. Tyres are good and not retreaded or rollers with non-sparking arrangement
2 No leaks from fuel tank and connecting hoses and fittings
3 Guarding to rotating parts- a. Pulley belt b. Radiator fan
4 PESO approved spark arrestor fixed to the exhaust.
5 Alternator in place and in good working condition.
6 All electrical components to be free of defects
7 Stands for parking - in good condition.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
DIESEL GENERATOR
WELDING & GRINDING EQUIPMENT
Page 148 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 3.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT
SAFETY ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS
IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety features: 1 Physical condition of welding machine
body. a) Body cover
b) Plug points
c) Rollers with non-sparking & brake arrangement.
2 Ammeter & Voltmeter knob condition
3 Condition of cable connectors and lugs
4 Provision for body earthing provided
5 Welding machine stability for
machines with wheels check the condition of wheels.
6 Machine guarding in tact
7 Condition of electrical cables
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP SIGNATURE
WELDING MACHINE
WELDING & GRINDING EQUIPMENT
Page 149 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 3.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT
OK Safety Features:
1 Condition of cable insulation shall be intact
2 Cable shall be free from cuts and damages
3 Lugs provided at cable ends for easier termination
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
WELDING CABLE
WELDING & GRINDING EQUIPMENT
Page 150 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 3.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Ensure that the welding holder is free
from breakages.
2 The holder insulation to be in tact.
3 Squeeze grip system to be in condition.
4 The electrical cable attached to the holder shall be free of any cuts and damages.
5 Lugs provided on the cable. Condition of cable insulation.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
WELDING HOLDER
WELDING & GRINDING EQUIPMENT
Page 151 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 3.5 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
DIESEL GENERATOR
WELDING & GRINDING EQUIPMENT
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Ensure that the physical condition of the
panel is OK.
2 Ensure that the Panel should be flame proof .
3 Panel to have provision for body earthing.
4 Panel should be equipped with 30 mA ELCB & MCB protection.
5 Panel should be painted, corrosion free and stable.
6 Electrical components in the panel shall be in good condition.\
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
Page 152 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 3.6 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Electrical extension boards shall be in
good physical condition.
2 Extension board’s body shall be metallic.
3 Extension board’s shall be flame proof.
4 30mA ELCB protection to be provided to the extension boards
5 Plug sockets shall be provided with caps.
6 Wooden electrical extension boards are not allowed.
7 Connected cables are well insulated and having no cuts and damaged insulation.
8 No loose or damaged plug sockets fixed in switch board.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
ELECTRICAL SWITCH BOARD
WELDING & GRINDING EQUIPMENT
Page 153 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 3.7 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Grinding machine body shall be double
insulated type.
2 Guard provided to the grinding wheel.
3 Electrical cable connected shall be in good condition and free from cuts and joints.
4 Three pin plug shall be provided for plug connections.
5 Speed of the grinding wheel shall be marked on the body of the grinding machine.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
GRINDING MACHINE
WELDING & GRINDING EQUIPMENT
Page 154 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 4.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date: S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 The torch shall be free from physical
defects
2 Gas cutting torch handle insulation in good condition
3 Nozzle free of foreign particles.
4 Flash back arrestor to be provided to the torch.
5 Valves of the torch to be in operating condition
GAS CUTTING TORCH
GAS CUTTING EQUIPMENT
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
Page 155 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 4
GAS CUTTING EQUIPMENT
S.NO Format Number Equipment CL-4.1 Gas cutting torch CL-4.2 Gas Supply hose CL-4.3 Gas cylinder regulator CL-4.4 Gas cylinder CL-4.5 Gas cylinder Trolley
Page 156 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 4.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Hoses marked with IS 447 marking.
2 Hoses to be free of cuts, joints,
abrasions and signs of wear and tear
3 Hoses as per color coding specified in IS 447 (Oxygen – Blue & LPG / Acyteline – Red)
4 Hoses are fitted with jubilee clamps.
GAS SUPPLY HOSE
GAS CUTTING EQUIPMENT
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
Page 157 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 4.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Regulators shall be with IS 6901
marked
2 Regulator shall be specific to the gas cylinder.
3 Pressure gauges in the regulator shall be in working condition.
4 Flash back arrestor to be provided along with the regulator
5 No grease or any sort of lubrication to be provided on the regulator body.
6 Sign of any physical damage on the regulator
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
GAS CYLINDER REGULATOR
GAS CUTTING EQUIPMENT
Page 158 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 4.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
1 Gas cylinder contents and color coding as per IS 4379
2 Cylinder body condition
3 Cylinder valve cap provided
4 Cylinder HT details marked
5 LPG cylinder shall be of Industrial gas cylinders only (Domestic LPG cylinders are not allowed)
6 Expiry date marked on the body for LPG Cylinders
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
GAS CYLINDER
GAS CUTTING EQUIPMENT
Page 159 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 4.5 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Gas cylinder contents and color coding
as per IS 4379
2 Cylinders shall be provided with valve caps.
3 HT details to be clearly marked on the cylinder body.
4 Expiry date to be marked on the body of LPG Cylinder.
5 LPG cylinder shall be of Industrial gas cylinders only (Domestic LPG cylinders are not allowed)
6 Gas cylinder key shall be provided with the cylinder
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
GAS CYLINDER TROLLEY
GAS CUTTING EQUIPMENT
Page 160 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 5
ACCESS & EGRESS EQUIPMENT
S.NO Format Number Equipment 1 CL-5.1 Scaffolding pipes & fittings 2 CL-5.2 Portable step Ladder 3 CL-5.3 Ladder
Page 161 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 5.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety features: 1 Scaffolding pipes shall be of Min. 40
mm dia with 4 mm thickness
2 Scaffolding pipe material shall be of IS: 2750 and it shall be a single pipe without joints
3 Scaffolding fittings as per IS:3696
4 Scaffolding pipes shall be free from
physical damaged, corrosion and bends.
5 Scaffolding pipes well painted.
6 Scaffolding pipes shall be non - slippery
due to oil and grease
7 Couplings to be well maintained greased and kept in separate place other than scaffold pipes
8 Work platform gratings free from physical damage, wear and tear & signs of corrosion.
9 Gratings shall not be having sharp edges or protruding connections.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
SCAFFOLDING PIPE & ITS FITTINGS
ACCESS & EGRESS EQUIPMENT
Page 162 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 5.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Portable step ladder shall be in good
physical condition.
2 It shall have locking provision for legs.
3 Rungs of the ladder shall be in good
working condition.
4 No alterations made to the original ladder.
5 Side rails and steps free of oil and grease
6 Inter distance between steps and rungs shall be 12”
7 Wooden step ladder not allowed inside Refinery
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
PORTABLE STEP LADDERS
ACCESS & EGRESS EQUIPMENT
Page 163 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 5.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Are all the rungs, cleats, or steps in
good condition?
2 Are the side rails intact without cracks, bends, or sharp projections?
3 Is the ladder free of corrosion?
4 Are the side rails and steps free of oil or
grease?
5 Are the ropes on extension ladders intact without fraying or excessive wear?
6 Slippery material on the rungs of the ladder
7 Legs of the ladder on the same level
8 No alterations made to the original
ladder.
9 Inter distance between steps and rungs shall be 12”
10 Wooden ladder not allowed inside Refinery.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
LADDERS
ACCESS & EGRESS EQUIPMENT
Page 164 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 6
FIRE FIGHTING EQUIPMENT
S.NO Format Number Equipment 1 CL-6.1 DCP Extinguisher 2 CL-6.2 CO2 Extinguisher 3 CL-6.3 Fire Hose 4 CL-6.4 Firefighting nozzle
Page 165 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 6.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Document: 1 Hydro-test certificate of 10 Kg DCP
extinguisher.
Safety Features: 2 10 Kg DCP Extinguisher shall be IS
2171 marked.
3 CO2 Cartridge inside the extinguisher shall have IS 4947 certification mark and manufacturers certificate.
4 CO2 cartridge unused. 5 DCP powder in free from bid or/ cake
formation.
6 Discharge hose, squeeze grip nozzle are in working condition and there is no sign of damage.
7 No sign of physical dent, bend & corrosion on the body of DCP extinguisher.
8 Name of the Contractor and HT done date to be clearly marked on the body of the extinguisher.
9 Cap piercing vent holes shall not be plugged.
10 Safety Clip available with DCP extinguisher.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
DCP EXTINGUISHER
FIRE FIGTING EQUIPMENT
Page 166 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 6.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Document: 1 Hydro-test certificate of 4.5 Kg CO2
extinguisher.
Safety features: 2 4.5 Kg CO2 Extinguisher shall be IS
2878 marked.
3 No sign of damages to discharge hose.
4 Hand held discharge hose portion is
insulated and there is no sign of damage to insulation.
5 Cylinder valve shall be in operable condition and lock pin to be provided with the valve.
6 Name of the contractor and HT details to be marked on the Fire extinguishers body.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
CO2 EXTINGUISHER
FIRE FIGTING EQUIPMENT
Page 167 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 6.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety features: 1 63 mm or 38 mm dia fire hose shall be
IS 636 marked of Type-B made of synthetic only.
2 Canvas hose is not allowed inside refinery.
3 The physical condition of the fire hose shall be free from pin holes, cuts, wear & tear.
4 The coupling shall be permanently binded to the hose with proper winding. No Temporary adjustment is allowed.
5 Male and female couplings shall be in good working condition and lugs shall be free to operate.
6 Gasket in female coupling shall be in working condition and good.
7 Free from physical damages and leaks.
8 Suitable F - rod for opening hydrant landing valve
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
FIRE HOSE
FIRE FIGTING EQUIPMENT
Page 168 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 7
HAND TOOLS AND TACKLES
S.NO Format Number Equipment 1 CL-7.1 All Types of Wrenches & Spanners 2 CL-7.2 Chisel 3 CL-7.3 Hammer 4 CL-7.4 Screw Driver 5 CL-7.5 Plier 6 CL-7.6 Spreader 7 CL-7.7 Crimping Tool 8 CL-7.8 Jack Hammer 9 CL-7.9 Driller
Page 169 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 6.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety feature: 1 63 mm or 38 mm dia firefighting
nozzle
2 IS: 2871 marked.
3 Made of either gun metal or SS
4 Triple purpose nozzle and smooth to operate.
5 No sign of physical damage and nozzle inlet is suitable for fixing in hose coupling.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
FIRE FIGHTING NOZZLE
FIRE FIGTING EQUIPMENT
Page 170 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Wrenches or Spanners shall be free
from oil, grease, dust and corrosion.
2 Wrenches should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 Wrenches or Spanners heads are not rounded up.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
ALL TYPES OF WRENCHES & SPANNERS
HAND TOOLS & TACKLES
Page 171 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Chisel shall be free from oil, grease,
dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 Chisel holder grip should be in good condition (Carpenter chisel).
5 In case of RCC works and Reinforcement rod works chisel should have handle.
6 Chisel head should not be bushed.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
CHISEL
HAND TOOLS & TACKLES
Page 172 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Hammer shall be free from oil, grease,
dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 Hammer head should have proper locking arrangement.
5 Hammer handle should be metal. No Wooden handle is allowed.
6 Hammer head shall not be round up or bald.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
HAMMER
HAND TOOLS & TACKLES
Page 173 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Screw driver shall be free from oil,
grease, dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 It should have proper gripping arrangement.
5 It shall not be blunt or bald.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
SCREW DRIVER
HAND TOOLS & TACKLES
Page 174 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.5 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS REMARKS
OK NOT OK
Safety Features: 1 Plier shall be free from oil, grease, dust
and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 It should have proper gripping arrangement.
5 The plier handle insulation shall be intact.
6 The plier nose shall not be round up or bald.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
PLIER
HAND TOOLS & TACKLES
Page 175 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.6 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Spreader shall be free from oil, grease,
dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 It should have proper gripping arrangement.
5 It shall not be round up or bald.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
SPREADER
HAND TOOLS & TACKLES
Page 176 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.7 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Crimping tool shall be free from oil,
grease, dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement on the body.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
CRIMPING TOOL
HAND TOOLS & TACKLES
Page 177 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.8 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Jack Hammer shall be free from oil,
grease, dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding
on the body.
4 It should have proper gripping arrangement.
5 Connected power cables are well insulated and having no cuts and damaged insulation
6 In case of pneumatic or hydraulic operated ensure that the tubes are properly connected and clamped.
7 The Jack hammer shall have on or off control switch at the tool itself.
8 Drill bits locking arrangement shall be sound.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
JACK HAMMER
HAND TOOLS & TACKLES
Page 178 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 7.9 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 Driller shall be sound in construction.
2 No make shift arrangement or welding on the body.
3 It should have proper gripping arrangement.
4 Connected power cables are well insulated and having no cuts and damaged insulation.
5 Drill bit locking arrangement shall be sound.
6 Guards provided to be in place.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
DRILLER
HAND TOOLS & TACKLES
Page 179 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 8
CIVIL WORKS EQUIPMENT
S.NO Format Number Equipment 1 CL-8.1 Crow bar 2 CL-8.2 Shovel 3 CL-8.3 Spade 4 CL-8.4 Gamela 5 CL-8.5 Concrete Mixer
Page 180 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 8.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Crow Bar shall be free from oil, grease,
dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 Hand grip area is to be properly insulated.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
CROW BAR
CIVIL WORKS EQUIPMENT
Page 181 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 8.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date: S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Spade shall be free from oil, grease,
dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
4 It should have proper gripping arrangement.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
SPADE
CIVIL WORKS EQUIPMENT
Page 182 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 8.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS REMARKS OK NOT
OK Safety Features:
1 Shovel shall be sound in construction.
2 No make ship arrangement or welding on the body.
3 It should have proper gripping arrangement.
CONTRACTOR OFFICIAL SIGNATURE NAME STAMP
SHOVEL
Page 183 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 8.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Gamela shall be free from oil, grease,
dust and corrosion.
2 It should not have any physical damage.
3 No damage or hole for bottom of the body.
4 Gamela should have no sharp edges.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
GAMELA
CIVIL WORKS EQUIPMENT
Page 184 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 8.5 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Tyres are good and not retreaded or
rollers with non-sparking arrangement.
2 No leaks from fuel tank and connecting hoses or fittings.
3 Guarding to rotating parts- a. Pulley belt b. Radiator fan
4 PESO approved spark arrestor fixed to the exhaust.
5 Alternator in place and in good working condition.
6 All electrical components to be free of defects.
7 Braking mechanism is in working condition.
8 It should not have any physical damage.
9 No damage or hole for bottom of the
bowl.
10 Bowl should not have sharp fold edge.
11 Locking arrangement to the mixer bowl.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
CONCRETE MIXER
CIVIL WORKS EQUIPMENT
Page 185 of 209
Visakh RefineryVisakh RefineryVisakh RefineryVisakh Refinery
CHECK LIST OF CATEGORY – 9
MISCELLANEOUS EQUIPMENT
S.NO Format Number Equipment 1 CL-9.1 Hydro-testing Pump 2 CL-9.2 Blow Lamp 3 CL-9.3 De-watering Pump 4 CL-9.4 Air Compressor 5 CL-9.5 Jack 6 CL-9.6 Grass cutting machine 7 CL-9.7 Fire proof Tarpaulin
Page 186 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 9.1 Ref Doc : SWP -06 Rev. : 0 Date : 18/03/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Hydro-testing pump shall be free from
oil, grease, dust and corrosion.
2 It should not have any physical damage.
3 No make shift arrangement or welding on the body.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
HYDRO - TESTING PUMP
MISCELLANEOUS EQUIPMENT
Page 187 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 9.2 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Blow lamp nozzle is in good condition.
2 Handle is fitted with insulated.
3 Lamp nozzle shall be free from dust.
4 Flash back arrestor to be provided to the blow lamp.
5 Hoses shall be attached using Jubilee clamps only.
6 Blow lamp valves shall be in operating condition.
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
BLOW LAMP
MISCELLANEOUS EQUIPMENT
Page 188 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 9.3 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS
OK NOT OK
Safety Features: 1 De-watering Pump shall be free from
oil, grease, dust and corrosion.
2 It should not have any physical damage. 3 De watering pump shall be diesel driven
only. (No petrol driven or kerosene driven pumps are allowed in refinery)
4 Guarding provided to all rotating parts.
5 PESO approved spark arrestor to be
provided at the exhaust.
6 Hoses shall be fixed up with proper clamping arrangement.
7 Proper arrangement for easy handling & shifting of the pumps.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
DE-WATERING PUMP
MISCELLANEOUS EQUIPMENT
Page 189 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 9.4 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Documents: 1 Test certificate of air compressor
2 Test certificate for hopper
Safety Features:
1 Tyres are good and not retreading or rollers with non-sparking arrangement.
2 No leaks from fuel tank and connecting hoses or fittings.
3 Guarding to rotating parts: a) Pulley belt b) Radiator fan
4 Body cover is well maintained and sound in construction.
5 No engine oil leakage.
6 Self-ignition is in working condition.
7 Lights are in working condition.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
AIR COMPRESSOR
MISCELLANEOUS EQUIPMENT
Page 190 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 9.5 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Documents: 1 Test certificate for the jack.
Safety Features: 2 Jack shall be sound in construction.
3 Jack shall be free from oil, grease, dust
and corrosion.
4 It should not have any physical damage.
5 No make shift arrangement or welding on the body.
6 Jack heads shall not be round up or bald.
7 No Hydraulic oil leakage from the jacks
CONTRACTOR OFFICIAL
SIGNATURE NAME DESIGNATION STAMP
JACK
MISCELLANEOUS EQUIPMENT
Page 191 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 9.6 Ref Doc : SWP -06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date: Contractor Name: Equipment ID: PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED
DEFECTS / REMARKS OK NOT OK
Safety Features: 1 Engine spark plug shall not be open and
should be of concealed construction.
2 Guards to be provided to the rotating parts.
3 The machine harness shall be physically good.
4 There should be no visible fuel leaks on the body of the machine.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
GRASS CUTTING MACHINE
MISCELLANEOUS EQUIPMENT
Page 192 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: CL – 9.7 Ref Doc : SWP -
06 Rev. : 0 Date : 18/3/11 Page 1 of 1
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY
ASSURANCE
MANUAL OF EQUIPMENT CHECKLIST
Date:
Contractor Name: Equipment ID:
PO NO & Date:
S.NO CHECKLIST STATUS IDENTIFIED DEFECTS / REMARKS OK NOT OK
Documents: 1 Fire retardant test to be carried out as
per IS:11871 and test certificate to be submitted.
Safety Features: 2 Fire retardant blanket should be woven
with ceramic fibre yarn reinforced with SS -304 wire.
3 Fire retardant blanket should not have physical damage.
4 Thickness should be min 3 mm.
5 Eyelets along all four side at a interval
of two feet for anchorage.
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
FIRE PROOF TARPAULIN
MISCELLANEOUS EQUIPMENT
Page 193 of 209
> Contractor Letter Head < . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date : ------------------------
List No
FORMAT NO: SWP-F-6.1
LIST OF EQUIPMENT, TOOLS & TACKLES PLANNED FOR USE IN HPCL -VR
P O NO DATE HPCL USER DEPARTMENT
We propose to use the following equipment in HPCL-VR premises. S.NO EQPT/ TOOL /TACKLE
NAME ID NO MAKE QTY
1 2 3 4 5 6 7 8 9 10 .. ..
CONTRACTOR OFFICIAL SIGNATURE NAME DESIGNATION STAMP
Page 194 of 209
> Contractor Letter Head < . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date: ------------------------
First entry Additional entry
Tick in appropriate box
TO:
HOD-Fire & Safety
FORMAT NO: SWP - F - 6.2
EQUIPMENT, TOOLS & TACKLES GATE ENTRY PLAN We propose to bring the equipment, tools & tackles into HPCL Refinery as per the dates below and lists attached.
Planned Date of Entry
List as per Annexure No (Annexure –I, II, III etc.)
• I declare that all the equipment, tools & tackles have been personally verified by me to be
conforming to the requirement of checklist as per SWP-06-G-6.1
• I understand that equipment, tools & tackles not conforming to its checklist of SWP-06-G-6.1, shall not be allowed entry into HPCL Refinery. I am prepared to handle such circumstances.
Please arrange for inspection at the entry gate and issue “ Equipment Safety Clearance Certificate”.
CONTRACTOR OFFICIAL
SIGNATURE
NAME DESIGNATION STAMP
Page 195 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: SWP- F- 6.3 Ref Doc : SWP -06 SAFE WORK PRACTICES
CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
EQUIPMENT SAFETY CLERANCE CERTIFICATE
Page 1 of 1
To Date:
This has reference to your “Equipment, Tools & Tackles Gate Entry Plan”( SWP-F-6.2) dated ……………… Based on the above, at the time of gate entry your equipment were checked and following is advised. I. Equipment allowed to enter. Sr. No Equipment Name Equipment ID Equipment
make/Qty. Stamp
1 2 3
II. Equipment not allowed to enter. Sr.No Equipment Name Equipment ID Quantity Reason for
rejection Stamp
1 2 3
You are advised as follows:
1. Please ensure that the equipment allowed is maintained in the proper condition during its entire period of usage.
2. The equipment will be periodically checked by HPCL and if found unsuitable, you will have to discontinue its usage and remove from Refinery premises. (already informed to you through SWP-06).
3. This “Equipment Safety Clearance Certificate” is not sufficient for gate entry. Further Security clearance is to be obtained for final gate entry.
HPCL F&S Department
Signature Name Location Equipment Entry Gate Office Stamp
CC: User Department ( ----- )
Contractor Name PO No Date of PO HPCL User Department
Page 196 of 209
VISAKH REFINERY F&S DEPARTMENT
Doc No: SWP-06-R 6.1
Ref Doc : SWP -06
SAFE WORK PRACTICES CONTRACTOR JOB EQUIPMENT SAFETY ASSURANCE
CONTACT ADDRESS OF FIRE & SAFETY DEPARTMENT
(For the purpose of SWP-06 only)
Location Contact details Timing of contact Gate Entry Office Officer’s Name: Mr.M.Siva Prasad
Address: Dy.Manager- F&S HPCL -Visakh Refinery PO: Malkapuram Post Box No: 15 South gate, Opposite to Kalyani Hospital. Visakhapatnam-530 011 Andhra Pradesh(India Tel No: E-mail: [email protected]
0900 to 1200 hrs & 1400 to 1530 hrs
F&S Main Office Officer’s Name: Mr.K.V.Singh Address: Sr.Manager- F&S HPCL – Visakh Refinery PO: Malkapuram Post Box No: 15 Visakhapatnam-530 011 Andhra Pradesh(India) Tel No: 0891-2740183/ 2894843 FAX No – 0891-2740183 E-mail: [email protected]
0800 to 1630 hrs
Approved by
Signature
Name K.V.Singh Designation Head Fire & Safety
Page 197 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS,
STEAM GENERATORS & OTHER IBR JOBS Annexure VIII : FSAFETY, HEALTH & ENVIRONMEN
Seal of the
Vendor
Signature & Name of the Authorised Signatory with Date
Visakh Refinery
SAFETY HEALTH & ENVIRONMENT
SAFETY:
By enforcing & following 1. Training, motivation and counselling the workmen - by arranging pep talks.
2. Compliance of standards, codes and specifications and systems, procedures & practices -by introducing in contracts and surprise check.
3. Permit rules and regulations- Control of illegal, unauthorised & hazardous work through permit system.
4. by arranging pep talks. & by introducing in contracts and surprise check 5. Product safety & MSDS conditions by arranging training/ demonstrations. 6. Health surveillance. 7. Reporting near misses and control of incidents by recommendations. 8. Labour and Factories act. through contract conditions. 9. Lifting & hoisting machinery, equipments, instruments tools & tackles calibrations
through certificates. 10. Transfer of tools & tackles to heights in closed bags 11. Scaffolding pipes properly and of good condition, person with double harness safety
belts through safety tags & Inspection. 12. Welfare rules and regulations like ESI, PF, min. wages trhough contract conditions. 13. Maximizing usage of mechanized tools like torque wrenches, bolt tensioners, flange
spreaders. 14. Barricading critical incident potential area by double taping all around.
HEALTH:
1. Selection of right supervisors for the right job by qualifications and experience. 2. Health / medical fitness certificate for all labours. 3. Protect workers and others from flushing, steaming, spreads, drainings, refractory
mixing & gunniting, blast cleaning, hydro jetting, chemicals, harmful and poisonous gases, noise, heat, air pollution i.e. dust, burns, suffocation & irritation, by ensuring usage of All PPE.
4. Ventilation and air circulation to be provided for closed things by proper and sufficient number good air hoses, exhaust fans and lighting arrangement of 24volts supply.
5. Dehumidification for comfort and fatigue reduction. 6. Protection form radiations (arc welding), X rays (UV rays) by safety boards, isolation. 7. Egronomical protection for back, eyes, neck etc. for office people.
Page 198 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS,
STEAM GENERATORS & OTHER IBR JOBS Annexure VIII : FSAFETY, HEALTH & ENVIRONMEN
Seal of the
Vendor
Signature & Name of the Authorised Signatory with Date
Visakh Refinery
8. Physical fitness each labour should get min. 06 hours of sleep by not allowing labours continuing more than 16 hrs of work.
9. Proper nutrition & hygiene ( provide tea & snacks and facility for lunch), clean drinking water, toilet facility, skin care ( boiler suits) and mental health by insurance clauses etc.
ENVIRONMENT:
1. Control toxic emissions/leaks in vehicles and generators by providing flame arrestors. 2. Chemical & hazards waste management. 3. Legal compliance like IBR, factory Inspectors by providing in contracts. 4. Proper Unloading, storage, housekeeping of flammable liquids, petroleum products,
hazardous chemicals, gas cylinders. 5. Control of use toxic, flammable, explosive, hazardous chemicals & gas cylinders, noise
producing tools & machines, corrosive and reactive substances, 6. Check for License for transportation of flammable and hazardous cylinders and
removing spill immediately by sand etc. 7. Controlling spreads of steam from flanges, hydro jetting by sheets/ tarpaulins. 8. Oil drains, flashings, release of hydrotest water in controlled / closed manner. 9. Following motor vehicles act by checking pollution certificates, following speed
controls, valid refinery licences, 10. Providing proper illumination by lighting, reduction of sound, noise & dust, gaseous
pollute by PPE. 11. Insurance policy under Public liability act for all employees. 12. Occupation health surveillance by medical certificates, providing first aid in HPCL
dispensary. 13. Incident/ accident management.( reporting, investigation, corrective action ). 14. Safety performance management by rewards through quizzes and punishment through
contracts.
15. Disposal of sludge, coke, loose wastes, refractories, Insulation wastes, cement etc in closed bags/ drums and transporting to safe designated areas.
Page 199 of 209
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
Visakh Refinery Annexure IX : Annexure IX : Annexure IX : Annexure IX : FORMAT FOR FORMAT FOR FORMAT FOR FORMAT FOR PHYSICAL FITNESS CERTIFICATEPHYSICAL FITNESS CERTIFICATEPHYSICAL FITNESS CERTIFICATEPHYSICAL FITNESS CERTIFICATE
Table 1 : Physical Fitness Certificate Format
1. Name of the agency / Sub contractor
2. Name of the employee
3. Age / Sex 4. Present health history 5. Previous health history
6. Measurements Height in Cms. Weight in Kgs. Chest Inspiration Expiration
_____________________________ _____________________________ _____________________________ _____________________________
7. Blood Pressure
8. Heart
9. Lungs 10. Abdomen
Liver Spleen
_____________________________ _____________________________
11. Limpth Glands
12. Hydrocele
13. Hernia
14. Vericosity 15. Eyes:
Without Glasses With Glasses Right Eye Left Eye Right Eye Left Eye Far Vision 6/ 6/ 6/ 6/ Near Vision P P P P
16. Physical Deformities Remarks of the Doctor :
Signature / Stamp with Registration no.
Page 200 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS Annexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCE
Seal of the Vendor
Signature & Name of the Authorised Signatory with Date
Visakh Refinery
1. PENALTY FOR NON-COMPLIANCE
1.1. The penalty system is divided into two categories, Minor and Major. (HPCL - Fire & Safety shall decide whether an infringement is minor or major for violations which are not listed below).
1.1.1. Minor violation: Examples
1.1.1.1. Not wearing personal protective equipment (PPE) at work
site. 1.1.1.2. Minor traffic violation (wrong parking, over speeding) 1.1.1.3. Blocking of emergency equipment or exits. 1.1.1.4. Using unapproved scaffolding Etc.
1.1.2. Major violation: Examples
1.1.2.1. Smoking in the refinery, carrying matches or lighter and
mobile telephone.
1.1.2.2. Working without valid work permit.
1.1.2.3. Not wearing proper breathing apparatus when instructed.
1.1.2.4. Not providing shoring / sloped excavation for the deep pits.
1.1.2.5. Not providing fire extinguisher / fire hoses for hot work.
1.1.2.6. Repeating minor violations more than twice.
1.1.2.7. Major traffic violation.
1.1.2.8. Found guilty negligent driving resulting in a vehicle accident.
1.1.2.9. Entering classified area without permit.
Page 201 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS Annexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCE
Seal of the Vendor
Signature & Name of the Authorised Signatory with Date
Visakh Refinery
1.1.2.10. Not complying with written instruction on the work permit.
1.1.3. INFRINGEMENT REPORT PROCEDURE
1.1.3.1. Manager and above of Fire & Safety department are authorized to issue Infringement Report to the Concerned - Manager about the Safety Violation.
1.1.3.2. The sponsoring department shall take action and provide
feedback to Fire & Safety (Copy of the infringement Report is attached as Annexure-IV)
1.2. TABLE OF PENALTY STAGES
Table 1 : Table of Penalty Stages
VIOLATION FIRST SECOND THIRD MINOR Caution Notice Penalty Rs.1000/- Penalty Rs.3000/- MAJOR Penalty Rs.3000/- Penalty
Rs.10,000/- on holiday list*
1.2.1. * Duration will be decided by General Manager - Oprns / Proj.
1.2.2. Note: HPCL reserves the right to impose more severe penalty, i.e.
suspend/terminate the contractor/employee, his supervisor or the Site-in-charge.
2. REPORTING OF ACCIDENTS / INCIDENTS
2.1. All the accidents/incidents minor/major and near misses shall be immediately reported in writing to the company supervisor.
2.2. All formalities as per statutory regulations shall be carried out by the
contractor where warranted.
Page 202 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS Annexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCEAnnexure X : PENALTY FOR NON COMPLIANCE
Seal of the Vendor
Signature & Name of the Authorised Signatory with Date
Visakh Refinery
2.3. Contractor shall assist the company supervisor in investigating the
accident/incident and furnish all details regarding the accident/incident.
2.4. Contractor shall pay all incidental and medical expenses for the injured and compensation, as per Govt. Rules, in case of fatality.
Page 203 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS
Visakh Refinery Annexure X : Annexure X : Annexure X : Annexure X : Application Format for verification of antecedentsApplication Format for verification of antecedentsApplication Format for verification of antecedentsApplication Format for verification of antecedents
(on the letterhead of the Party / Contractor)(on the letterhead of the Party / Contractor)(on the letterhead of the Party / Contractor)(on the letterhead of the Party / Contractor)
Date: To, The Station House Officer, ______________Police Station,
Visakhapatnam. Sub: - Verification of antecedents of workmen engaged by us. Dear sir, We have engaged following workmen for our job at M/s. Hindustan Petroleum Corporation Limited, Visakh Refinery, Visakhapatnam for the period of _____________________________.
Sl.No Name Address
1. 2. 3. 4. 5.
These workmen have been allowed inside the Refinery to perform the job on character certificate submitted by us for a period of one month, pending verification of the antecedents of these workmen. We request you to arrange to verify the antecedents of our above employees and submit the report to enable us to submit the same to HPCL Management. Thanking you,
Very truly yours, Authorized Signatory Name: Designation:
Page 204 of 209
RFQ No.12000438-HD-46002/VNK
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
Visakh Refinery
Annexure XII RADIOGRAPHY RULESAnnexure XII RADIOGRAPHY RULESAnnexure XII RADIOGRAPHY RULESAnnexure XII RADIOGRAPHY RULES
Provisions of Atomic Energy (Radiation Protection) Rules, 2004 for Radiography Agencies
Responsibilities of Radiography Agency (Contractor) for safety & security of radiography devices:
1) Whenever a contract for industrial radiography is awarded to any industrial radiography agency, the
Contractor/Radiography Agency shall ensure that:
a. The radiography agency is duly authorized by RSD, AERB to work at the particular site of
Contractor
b. The radiography agency carries out the radiography work by adhering to requirements of AERB
Safety Code on Industrial Radiography (AERB/SC-IR, 2001)
c. The radiographer who will be engaged by radiography agency for carrying out radiography work
of radiography agency is certified by BARC/AERB
d. the radiographer has a functional radiation survey meter and makes use of it during radiography
e. The radiographer cordons sufficient area to control access of unauthorized person during
radiography at the sit.
f. The radiography work is supervised by Radiological Safety Officer (RSO)/site-in-charge, if any, of
the Contractor.
2) The Contractor shall be responsible for providing adequate illumination, scaffolding and other facilities
required to facilitate the safe radiography work by radiography agency.
3) The Contractor shall inform well in advance to radiography agency about daily schedule of radiography
work and shall not insist upon the conduct of radiography work by radiography agency under adverse
conditions such as during heavy rains, storms when all the radiation safety precautions may not be taken.
4) The Contractor shall ensure that the radiography devices (camera(s)) with source are brought in or
moved out of the site with appropriate gate pass mentioning details of the equipment. The proper
records of incoming and out going of radiography devices are maintained at storage room and at security
department.
5) The Contractor shall provide to the radiography agency the safe and secure storage room as approved by
AERB, with round the clock effective physical security arrangements, for storing radiography devices,
emergency accessories and other associated equipment. It shall be ensured that adequate illumination is
present around source storage room during night and approach roads to the storage room are in good
condition.
6) The Contractor shall inform in writing to the HPCL Security Department or concern Section (say
Maintenance-Onsite) on details of personnel of radiography agency authorized to take out radiography
devices from the pit room along with their specimen signatures.
7) The radiography agency should verify that the radiography agency stores securely the radiography devices
inside the pit of the storage room when no work of radiography is carried out.
8) The Contractor shall verify that the radiography agency has emergency plans, preparedness and contact
numbers in case of emergency/incidents involving radiography devices.
****
Page 205 of 209
RFQ No.12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS Visakh Refinery
Annexure XIII : Annexure XIII : Annexure XIII : Annexure XIII : SPECIFICATSPECIFICATSPECIFICATSPECIFICATIONS FOR FIRE RETARDENT BLANKETIONS FOR FIRE RETARDENT BLANKETIONS FOR FIRE RETARDENT BLANKETIONS FOR FIRE RETARDENT BLANKET
1. Application : For using as curtain against sparks generated from arc welding, gas cutting and
grinding works.
2. Specifications : Fire retardant blanket woven from ceramic fibre yarn reinforced with SS -304 wires.
Other specifications are as follows:
a). Thickness : 3.0 mm b). Width : 1 – 2 Meter c) Length : As specified in roll d) Weight : 1500 GSM(Gram per square meter) e) Max use temperature: 1260 0 C f) Anchor Methods : Eyelets along all four side at a interval of two feet for anchorage g) Test certificate : Fire retardant test to be carried out as per IS:11871 and test report to be submitted along with supply of materials. h) The party has to send sample piece of ( 0.5 M x 0 .5 M size) for verification by HPCL,Visakh Refinery along with quotation submission. Suggested parties:
1. M/s Murugappa Morgan Thermal Ceramics Ltd, New No.2, N.S.C Bose Road, Dare House Annexe 5th Floor, Chennai 600 001. India. Phone : +91-44-2530 6894(Direct) / Mobile : 09600077893 Fax : +91-44-2534 5985 E-mail : [email protected]
2. FIRETEX PROTECTIVE TECHNOLOGIES PVT. LTD. Dee-Kay Estate, Lake Road,
Near Bhandup Police Station, Bhandup (W), Mumbai - 400 078.
Tel: 022-41585959/ 25952901/02/03 Fax: (022) 25946179. E-mail: [email protected] . Website: www.frictionindia.com
Page 206 of 209
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
Annexure XIV : Annexure XIV : Annexure XIV : Annexure XIV : QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR
CONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISOR
Visakh Refinery
1. Safety Engineer
In case the strength of contractor workers including sub-contractor workers in more than 250 Nos., Safety Engg to be engaged by contractor who will own overall responsibilities of HSE Management of the particular contractor.
a. Qualification - Degree in Science / diploma in any Engg.
b. Technical qualification - Fire or Safety diploma / certificate from Govt. or private institute.
c. Experience - Minimum 3-5 years experience of working in construction site/ shutdown activities in the field of safety or minimum one T&I experience
d. Candidate is required to read, write and speak in English with fluency in Telugu or Hindi Language.
e. The bio data of the safety Engg. shall be submitted to HPCL safety division and only the personnel cleared by the safety division shall be engaged by the agency.
2. Safety Supervisor:
In case the strength of contractor workers including sub-contractor workers in more than 30 Nos., Safety supervisor to be engaged by contractor. Based on guideline of contactor safety regulations, the number of safety supervisors to be engaged.
a. Educational Qualification - Higher Secondary ( 10+2)
b. Technical qualification - Fire or Safety diploma / certificate from Govt. or private institute.
c. Experience - Minimum 2- 3 years experience of working in construction site/ shutdown activities in the field of safety or minimum one T&I experience
d. Candidate is required to read, write and speak in English with fluency in Telugu or Hindi Language.
e. The bio data of the safety supervisors shall be submitted to HPCL safety division and only the personnel cleared by the safety division shall be engaged by the agency. The Safety supervisor’s team shall be led by contractor Safety Engineer.
Page 207 of 209
ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM GENERATORS & OTHER IBR JOBS
Annexure XIV : Annexure XIV : Annexure XIV : Annexure XIV : QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR QUALIFICATION AND CRITERIAS FOR
CONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISORCONTRACTOR SAFETY ENGG. AND SAFETY SUPERVISOR
Visakh Refinery
f. The safety supervisors of the agency shall constantly coordinate with HPCL's Safety, Operations and executing departments for the smooth and safe execution of jobs.
Note: F&S will arrange one day training programme on Role & Responsibilities of Safety Enggs./Safety supervisors based on the request of executing department and will issue individual training card.
* * *
Page 208 of 209
Annexure XV to RFQ 12000438-HD-46002/VNK ANNUAL SERVICE CONTRACT FOR OVERHAULING OF BOILERS, STEAM
GENERATORS & OTHER IBR JOBS MINIMUM REMINIMUM REMINIMUM REMINIMUM RESOURCES TO BE MOBILISEDSOURCES TO BE MOBILISEDSOURCES TO BE MOBILISEDSOURCES TO BE MOBILISED
Visakh Refinery
Agency shall possess following minimum resources that are to be mobilised to site after PO placement for carrying out various piping jobs in various units simultaneously. 1. HPCL approved or reputed TPI (like EIL) approved welders - 2 nos. IBR certified Welders and 1 TIG welder 2. 2 nos. each of Skilled fitters, fabricator and Gas cutter/grinders 3. 8 nos. Helpers/Khalasis 4. 2 nos. Safety Supervisors 5. 2 nos. Job Supervisors 6. 5 nos. 1” Dia. air hoses of each 25 meters 7. 5 nos. 1” Dia. water hoses of each 25 meters 8. 5 nos. standard fire hoses 9. Fire Retardant cloths – 5 nos. (3’x 12’ size – 5 nos. and 6’ x 12’size – 5 nos.) 10. Temporary Power Panels – 2 nos. 11. Pneumatic / Electric Concrete Chipping Machines – 2 nos. 12. Welder Helmets – 3 nos. 13. DCP Fire Extinguishers – 3 nos. 14. Chain Blocks – 2 nos. (1 Ton Capacity – 1 no. and 3 Ton Capacity – 1 no.) 15. Full body type double harness safety belts – 6 nos. 16. System (CUPLOK) scaffolding material ( 60 nos. horizontals, 20 nos. Verticals, 20 nos. base plates, gratings of 10 Sq. Mtr.) 17. GI and Asbestos sheets – 10 nos. each (Size 1m x 2 m (approx.)) 18. Barricading Tapes – 10 nos. 19. Hydro testing pumps – 2 nos. 20. Vehicle – 1 no. for attending emergency jobs in the Refinery 21. 3 nos. Electric Welding machines & 1 no. DG Welding machine 22. Other PPE as mentioned in SWP-01 & SWP-02.
Page 209 of 209