Name of Work: - Providing HDPE suction pipe lines and accessories for the sea water pumps of Bio

Fouling Test Loop for BARC at Kalpakkam.

1.0 INTRODUCTION Bio Fouling Test Loop (BFTL) is located in a building situated near Madras Atomic Power Station (MAPS). The entry to the loop facility is through Nuclear Desalination Demonstration Plant (NDDP) located between MAPS and BHAVINI. This building is located approximately 175 m away from the shore. The facility is meant to carry out sea water related experiments, for which continuous fresh sea water is required at a flow of 160 Cu. m /hr. (2667 LPM). To achieve this, it is proposed to lay a suction line into the sea, as per the drawing attached herewith (WSCD/BFTL/SWP/NEW SUCTION/01). This specification covers the details of various equipments and accessories required for Bio Fouling Test Loop. 2.0 SCOPE OF WORKS AND SERVICES Scope of Works: Scope of work includes supply, transport, handling and cleaning of HDPE pipes, valves and fittings, design and fabrication of anchor blocks, designing and fabrication of suction strainer block, design of layout of suction line, fabrication, deployment and installation of suction pipe line in the sea to the lengths as given in the drawing, fabrication, laying and installation of pipe on shore to connect to sea water pumps, supply of vacuum pumps, erection of sea water pumps and vacuum pumps in the pump room, testing of HDPE piping, commissioning of the suction line and sea water pumps at BFTL, Kalpakkam as per the technical specification, schedule of items and quantities and approved drawings. Scope shall include design, engineering, fabrication, assembly/ preassembly, tests at manufactures works, supply of equipments complete with all accessories, auxiliaries as specified hereinafter, install both the offshore and onshore, as required for safe, reliable and trouble free continuous commercial operation, in a manner acceptable to Purchaser. The scope of work also includes erection/installation, supervision, including unloading, storage and handling at site, final painting, site testing, commissioning, trial run, performance and guarantee tests and other erection services to ensure trouble free operation and commissioning of the system. Any additional plant, equipment, material, services which are not specifically mentioned here, but are required to make the plant/systems in the scope of the tenderer complete in every respect in accordance with the technical specification and safe operation and guaranteed performance, shall be deemed to be covered under the scope of this specification. SEV-V Page 1 of 19

Scope of Services: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 3.0 Supply, testing, laying and installation of HDPE pipes, fittings, Butterfly valves & Duplex Suction Filter. Surveying of on-shore profile and designing the piping layout. Submission of detailed Drawings/Documents (Including Soft copies) etc. Submission of final tracings, as built drawings and document/manuals etc to BHAVINI. HDPE Pipe welding at site. Design, fabrication, testing, supply and under sea installation of anchor blocks. Design, fabrication, testing, supply and under water installation of suction strainer block. Deploying, testing, laying & installation of HDPE pipe line in the sea. Laying & installation of HDPE pipe on shore under soil and at pump room end. Erection, testing & commissioning of sea water & vacuum pumps. Complete quality management requirement covering all quality control and quality assurance Manuals as per the requirement of the BHAVINI. Complete erection unloading, Storage and handling of materials at site.

CODES AND STANDARDS Following Indian Standards/Codes (latest revision with amendments if any) and other relevant codes shall form part of this specification to the extent they are relevant. Where the Indian standards are in conflict with the stipulations of this specification, these specifications prevail over the Indian Standards. Wherever required stipulation are not covered in IS codes, the relevant ASTM, ACI, BS standards shall be followed. BUREAU OF INDIAN STANDARDS IS 4984 1995 IS 8360 (part- I) High Density Polyethylene Pipes for Water Supply Specification Specification for Fabricated High Density Polyethylene Fittings For Potable Water Supplies General Requirements Specification for Fabricated High Density Polyethylene Fittings For Potable Water Supplies Specific Requirements for 90 Deg. Tee Specification for Fabricated High Density Polyethylene Fittings For Potable Water Supplies Specific Requirements for 90 Deg. Bends Standard practice for Heat Fusion Joining of Polyolefin Pipe and Fittings SEV-V Page 2 of 19

IS 8360 (part- II)

IS 8360 (part- III)

ASTM D 2657 03

ISO 12176 (part- I) IS 7634 (part- I)

Plastic pipes and fittings Equipment for fusion joining polyethylene systems Butt Fusion Code of Practice for Plastic Pipe Work for Potable Water Supplies Choice of Materials and General Recommendations Code of Practice for Plastic Pipe Work for Potable Water Supplies Laying and Joining Polyethylene (PE) Pipes Butterfly Valves For General Purpose Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification General Requirements for fittings Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for 90 Deg. Bend. Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for 90 Deg. Tee. Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for Reducers. Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for Ferrule Reducers. Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for Pipe Ends. Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for Sandwich Flanges. Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for Reducing Tees. Injection Moulded / Machine High Density Polyethylene (HDPE) Fittings for Potable Water Supplies Specification Specific Requirements for End Caps SEV-V Page 3 of 19

IS 7634 (part- II) IS 13095 1991 IS 8008 (part-I)

IS 8008 (part-II)

IS 8008 (part-III)

IS 8008 (part-IV)

IS 8008 (part-V)

IS 8008 (part-VI)

IS 8008 (part-VII)

IS 8008 (part-VIII)

IS 8008 (part-IX)

4.0 4.01

PROJECT DATA / SITE CONDITIONS PROJECT DATA Purchaser Project Title Location : Bharatiya Nabhikiya Vidyut Nigam Limited (BHAVINI) : Sea Water Suction Line : Kalpakkam, 68 km south of Chennai on the coast of Bay of Bengal; Latitude 12 33 North & Longitude 80 11 East : Chennai-68 km from Kalpakkam : Chennai (Domestic and International) 47 km from Kalpakkam : Chengelput 32 km from Kalpakkam : NH-45 passing through Chengelput : By road, rail and sea : : 316.6 K (43.6 C) : 290.6 K (17.6 C) : Max. RH = 100%, Min. RH = 15%, Maximum likely RH at 318.0 K (45 C) is 80% : Average annual rainfall = 1332.5mm , highest = 2112 mm, minimum = 567 mm : Applicable to Zone-III as per IS 18932002 shall be followed

1.01.00 1.02.00 1.03.00

1.04.00 1.05.00 1.06.00 1.07.00 1.08.00 1.09.00 1.09.01 1.09.02 1.10.00

Nearest Seaport Nearest Air Port Nearest Rail head Nearest National Highway Transport Ambient temperature Maximum dry bulb temperature Minimum dry bulb temperature Relative humidity (RH)

1.11.00 1.12.00

Rain fall Seismology

1.13.00

Wind pressure & Wind speed

: The design basis 3 sec. gust wind speeds at 10 m level in terrain category 2 for specific mean return periods are as below

SEV-V Page 4 of 19

a)

Mean return period (Years) 100

Design basis 3 sec. Gust wind speed m/s 67

These design basis 3 sec gust wind speeds have to be used in line with IS 875(part-3) 1987 along with appropriate K2 and K3 factors only, since the probability factor k1 is already included in these values

4.02

SITE CONDITIONS Shore line at Kalpakkam, completely open to Bay of Bengal, is directly subjected to winds and waves of the sea. Site observations indicate that waves approach the shore from south west to south quadrant for about 6 months (April to September), from the north to east quadrants during 4 months (November to March), and the months of March and October being transition months in a year. The along-shore component of the wave force results in movement of sea bed material termed Littoral Drift which is predominant from south to north. Apart from Littoral Drift the coast line is also subjected to cyclonic storms which occur practically in all the seasons of the year in the Bay of Bengal Cyclonic storms are more frequent in the months of October and November. Monsoons occur twice in a year from November to January and from June to September. Annual Average rainfall is approximately 1332.5mm occurring mainly in the months of August-December. Mean tidal range at site is of the order 1.2m to 1.5m in spring season, and between 0.3m to 0.6m for neap tides. The corresponding slack water periods being approximately 1 to 2 hours and 2 to 2 hours at spring and neap tides respectively.

4.03

SITE / FIELD INVESTIGATION All the dimensions shown in the drawing are approximate only. Hence the location on the shore has to be surveyed and the elevations and distances have to be exactly measured. The details of levels in the sea in the referred location shall be obtained form the bathymetry chart which will be provided at the time of execution of works. Hence no separate seabed profile survey is as such necessary. However an additional diving survey, along the proposed pipeline route, shall be in the scope of this tender.

5.00

WORK REQUIREMENTS Erection and installation methods and workmanship shall follow accepted practices as described in relevant codes and standards and as per specification. The successful bidder shall prepare and furnish the following documents for the approval of BHAVINI. SEV-V Page 5 of 19

A procedure of deploying, testing, laying and installation explaining the sequence of laying the HDPE pipe lines in the sea and on the shore and at pump room. This document also include the sequence of supply, handling, testing, cleaning and installation of HDPE pipe with all accessories, design and fabrication of anchor blocks, design and fabrication of suction strainer block. Project planning document illustrating complete QA/QC procedures. Detailed program of work in the form of a CPM / bar chart network showing the commencement, duration and completion time of all the major items of work including procurement of all materials etc, highlighting the critical activity from time to time. 6.00 GENERAL OPERATING CONDITIONS Service fluid Temperature of fluid Pressure Humidity in atmosphere Ambient temperature 7.00 TECHNICAL SPECIFICATIONS: The details of scope of supply and services for the sea water suction line have been brought out in this technical specification. These specifications are intended for general description of quality and workmanship of materials and finished work. They are not intended to cover minute details. The work shall be executed in accordance with best modern practices. These specifications shall have precedence in case anything contrary to this is stated anywhere in the contract document. The Engineerin-charge decision shall be final on any issues arising out of such discrepancies. Unless specifically mentioned otherwise all the applicable codes of standard published by the Bureau of Indian standard and all other standards which may be published by them before the date of receipt of tenders shall govern in respect of design, workmanship, quality and properties of materials and method of testing, method of measurement etc. Contractors offer shall be deemed to include all minor details of work, which are obviously, and fairly intended and which may have not been referred to especially in the tender documents but which are essential for satisfactory completion of items referred to in schedule of quantities and rates, specification etc The rates for the items included in the Schedule of Quantities and Rates are inclusive of all material, labour, plant and equipment, transport and storage of material and equipment, mobilization, demobilization, necessary supervision by Contractors / manufacturers authorised representatives, overheads, profits and all incidental expenditure(s) as may be required for the complete and satisfactory execution of the work covered under this contract. 7.01 7.01.1 Supply of HDPE pipes, fittings, Butterfly valves & Duplex Suction Filter: Supply of High Density Polyethylene (HDPE) pipe line made of PE 100 grade resin, having size DN 355, DN 200, DN 150 and DN 50 of PN10 rating and shall SEV-V Page 6 of 19 : Sea water : 20 to 30 C : Ambient : 80 to 100 % non condensing : 25 to 40 C

conform to IS 4984 1995 or its latest amendments. Length of each pipe shall be of 12 m in length and shall be marked with BIS mark. Tolerance and ovality shall be as per the IS standard. Depending on the site condition, in case of requirement, additional pipe lengths, in steps of 12 m lengths, will have to be supplied on additional payment basis, at the same rates as quoted in this tender. 7.01.2 Supply of MS Hot Dip Galvanized (HDG) slip on flanges of size DN 355, DN 200, DN 150 and DN 50. Supply of HDPE stub ends, blind flange of size DN 200, 200 X 150 concentric reducer and 355 X 200 size eccentric reducer as per IS 8008. In case of requirement during the execution, a few of the above fittings may have to be supplied additionally on payment basis, at the same rates as quoted in this tender. All the flanges shall be as per BS 10 Table D. Supply of 200 mm size flanged SS 316 expansion bellows. Supply of 355 & 200 mm size of wafer type butterfly valves of standard make. Material of construction shall be CI (IS210 Gr. FG220) for body, the disc shall be epoxy powder coated CI (IS210 Gr. FG220) or IS226 and seat & O-rings shall be made of Nitrile rubber. The valve design and testing shall conform to IS 13095 or BS 5155. The valve shall be of tight shut off class & of PN10 pressure rating. The valve shall fit into a pair of flanges supplied under this contract. In case of requirement during the execution, additional valves may have to be supplied on payment basis, at the same rates as quoted in this tender. The dimension of flanges holding the butterfly valves are as per BS 10 Table D. Supply of polypropylene body ball valves of 50 mm size flanged ends. The valves shall be rated for an operating pressure of 6 Kg/ sq cm. In case of requirement during the execution, additional valves may have to be supplied on payment basis, at the same rates as quoted in this tender. All the flanges shall be as per BS 10 Table D. Supply of duplex suction filter to be fitted in the 355 mm line near the pump in the pump room. The filter shall be made out of MS Rubber Lined body with cupronickel (90:10) filter element. The body shall have 355 mm size flanged ends. The design of the filter shall be such that the filter element is easily removed, cleaned and refitted. All the flanges shall be as per BS 10 Table D. Supply of stainless steel water-ring vacuum pump with motor, base plate, vacuum gauge, silencer. The vacuum pump shall have the following specifications: a. Capacity: 50 Cu. m / Hr b. Vacuum pressure 710 mm Hg (Max) c. Speed 2850 rpm d. Water pressure available 7 m of WC e. Material of construction All the wetted parts shall be made of SS 316 f. Pump Make & design Shall be of standard company make. The design shall be sturdy and free from vibration while working in all conditions g. Vacuum gauge Shall be of liquid filled type with an isolation valve SEV-V Page 7 of 19

7.01.3 7.01.4

7.01.5

7.01.6

7.01.7

h. i. j.

Additional ports Relief valve Inspection

k. l. 7.01.8

Motor Power supply

Apart from water inlet, vacuum port, exhaust etc the casing shall have a vent and drain valves Shall be mounted to take care of the equipment in case of high vacuum The vacuum pump will be tested & inspected in all respect, after receiving the material test certificates for the pump material of construction, at the manufacturers / suppliers site before dispatching it to site and the cost shall be included in the unit cost of the item. Squirrel cage motor with IP65 or better enclosure. It should have ISI mark and made of standard company Single phase, 230 V 50 Hz, AC

Supply of Budenberg make or equivalent high quality, high precision, liquid filled pressure gauges with chemical seal as per the following specification: a. Dia Size: 150 mm b. Dial marking Black on white background in Kg/sq cm units c. Scale length 270 degrees d. Accuracy +/- 0.5 % of span e. Overload 130 % of span f. Process fluid Sea water at 40 deg. C max. temp. g. Pressure element Bourdon tube of AISI 316 SS internals h. Case seal SS 304 / 316 i. Enclosure class IP 65 or better j. Blow off disc At the top of the case k. Window Toughened glass l. Connection Bottom entry with chemical seal and SS 316 flange end to suit standard 50 mm size HDPE flange. All the flanges shall be as per BS 10 Table D. m. Chemical seal Top housing SS 316, Diaphragm SS 316 with Teflon lining, bottom flange SS 316 with Teflon lining, sealing fluid Silicon oil n. Range 0 to 5 Kg/sq cm with 100 equal divisions with main divisions in steps of 0.5 Kg/sq cm o. Inspection & testing The material shall be supplied with material test certificate and calibration certificate Supply of high quality, high precision liquid filled vacuum gauges as per the specification given in para 3.8 except the range being 0 to 760 mm Hg. In case of requirement during the execution, additional gauges may have to be supplied on payment basis, at the same rates as quoted in this tender.

7.01.9

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7.01.10

Supply of required sizes & number of MS HDG studs/bolts, nuts & washers and Neoprene commercial grade rubber gaskets for connecting all the flange joints in this proposed pipeline work. The stud sets shall be as per relevant IS. All pipes & fittings should be indelibly marked with information regarding the pressure class, dimensions, rating, manufacturers name, BIS mark with standard number and other details as per the standards. Appropriate packing and protection should be provided to the pipes & fittings during shipment and handling as per relevant codes. The pipes & fittings should be unloaded and stored without bare metal contacting the material or damaging the pipes. Loading, unloading material handling, storage and securing all the materials, machinery, tools & tackles are in the scope of contractors. Pipes & fittings shall be handled with care during fabrication & laying also. Final visual inspection will be done for any physical damage of the pipes, before refilling the excavated soil. A floating marker buoy shall be supplied and deployed in the sea near the suction strainer block. The buoy shall be made of MS Epoxy coated and filled with suitable material like PU Foam or equivalent. The buoy shall be tied to a separate concrete anchor block using a MS HDG link chain. The diameter of the buoy shall be around 900 mm. The marker buoy system shall be designed to give a satisfactory service of atleast 2 years. Surveying of on-shore profile and designing the piping layout All the dimensions shown in the drawing are approximate only. Hence the location on the shore has to be surveyed and the elevations and distances have to be exactly measured. The details of levels in the sea in the referred location shall be obtained form the bathymetry chart which will be provided at the time of execution of works. Hence no separate seabed profile survey is as such necessary. However an additional diving survey, along the proposed pipeline route, shall be carried out and the cost of the same shall be included in cost of designing of layout. Depending on the on-shore profile and feasibility of work, a piping layout has to be designed and a layout drawing & isometric drawing for laying HDPE pipeline to a distance of about 450 m in to the sea and a distance of about 150 m on shore (from the shoreline to BFTL pump room) has to be submitted for the approval of Engineer-in-Charge. The drawing should include all details including exact elevations, distances, dimensions, pipe layout, sea water levels, pump room layout, pump locations, pump elevation, position of suction strainer block, suction & discharge piping layout in the pump room etc. The discharge line of the seawater pump shall be of 200 mm HDPE piping which has to be laid and terminated at a sump situated near the proposed pump room. Care shall be taken that the gradation of the pipe is gradually increasing towards the pump and ensure that there is no up-down positioning of the pipe through out the line. SEV-V Page 9 of 19

7.01.11

7.01.12 7.01.13

7.01.14

7.01.15

7.02 7.02.1

7.02.2

7.02.3

While the piping layout is designed it has to be noted that the suction line will be terminated at the seawater pump to be erected in a pit of pump room situated near BFTL. The pit inside the pump room shall be at a depth of around 3.5 m. Depending on the pipe friction pressure drop, sea water levels, suction lift etc, NPSH available has to be calculated and compared to satisfaction with the NPSH required for the seawater pumps, which is 1.3 m. The calculation has to be submitted to the Engineer-in-Charge. The elevation of suction line of the seawater pumps can be adjusted to a required height, to improve the NPSH available. After the order is placed, the contractor shall prepare and submit layout and routing drawings only after discussing with the Engineer-in-Charge. HDPE Pipe welding at site Both the off shore and on shore piping has to be made by joining the 12 m length HDPE pipes through fusion butt weld process. Even though this proposal is for 600 m of piping, in case of requirement during execution of the work, an additional piping may have to be welded on chargeable basis. Welding procedure along with welding parameters should be submitted for approval to the Engineer-in-Charge before commencement of welding. The welding procedure and testing shall be as per ASTM D 2657 or ISO or DVS or other equivalent standards. The pipe should be fused by a qualified fusion technician with a fusion machine having a data logger conforming to ISO 12176 1 and validation tests shall be carried out as per approved standards. The technician will be qualified by our Quality Agency for visual, bend test and other destructive tests of a sample piece. The consumables, equipment and all other charges of testing, qualification and inspection are in the scope of the contractor. Any deviation in the setting of the data logger will be permitted only with written permission from the Engineer-in-Charge. Pipe welding should include fabrication of miter bends and miter tees for connecting the suction line to two numbers of seawater pumps to be erected in parallel in the pump room and in the discharge line of the pumps as given in the piping layout drawing. Standard IS 8360 (part- I, II & III) Specification for Fabricated High Density Polyethylene Fittings For Potable Water Supplies shall be followed for this work. The pipeline shall be laid & installed with minimum number of joints. The material planning may be done accordingly.

7.02.4 7.03 7.03.1

7.03.2

7.03.3

7.03.4

7.03.5 7.03.6

7.03.7

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7.04 7.04.1

Design, fabrication, testing, supply and under sea installation of anchor blocks The design calculations and drawing for the weight and spacing of anchor blocks, to be laid on the seabed for 355 mm size HDPE pipes, have to be made and submitted for approval of the Engineer-in-Charge. It has to be noted while designing the anchor blocks that the earlier surveys of the seabed in the same locations have revealed that there is a lot of sand drift on the seabed. Hence while laying the pipeline on the bed, a slack is recommended to enable correct settlement. After the approval of the design & drawing, the anchor blocks have to be fabricated, tested and supplied to the site for erection. The anchor blocks shall be deployed in to the sea as per the standard approved procedure. In case of requirement during the execution of work, an additional anchor blocks, required for length of pipe in steps of 12 m, may have to be fabricated, supplied, tested and installed in the sea along with additional HDPE piping at additional cost. Design, fabrication, testing, supply and under sea water installation of suction strainer block A suction strainer block of a standard design shall be made and submitted for the approval of the Engineer-in-Charge along with a fabrication drawing. The strainer block shall consist of an elbow of suitable material with stub ends, embedded in a concrete block. The elbow shall turn the suction line to up right position to a designed height with diffuser. The strainer element shall be of removable type basket arrangement on the top of strainer block made of suitable materials like Cupronickel (90:10). After approval of the suction strainer drawing the same shall be fabricated, tested and supplied. The strainer block shall be supplied with a spare strainer element. After the deployment of the off shore piping in to the sea, the strainer block shall also be deployed in the sea and attached suitably with the suction line using flange joints. The total filter area shall be atleast 10 times the total suction pipe flow area. Deploying, testing, laying & installation of HDPE pipe line in the sea Out of 600 m of HDPE pipe that will be supplied under this order, approximately 150 m has to be laid on the shore (including pump room piping). The remaining length of pipe shall be laid on the seabed from the shoreline. In case of SEV-V Page 11 of 19

7.04.2 7.04.3 7.04.4

7.05 7.05.1

7.05.2 7.05.3 7.05.4

7.05.5 7.06 7.06.1

requirement during execution, this length of pipe may have to be increased, which will be done in steps of 12 m, at an extra cost. 7.06.2 The deployment shall be using control sinking or pushing / toeing methods or any other acceptable procedure. All safety precautions as deemed necessary shall be taken by the contractor. Anchor blocks shall be carefully laid and immersed along with the piping. Care shall be taken that there is no damage to the pipe and the anchor blocks during the process and is placed on the seabed in the right position. The part of the piping on the shoreline shall not be exposed to the outside climate. The pipeline has to be buried under the soil at certain depth starting from a point atleast 10 m inside the sea, measured from the low tide shoreline. A procedure of deployment, testing, laying & installation shall be submitted for approval from the Engineer-in-Charge before taking up the work. Laying & installation of HDPE pipe on shore under soil and at pump room end Approximately 150m of HDPE shall be laid across the proposed integrated protection work for PFBR consisting of Shore protection work Outfall Channel Bund for protection against Tsunami Fig 5 shows the general arrangement of the above in detail. Some portion of HDPE piping shall be laid buried in the soil as per the approved drawing, from the shoreline to seawater pumps in pump room at BFTL site, which involves excavation of earthwork to a required depth. In case of requirement during execution, this length of pipe may have to be increased, which will be done in steps of 12 m, at an extra cost. Care shall be taken that the gradation of the pipe is gradually increasing towards the pump and ensure that there is no up-down positioning of the pipe through out the line. While laying the pipes care shall be taken from rolling and dropping into the trenches. It shall be placed into the trench gently. Before the laying / joining, pipes shall be cleaned from inside to remove any soil that might have accumulated therein. Refilling of trenches shall be done using the excavated soil but care shall be taken that the soil is free from sharp stones or any other objects and the filling soil should not be thrown from a height to avoid any damage to the pipe.

7.06.3

7.06.4

7.06.5 7.07 7.07.1

7.07.2

7.07.3

7.07.4 7.07.5 7.07.6

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7.07.7

If water is met due to seepage, subsoil water, rain or other causes, it shall be removed by the contractor by suitable diversions, pumping or bailing out and the excavated and prepared surface of each layer shall be kept dry as directed by the Engineer. No extra payment will be made for such dewatering. Those areas where hard strata are encountered, the pipe shall be provided with sand padding with minimum thickness of 100 mm all around the pipe, before backfilling. Inside the pump room, the suction pipeline shall be connected to the seawater pump suction flange as per the drawing. The suction flange size for the seawater pumps is 200 mm. Suitable stubs, reducers and flanges shall be welded to the end of the pipe for connecting it to the pump. This may also include branching of the 355 mm size suction line in to two line by fabrication a miter tee and connecting the lines to the suction of sea water pumps by fabricating miter bends of 355 mm size, connecting the suction filter & butterfly valves and then reduce the line size by connecting 355 X 200 mm eccentric reducer and connecting 200 mm SS 316 expansion bellows. Both the vacuum pumps have to be connected to the suction side of seawater pumps through 1 size heavy-duty GI pipes & fittings with suitable isolation valves and conjecture fitting for connecting it to the HDPE suction line or to the pump casing. The vacuum pumps shall be connected in such a way that both the vacuum pump can be used for any of the seawater pumps. Raw water connection for the vacuum pumps and electrical connections for all the pumps will be given by the department. The layout drawing of all the four pumps, suction lines, discharge lines and GI vacuum lines shall be submitted for approval of Engineer-in-Charge before starting the work. Discharge line of the pump shall be laid up to the seawater sump situated near the proposed pump room. The discharge flange size of the pump is 150 mm. The discharge line has to rise from the discharge flange, expand to 200 mm size using a butt weld end type 200 X 150 mm size HDPE reducer and has to be terminated at seawater sump, through butterfly type discharge valves. The discharge line shall have two branching lines of 200 mm size. One line shall be a drain line having a butterfly valve and other line shall be blinded off using a blind flange. The suction line inside the pump room, the discharge lines and the by pass line have to be laid along with the equipments, installed & duly supported using MS structural materials. The supports shall be painted one coat with metal primer and two coats of coal tar epoxy paint. The supports shall be grouted properly using cement concrete work or providing anchor bolts as may be required by the site conditions. The work includes supply of all MS support structural material, paint, painting materials & equipments and anchor bolts which is in the scope of the contractor. The pipeline shall be securely clamped to the MS supports. SEV-V Page 13 of 19

7.07.8

7.07.9

7.07.10

7.07.11 7.07.12

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7.07.15

Two 50 mm size branching lines shall be made from the suction & discharge lines for installing vacuum & pressure gauges with isolation PP ball valves, as shown in the drawing. Payment for pipe laying and installation shall be paid as per the measurements taken for total length of piping including fittings. A detailed procedure shall be submitted for approval of Engineer-in-Charge before starting the work. Erection, testing & commissioning of sea water & vacuum pumps Two numbers of seawater pumps, which will be issued to the contractor free of cost by the department and two numbers of vacuum pumps, supply of which are included under this contract, have to be erected in the pump room of BFTL. Both the seawater pumps, which are of 160 Cu. m capacity, 30 m of WC head & 26 KW, have to be suitably erected in the BFTL pump room and connected to the 355 mm suction line to operate them in parallel as per the approved drawing. The erection, testing & commissioning involves placing the pumps over the foundation for the sea water & vacuum pumps, suction line connection and alignment, overhauling of pump & motor, electrical testing of motor, alignment of pump & motor, and testing of pump with motor to its rated conditions. Each pump has to be commissioned & tested for atleast two days continuously. INSPECTION Engineer-in-Charge has the right to inspect during stage inspection or final inspection and also during material handling. In case of any material damage found at the time of supply at site or during storage or on site fabrication or deployment period, it shall be replaced with new material without extra cost. The bidder has to submit a draft copy of Quality Assurance Plan indicating the various stages of testing and inspection and the involvement of internal and departmental quality agencies along with quotation. Material test certificate shall be provided for the pipe, fittings, valves and all other materials to be supplied under this contract, for the confirmation with the relevant standards. Inspection report certification by SPCL/GAIL/SGS/BVQI) is required. internationally approved bodies (like

7.07.16 7.07.17 7.08 7.08.1

7.08.2

7.08.3

7.08.4 8.00 8.01

8.02

8.03

8.04 8.05

The welding and testing shall be done as per standard ASTM D 2657 or ISO or DVS or other equivalent standards. SEV-V Page 14 of 19

8.06

The welding equipment and the welder will have to qualify the mockup test, as per the pre-approved procedure, conducted in presence of departmental quality agency. A report in this respect has to be made and submitted to Engineer-inCharge before taking up the actual work. All the HDPE pipe weld joints will be inspected & cleared by departmental Quality Agency. As per the standard, visual inspection of the joint will be done for the uniform bead finish, size & shape. If any of the weld joints is not acceptable, the same shall be cut & re-welded and in which case no extra payment will be made for the additional work. Hydro pressure testing has to be done on the completed pipe length for a minimum pressure-retaining period of 4 hours, at a test pressure as mentioned in IS 4984 1995 or its latest amendments. The acceptance criteria for hydrostatic test are no permanent deformation of any part of the pipeline fitting or equipments and there shall not be any leakage through any of the joints. A report shall be made by the contractor and submit the same to the Engineer-in Charge after the successful completion of the hydro test. Hydro pressure testing has to be done for all the valves as per IS 13095 1991 or latest, at the manufacturers end and a report has to be submitted to the Engineerin-charge. The contractor shall maintain all the records for the QA procedures, tests records and reports. All the necessary consumables, equipments, tools & tackles required for the testing & inspection has to be arranged by the contractor. The on-shore piping, pump room piping and off shore piping & deployment will be inspected during the execution of work and after execution of work. The deployment of pipes, anchor blocks and suction strainer block under seawater will be inspected after work of deployment is completed, by departmental agency. The department may deploy either its staff or a hired agency personnel for the above piping inspection and for the inspection of the pipe & suction strainer block deployed in the sea. The surveillance provided by the Engineer-in-Charge or approved quality agency for the finished works shall not relieve the contractor from any of his responsibilities under this tender document. Any work not meeting the requirement of this specification is liable for rejection at any time. SAFETY SEV-V Page 15 of 19

8.07 8.08 8.09 8.10

8.11

8.12 8.13 8.14

8.15

8.16

9.00

The contractor shall follow all the safety and security precautions for prevention of injury or accidents and safeguard human lives and property. The contractor shall further comply with any instructions issued by the Engineer-in-Charge in respect of safety, which may relate to temporary or permanent works, working tools, plant and equipments, means of access or any other aspect. The contractor shall provide all necessary first aid measures, rescue and life saving equipments etc., in proper condition, which shall be readily available for use at all times. The contractor shall provide and maintain barricades, signs, lights and flagman as necessary in discretion area. The contractor shall adopt all the above safety measures at his own cost. A detailed safety & security instruction are given in the section-III of this specification. 10.00 PROGRAM AND PROGRESS Immediately after receiving the work order, the contractor shall submit a detailed program of work in the form of a PERT/CPM / bar chart network showing the commencement, duration and completion time of all the major items of work including procurement of all materials etc, highlighting the critical activity from time to time. The sequence of work shown in the program must be practicable and compatible with the technical specification and conditions prevailing at the site. The contractor shall maintain the progress of work as per the approved program. In case of any slippage of program the Engineer may insist the contractor to augment the input of plant, equipment, labour of any item as he may deem fit. The contractor shall comply with the Engineers directive in this regard, with out any extra charge whatsoever. In case of delays caused due to conditions or circumstances beyond the control of the contractor, the delays must individually be informed to the Engineer forthwith in writing and his acceptance in writing obtained. 11.0 DRAWINGS, DATA AND MANUALS Drawings, specifications, testing and other Data and Manuals showing details of fabrication, testing, erection and installation of the above pipe line, together with complete data covering all materials shall be submitted prior to commencing any works. The above information shall be submitted to BHAVINI for approval, reference and record purpose as per the requirement of BHAVINI. 11.01 TO BE SUBMITTED WITH THE BID The bidder has to furnish the following documents along with the tender a. b. The bidders Engineering work Experiences list. The bidders similar structures and sea water intake structures-related experiences, if any, during last seven years. In support of this purchase order / work order, completion certificate and track record from the agency has to be submitted If the contractor plans to carryout any of the works through subcontractor, a letter of association with sub-contractor shall be furnished. SEV-V Page 16 of 19

c.

d. e. f. g. h. i. j. 11.02

In such case credentials of sub-contractor for executing similar type of work shall also be enclosed. Detailed erection, design, fabrication and welding procedure (i.e. methodology and procedure for carrying out this work) and installation technique for carrying out the entire works. All technical details as required by this specification should be provided with suitable supporting documents Tentative General arrangement drawings (if any) proposed by the bidders based on their past experience in similar work. List of equipment, machinery, tools & tackles to be used by the bidder and complete Equipment plan. Dewatering Scheme for laying of pipe on the shore. List of engineers, welders, workmen & miscellaneous staff to be engaged during process of work along with their experience list. QA measures for carrying out the work

TO BE SUBMITTED AFTER THE AWARD OF CONTRACT: a. b. c. d. Schedule for the job (mobilization of material along with resource planning, man power setup), equipments with rated capacities. PERT Network showing sequence of supply, fabrication, testing, erection and installation activities. Format for work permit and laboratory test results. Documents on deployment of man power, complete equipment plan, tools & tackles, and ordering status of supply items and relevant details as may be requested by the Engineer and necessary for timely completion of the work. . Testing laboratory details with manpower, accreditation and listing of testing machines. Complete QAP/QCP (Quality assurance program and Quality control program) Submission of detailed work procedure documents. Preparing and submission of the piping layout drawings and written work procedures describing in detail proposed laying method and entire operation etc. and getting the same reviewed and approved by the Engineer to include: Welding procedure, mockup procedure and qualification & inspection tests procedures Layout of piping including pump room suction & discharge piping and locations of sea water & vacuum pumps Piping pressure drop and support details and calculations Anchor block drawing & design calculation Suction strainer block drawing and design calculation Deployment procedures Procedure for laying on-shore piping Drawing and details of Duplex suction filter Erection, testing & commissioning procedures for all pumps SEV-V Page 17 of 19

e. f. g. h.

i. j. k.

Submission of final approved documents/drawings to the engineer in requisite no. of copies as mentioned elsewhere in the specification Submission of requisite no. of as built documents/drawings in hard (Print & Tracings) and soft copies as mentioned elsewhere in the specifications. Any other item not mentioned above but necessary as per the requirements of the purchaser shall be submitted to the purchaser / purchasers consultant, engineering in charge during the execution of work.

12.00 12.01

OTHER TECHNICAL & COMMERCIAL CLAUSES The contractor should arrange the manpower, machinery, equipments, consumables, tools and tackles required for all the above works at his own cost. Transportation & material handling is the scope of contractor. At the time of approval of drawings and work procedures, submitted by the contractor and during execution, the Engineer-in-Charge reserves the right to modify the design as per the prevailing situations. The contractor may at his own cost insure for the pipes and other material to be deployed in the sea which will be valid atleast till the period of handing over of the pipe line to the department for operation, is completed. During execution of work, the contractor shall ensure that no system or building or part of any structure is damaged. Otherwise the cost of the repair or replacement work shall be recovered form the contractor. Engineer-in-Charges decision will be the final and binding in this regard. All technical details as required by this specification should be provided with suitable supporting documents along with the commercial details in quotation. Maximum stress permitted in tension, bending and shear, curves of stress, strain for short and long term and creep modulus for the pipe material are to be submitted along with quotation. A detailed procedure of work in stages, inspections & testing procedures and Quality Assurance Plan to be carried out shall be attached. Welding procedure along with the welding parameters and the standard code to be followed must be submitted along with the bid. The values of temperature, pressure and method of computation of welding parameters must be included in the quotation. Other documents, which may be necessary to support any technical or commercial points should be enclosed along with the bid. SEV-V Page 18 of 19

12.02

12.03

12.04

12.05 12.06

12.07 12.08

12.09

12.10

The quotation should accompany the detailed stages & works involved and time required to complete each work. For eg. Supply of pipes & fittings, Submission of various drawings, procedures and calculations, fabrication and supply of anchor blocks and strainer blocks, welding of off-shore line, welding of on-shore line, deployment, pump room piping etc. The total price of different items should be indicated as given in the schedule of quantities. In the event of any technical requirement not spelt out in this tended document, the contractor shall discuss with the Engineer-in-Charge prior to the submission of bidding and the same shall be highlighted in his offer. Incomplete bids are likely to be rejected.

12.11 12.12

12.13

SEV-V Page 19 of 19